1. cs3001 u-deck operator's instructions

Atlas Copco Exploration Products

CS3001 Core Drill Rig Operator’s Instruction Manual

Universal Deck Version

Printed Matter No. 6991 1458 01

Operator's Instruction Manual for CHRISTENSEN CS3001 Universal Deck This instruction manual is intended for operators of the Christensen CS3001 (Universal Deck Version) high capacity diamond core drill. Instructions are given for set up, drilling, and maintenance procedures to be carried out by the operator and maintenance personnel. For further information concerning service measures for the drill rig, please contact your nearest Atlas Copco representative. Safety instructions applicable to operating and maintaining the drill are given in the section 2, Product Safety Instructions. This section must be read carefully and fully understood before starting to use the rig. Any questions regarding these instructions should be referred to your nearest Atlas Copco representative. All rights reserved. The owner of the equipment is granted the permission to take copies of this publication solely for internal use. It is recommended, however, to order additional copies from your nearest Atlas Copco representative in order to benefit from the latest revision. Atlas Copco Exploration Products reserves the right to make changes, without notice, in its products in order to improve design or performance characteristics. The information in this publication is assumed to be accurate at the time of publication, but is subject to changes in order to remedy detected deficiencies or to follow changes in the product. Users of this publication are requested to inform Atlas Copco Exploration Products about deficiencies found, particularly in matters concerning product safety. ATLAS COPCO EXPLORATION PRODUCTS NORTH BAY, CANADA 2007-8 Printed Matter No 6991 1458 01

Issue Date December 6, 2007

Contents Page Page

1 Introduction______________________ 1

2 Safety Instructions ________________ 3 2.1 Organizational Measures ___________3 2.2 Operation (General) _______________5 2.3 Moving The Drill __________________7 2.4 Set-Up Of Drill____________________8 2.5 Drilling __________________________9 2.6 Tear-Down Of Drill_______________10 2.7 Maintenance and Servicing ________11 2.8 Special Safety Signs_______________12 2.9 Safety Decals ____________________13 2.10 Fire Extinguisher________________14

3 Environmental Instructions ________ 15

4 Hoisting the Drill ________________ 17

5 Specifications ___________________ 19 5.1 General _________________________19 5.2 CS3001 Technical Specifications ____20 5.3 Dimensions ______________________22

6 Design Features _________________ 25 6.1 Mast And Feedframe______________25 6.2 Rotation Unit ____________________26 6.3 Crown Block ____________________26 6.4 Control Console __________________27 6.5 Wireline Winch __________________27 6.6 Main Winch _____________________28 6.7 Hydraulic Tank __________________29 6.8 Mechanical Guards _______________30 6.9 Optional Spin-Out Tool ___________30

7 Controls ________________________ 31 7.1 Main Control Panel (Pilot Operated) 31 7.1 Engine Control Panel _____________37

7.2 Secondary Control Panel__________ 37 8 Diesel Engine Start-Up ____________ 39

8.1 Pre-Start _______________________ 39 8.2 Engine Start ____________________ 42 8.3 Engine Shut-Down _______________ 42

9 Drill Set-Up _____________________ 43 9.1 Start-Up _______________________ 43 9.2 Secondary Controls ______________ 44 9.3 Levelling The Drill _______________ 45 9.4 Operator’s Platform _____________ 46 9.5 Mast Slide ______________________ 46 9.6 Ground Support & Wind Conditions 47

10 Drilling _______________________ 51 10.1 Before Drilling Starts____________ 52 10.2 Start the Power Unit ____________ 52 10.4 Adjust the Flow of Mud/Water____ 53 10.5 Start Rotation __________________ 53 10.6 Start Drill Feed_________________ 54 10.7 Stop Drilling ___________________ 54 10.8 Controlled Wireline Lowering ____ 56 10.9 Controlled Wireline Winching ____ 56 10.10 Thread Compensation __________ 56 10.11 Adding a Drill Rod_____________ 57 10.12 Removing a Drill Rod __________ 57 10.13 Water Pressure Dump Valve ____ 58 10.14 Operating Main Winch _________ 58 10.15 Rod Handling _________________ 59 10.16 Drill Rod Break-In Procedure ___ 61

11 Maintenance And Servicing _______ 63 11.1 General _______________________ 63 11.2 Periodic Maintenance and Service Schedule __________________________ 63

Contents Page Page

11.3 Lubricant Recommendations ______65 11.4 Service Point Detailed Instructions _66 11.5 Periodic Inspections _____________75 11.6 Hydraulic Hoses & Fittings Inspection___________________________________77

12 Hydraulic Circuit Description _____ 79 12.1 Hydraulic Pumps________________79 12.2 Filtration ______________________80 12.3 Main Pump Circuit ______________82 12.5 Secondary Pump Circuit__________90 12.6 Return Oil Circuit And Hydraulic Tank ______________________________91 12.7 Hydraulic Oil Cooler_____________92

13 Electrical Circuit Description______ 93 13.1 Electrical Fault Panel ____________93 13.2 Safety Systems (Electrical Circuit) Description _________________________94

14 Trouble-Shooting _______________ 95 14.1 Trouble-Shooting - General ______ 96 14.2 Trouble-Shooting Auxiliary Pump Circuit ____________________________ 98 14.3 Trouble-Shooting Main Pump Circuit_________________________________ 102 14.4 Trouble-Shooting Secondary Pump Circuit ___________________________ 105

15 Hydraulic Set-Up Procedure _____ 107

16 Spin-Out Tool Option ___________ 119 16.1 Safe-T-Spin Wireline Rod Make/Break Tool _____________________________ 119 16.2 Safe-T-Spin Operator’s Manual __ 120 16.3 Safe-T-Spin Maintenance _______ 127

17 Addendum Sheets ______________ 129

1 Introduction

1

1 Introduction Thank you for choosing the CS3001as your next core drill. The team at Atlas Copco Exploration Products is certain that it will provide you with years of productive service. This operator’s instruction manual contains information and safety instructions to assist in the safe operation and maintenance of the CS3001 in the standard configuration. Some CS3001 drills have special customer ordered features that differ from the standard drill configuration. These are described in Section 18 – Addendum Sheets Core drilling by its nature can be dangerous work. Care must be exercised when operating and servicing this product. Never operate this machine without all guards, pins and safety devices in place and in good working order. A safe and careful operator is the best insurance against an accident. If you require any assistance, or for Parts ordering, please contact your nearest Atlas Copco sales office or contact: Atlas Copco Exploration Products A Division of Atlas Copco Canada Inc. 640 McKeown Avenue North Bay, Ontario P1B 8H2 Canada Telephone: (1) 705 472-3320 Fax: (1) 705 472-6843

1 Introduction

2

2 Safety Instructions

3

2 Safety Instructions Dear operator, Before putting your new equipment into use, we would like to direct your attention to the safety aspects. Drilling can be hazardous to you and to the environment. Good order, training and well maintained equipment are the key factors for safe operation. This manual is no replacement for thorough training, but will, as a training aid and a reference book, help you to maintain a safe working environment and keep the rig in good operating condition. Yours faithfully, Atlas Copco Exploration Products Intended Use The CS3001 diamond core drill is intended for Surface exploration and investigation drilling within the published depth ratings of the drill. Any use going beyond this shall be considered "not intended use". The manufacturer is then not liable for damage incurred as a result. Unintentional use shall be at the owner's risk. Proper use also includes observing the safety instructions and procedures in the operation, maintenance, and service manuals as described by the manufacturer. The CS3001 should be operated, serviced and repaired by personnel properly trained for their task. These personnel must have sound knowledge about hazards in their respective profession. General safety regulations must be observed. Personnel should be aware of dangers resulting from abuse of drugs and alcohols as well as effects of medicines legally prescribed, or mixture of any of them. No unauthorized alterations should be made to the drill. The manufacturer is not liable for any damage caused by unauthorized alterations.

2.1 Organizational Measures 2.1.1 The CS3001 core drill shall be operated

only by personnel who have been fully trained on the rig. Particular emphasis shall be put on the Safety Instructions and proper maintenance of the drill.

2.1.2 Keep this instruction book available on

the rig at all times. 2.1.3 Always use personal protective

equipment as required by circumstances or demanded by regulations. Always use safety harnesses when climbing the service ladder.

2.1.4 If, during operation of the unit, any

abnormal action in the safety or operational systems is observed, the unit should be stopped and the problem investigated and rectified.

2.1.5 Warning signs must be kept legible at all

times. Damaged signs should be replaced immediately.

2.1.6 Hydraulic and electrical systems are of a

complex nature, and can cause injury or damage if not handled with care. Repair and service shall be carried out by personnel with documented experience for these systems.

2.1.7 Welding repairs should only be carried

out by a qualified welder in order to meet the high standards that apply to Atlas Copco products. Special attention must be given to components which could cause injury or serious damage.

2.1.8 After repairs, make sure that the rig has

been inspected and approved by the proper authorities before being brought back to normal operation.


4

2.1.9 Never make alterations or modifications

to components of the unit, or alter pressure settings, particularly to the safety systems, which might result in hazardous consequences. The manufacturer’s approval should be requested for any modification done to the unit.

2.1.10 Mechanical aids should be used

whenever it is necessary to lift more than 25 kg (50 lbs)

2.1.11 Do not operate the drill when the wind

speed exceeds 20 m/sec (45 mph). 2.1.12 Always practice good housekeeping.

Keep the drill deck clear and the working area tidy. Prevent slippery conditions underfoot on the deck, the driller platform, the helper’s platform (if so equipped) and the area surrounding the drill.

2.1.13 Do not store any flammable liquids or

gas bottles near the drill. Never store any blasting caps or explosives near the drill.

2.1.14 Always use the deck access ladder

when climbing onto the rig platform

2.1.15 Fall arrest and restraint equipment must

be used whenever the vertical drop exceeds 3 m (10 ft) or as specified by local safety regulations. When climbing ladders (e.g. service ladder to the crown block), it is recommended to use a guided type of fall arrest system in which a rope grab is attached to a body harness (See Figure 2.1). Fall restraints and a guided type of fall arrest system are available, Atlas Copco part 3760009042. Follow instructions supplied with the fall arrest and fall restraint equipment. Do not alter or misuse this equipment.

A body harness as shown in Figure 2.1 is available from Atlas Copco as part 3760008964. It should be used to climb the service ladder to the crown block.

Fig 2.1 Fall Arrest System for Climbing Ladders


5

2.2 Operation (General) 2.2.1 In addition to this manual you should

have a good knowledge of generally recognized safety and accident prevention regulations. If you follow the regulations you stand a better chance of accomplishing your task without harm to either man or equipment.

2.2.2 Prior to starting up for the first time,

familiarize yourself with the rig's features, its controls and their functions.

Fig 2.3 Read the Instruction Book before

Starting Up The drill

2.2.3 Various safety devices are built into the system of the rig for your personal safety. These devices must be checked at least once at the beginning of each shift to ensure that they are in proper working order. The equipment should not be used unless safety checks and maintenance have been carried out.

2.2.4 The drill is equipped with a fire

extinguisher when shipped from the factory. Always ensure that the fire extinguisher is kept on the drill and is in good working order (see section 2.10)

2.2.5 Operators and helpers should wear

helmets with ear protectors, safety glasses, safety shoes, gloves and suitable clothing. Loose fitting clothing and jewellery can become caught in the moving parts of the machinery, causing serious injury or even death. Use suitable respirators in dusty conditions

2.2.6 During drilling, no unauthorized person(s) should be allowed near the rig.

2.2.7 Set control levers and switches to the

neutral positions prior to starting up, otherwise the rig could start uncontrollably. Some of the levers are spring-loaded so that the operation will stop once released. This is part of the safety system. Never lock these levers into operating position using strings, sticks or similar items. The drill should always be started from the control panel.

2.2.8 Shut the rig down for refuelling. Fuels

must be handled with care, at a safe distance from fire, sparks or electrical systems. Smoking is not allowed within 10 metres of the fuel! Do not fill the tank in an enclosed space without ensuring adequate ventilation. Fumes are poisonous. Dispose of spilled fuel in accordance with safety and environmental regulations (Use absorbents or dig out the contaminated soil and transport it to an approved storage). Do not overfill the fuel tank.

2.2.9 If you top up the fuel tank in the

morning, expansion of the fuel, as the temperature increases later in the day, may cause fuel to spill from the tank. Tank breathers clog easily if the level of fuel is too high.

2.2.10 Never leave the rig unattended with the

engine running. Carry the ignition key with you.

2.2.11 Use extreme caution while handling

starter batteries. Wear gloves and protective glasses when servicing batteries. The batteries contain strong acid which can seriously burn eyes, skin and damage cloth, insulation and metal. First aid in case of acid in the eyes: wash with plenty of clean water and seek medical help. Disconnect the ground cable from the battery before carrying out service in the electrical system.


6

The battery gas is explosive! Never use

matches when checking the acid level. Be careful using iron tools near the

battery, a spark might set off an explosion.

2.2.12 Hydraulic oils are poisonous. Use eye

protection and gloves. Hydraulic oils, like fuel, must be treated in compliance with safety and environmental regulations.

2.2.13 Before any repair or service is carried

out on the drills hydraulic or water systems, make sure the engine is stopped and systems are depressurized.

2.2.14 Be very careful while tracing leaks in the

pressurized systems. Hydraulic oils, water or air under pressure could penetrate under the skin and cause complicated injuries or infection. If this happens, see a doctor at once.

2.2.15 Dispose of engine oils, hydraulic oils,

fuels, filters and acids in a safe manner according to environmental protection regulations.

2.2.16 Avoid the use of cleaning agents containing solvents like carbon tetrachloride. There are environmentally

better alternatives now available on the market

2.2.17 Use only authorized parts (Atlas Copco

parts). Any damage or malfunction caused by the use of unauthorized parts is not covered by warranty.

2.2.18 Any warranty, for work performed, only

covers Atlas Copco products, Atlas Copco components and work performed by authorized personnel.

2.2.19 Establish and use a standard means of

communication between all drill personnel. Remain in eye contact with each other where possible. The CS3001 drill is provided with an audible

alarm (beeper) similar to a truck backup warning device that is activated when hydraulic functions are used during set-up and tear-down. Stand clear of jacks and mast when this device has been activated.

2.2.20 Obtain MSDS data sheets for the fluids

that you use for the drill and follow the instructions in the data sheets in case of accidental ingestion, skin contact or spills.

Fig. 2.4 Use Only Genuine Atlas Copco Parts


7

2.3 Moving the Drill

2.3.1 Always lower the mast to the transport position and raise the jacks before moving the drill. Ensure that the jacks and mast slide securing pins are in place. Driving with mast out of transport position could cause rig upset.

2.3.2 Always safely stow and secure

the overshot and water swivel on the deck before moving. Never move the drill with loose items on the deck

2.3.3 Do not allow any personnel to

ride on the deck while the drill is moving. Personnel must ride in cab of truck only

2.3.4 Always test brakes before

descending a ramp or steep incline.

2.3.5 For truck mounted drills, ensure

that truck’s operator’s manual is supplied and is kept in the truck.

2.3.6 Always check your surroundings

before moving the drill so you become aware of any hazards.

2.3.7 While moving the rig, no

unauthorized person should be allowed near the rig. Ask a supervisor for assistance when moving the rig into dangerous positions such as close to the edge of a quarry bench. Make sure the visibility is good. Don't drive the rig into a dust cloud.

2.3.8 When the drill is mounted on

tracks and is moved with the operator at the console position, always use a spotter in communication with the operator to ensure that the drill is being safely moved since

visibility from the console position is very limited.

2.3.9 Even with the mast down, the drill when mounted on a truck or tracks has a high center of gravity. To prevent sideways tipping, never move the rig on a side slope greater then 1 in 5.

2.3.10 If the drill is mounted on tracks or a

truck by the customer, the customer must mount an inclinometer at the driving position so the driver is aware of the slope. An inclinometer is available from Atlas Copco, Part # 3760005026

2.3.11 The driver must be aware of the

possibility of soft ground or soft road shoulders at all times since sinking of the wheels or tracks in soft ground can rapidly increase the sideways slope of the rig and lead to tipping of the rig and personnel injury.

2.3.12 Always ensure there is sufficient

visibility when moving the rig. When driving on poor roads, drive only in daylight.

2.3.13 Take extreme precautions on rough

roads. Do not exceed posted speed limits and match speeds to the road conditions.

2.3.14 Before lowering the mast onto the front

support frame, ensure the mast is located in its proper dumped position (matching alignment arrows on mast and saddle).

2.3.15 Ensure that the rig meets allowed

overall height limits. 2.3.16 Always check the clearance of overhead

structures. When sufficient clearance is in doubt, stop and check the clearance. A common road accident with drills is a collision with an overhead structure.

2.3.17 On trips, the driver should periodically

check for any leaks (hydraulic oil, engine radiator, fuel tank and lines). It is recommended that a spill kit and absorbent be carried on the rig.


8

2.3.18 For long distance shipping, or in

sensitive environmental areas, it is recommended to drain the hydraulic reservoir and fuel tank.

2.4 Set-Up of Drill 2.4.1 When inspecting the site where the drill

is to be set up, ensure that there are no underground utilities present (gas, water, electric cables) and that there are no overhead wires that can be contacted.

2.4.2 Before setting up the drill (lowering the jacks and raising the mast), ensure that the ground is sufficiently firm to support the drill. Where required use jacks pads or if necessary, timber or concrete pads. (See section 9.8.1 for details).

2.4.3 Check that the Set-up Audible Alarm is working when any of the set-up controls are moved (jacks, console extend, mast raise, mast slide). The purpose of the alarm is to let personnel know that a movement is taking place and all personnel except the operator should stand clear.

2.4.4 When lowering the jacks, never use

your finger to check the pin hole alignment (several people have lost a portion of their finger doing this!). Use a visual check only, using a second person if required. Always secure the jacks with the locking pins provided.

2.4.5 When raising the mast, ensure that no

hoses, winch rope or cables are snagged. Snagging of hoses could damage them and lead to leaks, and snagging of winch rope or cables could damage them as well. Always secure the mast with the safety pins in the backstay leg(s).

2.4.6 It is important that the bottom of the

mast be supported and that the support is robust enough to take the full force exerted on the rod when pulling with the

main winch and/or the drillhead. If the support moves while pulling on a stuck rod, the front of the drill could move up, depending on the angle of drilling.

2.4.7 Always secure the mast slide with the

securing pins provided 2.4.8 If there is a possibility of thunder or an

electrical storm, a lightning conductor should be installed on the drill.

2.4.9 Ensure parking brakes are set and

wheel chocks are used to prevent movement of truck mounted drills after the drill has located for drilling.


9

2.5 Drilling 2.5.1 Check that the emergency E-stops are

in good working order at the beginning of each shift. Also check that the drillhead guard and perimeter guards for the main and wireline winches are in place.

2.5.2 All controls should be in neutral before

starting engine. Check that neutral switch for the rotation control lever is working. It should not be possible to start the engine if the rotation lever is not in the neutral position. This is an important safety device.

2.5.2 All main controls are live and dangerous

if accidentally activated. Do not wear loose clothing. Do not stand on the console or place tools or equipment that can accidentally fall and operate the controls. Use approved hand protection that allows for positive and safe use of all controls.

2.5.3 Use the wireline winch only for the

purpose intended, never for general service. The wireline winch moves too fast for any general service winching.

2.5.4 The main winch block limit switch,

located at the crown block, is meant for emergency use only to prevent the winching plug from being pulled into the crown block. Do not use it for stopping upward travel when winching the drill rod.

2.5.5 Always keep a minimum of 3 wraps on

the main winch drum and the main winch rope in a singe layer. Ensure that the rope end is well anchored on the drum flange.

2.5.6 Monitor the condition of the main winch

rope. At the first sign of wear or broken strands, the main winch rope must be replaced.

2.5.7 Whenever possible, do not use pipe

wrenches to break rod joints. Break the rods between the drillhead and rodclamp or use the optional spin-out tool.

2.5.10 Always protect your hearing with both

ear plugs and ear muffs (a total attenuation rating of 15 dBA) when working on the rig.

2.5.11 Grease and inspect the water swivel

every shift to avoid bearing failure and seizure. Waterswivel failure can cause hose whipping leading to injury or death

2.5.12 Ensure that the waterswivel is rated to

maximum load that can be applied to it. 2.5.13 Report excessive vibration to your

manager or foreman immediately when it occurs. Excessive vibration will cause machine damage and premature wear

2.5.14 Ensure that the operator and helper are

not exposed to continuous vibration since this can cause white finger and other disease

2.5.15 The audible alarm will sound on low

hydraulic oil level or high hydraulic oil temperature (a light on the electrical panel will show whether low level or high temperature caused the alarm). The engine will shut down in about 30 seconds after start of the alarm (time period is adjustable). This gives the driller time to stop drilling, pull the rods back and secure the drill hole.

2.5.16 Ground conditions can deteriorate after

heavy rainfall. Inspect jack and mast support areas daily.

2.5.17 Never operate the drill when the wind

speeds exceed 20 m/sec (45 mph) See section 9.8.3 regarding guy wire requirements

2.5.18 Do not operate the drill in lightning storms. This could result in electrocution.


10

2.5.19 Snow/ice/freezing rain can make the

work area hazardous. Take necessary precautions prior to working. Provide wind protection for personnel when operating in cold and windy conditions. Working in cold conditions can make it difficult to work safely.

2.5.20 Take precautions when drilling in gaseous deposits – methane gas can cause explosions and uncontrolled run-away of diesel engines. When drilling gaseous ground, use a B.O.P. (blow out preventer), if required.

2.5.21 The operator should periodically check for hydraulic oil, fuel and radiator leakage. Any leaks found must be rectified. It is recommended that a spill kit and absorbent be available at the drill site.

2.5.22 It is important to practice good housekeeping and prevent slippery underfoot conditions in the working areas.

2.5.23 Oily rags, bare conductors, spilled or leaking fuel or oil present a fire hazard and must be prevented

2.5.24 The foot clamp can crush feet or hands. Keep feet and hands away from the foot clamp.

2.6 Tear-Down of Drill 2.6.1 Always put mast into transport position,

fully retract jacks, and retract the console before moving the rig.

2.6.2 Before lowering the mast onto the front

support frame, ensure the mast is located in its proper dumped position (matching alignment arrows on mast and saddle)

2.6.3 Be careful to avoid snagging or

damaging any hose, winch rope or cable when moving the mast to the travel position.

2.6.4 Always ensure that securing pins are in

place (jacks, backstay legs, mast slide, and guards)

2.6.5 Always secure any loose items so they

cannot fall off the deck. 2.6.6 Ensure that the rig meets the allowed

overall height limit. 2.6.7 When preparing for a long trip, it is

recommended that the fuel tank and hydraulic reservoir be drained. This will prevent a major environmental problem in case of any hydraulic hose/fuel line or incident with the rig.


11

2.7 Maintenance and Servicing 2.7.1 Personnel must be properly trained and

have documented experience for the type of maintenance/service work they are doing in order to avoid injuries and possible damage.

2.7.2 Any maintenance should be done using

acceptable lockout procedures to ensure personal safety.

2.7.3 Make sure the engine is stopped and hydraulic, air, and water circuits are properly depressurized before being worked on.

2.7.4 Make sure all components that can move when hydraulic lines/components are disconnected (e.g. drillhead, mast, etc.) are in the lowest position or supported by temporary means such as blocks or chains before working on the drill.

2.7.5 When replacing components, always purge air from the components prior to use to prevent uncontrolled movement.

2.7.6 Be very careful when tracing leaks in the pressurized systems. Hydraulic oils, water or air under pressure could penetrate under the skin and cause complicated injuries or infection. If this happens, see a doctor at once.

2.7.7 Do not use pressure settings different from factory settings without consulting with the factory. Mechanical failures or other dangerous situations resulting in death or injuries could occur with settings that are different from factory settings.

2.7.8 Use safe lifting practices. Use power assisted lifting wherever possible. Do not lift more than 25 kg (56 lbs) per person or as local regulations dictate.

2.7.9 Remove suspended loads on any winch

before commencing maintenance

2.7.10 When working on electrical circuits,

the battery ground cable should be disconnected to prevent accidental shorting.

2.7.11 Batteries contain corrosive acid.

Wear protective equipment before doing any maintenance on batteries.

2.7.12 Welding near computer controlled

engines can cause ECU damage. Disconnect batteries and ECU harness prior to welding.

2.7.13 Use only certified welders for any

welding repairs.

2.7.14 Avoid hot areas of the rig such as the engine exhaust system when maintaining/servicing the rig. Allow cool-down time prior to removing heat shields and guards

2.7.15 A qualified person should inspect

high stress locations on a yearly basis.

2.7.16 Never use oversize fuses or

breakers. These present a fire hazard.

2.7.17 Periodically check that all danger and

warning labels, as specified in the parts manual, are present and legible. Any missing decals must be replaced.

2.7.18 Never climb the mast using the

service ladder while the rig is running.

2.7.19 Procedures in section 15 must be

used for setting min displacements on replacement hydraulic motors for rotation and the main winch. Failure to do this can cause over speeding and failure of the motors and damage to the drillhead or main winch.


12

2.8 Special Safety Signs The following warning signs are used on the rig and in the manual: 2.8.1 Fig. 2.5 warns for immediate hazards,

which when ignored, can lead to serious personal injury or death!

2.8.2 Fig 2.6 warns for hazards or unsafe

practices which, when ignored, could lead to serious personal injury or death

2.8.3 Fig 2.7 indicates hazards or unsafe

practice, which could lead to minor personal injury or damage to equipment.

2.8.4 Fig.2.8 is used for recommendations

such as how to run the unit efficiently, economically and in compliance with environmental regulations.

Fig. 2.5

Fig. 2.6

Fig. 2.7

Fig. 2.8


13

2.9 Safety Decals

The following safety decals are used: 2.9.1 Fig. 2.9 Lifting points. This sign is

located where it is recommended that slings be attached.

2.9.2 Fig 2.10 Ear protectors. Ear protectors

should always be worn. 2.9.3 Fig. 2.11 Risk of crush. Be aware of the

risk from crushing. Fig. 2.9 Fig. 2.10 2.9.4 Fig 2.12 Diesel fill location.

2.9.5 Fig 2.13 ATTENTION: Before starting,

oil must be filled according to Lubricant Recommendations

2.9.6 Fig 2.14 Electrical hazard

Fig. 2.11 Fig. 2.12 2.9.7 Fig 2.15 Foot Crushing hazard

Check periodically that safety decals are legible and in place. Replace as required. See Parts Manual for safety decal location and part numbers.

Fig. 2.13

Fig. 2.14

Fig. 2.15


14

2.10 Fire Extinguisher 2.10.1 The drill rig is equipped with a portable

fire extinguisher. The fire extinguisher is shipped with the drill. This fire extinguisher is suitable for fire in electrical cables, fuel and engines and lasts for approximately one minute when operated continuously. To use, remove the safety pin and press handle. Direct the jet towards the base of the fire. This type of fire extinguisher puts out the fire by eliminating access to oxygen. Embers might start the fire again. Use water for fighting fire in wood, paper and similar materials.

2.10.2 If the fire extinguisher has to be replaced, the replacement must be rated for both oil and electrical fires with a mass rating of not less than 6 kg (13 lbs) and as required by local regulations.

3 Environmental Instructions

15

3 Environmental Instructions Dear operator, Atlas Copco Exploration Products recognizes the importance of environmental issues. As part of our commitment to a better environment, we want to inform you, the customer, of how you can minimize the effect on the environment when using an Atlas Copco product. These simple but important instructions will help to preserve the environment. Oil Leaks of hydraulic and lubrication oils pose an environmental threat. Changing lubricating and hydraulic oils, hydraulic hoses and hydraulic filter elements also pose a potential threat to the environment. Collect all oil spills and waste (e.g. oil filter elements) contaminated with oil. Dispose of according to national regulations. Use biologically decomposable hydraulic oils and lubricating oils for Atlas Copco products wherever possible. Contact your nearest Atlas Copco office for more information. Engine Engine emissions are toxic and pose an environmental threat. Always provide for fresh air when an engine is running. Well-maintained air filters help keep emissions at a low level. Fuel (Petrol/Gas, Diesel): Fuel spillage poses an environmental threat. Collect all wastes and fuel spillage and dispose of according to national regulations. Grease Lubricating grease poses a threat to the environment. Collect all wastes and spillage and dispose of according to national regulations. Batteries Batteries contain acids and heavy metals. Used batteries can therefore pose a threat to the environment and to your health. Avoid all contact with acids and dispose of used batteries according to national regulations. See also section 2.2 for further information.

Chemicals Dispose of chemicals such as drilling additives, other additives, glycol etc. according to the manufacturer’s instructions and local regulations. Avoid the use of cleaning agents containing chlorinated solvents. There are environmentally better alternatives now available on the market. Follow national regulations regarding handling and disposal of wastes. Metals (steel, aluminium, etc.) These products are recyclable and should be taken care of according to national regulations and recycled where local programs exist. Plastics and rubber These products are often labelled according to different classes. In those cases they are recyclable and should be disposed of according to national regulations and recycled where local programs exist. Electrical components (cables, electronics, etc) Used components should be disposed of according to national regulations and recycled where local programs exist. Spill Kit and Absorbent Always carry a spill kit and suitable absorbent for hydraulic oil and anti freeze. Daily Inspection Inspect fuel tank, hydraulic tank, radiator and cooler for leaks daily.

Obtain MSDS data sheets for the fluids that you use for the drill and follow the instructions in the data sheets to deal with accidental ingestion, skin contact or spills.

3 Environmental Instructions

16

4 Hoisting the Drill

17

4 Hoisting the Drill 4.1 Ensure that mast is in the transport position

on the mast support. 4.2 Locate the rotation unit above the main

winch to obtain a good point of balance and centre of gravity.

4.3 Lift the drill using the lifting points at the 4 jacks and spreader bars (see Fig. 4.1 & 4.2) to ensure that the forces on the jacks are vertical only.

4.4 If spreader bars are not available, use slings at least 7m (23 ft) in length to prevent high side forces on the jacks and ensure that no hoses or mechanical components are touched by the slings.

Fig 4.1 Spreader Bars For Hoisting the Drill

– The sling must be sized for lifting 16 tons (Drill unit) to provide a safety margin.

– Never use a damaged rope/sling. – Always make sure that nobody is

under or anywhere near, a suspended load or within the swing radius of the rope/sling.

Failure to use spreader bars, or long enough slings (see section 4.4), can cause damage and permanent distortion of the deck

Fig. 4.2 Lifting Point on Drill Jack

4 Hoisting the Drill

18

.

5 Specifications

19

5 Specifications

5.1 General

CHRISTENSEN CS3001 is an all-hydraulic operated diamond core drill.

The CHRISTENSEN CS3001 is an all-hydraulic diamond core drill for deep hole surface exploration drilling. The CS3001 is designed to be mounted on a truck and can also be mounted on tracks. The CHRISTENSEN CS3001 uses well proven technology for diamond core drills together with safety improvements to provide a reliable, safe drill. An optional spin-out tool avoids the use of pipe wrenches for breaking rods

Recommendations To achieve the best results with regard to:

• high penetration • optimal core recovery • low drilling costs

It is of primary importance that drill rods, core barrels and coring bits are of the right type and quality, matched to the drill and to the prevailing rock conditions. Bearing in mind the core drill’s speed of rotation, its depth rating and chuck diameter, the CHRISTENSEN CS3001 is best suited to drill N to P size holes using wire line rods.

5 Specifications

20

5.2 CS3001 Technical Specifications Drill Mast Feed stoke ...............................3.35 m (11 ft) Mast slide .................................. 2.0 m (80 in) Rod pull ..................................... 6.1 m (20 ft) Mast style………….…..One-piece Weldment Feed pull..........................155 kN (35,000 lbf) Feed thrust……………....62.2 kN (14,000 lbf) Drill rod centerline location.... In front of mast Main Winch Main winch pull................133 kN (30,000 lbf) Main winch speed: .. 0.74 m/sec (146 fpm) @ max displacement .. 1.17 m/sec (230 fpm) @ min displacement Rope size. ..............................19 mm (3/4 in) Drillhead Chuck axial holding capacity: …………………………….178 kN (40,000 lbf) Actuation ......Spring apply, hydraulic release Number of jaws ........................................... 5 Drillhead ........Chain final drive plus 4 speed .................................................. transmission Chuck mounting ................................. Bolt on Final drive ratio ................................... 2.48:1 Drillhead spindle ID………..119 mm (4.68 in) Wireline Winch Drum Capacity: -4.7 mm (3/16 in) wire rope .... 4,600 m (15,000 t) -6.3 mm (¼ in) wire rope ......... 2,600 m (8,530 ft) Levelwind for even spooling ...........Standard Parking brake ……………………….Standard Winch position..................... Raised on stand Control Console Console movement ....... Hydraulic in and out Weight (less truck): …………………………12,810 kg (28,240 lbs) ……………………………will vary with options

Foot Clamp • Hydraulically operated, self energizing foot

clamp • Easy-to-remove jaws • Common jaws from 44.5 mm (1.75 in) to

177.8 mm (7 in) • Casing and rod jaws for all popular sizes • 224 mm (8.8 in) foot clamp opening • 320 mm (12.5 in) mast bottom opening

Fig. 5.1 Foot Clamp & Optional Spin-Out Tool (Shown With Foot Clamp Guard Removed)

Fig. 5.2 Control Console & Drillhead

5 Specifications

21

Diesel Engine - See Drill Manual Section II for information on the Diesel engine. Diesel Fuel Reservoir Capacity…………………….950 L (250 gal) Filling method………………By hand pump …………….connected to main return filter Hydraulic System Hydraulic tank capacity ……500 litres (132 gal) Max. operating pressure

- Main pump................. 324 bar (4,700 psi) - Auxiliary pump ......... 190 bar (2,800 psi) - Secondary pump* … 207 bar (3,000 psi)

Max. flow - Main pump................. 272 l/min (72 gpm) - Auxiliary pump .......... 125 l/min (33 gpm) - Secondary pump*........ 95 l/min (25 gpm)

*Note: This is the secondary pump pressure and flow on the standard CS3001. The drill may have a different secondary pump if the mud/water pump is different than the standard FMC W1122BCD. See the addenda sheets (section 18), parts list and hydraulic schematic for the drill. Options • Spin-Out Tool for mechanized rod make-

up and break-out

Depth Capacity Coring* B Wireline ………………….. 2,360 m (7,740 ft) N Wireline .......................... 1,830 m (6,000 ft) N Wireline – Upset Ends...... 2,120 m (6,950 ft) H Wireline ............................ 1,200 m (3,930 ft) P Wireline................................ 830 m (2,720 ft) * For vertical, straight, water filled hole Drillhead RPM and Torque Ratings at max. & min. displacements: -At rotation pressure of 4,300 psi -Max displacement of 80 cc -Min displacement of 62 cc

RPM Torque Nm (ft lbf) Gear Max Dis-

placement Min Dis-

placement Max Dis-

placement Min Dis-

placement 4th 1,300 Limited

to 1,300 843 (622) 653

(482) 3rd 759 980 1,449

(1,069) 1,123 (828)

2nd 412 532 2,671 (1,970)

2,070 (1,527)

1st 182 254 5,587 (4,121)

4,329 (3,193)

5 Specifications

22

5.3 Dimensions Dimensions (in mm) are subject to change. If required, consult with factory to get dimensions certified.

Fig. 5.4 Shipping Dimensions – Elevation

Fig. 5.5 Shipping Dimensions – Plan View

5 Specifications

23

Fig. 5.6 Truck Mounted Drill in Transport Position - Elevation

5 Specifications

24

6 Design Features

25

6 Design Features Design features are described for the main drill components: mast and feed frame, rotation unit, crown block, control console, wireline winch, main winch, hydraulic tank and optional spin-out tool.

6.1 Mast and Feedframe The 6 m (20 ft) pull mast is a single piece weldment which is stress relieved and straightened after welding. The feedframe section of the mast uses a 3.3 m (11 ft) stroke, direct acting feed cylinder. The drillhead carriage is guided by rollers. This design gives maximum drillhead pulling efficiency (minimum friction). The mast is raised by two mast lift cylinders equipped with hard-plumbed counterbalance valves. It is held in the drilling position by two short telescopic backstay legs which are pinned in position

6 Design Features

26

6.2 Rotation Unit The rotation unit hinges sideways to clear the hole. It consists of a variable speed bent axis hydraulic motor for maximum efficiency, a four speed transmission, a transfer case with a heavy duty chain and a P size hydraulic chuck. The drive chain in the transfer case can be adjusted if required. The four speed transmission and transfer case are pressure lubricated.

6.3 Crown Block The crown block is equipped with large 30 inch sheaves (grooves for 3/4” rope) running on bearings which are remotely lubricated from drill level. A block limit switch, that prevents the hoisting plug from being pulled into the crown block, is standard. Use fall arrest and fall restraint equipment when accessing the crown block

Fall arrest and fall restraint equipment must be used whenever the vertical drop exceeds 3 m (10 ft.). Follow instructions for the proper use and maintenance of this equipment (instructions are supplied with the equipment).

6 Design Features

27

6.4 Control Console The control console is compact for improved visibility of the drill deck for the operator. It is hydraulically adjustable in and out to allow improved ergonomics as the drill angle changes. The rotation control has a neutral switch which prevents engine starting unless the control is in neutral. The remaining controls (main winch, wireline winch and fast travel) have neutral locks as standard to prevent accidental movements.

6.5 Wireline Winch The high capacity wireline winch is equipped with a direct drive hydraulic motor, levelwind and parking brake. The winch is equipped with a load holding counterbalance valve. The parking brake is a wet type using case drain fluid from the motor. It is necessary to use different drive chain kits for the levelwind drive depending on whether 4.7 mm (3/16 in) or 6.3 mm (1/4 in) wireline rope is used. 4.7 mm (3/16”) cable: Drive sprocket A/C # 3760009249 (11T), chain A/C # 3760008617 6.3 mm (1/4” kit) cable: Drive sprocket A/C # 3760009210 (14T), chain A/C # 3760009128

6 Design Features

28

6.6 Main Winch The main winch is designed to operate with single layer of 19 mm (3/4 inch) diameter rope. The 6 m (20 ft) pull rods are run out. The main winch is equipped with a top pressure roller for improved rope management. The pressure roller is equipped with 2 limit switches. One limit switch signals that three or fewer wraps are left on the drum (there should always be a minimum of 3 wraps on the drum). The other limit switch signals that the pressure roller is higher than for a single layer of rope). This informs the operator that the rope is crossing which can kink and/or damage the rope. Both limit switches sound the audible alarm and a winch indicator light lights up in the control console to let the operator know that one of the main winch limit switches is triggering the audible alarm. The winch is equipped with a continuously variable, bent axis, piston motor. This allows the main winch speed to be increased by up to 58% when the rod string load is reduced as the rod string is pulled out of the hole. The winch motor displacement control should be adjusted so the main winch hydraulic pressure is maintained at 297 bar (4,300 psi) as long is there sufficient load on the hoist.

6 Design Features

29

6.7 Hydraulic Tank The hydraulic tank is equipped with a combination sight glass/thermometer and a combination low oil level/high oil temperature switch. If the oil level drops below the level of the sight glass or the temperature increases to over 80°C (176° F), the audible alarm will sound and the oil level or oil temperature indicator light in the electrical panel will light up. An adjustable timer will then shut the engine down in about 30 seconds (time is adjustable). This will prevent hydraulic system damage and give the operator time to safeguard the drill hole (e.g. pull back the rods, stop rotation and flush the cuttings out) before the engine stops. The indicator light (for the fault which triggered the alarm) will stay lit to tell the operator which fault occurred. The indicator light can then be cancelled with the reset button (see section 13.1) The tank is pressurized with 0.55 bar (8 psi) air from the engine mounted compressor for high altitude operation. Two breathers mounted on the tank filter incoming air and limit max tank gauge pressure to 0.68 bar (10 psig). The main return filter is mounted in the top of the tank.

6 Design Features

30

6.8 Mechanical Guards Mechanical guards are supplied for the following locations: -Perimeter guards (4 pieces) restrict access to the engine (turbo side), main winch and wireline winch -Hinged drill rod guard at the bottom of the mast -Guard over foot clamp actuator arms

6.9 Optional Spin-Out Tool An optional spin-out tool is available to make and break the rod joints when tripping into and out of the hole without using the chuck or a pipe wrench. See Section 16 for details

7 Controls

31

7 Controls 7.1 Main Control Panel (Pilot Operated)

Figure 7.1 CS3001 Main Control Panel

7 Controls

32

7.1 CS3001 Main Control Panel - Pilot Operated (cont’d) (Numbers refer to Balloon Numbers in Fig. 7.1)

The following acronyms are used in this section: CCW or ccw means counterclockwise CW or cw means clockwise

1. Light Switches- Control console and deck lighting.

2. Pull Down Pressure – Controls pressure on pulldown side of feed cylinder. CW rotation increases pull down pressure.

3. Feed Rate – Controls feed rate. CCW rotation increases feed rate.

4. Slow Feed Direction – When the lever is lowered, the drill head will feed into the hole. When the lever is raised, the drill head will raise.

5. Head Opener Cylinder – Swings drillhead open hydraulically

6. Hydraulic Chuck Contro

l – Opens the hydraulic chuck when the lever is lowered. When the lever is returned to the central position, the chuck is closed and grips the drill rod.

7. Emergency Stop Button – Drains the main pump load sense line to tank, thus stopping functions powered by main pump. Also shuts engine down. Pull out to reset.

8. Main Winch Control – Controls the direction and speed of the main winch.

7 Controls

33

9. Fast Travel Control – Controls the fast travel speed and direction of the drillhead.

10. Wireline Winch Control – Controls the speed and direction of the wireline winch

11. Rotation Control – Controls the speed and direction of the rotation motor. This control must be returned to neutral before the engine can be started

12. Mud/Water Pump Speed Control – Controls the speed of the mud/water pump.

13. Water Pressure Release – Allows water pressure in the drill string to be released.

14. Main Winch Motor Control – Controls the main winch motor displacement. Turning the knob counter cw decreases motor displacement (torque) and therefore increases speed.

15. Engine Speed Control – For Tier I Diesel engine only. For Tier II and III engines, the engine speed control is in the Engine Control panel See Manual Section II – Diesel Power Unit, for details

Do not use wireline hoist for general service since speed is too high.

16. Winch Brake Release – Move up to apply brake and down to release brake on main winch.

17. Foot clamp – Opens and closes the hydraulic foot clamp.

7 Controls

34

18. Thread Compensation – Middle position is for normal drilling. Put in upper position to compensate for drillhead weight on the threads for both make (drillhead moves up) and break (drillhead moves down) operations. Put in lower position to float drillhead. The adjusting knob behind the directional valve adjusts the force used to compensate for the drillhead weight for make and break.

19. Mud Mixer Speed – Controls flow to the mud mixer.

20. Mud/Water Pump Hi/Lo Speed – Sets mud/water pump motor to hi or low speed.

21. Make /Drill Pressure – Selects max rotation pressure as pump compensator (drill setting) or a preset pressure for rod joint make-up (adjustable at the back of the console to suit rod size).

22. Hydraulic Tank Pressure Gauge – Indicates hydraulic tank charge pressure. Do not operate the drill when pressure is below 0.3 bat (4 psi).

23. Auxiliary Pump Pressure Gauge – Indicates the system pressure in the auxiliary pump circuit.

24. Water Pressure Gauge – This gauge is connected to the mud/water pump outlet and indicates the mud/water pressure.

25. Main Pump Load Sense Pressure – Gives system pressure in the main pump function currently being used (main winch, fast travel, wireline or rotation).

7 Controls

35

26. Engine Control Panel (not shown) - Contains key switch, throttle control, tachometer, and other engine monitoring gauges.

27. Audible Alarm (not shown) - Provides audible warning for low oil level & high oil temperature, main winch rope management (see section 6.6), operation of secondary console controls (hyd jack movements, mast raising etc.).

28. Rotation Motor Displacement Control – Controls the rotation motor displacement, and is continuously variable during drilling. Turning the knob cw decreases motor displacement and therefore increases motor speed. For given rod torque, the rotation pressure will be increased. Turning the knob ccw increases the motor displacement and therefore decreases motor speed. For a given rod torque, the rotation pressure will be decreased.

29. Spindle Tachometer – Provides the chuck rpm.

30. Flow meter – Provides mud/water pump flow by measuring mud/water pump rpm.

31. Pulldown Pressure Gauge – Shows pressure on the pulldown side of the feed cylinder. A calibrated decal ring is translates the pressure to feed cylinder pulldown force (in pounds).

32. Holdback Pressure Gauge – Shows pressure on the holdback side of the feed cylinder. A movable calibrated decal ring can be used to indicate the net bit force.

33. Circuit Breaker – Provides protection of main electrical control panel.

34. Spin-Out Tool (Optional) – Allows user to make or break rods

35. Spin-Out Tool Torque Adjustment – Raises or lowers Spin-Out Tool (UDR Safe-T-Spin) make-up torque.

7 Controls

36

36. Pressure Gauge – Shows make-up pressure applied to the Spin-Out Tool

37. Rod Lifter – Lifts the rod to lineup with the chuck centerline.

38. Test Button for Audible Alarm (not shown) – Used to test audible alarm

7 Controls

37

7.1 Engine Control Panel

The drill can be equipped with a number of different engines depending on customer requirements. Information on the engine control panel is contained in Section II of the Drill Manual

7.2 Secondary Control Panel

1 8 7 6 5 4 3 2

Fig. 7.2 CS3001 Secondary Control Panel

6. Mast Raise – Raises and lowers mast 1. Selector valve – Directs hydraulic oil to either main control panel or secondary control panel (prevents inadvertent movement of set-up control while drilling) 7. Mast Slide – Slides mast so mast bottom can

be supported on ground.

2, 3, 4, 5 Hydraulic Jacks – Controls jacks. Locking pins must also be used. 8. Console Extend – Extends/retracts console

7 Controls

38

8 Diesel Engine Start-Up

39

8 Diesel Engine Start-Up Always follow the Safety Instructions in Section 2. Before starting the diesel engine, certain checks and measures must be carried out to prevent accidents, unnecessary stops or breakdown. Some of these measures must be carried out regularly as a part of the CS3001 Maintenance Schedule - see Table 11.1. The following start-up information applies to all diesel engines – however the pictures are for the Cummins QSC 8.3 litre engine and will be only representative for the other engines. Specific Information on the engine installed on the drill is included in Section II of the Drill Manual – Diesel Power Unit

8.1 Pre-Start Check that all controls are in neutral position. Check that none of the emergency stop buttons are depressed. E-stop buttons are located on the main control panel, secondary control panel, on right side of drill and on the helper’s platform (if drill equipped with optional rod rack) 8.1.1 Check the oil level in the diesel engine

• fill when necessary

8.1.2 Check coolant level

• fill when necessary


40

8.1.3 Check the engine air intake filter. • Clean or replace cartridge. Remove coarse particles daily at X

X 8.1.4 Check oil level in hydraulic oil tank.

• Use only hand pump to add hydraulic oil when required

Temperature and Level gauge Hand Pump for filling 8.1.5 Check fuel level.

• Top up before beginning of each shift.

Filler Cap Level Indicator for Fuel Tank.


41

8.1.6 Activate Battery Disconnect switch Q1. Press in and turn in clockwise direction.

Q1 8.1.7 Starting instructions vary between the different engines. See 2. Engine Control Panel Starting

Instructions, which can be found in Manual Section II – Diesel Power Unit.


42

8.2 Engine Start 8.2.1. After starting the engine, check that none of the indicator lamps is lit when the engine is running.

If any lamp remains on, switch off the engine, investigate and remedy 8.2.2 Check the oil temperature on the combined temperature and level indicator mounted on the oil

tank. If the temperature is below +20°C, let the engine run a few minutes until this value is reached before activating any control levers.

8.2.3 Check that the tank pressure is 0.55 bar (8 psi) to prevent pump cavitation at high altitude.

Hydraulic pumps will cavitate at high altitude if boost pressure fails.

8.3 Display Parameters

When starting up in cold weather, (below + 5°C ), run engine at 1000 rpm until the engine temperature is about +10°C.

8.3 Engine Shut-Down Allow the engine to idle for a few minutes before switching it off. This particularly applies when the rig has been operating for lengthy periods.

The diesel engine should only be shut down directly from its operating rpm in the case of emergency.

9 Drill Set-up

43

9 Drill Set-Up Always follow the Safety Instructions included in Section 2 and specifically those in section 2.3 for Moving The Drill and section 2.4 for Setting Up The Drill

It is the responsibility of the owners, operators or drivers, to ensure that this vehicle meets all and any highway regulations for road passage used by this vehicle. Liability as a result of failure to comply with road/transport regulations is the responsibility of the Owner and not Atlas Copco or its employees.

9.1 Start-Up Before engine start, ensure that the checks to be done each shift in Table 11.1 – CS3001 Maintenance Schedule, have been completed and that all controls are in the neutral position. With all checks made and systems warmed up, move throttle to high engine speed to begin operation. The engine and all systems are designed to operate at 2100 rpm. Check Hydraulic tank pressure. Pressure should be 0.55 bar (8 psi).

Do not operate this drill if this pressure is below 0.3 bar (4 psi).

9 Drill Set-up

44

9.2 Secondary Controls The secondary controls operate the four jacks, mast raise, mast slide and console retraction. The selector valve at the left side of the secondary control console directs hydraulic oil to either the secondary controls or the main control console. This feature prevents accidental movement of the secondary controls when operating the main control console. Establish and use a standard means of communication between all drill personnel. Remain in eye contact with each other where possible. The CS3001 drill is provided with an audible alarm (beeper similar to a truck backup warning device) that is activated when secondary controls are operated. Stand clear of jacks, mast and main console when the audible alarm sounds when operating the secondary controls. Selector Valve A/C # 3760009862

9 Drill Set-Up

45

9.3 Levelling the Drill

Ensure that drill is levelled on stable ground and pins are in place. Follow guidelines in section 9.6.1 & 9.6.2 – Precautions Required for Ground Conditions

Level the drill using the 4 levelling jacks located at each corner of the machine. Controls for these jacks are located in the secondary control panel, at the left rear corner of the drill deck. Pin all 4 legs with the safety pins provided - safety pin A/C # 3760010587

Check hole alignment visually only. Do not check for hole alignment using a finger (fingers have been lost doing this!).

Inspect footings every shift. Watch for changing conditions due to weather / environment.

9 Drill Set-Up

46

9.4 Operator’s Platform Attach operator platform with four ½”-13 NC x 5” long grade 8 bolts and nuts. Torque to 107 ft/lbs. (145Nm). Platform can be adjusted up or down to suit drillers needs.

9.5 Mast Slide Slide mast down using the mast slide lever located in the secondary control panel section 9.2. When mast is in desired position, pin mast to mast saddle with two pins – A/C # 3760010588. Mast must always rest on the ground, using blocking if required. (Picture shown has 2 bolts to secure mast to saddle for shipping reasons. Pins are shipped with drill for customer.)

Do not operate the drill without the mast lock pins in place

9 Drill Set-Up

47

9.6 Ground Support & Wind Conditions Stability Precautions The CS3001 with the 20 foot pull mast in the raised position is stable under most operating and environmental conditions. This section describes some environmental and abnormal operating conditions which can cause sudden motion or upset of the drill and what the operator can do to safeguard against this and reduce the risk of personal injury or property damage. The environmental conditions considered are ground conditions and wind. Earthquakes and hurricanes can also cause sudden motion or upset of the drill but these are not considered here. 9.6.1 Precautions Required For Ground Conditions – Jacks Before setting up the drill, check the ground conditions. If the ground is soft enough, it can yield under the jack and cause misalignment of the drill or in extreme cases tilting and upset of the drill. Also the ground should not be sloped more than 1 in 10 in any direction. Where the ground is not hard enough to support the standard jack foot, jack pads, shown in Fig 9.1, or a stronger support such as a timber or concrete pad must be used. The fabricated jack pads in Fig 9.1 are available from Atlas Coco as part 3760012873. Also fabrication drawings for this part are available upon request. Figure 9.1 Jack Pad 3760012873 As a general guide, the cut-off ground soil strength between using the standard jacks and 0.5 m (2 ft) diameter jacks pads is a sub grade modulus reaction of 80,000 kN/m3, and the cut-off soil strength between the jack pads and a timber/concrete platform is 48,000 kN/m3. The soil bearing ratings shown here are based on a standard 76 cm (30 in) disc test. A civil engineer or geologist can do a soil test to obtain the ground rating. Suitable soils are typically as follows: Standard jacks: hard, rocky ground, gravel, gravel clay, well graded sand Jacks with 0.5 m (2 ft) pads: uniformly or poorly graded sand, sandy clay Concrete/timber platforms: compressible silts, clays and organics If expert advice is not available, a simple test of the soil strength can be done with a 13 cm (5 in) diameter, 5 cm (2 in) thick test disc:

• with a truck mounted drill, place the test disc under the front or rear jacks • with drills not mounted on trucks, raise the mast to the vertical position and place the test discs

under the rear jacks.

9 Drill Set-Up

48

Check after 6 hours:

• if there is no significant sinking of the test disc, standard jack pads should be sufficient • if disc has sunk 1.3 cm (½ in) or less, the use of jack pads is recommended • if the disc has sunk more than 1.3 cm (½ in), a wooden or concrete platform is required.

The mast should always be lowered so that it is supported on the ground, using blocking if required. This will prevent the deck from lifting at the front during angle drilling if the operator pulls with both the winch and drillhead. This is an abnormal operating condition, but could be done by an operator trying to free a stuck drill rod. The closer the drilling angle is to 45 degrees, the more important a solid support of the end of the mast becomes. The operator must also be aware that ground conditions can change in the case of prolonged rainfall or improper drainage of drilling fluid return. Support of the jacks and the mast base should be checked each shift. 9.6.2 Precautions Required For Ground Conditions – Mast Support When setting up the drill, the dumped mast must always be supported on the ground by setting on a firm support and blocking as required. If the ground becomes soft enough from rain or drilling fluids to yield under the dumped mast so the mast is no longer fully supported on the ground, shear forces can be generated in the bolted connection between the deck and the jack leg. If pulling with maximum forces (drillhead and main winch) on drilling angles between 20 and 45 degrees off vertical, and under conditions where the ground can yield under the mast base, then two optional diagonal braces (2 x kit part # 3760012851) should be installed between the jack and the deck This will prevent excessive shear forces in the bolted connection and possible mechanical damage. Fig 9.2 shows the diagonal brace installed. For a truck mounted drill, the outer rear tires must be removed to install the diagonal brace. Fig. 9.2 Diagonal Brace Kit Installed on Truck Mounted Drill

Diagonal Jack Braces may be required if can lose firm ground support under the mast base while angle drilling – See sect. 9.6.2

9 Drill Set-Up

49

9.6.3 Precautions Required For Windy Conditions Wind can exert very high forces on the drill, even upsetting the drill if the wind velocities are high enough. The following guidelines should be followed in regards to wind conditions: -The maximum wind speed for safe operation is 20 m/sec (45 mph). Do not operate the drill if wind speed exceeds 20 m/sec (This is a requirement of EN 791, the European Safety Standard for Drilling Equipment). -If there is a possibility of wind speeds greater 36 m/sec (80 mph), the mast should be lowered.

9 Drill Set-Up

50

10 Drilling

51

10 Drilling Always follow the Safety Instructions included in Section 2 and specifically those in section 2.5 for Drilling To achieve the best results with regard to:

• high penetration • optimal core recovery • less deviation • low drilling costs,

It is of primary importance that drill rods, core barrels, reaming shells and coring bits are of the right type and quality, matched to the drill and to the prevailing rock conditions. Core barrels should have the right type of stabilization. Based on the core drill’s speed of rotation and chuck diameter, the CHRISTENSEN CS3001 is best suited to drill holes in diameter N to P (76 mm-123 mm).

Familiarize yourself with the location and operating principals of all emergency stops. Assign responsibilities for operation of the E-stops to the driller and helper as applicable and complete training on usage.

Always protect your hearing with both ear plugs and ear muffs with a total rating of 15 dBA when working on this drill.

Report excessive vibration to your manager or foreman immediately when it occurs.

10 Drilling

52

10.1 Before Drilling Starts Make sure that the supply of water is adequate. Ensure that the suction hose to the mud/water pump in good condition, strainer clean and not clogged.

10.2 Start the Power Unit

a. Activate master disconnect switch (Q1) in Fig 10.1

b. Start the engine as described in Section II of Drill Manual - Diesel Engine Unit

10.3 Start the Mud/Water Pump 10.3.1 Water flow control knob. Controls oil flow to mud/water pump motor and therefore water flow. CCW rotation increases pump speed, CW rotation decreases pump speed (Fig 10.2, pos 2.) 10.3.2 Hi/Lo mud/water pump control knob. Controls speed of mud/water pump motor between Lo speed position (used for drilling with lower flow, higher pressure) and Hi speed position (used for washing the hole with higher flow, lower pressure). (Fig. 10.3, pos 1) Turn knob cw for Hi speed position. Turn knob ccw for Lo speed.

Q1

S1

Fig. 10.1 Q1 Master Disconnect switch

Keep all guards in place and in good working condition.

2

• •

Fig. 10.2 Start Mud/Water Pump

1

Fig. 10.3 Select Hi or Lo Mud/Water Pump

10 Drilling

10 Drilling

53

10.4 Adjust the Flow of Mud/Water

a. Set the Hi/Lo knob in the Lo speed position for drilling

b. Start the mud/water pump with the control knob (Fig 10.4, pos 1) at the front on the panel.

c. Read the water flow rate on the flow meter (Fig 10.4, pos 2) on the control panel.

d. Read the water pressure on the gauge (Fig 10.4 pos 3) in the control panel.

10.5 Start Rotation Before starting rotation, select gear on the rotation gear box that gives you the right rpm range for the ITH equipment.

a. Position the drill string with the core barrel and the drill bit about 50 cm (20 in) above the bottom of the drill hole.

b. Open the foot clamp c. Start the drill rotation with rotation lever. d. Adjust the rotation speed to the desired

RPM on the display.(Fig 10.5, pos 1)

The rotation speed must be adjusted lower as the hole deepens and the drilling torque increases so the maximum rotation pressure remains at 297 bars (4300 psi). (Fig 10.5, pos 2)

3 2

1

Fig 10.4 Adjusting Mud/Water Flow

2 1

Fig 10.5 Start Rotation

10 Drilling

54

10.6 Start Drill Feed

a. Before the drilling operation can be started, the rod weight must be compensated for so the actual bit force can be read.

b. Adjust rpm and mud/water flow, with the fine feed directional valve (Fig 10.6, pos 4) in the neutral position. The pulldown pressure can be read on the gauge (Fig 10.6, pos 31) and should be zero. The pulldown force can be read on the calibrated decal located around the gauge.

c. Turn the feed rate valve knob (Fig 10.6, pos 3) clockwise (zero feed rate position). The holdback pressure can be read on the gauge (Fig 10.6, pos 32).

d. Adjust the calibrated ring for reading the bit force (located around the holdback gauge) to zero at the point of the holdback gauge needle.

e. When the rod weight has been balanced, the drill feed can be activated with lever (Fig 10.6, pos 4) without any danger that the drill string will plunge to the bottom of the drill hole and damage the drill bit.

f. Increase the fine feed rate knob slowly ccw until the drill bit reaches the bottom of the hole and the bit force reaches the desired value for the chosen drill bit and formation. The pulldown pressure may have to be increased, depending on the current rod string weight.

g. Do not apply more bit weight than is recommended for the drill bit.

h. Continue drilling to the end of the feed stroke, fill the inner tube, or until you get core blockage.

10.7 Stop Drilling

a. Stop the drill feed by moving the fine feed lever (Fig 10.6, pos 5) to the neutral position.

b. Stop the rotation by moving the drill

rotation lever (Fig.10.6, pos 11) to neutral

c. It is recommended to flush the drill hole

for some minutes after stopping drilling to avoid problems with cuttings and sludge especially at the end of the work shift.

10 Drilling

55

Figure 10.6 Main Console Controls

10 Drilling

56

10.8 Controlled Wireline Lowering

a. To spool out rope from the wireline drum, push the lever slowly forward (away from you). The drum will start to rotate.

1b. To increase the speed, push the lever

further forward.

c. Always stop the winch smoothly. If the lever is dropped, the spring force will move it back to neutral.

10.9 Controlled Wireline Winching

a. To spool in rope onto the wireline drum, pull the lever slowly backwards (towards you). The drum will start to rotate.

b. To increase the speed, pull the lever

further backward.

c. Always stop the winch smoothly. If the winch comes to a sudden stop it can cause a jump. This in turn can cause the core lifter to loosen its grip on the core and lose the core.

d. When the lever is dropped, the spring

force will move it back to neutral, where it will stop automatically.

10.10 Thread Compensation

a. Thread compensation balances the weight of the rotation unit and drill rod being unscrewed and prevents the weight of these components from loading the threads when the joint is being unscrewed. The amount of thread compensation should be adjusted when starting with a new drill rod size or a large change in drilling angle.

b. When making the joint, the feed cylinder

is disengaged through the slow feed lines. It is recommended that the helper

turns the rod in at least one full turn before the rest of the joint is made with the rotation unit.

c. Turn the thread compensation

adjustment screw (Fig. 10.7, pos 1) cw to increase the thread compensation force or ccw to decrease the thread compensation force. Tighten the lock screw after making the adjustment.

Fig. 10.7 Adjusting Thread Compensation

Always make sure the thread compensation has been correctly adjusted and set before rod breaking starts. If this drillhead weight compensation is set too low, the threads will wear prematurely and leak. When rod threads leak, it is difficult to judge how much flushing water is reaching the drill bit. It is also necessary to occasionally check the condition and diameter of the rods being used. Worn rods can slip in the jaws.

10 Drilling

57

10.11 Adding a Drill Rod

Note: If the drill is equipped with the optional Spin-Out Tool, see section 17.1 for instructions on how to use this tool.

a. Move the thread compensation control

(Fig 10.6, pos 18) into “joint making” position. Rod ends can screw together without damage to the threads (feed cylinder is disengaged through the slow feed lines).

b. Ensure the preset makeup torque

pressure is set to the desired value for the drill rod being used (select pressure from Tables 10.1 & 10.2). Move the make/drill pressure control (Fig. 10.6, pos 21) to “joint making” position.

c. Screw out the rotation motor

displacement control (Fig.10.6, pos 28) so motor is at max displacement.

d. When adding a drill rod, ensure that the

threads are properly engaged, by spinning the rod in one full turn by hand, before making the remainder of the joint with the machine.

e. To make the joint, close the chuck and

start the rotation head to rotate clockwise.

10.12 Removing a Drill Rod

a. Move the thread compensation control (Fig 10.6, pos 18) into “joint breaking” position. Rod ends can screw apart without damage to the threads (drillhead weight is compensated for)

b. Move the make/drill pressure control

(Fig. 10.6, pos 21) to “drill” position. Screw out rotation motor displacement control (Fig.10.6, pos 28) so motor is at max displacement. Shift the transmission to a suitable gear to break the joint.

c. To break the joint with the rod holder

closed, start the rotation unit to rotate ccw.

d. Do not unscrew the joint fully. Leave at

least one turn of the thread engaged. When the rod is lifted out, the last thread is screwed out by hand.

Use caution when making or breaking rod joints and handling the rods.

10 Drilling

58

10.13 Water Pressure Dump Valve Dump valve (Fig. 10.6, pos 13) relieves the water pressure in the drill string. Push the lever down to open the valve.

10.14 Operating Main Winch (See section 6.6 for a description of the main winch features)

a. To spool in rope onto the main winch drum, pull the lever slowly backwards (towards you). The drum will start to rotate.

b. To increase the speed, pull the lever

fully backward (main valve passes max flow). If winching pressure is less than 297 bar (4300 psi), increase winch speed by decreasing winch motor displacement by turning in winch speed control (Fig.10.6, pos 14). Periodically adjust this control to maintain winching pressure at 297 bar (4300 psi).

c. Always start and stop the winch

smoothly.

d. Always leave at least 3 wraps on the winch drum and keep the rope in a single layer. The audible alarm will sound if there is less than 3 wraps on the drum or the rope climbs on a second layer.

e. Use a hoisting plug that is heavy

enough to pull the rope down the rod slide when lowering

Use the main winch for raising, lowering and handling drill rods only. Do not use for general service or pulling off line except when handling drill rods.

The block limit switch is a safety device to prevent the winching plug from being pulled into the crown block. Do not use it to stop upward movement of the winching plug

Monitor the condition of the main winch rope. At the first sign of wear, such as broken strands, replace the winch rope.

10 Drilling

59

10.15 Rod Handling There are 3 ways of handling rods when tripping rods into and out of the drill hole:

i. Using the drillhead to break/make the rod joint

ii. Using the optional Spin-Out Tool to break/make the rod joint

iii. Using the a pipe wrench above the drillhead to break the rod joint (This procedure is not recommended and is not permitted in some jurisdictions)

10.15.1 Rod Handling Using Drillhead – Tripping Out

Drillhead is in first gear and thread compensation control (Fig. 10.6 pos 18) is in thread compensation up position.

a. Attach main winch hoisting plug and plug extension to rod string (rod joint is located

between drillhead and foot clamp). Remove any slack in the main winch rope until slack is removed and rope is slightly tensioned.

b. Open foot clamp and raise drill string until rod joint to be broken is located between chuck

and rod clamp.

c. Close foot clamp and then chuck

d. Break rod joint using drillhead (drillhead is in first gear and thread compensation is engaged)

e. When joint has separated, take up the rope slack, lift drill rod through drillhead and run

out to horizontal position or stack in optional rod rack.

f. Move drillhead back to starting position and lower/guide hoisting plug extension through chuck and repeat.

10.15.2 Rod Handling Using Drillhead – Tripping In

Make/drill Control (Fig 10.6 pos 21) is in make setting, make up torque is adjusted to suit drill rod and transmission gear (see Table 10.1), thread compensation control (Fig. 10.6, pos 18) is in float position.

a. Locate chuck in lowest position and rod joint above chuck

b. Lift rod into place with hoisting plug, connect joint and hand tighten with pipe wrench. Use the drill rod alignment device to align the rods and prevent cross threading when starting the joint

c. Lower rod joint between chuck and clamp, close chuck and clamp

d. Pre-torque rod joint using drillhead (ref Table 10.1). Note that rotation motor

displacement control (Fig. 10.6, pos 28) must be turned fully ccw

e. Open chuck, tension rope, open foot clamp and lower rod(s), leaving next rod joint above the chuck.

10 Drilling

60

f. Close foot clamp and repeat

Rod size Gear Gear

Ratio BT NT HT PT

Recommended Make Up Torque

1,016 Nm 750 ft lbf

1,360 Nm 1,000 ft lbf

1,490 Nm 1,100 ft lbf

2,030 Nm 1,500 ft lbf

1 6.63 54 bar 780 psi

72 bar 1,040 psi

79 bar 1,150 psi

108 bar 1,560 psi

2 3.17 113 bar 1,640 psi

150 bar 2,180 psi

165 bar 2,400 psi

226 bar 3,270 psi

3 1.72 208 bar 3,010 psi

Recommended

Make UP Pressure In Various Gears

4 1 Table 10.1 CS3001 Recommended Make-Up Torque And Corresponding Rotation Pressure Based

On: -Rotation motor set at max displacement of 80 cc – rotation speed control turned fully counter clockwise -Total mechanical efficiency of 90% for drillhead -No allowance for inertial effects

Spindle Torque – Ft LBF 4th gear 3rdh gear 2nd gear 1st gear

Rotation Pressure

PSI Min Disp Max Displ Min Disp Max Displ Min Disp Max Displ Min Disp Max Displ

4300 482 622 828 1,069 1,527 1,970 3,193 4,1214000 448 578 995 770 1,420 1,833 2,970 3,8343800 426 549 732 945 1,349 1,741 2,821 3,6423600 403 520 693 895 1,278 1,650 2,673 3,4503400 381 491 655 845 1,207 1,558 2,524 3,2583200 358 463 616 796 1,136 1,466 2,376 3,0673000 336 434 578 746 1,065 1,375 2,227 2,8752800 314 405 539 696 994 1,283 2,079 2,6832600 291 376 501 646 923 1,191 1,930 2,4922400 269 347 462 597 852 1,100 1,782 2,3002200 246 318 424 547 781 1,008 1,633 2,1082000 224 289 385 497 710 916 1,485 1,9171800 202 260 347 448 639 825 1,336 1,7251600 179 231 308 398 568 733 1,188 1,5331400 157 202 270 348 497 642 1,039 1,3421200 134 173 231 298 426 550 891 1,1501000 112 145 193 249 355 458 742 958

800 90 116 154 199 284 367 594 767600 67 87 116 149 213 275 445 575400 45 58 77 99 142 183 297 383

Table 10.2 CS3001 Spindle Torque (ft lbf) For Range Of Rotation Pressures (psi) Based On: -Rotation motor displacement at:

-minimum at 62 cc, displacement control screwed in

10 Drilling

61

-maximum at 80 cc, displacement control screwed out -Total mechanical efficiency of 90% for drillhead -No allowance for inertial effects

10.15.3 Rod Handling Using Optional Spin-Out Tool

See Section 17.1 for instructions in using this tool. The drillhead is moved aside and not used when tripping drill rods with this tool.

10.16 Drill Rod Break-In Procedure It is recommended that rod joints of exploration drilling rods be pre-torque to the recommended values. Wireline drill rods are typically manufactured using conical threads, and in such a manner to allow for a stand-off between box and pin when hand tightened. Because these threads are intended to be in a state of tension while in use, closing the standoff and further pre-loading of the joint through adequate mechanical pre-torque accomplishes this. A properly made up and lubricated tool joint reduces the likelihood of galling and wear through movement between mating surfaces. A properly made-up joint also reduces the likelihood of service failure from fatigue due to cyclic bending, (tension/compression/tension). ACEP Platinum Series wireline drill rods are surface treated on the pin thread to provide a low friction surface that absorbs lubricant and promotes a smooth break in and conditioning of the new rod joint, particularly during the critical first make-ups and break-outs. Proper break-in practices promote long service life and joint integrity. Particular attention to proper joint make-up should be exercised where one or more conditions could contribute to a joint running loose. Hole depth, deviation, dry holes, spin-outs from rapid deceleration, and vibration as examples. The recommended pre-torque values for Platinum wireline drill rods are given in Table 10.1. For more information, please contact your nearest ACEP representative.

Pipe wrenches and breakout tools can cause serious injuries. Take extreme precautions.

10 Drilling

62

11 Maintenance and Servicing

63

11 Maintenance And Servicing

11.1 General Always follow the Safety Instructions included in Section 2 and specifically those in section 2.7 for Maintenance and Servicing The performance and reliability of the Christensen CS3001 is largely dependent on the amount of care and attention shown to it. Regular checks and inspection of wear prone components prevent breakdowns and costly downtime. Dirt is the primary cause for most malfunctions in a hydraulic system. Therefore:

• Always try and keep the drill clean and free from dirt and other pollutants. It is much easier to detect faults or oil leakage on clean equipment

• Never leave any part of the hydraulic system open or exposed to external influence • Always attach tight fitting plugs to disconnected hose ends • Always refill oil into the hydraulic system by using the fill pump • Never use Teflon tape or similar material for sealing threads – fragments can dislodge , enter the

system and damage sensitive components or plug orifices

11.2 Periodic Maintenance and Service Schedule The maintenance and service schedule specifies periodic lubrication and servicing instructions following a certain number of operating hours. Use this schedule to get the most reliable service from your equipment.

Table 11.1 CS3001 Maintenance Schedule

Service Interval In Hours Of Operation Ref #

Check & Service Points 8 250 500 1000 2000

Notes

11.4.1 Engine oil level Check Change oil 11.4.2 Engine oil filter Replace

filter

11.4.3 Primary & Secondary Fuel Filters

Replace filters (2)

11.4.4,& 11.4.2

Engine Radiator Check level Clean fins Replace coolant filter & check cooling system

Drain cooling system, flush, replace coolant

11.4.5 Engine air intake filter

Remove coarse particles

Check filters

Change filters as required

Change filters more often in dusty conditions

11.4.6 RACOR engine fuel filter/water separator

Drain water at separator

Replace Filter Element

11.4.7 Hydraulic tank level and oil condition

Check level, drain water as required

Change oil or a minimum of once per year

Water may have to be drained daily if humidity high & tank


64

cools between shifts Hydraulic oil

cooler Clean fins

Table 11.1 CS3001 Maintenance Schedule (cont’d)

Service Interval In Hours Of Operation

Ref

Check & Service Points 8 250 500 1000 2000

Notes

11.4.9 11.4.10

High pressure filters (3) :

-main pump -auxiliary pump

-secondary pump

Replace

filter elements

Or earlier if pop-up indicator remains

up with oil at operating temp.

11.4.11 Hydraulic tank return filter

Replace filter

element

Or earlier if pop-up indicator remains

up with oil at operating temp.

11.4.12 Case drain filters (2) Replace

filters

11.4.8, 11.4.13

Compressed air tank & charge air

filter

Drain water at air tank Replace

filter

11.4.8 Hydraulic tank breathers (2) Replace

breathers Every 500 hours in dusty conditions

Electric oil transfer pump (if equipped) Replace filter

11.4.15 Drillhead oil level and filter Check level

Change oil and filter,

clean strainer

Replace oil & filter, clean strainer of

new drill or rebuilt drillhead at 100

Hrs.

11.4.15 Rotation unit chain tension Check

tension Check tension of new drill or rebuilt

drillhead at 100 Hrs

11.4.16 Hydraulic chuck Grease 3 fittings

11.4.17 Mud/water pump Check oil level

Change oil & clean

magnetic plug

Replace oil & clean magnetic plug after

first 100 Hrs for new or rebuilt pump

11.4.18 Main winch Check oil level Change

oil Change oil after

100 hrs for new or rebuilt hoist

11.4.19 Wireline hoist Grease

levelwind screw

Grease bearings, oil

levelwind chain

11.4..20 Foot clamp Grease hinge pins

11.4.20 Carriage rollers Grease 8 rollers

Stop greasing when grease

escapes around roller seal

11.4.20 Mast pivot pins (2), mast raise cylinder

pins (4) Grease

Chuck jaws

Inspect inserts and

clean if necessary

Main hoist rope Lubricate main cable

Cable should be lubricated at first

use of a new cable


65

11.6 Hydraulic hose and

elastomeric seal replacement

See section 11.6

for recommendations

11.3 Lubricant Recommendations

Table 11.2 Recommended Lubricants Lubricant Service Point Recommendation Hydraulic oil 11.4.7 Use mineral-based hydraulic oil with good anti-wear, rust

(oxidation) and foam inhibiting properties, as well as effective air and water separation abilities. The viscosity grade should correspond to the ambient temperature and ISO 3448, as follows: Ambient temp. °C (°F) Viscosity grade Viscosity Index +25 to +40 C (77 to 104 F) ISO VG 68 Min. 150 0 to +25 C (32 to 77 F) ISO VG 46 Min. 150 -30 to 0 C (-22 to +32 F) ISO VG 32 Min. 150 Examples of oil grades in the temperature range 0 to + 25°C: Shell Tellus T46 BP Bartran HV 46 Castrol Hyspin T 46 Mobil DTE 15M Texaco Rando HDZ 46 Exxon Univis HP 46 For use of flame proof or biodegradable hydraulic oil, please contact nearest Atlas Copco representative for information

Drillhead transmission & gearcase oil

11.4.15 Summer operation: 80w90 weight API Classification GL5 Winter operation: hydraulic oil ISO VG 46

Transmission oil (mud/water pump & main hoist

11.4.17, 11.4.18

80W90 weight API Classification GL5

Grease 11.4.20 Universal grease NLG12..........Operating temperature °C (°F) -Lithium/molybdenum ..................................Max. 100 C (212 F) additive -Synthetic sodium or calcium grease… Max. 140 C (284 F) Example of grease grades: Shell Retinax AM Esso MP Grease BP Energrease LS-EP 2

Engine oil and Coolant

11.4.1, 11.4.4

Use engine oil and coolant according to diesel engine Instruction Manual


66

Main Hoist Rope

Brilube 30 or Brilube 35 (light oils with anticorrosion additives that can be applied by spray or brush. Will penetrate cable and not build up on surface to inhibit inspection)

11.4 Service Point Detailed Instructions These instructions provide Atlas Copco and manufacturer’s part numbers for filters/filter elements, pictures and other information of interest. 11.4.1 Engine Oil Level - See section 4.1 in Diesel Power Unit (Drill Manual Section II) 11.4.2 Engine Oil And Coolant Filters - See section 4.2 in Diesel Power Unit (Drill Manual Section II) 11.4.3 Fuel Filters - See section 4.3 in Diesel Power Unit (Drill Manual Section II) 11.4.4 Engine Radiator - See section 4.4 in Diesel Power Unit (Drill Manual Section II) 11.4.5 Engine Air Filter - See section 4.5 in Diesel Power Unit (Drill Manual Section II)

11.4.6 Engine Fuel Filter/Water Separator In addition to the fuel filters supplied by the engine manufacturer, the drill is equipped with a RACOR model 1000FH fuel filter system. See the RACOR Fuel Filter owner’s manual in the parts manual for information regarding this system. Replacement Element – 3760008961


67

11.4.7 Hydraulic Tank Oil Level, Draining Water and Cleaning

• Maintain the hydraulic oil level by inspecting the sight glass. The recommended operating level of hydraulic fluid is 2/3rds of the way up the sight glass. The tank should be topped up if the level drops to the bottom of the sight glass.

• Hydraulic tank capacity 500 liters (132 U.S. gallons) • Drain water from tank as required. Water may have to be drained daily in humid conditions

and if tank cools down between shifts • When cleaning out the tank, it is important to remove and clean the permanent magnets

located in the tanks

11.4.8 Hydraulic Tank Breathers and Charge Air filter

• Replacement charge air filter element 3760007158 • Replacement breathers 3760009018 • Use only A/C approved breathers since they must meet the following requirements: filter rating of

10 micron and relief pressure setting of 10 psig to limit max tank pressure to 10 psig • Schedule calls for replacement every 500 hours but replace more frequently in dusty conditions

Breathers Charge Air Filter


68

11.4.9 High Pressure Filter (Main Pump)

• Replacement element – 3760004888, HYDAC model # 5.03.27D20BN HYDAC material # 02065006 (20 micron absolute, 685 mm (27 inch) long version, collapse pressure of 17 bar (250 psi) differential pressure

• A pop-up indicator with automatic reset (located at the base of the filter) indicates when the pressure drop exceeds 1.9 bar (27 psi). The bypass valve is set at 6 bar (87 psi) differential pressure

• Schedule calls for replacement every 1,000 hours but replace earlier if pop-up indicator stays up when hydraulic oil is at operating temperature

Do not substitute filter element. Warranty void if specified filter element is not used.

11.4.10 High Pressure Filters (Auxiliary & Secondary Pumps)

• Replacement element – 3760004890 , HYDAC model # 0240D020BN3HC (20 micron absolute, size 240, collapse pressure of 17 bar (250 psi) differential pressure

• A pop-up indicator with automatic reset (located in the top of the filter) indicates when the pressure drop exceeds 1.9 bar (27 psi). The bypass valve is set at 6 bar (87 psi) differential pressure

• Schedule calls for replacement every 1,000 hours but replace earlier when pop-up indicator stays up when hydraulic oil is at operating temperature

Do not substitute filters element. Warranty void if specified filter element is not used.


69

11.4.11 Hydraulic Tank Main Return Filter

• Replacement element – 3760004894, HYDAC 0660R010BN3HC (size 660, 10 micron absolute)

• A pop-up indicator with automatic reset (located at the top of the filter) indicates when the pressure drop exceeds 1.9 bar (27 psi). The bypass valve is set at 6 bar (87 psi) differential pressure

• Schedule calls for replacement every 1,000 hours but replace earlier if pop-up indicator stays up when hydraulic oil is at operating temperature


11.4.12 Case Drain Filters (2)

• The case drain filters are located on opposite sides of the hydraulic tank • Replacement element (same for both filters) - 3760005230, MP Filtri Inc. # CSG100A25A

(25 Micron), or Fleetguard # HF6725 • The bypass valve is set at 0.2 bar (3 psi) differential pressure to limit case pressure in the

auxiliary and secondary pumps



70

11.4.13 Compressed Air Tank System (Drills with Cummins Diesel Engines)

• The air tank is fed air from the engine compressor to a pressure of approx. 6.2 bar (90 psi). It is equipped with an auxiliary Quick Disconnect for a customer supplied air hose. It is also equipped with a drain plug.

• The air is used to charge the hydraulic tank to 0.55 bar (8 psi) through a pressure reducing valve and charge air filter (filter also referenced in section 11.4.8)

• Refer to Parts Manual for complete parts, fittings & hose information. • Water should be drained from the tank daily

Note: Drills equipped with John Deere Engines use a small compressor (not shown) and the Diesel engine turbo to pressurize the hydraulic tank (not shown)

11.4.14 Hydraulic Oil Fill Pump

• Hydraulic oil is added to the hydraulic system by use of the fill pump located on the side of the drill. The hydraulic oil is filtered through the main return filter before being added to the tank.

• Replacement pump - 3760003200 • Manufacturer – Tuthill Transfer Systems # Fill Rite FR-110

Do not add hydraulic oil to the hydraulic system using any other method. Hydraulic system contamination and hydraulic system damage may result.


71

11.4.15 Drill Head Oil Level and Filter

• Replacement oil filter element 3760007158, LHA # SPE-15-10 or Fleetguard # HF6510 • When the drill head is rotating, oil flow must be present in the clear line on the side of the

drill head. Without this flow, damage will result. • The transmission and the drill head chain case use the same oil. The oil level for both

components is checked on the chain case and is maintained at the level of the lower plug. (See arrow below)

• Check level when oil is warm or has had time to drain down if checked cold. The method of checking the oil level is the same for drilling angles 45 to 90 degrees.

• See service schedule (Table 11.1) for change intervals and lubricant recommendations section 11.3, for oil recommendations. Change oil more frequently if visibly dirty or discolored, also change at 100 hours after putting a new or rebuilt drillhead into operation.

Remove plug to check chain tension 11.4.16 Hydraulic Chuck Grease Fittings

Oil Filter

Oil Pump Strainer

Check vertical level here, plug on side of transfer case

• On the drill head there are 3 grease fittings, two on the chuck bonnet, and one on the bearing

retainer. • Grease these fittings per schedule in Table 11.1using good quality multi purpose E.P. grease.

I Clean grease fittings before adding grease to prevent contamination

Grease here plus one on opposite side

Grease here


72

11.4.17 Mud/Water Pump

• Check the mud/water pump oil level daily. • For maintenance, start-up and shut-down procedures of the pump, see the FMC

Operator’s Manual located in the Service & Repair Section located in Section IV of the Drill Manual

Model Shown FMC W1122 BCD 11.4.18 Main Winch

• Check the main winch oil level daily. • See the Braden Winch insert in the Parts Manual for service information.

Inspect entire winch rope weekly. Do not use rope if it is kinked or has broken strands.

Poor rope condition can lead to instant failure causing death. Do not use drill with damaged rope.

Check level here

Drain oil here


73

11.4.19 Wireline Winch

• Grease level wind screw per schedule in Table 11.1using good quality multipurpose grease • Oil levelwind chain per schedule in Table 11.1 with SAE 30 weight oil.

Levelwind screw

Levelwind chain located under cover

11.4.20 Grease Fittings Follow the schedule in Table 1.1 for greasing these components Foot clamp grease fittings (4 fittings) Grease hose into fitting (Guard shown removed) (2 locations)

Grease crown block here


74

11.4.20 Grease Fittings – Cont’d

Grease fitting inside roller shaft (4 locations)

Lift cylinder clevis pins (4 locations)

Mast pivot pins (2 locations)


75

11.5 Periodic Inspections Periodic inspections are recommended to ensure that the machine is in a safe and serviceable condition. The inspections should check the following:

• emergency devices are functioning • all mechanical guards are in place • condition of the main winch cable • bolts are tight and have not worked loose • pin retainers are in place and secured • no cracks have developed in welds or parent material • there is no oil leakage from tank, fittings, hoses and components • Lifting components (water swivel and hoisting plugs) are in good condition • audible alarm is functioning

Recommended inspection intervals are given in the Table 11.3. Even though the inspection should be general, special attention should be given to the areas detailed in the table.

Use extreme caution when checking hoses for pin hole leaks. Pin holes in high pressure hoses can eject small but powerful and hard-to-see streams of hydraulic fluid that can penetrate under the skin.


76

Table 11.3 Periodic Inspections and Intervals

Inspection Frequency

Inspection Point

Dai

ly

Wee

kly

Mon

thly

Hal

f - y

early

Year

ly

Comments

Emergency Devices & Alarms: -E-stop buttons -Main winch block limit switch -Audible alarm

X X X

-Audible alarm test button is located on console -Check audible alarm sounds when using secondary control panel

Guards X Ensure guards are in place and are functioning

Main winch rope X Replace rope if rope is kinked, has broken strands, or is worn

Crown block sheave for main winch

X Check for wear & surface cracks

Tightness of Bolts: -rope clamp on main winch drum -crown block to mast -jacks to deck -main winch to deck -bolts retaining mast in saddle -carriage rollers (8) -roller mounting plates -hose end anchors

X X X X X X X X

Inspect all bolts for tightness every month but pay special attention to the bolts listed. Re-torque as required

Pin retainers in place: -hoisting plug -waters swivel -hoist block limit switch -mast raise cylinders -mast backstay legs

X X X X X

Ensure pin retainers are in place and secured

Weld and Material Cracks -rod clamp table to mast -saddle weldment -backstay legs -cylinder ends

X X X X

Oil leakage from tank, fittings, hoses and components

X

Hoisting plug, water swivel X Inspect these load carrying items for damage and condition


77

11.6 Hydraulic Hoses & Fittings Inspection Hose and Fitting Maintenance and Replacement Instructions Even with proper selection and installation, hose life may be significantly reduced without a continuing maintenance program. The severity of the application, risk potential from a possible hose failure, and experience with any hose failures in the application or in similar applications should determine the frequency of the inspection and the replacement for the products so that products are replaced before any failure occurs. A maintenance program must be established and followed by the user. Visual Inspection Hose/Fitting: Any of the following conditions require immediate shut down and replacement of the hose assembly: • Fitting slippage on hose, • Damaged, cracked, cut or abraded cover (any reinforcement exposed); • Hard, stiff, heat cracked, or charred hose; • Cracked, damaged, or badly corroded fittings; • Leaks at fitting or in hose; • Kinked, crushed, flattened or twisted hose; and • Blistered, soft, degraded, or loose cover. Visual Inspection Other Items: The following items must be tightened, repaired, corrected or replaced as required: • Leaking connections; • Excess dirt build up; • Worn clamps, guards or shields; and • System fluid level, fluid type, and any air entrapment. Functional Test: Operate the system at maximum operating pressure and visually check for possible malfunctions and leaks. Personnel must avoid potential hazardous areas while testing and using the system. Replacement Intervals: Hose assemblies and elastomeric seals used on hose fittings and adapters will eventually age, harden, wear and deteriorate under thermal cycling and compression set. Hose assemblies and elastomeric seals should be inspected and replaced at specific replacement intervals, based on previous service life, government or industry recommendations, or when failures could result in unacceptable downtime, damage, or injury risk. Hose Inspection and Failure: Hydraulic power is accomplished by utilizing high-pressure fluids to transfer energy and do work. Hoses, fittings, and hose assemblies all contribute to this by transmitting fluids at high pressures. Fluids under pressure can be dangerous and potentially lethal and, therefore, extreme caution must be exercised when working with fluids under pressure and handling the hoses transporting the fluids. From time to time, hose assemblies will fail if they are not replaced at proper time intervals. Usually these failures are the result of some form of misapplication, abuse, wear, or failure to perform proper maintenance. When hoses fail, the high-pressure fluids inside can escape in a stream which may or may not be visible to the user. Under no circumstances should the user attempt to locate the leak by “feeling” with their hands or any other part of their body. High-pressure fluids can and will penetrate the skin and cause severe tissue damage and possibly loss of limb. Even seemingly minor hydraulic fluid injection injuries must be treated immediately by a physician with knowledge of the tissue damaging properties of hydraulic fluid.


78

If a hose failure occurs, immediately shut down the equipment and leave the area until pressure has been completely released from the hose assembly. Simply shutting down the hydraulic pump may or may not eliminate the pressure in the hose assembly. Many times check valves, etc., are employed in a system and can cause pressure to remain in a hose assembly even when pumps or equipment are not operating. Tiny holes in the hose, commonly known as pinholes, can eject small, dangerously powerful but hard to see streams of hydraulic fluid. It may take several minutes or even hours for the pressure to be relieved so that the hose assembly may be examined safely. Once the pressure has been reduced to zero, the hose assembly may be taken off the equipment and examined. It must always be replaced if a failure has occurred. Never attempt to patch or repair a hose assembly that has failed. Never touch or examine a failed hose assembly unless it is obvious that the hose no longer contains fluid under pressure. The high-pressure fluid is extremely dangerous and can cause serious and potentially fatal injury. Elastomeric seals: Elastomeric seals will eventually age, harden, wear and deteriorate under thermal cycling and compression set. Elastomeric seals should be inspected and replaced. Caution: Matches, candles, open flame or other sources of ignition shall not be used for hose inspection. Leak check solutions should be rinsed off after use.

12 Hydraulic Circuit Description

79


12.1 Hydraulic Pumps The system consists of three separate hydraulic circuits. The three pumps (main, secondary, and auxiliary) are driven directly from the power unit flywheel. The three pumps are mounted in tandem and are connected directly to the engine flywheel by a steel adapter and hub. The main and secondary pumps are an axial piston load sense type. The auxiliary is an axial piston pressure compensated type. There are full bore, lockable shut off valves in the suction lines from the hydraulic tank.

30psiMax

20 µ87 psi 20 µ

87 psi 20 µ87 psi

12.1.1 Main Pump (Item 1) The main pump, item 1 is a load sensing pump. It produces 272 lpm (72 gpm) at 2100 rpm and has a compensator setting of 324 bar (4,700 psi). The pressure side of main pump is directed to the pressure compensated main valve which controls 4 functions- main winch, drillhead rotation, wireline hoist and fast travel. Hydraulic pressure from these 4 functions can be observed on the main pump load sense pressure gauge located on the control panel.


80

12.1.2 Auxiliary Pump (Item 2) The auxiliary pump is a pressure compensated pump. It produces 125 lpm (33 gpm) at 2100 rpm and has a compensator setting of 193 bar (2,800 psi). The pressure side of the auxiliary pump is directed to the either the main control console or the secondary control console be means of a selector valve. This prevents the two control panels from being active at the same time. The auxiliary pump connection to the main console powers all controls required for drilling (see section 12.4) as well as the hydraulic driven air/oil cooler and mud pump. The auxiliary pump connection to the secondary console powers all positioning cylinders required for drill set up. 12.1.3 Secondary Pump (Item 3) The standard CS3001 secondary pump is a load sensing pump with a compensator setting of 206 bar (3,000 psi). It produces 87 lpm (23 gpm) at 2,100 rpm. The secondary pump powers only the mud/water pump through a control valve. A two-speed hydraulic motor is used on the water/mud pump.

Note: The manual describes the standard CS3001 secondary pump, standard mud/ water pump (FMCW1122BCD), and the standard control components. If another mud/water pump has been specified by the customer, the secondary hydraulic pump and control components may vary. Details on the non-standard components are available in Addendum Sheets in section 18 and the specific drill schematic in the Parts Manual.

12.2 Filtration The main factor affecting problem free operation and long life of hydraulic system components is the cleanliness of the hydraulic oil. Experience shows that most hydraulic problems are due to hydraulic oil contamination. To eliminate contamination, the CS3001 uses five types of filters to protect the hydraulic system: pressure filters, main return filter, case drain filters, hydraulic tank breathers and charge air filter 12.2.1 Pressure Filters (Items 30, 31A and 31B) The pressure filters are located downstream of each of the three hydraulic pumps. This protects the valves and components that receive oil from the pumps, from contamination caused by failure of the pumps. The pressure filters use a 20 Micron absolute element (ISO level 20/18/15). A pop-up indicator signals a differential pressure of 1.9 bar (27 psi) across the element and has an automatic reset. All three pressure filters use an internal bypass valve cracking pressure of 6 bar (87 psi) differential pressure. 12.2.2 Case Drain Filters (Item 33A and 33B) The case drain filters are located at the hydraulic tank in the case drain return of the hydraulic pumps and motors. This protects the hydraulic tank from contamination in case of hydraulic pump or motor failures which can generate particles in the case drain connections. The case drain filters use a 25 micron absolute element and have low bypass pressures of 0.2 bar (3 psi) to avoid exceeding max differential pressure allowed between suction and case drain for the auxiliary and secondary pumps. 12.2.3 Return Filter (Item 32) All hydraulic oil returns to tank through the main return filter located in the top of the tank. The return filter uses a 10 micron absolute element (ISO 19/17/14). Because this filter retains the smallest particles of any of the hydraulic fluid filters, it collects most of the contamination particles and is designed to have the


81

highest dirt holding capacity. A pop-up indicator signals a differential pressure of 1.9 bar (27 psi) across the element and has an automatic reset. The bypass valve is set at 6 bar (87 psi) differential pressure 12.2.4 Hydraulic Tank Breathers (Item 74A and 74B) The hydraulic tank breathers have a built in 10 micron filters and prevent dust/dirt from entering the hydraulic tank when the tank temperature and pressure decrease after shutdown. The breathers also act as relief valves to limit the hydraulic tank pressure to a maximum of 0.69 bar gauge (10 psi) pressure. 12.2.5 Charge Air filter (Item 79) The charge air filter, with a 10 micron rating, cleans the air coming from the compressor to pressurize the tank to 0.55 bar (8 psi) for high altitude operation.

Do not substitute filter elements. Warranty void if

specified filter element are not used.

Premature and repeated failure of hydraulic components has occurred when customer substituted wrong type of filter elements.


82

12.3 Main Pump Circuit

The pressure output of the main pump passes through a pressure filter to the main valve, item 80. The main valve is pressure compensated, has a built-in relief valve set at 362 bar (5260 psi), and is hydraulic pilot operated. The pilot controllers get the supply pressure from the auxiliary pump. The main valve powers the main winch, drillhead rotation, wireline winch, and drillhead fast travel. Maximum flows and pressures vary for the various functions as shown. 12.3.1 Main Winch (Item 5) Maximum flow to the main winch is 272 lpm (72 gpm), max pressure is 324 bar (4,700 psi) Load lowering is controlled by a load holding valve. The load holding valve is direct mounted on the winch motor to prevent load dropping in case of hose failure. A manual brake control is used to release the winch brake and pilot open the counterbalance valve when drilling, so the winch rope can unspool as the drillhead is feeding down.


83

The main winch motor is a variable displacement bent axis design with motor displacement continuously variable between min and max displacement settings by means of a rotary hydraulic control on the control panel. This allows the operator to increase the main winch speed as the rod load decreases when tripping out. Note that the min and max displacement adjusting screws must be set up on a new motor using the set-up procedure in section 15. Also see Braden service manual in the part manual for installation, maintenance, and service instructions.


84

12.3.2 Rotation Motor (item 4) Maximum flow to the rotation motor is 272 lpm (72 gpm), max pressure is 297 bar (4,300 psi) The rotation motor is a variable displacement bent axis design with motor displacement continuously variable between min and max displacement settings by means of a rotary hydraulic control on the control panel. This allows the operator to change the rotation speed/torque as required. Note that the min and max displacement adjusting screws must be set up on a new motor using the set-up procedure in section 15, to prevent overspeed conditions and damage to the drillhead and rotation winch motor.

12.3.3 Wireline Winch (Item 6) Maximum flow to the wireline winch is 113 lpm (30 gpm), max pressure is 207 bar (3,000 psi). Load lowering is controlled by a counterbalance valve item 102. An optional direct mounted parking brake is automatically released when the hoist is activated in either direction. The parking brake prevents downward creeping of the overshot due to weight and hydraulic motor leakage when the control valve is in the neutral position. Brake release valve item 96 uses pressure from the auxiliary pump which is then reduced to 20.6 bar (300 psi) by pressure reducing valve item 97, to release the brake even when motor port pressures are less than the 20.6 bar (300 psi) brake release pressure.


85

12.3.4 Fast Travel of Feed Cylinder (Item 7) Maximum flow to the feed cylinder is 272 lpm (72 gpm) in the up direction and down direction. Max pressure 193 bar (2,800 psi) in the up direction and 96.5 bar (1400 psi) in the down direction. The cylinder ID is 127 mm (5 in) and the rod diameter is 76.2 mm (3 in). Load lowering is controlled by a counterbalance valve item 84. The counterbalance valve is direct mounted on the feed cylinder to prevent load dropping in case of hose failure. A pilot operated check valve item 85 isolates the fast travel circuit from the slow feed circuit on the rod end of the cylinder


86

3650psi


87

12.4 Auxiliary Pump Circuit The auxiliary pump pressure is connected to the air cooler fan motors and a selector valve item 100 which directs oil from the auxiliary pump to either the secondary control console item 93 or the main control console. This selector valve prevents inadvertent movement of the positioning cylinders when using the main control console for the drilling operation 12.4.1 Positioning Valves (Secondary Control console) When the selector valve directs oil to the secondary control console, the positioning cylinders used for setting up the drill in the drilling position can be activated.

The auxiliary pump compensator setting sets the max circuit pressure at 3000 PSI

1. Control panel slide 2. Mast dump 3. Mast raise (a relief valve limits the pressure in the mast lowering direction) 4. Valve for front right jack 5. Valve for front left jack 6. Valve for rear right jack 7. Valve for rear left jack

3x .062

100

psi80

psi

TP

X X


88

12.4.2 Controls in Main Console and Other Functions Powered By Auxiliary Pump When the auxiliary pump selector valve directs oil to the main control console, the following control valves are supplied with hydraulic oil and can be activated -reference schematic in Fig. 12.1 Functions Powered By Auxiliary Pump. Item 16 Slow feed directional valve Item 28 Pulldown pressure cartridge Item 17 Feed rate valve Item 18A Chuck open/close Item 24A Head opener Item 20 Hi/lo water pump Item 18B Main winch brake release Item 24B Rod kicker Item 19 Foot clamp open/close Item 47 Thread compensation (adjustable setting) Item 23A Main winch motor displacement (speed/torque) control (Not Shown) Item 23B Rotation motor displacement (rpm/torque) control (Not Shown) Item 15 Mud mixer (placed in series with air/oil cooler fan motors 12.4.3 Other functions powered by auxiliary pump Item 63A/B Fans motors on air/oil cooler Item 81 Pilot controllers for main valve Item 96 Wireline hoist brake release Item 50 Optional Spin-Out tool


89

5000M ax PSIM ax PSI

3000

Fig 12.1 Functions Powered By Auxiliary Pump


90

12.5 Secondary Pump Circuit The standard CS3001 secondary pump is a load sensing pump producing 87 lpm (23 gpm) at 2,100 rpm and has a compensator setting of 206 bar (3,000 psi).The secondary pump item 2 powers the mud/water pump only. The standard water/mud is a FMCW1122 BCD powered by a 2 speed motor (Hi/Lo motor) item 8. The hydraulic motor is switched between “Hi” and “Lo” by a control valve item 20 which is powered by the auxiliary pump. “Lo” speed setting is used for drilling (high pressure, lower flow) and “Hi” speed setting is used for hole flushing (max flow). The water/mud pump relief valve must be set at 69 bar (1,000 psi) to prevent water pump overpressure.

Note: This section describes the standard CS3001 secondary pump, standard mud/ water pump (FMCW1122BCD), and control. See Addendum sheet in Section 18 if customer has specified a different mud/water pump requiring a different secondary hydraulic pump and/or control components. Also see drill hydraulic schematic in Parts Manual.

1000 psi

Max PSI2000


91

12.6 Return Oil Circuit and Hydraulic Tank Oil which has been circulated by the hydraulic pumps through the various valves and actuators is returned to the hydraulic oil tank.

On its way back it passes through a thermostatic valve item 60 which directs the oil to the cooler item 62 when it reaches a temperature of 54°C (130°F). This allows the hydraulic oil to reach operating temperature even in cold weather. A spring loaded bypass item 61 limits the pressure drop across the cooler to a maximum of 4.5 bar (65 psi).

The hydraulic oil then passes through the return filter item 32 (see section 12.2.3 for detailed description) mounted in the top of the hydraulic tank

The system includes a hand operated pump item 37 for filling the hydraulic tank. This pump is permanently connected to the system through a check valve item 56. Hydraulic oil introduced by the fill pump travels through the main return filter before reaching the hydraulic tank. This prevents ingress of contamination when adding hydraulic oil to the system. The hydraulic tank size is 500 litres (132 gallons) of oil. It is equipped with a combination sight glass and thermometer (item 77) and a combined temperature and level switch item 78 mounted in the lid. The tank bottom is sloped to bring any water to a drain port. A permanent magnet to trap iron particles is located in the tank and is cleaned at the time the tank is drained and cleaned. The hydraulic tank is pressurized for high altitude operation by an engine mounted compressor. The compressor charges an air tank to 4.1 bar (60 psi) which can be used for air powered tools. Air from the tank passes through a pressure reducing valve set at 0.55 bar (8 psi). The low pressure air then passes through the charge air filter item 79 into the hydraulic tank. Breathers, items 74A and 74B, filter air drawn into the tank when it cools and also protect the tank from overpressure with built-in 0.69 bar (10 psi) relief valves.

25 µ3 psi10 µ

25 psi

25 µ3 psi

6 GPM

65 psi

10psi

10 µ

8 psi

10psi

10 µ

10 µ

TEMP130 °F

1725 MAXRPM

TEMPSETTING176 °F

6000Max PSI

30psiMax

60 psi

125 psi


92

12.7 Hydraulic Oil Cooler

The high cooling capacity air/oil cooler uses 2 fans driven by hydraulic motors items 63A & 63B which are connected in series. Since the pressure drop across both fan motors is only 1,000 psi, the oil exiting from the motors is used to power the hydraulic mud mixer. This reduces the waste heat that would be generated if the return oil from the hydraulic fan motors was returned directly to tank. A flow divider is used to control the mud mixer flow.

13 Electrical Circuit Description

93


13.1 Electrical Fault Panel The electrical fault panel serves the following functions:

• A monitoring system for the hydraulic tank oil temperature and oil level. • A delayed automatic shutdown of the diesel when in a fault condition. • 12 volt power source for the mast lights, console lights, and console accessories.

13.1.1 Normal Operation Sequence

• When battery power is available, the console lights and mast lights will function by means of the corresponding light switches mounted on the operator console. (Note: The engine does not need to be running for these lights to work.)

• To crank and start the engine the following is required: -all E-Stop buttons (3 on the drill) must be in the normal (out) position. -the friction lock rotation control lever must be in the neutral position since it is equipped with a neutral switch.

• To crank and start the engine all 3 E-Stop buttons on the drill must be in the normal (out) position. Also all controls must be in the neutral position.

• When the ignition key switch is activated under normal conditions the Fault Panel indicating lights will be off and the audible alarm will be silent.

13.1.2 Fault Condition Sequence

• Should a hydraulic oil temperature or hydraulic oil level fault occur while the diesel is operating the corresponding indicating light on the fault panel will be illuminated and the audible alarm will sound to alert the operator to the fault condition.

• If the diesel continues to run for more than 30 seconds (interval is adjustable) in a fault condition the Fault Panel will shut the diesel down automatically. The purpose of the delay is to give the operator time to pull back the drill string, secure the hole and if possible, idle the diesel.

• When the Fault Panel automatically shuts down the diesel, the fault horn will continue to sound and the corresponding fault indicating light will remain illuminated until the fault is recognized by one of two actions: • The ignition key is turned off • The fault reset button is depressed

• If the ignition key is turned off in a fault condition, the fault horn will be silent but the fault indicating light will remain illuminated until the fault reset button is depressed. The purpose of the indicator light is show which fault has occurred.

• Once the fault has been corrected, depress and release the fault reset button on the fault panel. • If no fault is present, the fault indicating light will remain off, and the diesel will be ready to start

and run normally. • If the fault has not been corrected the corresponding fault light will once again be illuminated and

shut the diesel after 30 seconds. • If the fault reset button is depressed and released without correcting an indicated fault condition,

the corresponding fault light will again be illuminated. In this event the ignition key could start and run the diesel, but only until the 30 second time delay expires and the engine is once again automatically shutdown.

• Any time the ignition key is in the “on” position and a fault condition exists, the audible alarm will sound.


94

13.2 Safety Systems (Electrical Circuit) Description The CS3001 is equipped with several safety systems which use the electrical circuit. These safety systems are for the protection of personnel and must be checked at the beginning of each shift. 13.2.1 Emergency Stops (E-Stops) • Activating any one of the emergency stops cuts power to the normally open solenoid valve connected

to the main pump load sense line, and at the same time, initiates engine shut-down. Cutting power to the solenoid valve connects the load sense line to tank and therefore reduces pressure and flow from the main pump functions (rotation, main winch, wireline winch and fast travel). Pressure or flow from the auxiliary and secondary pumps will cease when the engine has comes to a stop

• The E-stops must be reset before the engine will crank and start and the main pump develops

pressure and flow. • E-stops are located on the main control console, at the secondary control console, and the right side

of the drill opposite the secondary control console (closest location for helper when running rods out) 13.2.2 Rotation Pilot Controller Neutral Switch • The rotation pilot controller is equipped with a neutral switch which prevents the starting circuit from

closing and starting the engine, unless the rotation control lever is in the neutral position. This prevents unexpected chuck rotation if the engine is started with the rotation lever (held in position by friction) still in an operating position.

13.2.3 Crown Block limit Switch • The crown block is equipped with a limit switch to prevent the hoist plug/water swivel from being

pulled into the crown block. Tripping the limit switch cuts power to a normally open solenoid valve which will then connect the pilot line (to the main valve “winch raise” valve section) to tank. This stops the winch raising.

• The operator can then lower the winch. This will reset the limit switch, the normally open solenoid

valve will close and the main winch can be operated again in both directions. 13.2.4 Audible Alarm When Operating Secondary Control Console • The audible alarm (beeping sound) will sound when operating any of the controls used for drill set-up

in the secondary control panel. A pressure switch senses when the tank side pressure of the control valve increases above 5.5 bar (80 psi).

• The audible alarm will make helper(s) aware that the jacks, mast or control console are being moved. • A test button on the main control console is used to test the audible alarm.

14 Trouble-Shooting

95

14 Trouble-Shooting

Potential problems and solutions • The following guide is designed to help you identify and solve

hydraulic problems. The explanations may not provide all the answers and but may be helpful.

Safety first • Remember to observe Safety Instructions listed in Section 2 in this

manual. Always use safe work practices.

Section 15 in this manual contains the procedures used by the factory to set up the hydraulic system pressures, adjustments etc. It is included to aid the mechanic with detailed instructions when parts of the hydraulic system are out of adjustment and have to be reset, and to reset minimum and maximum displacement settings on replacement main winch and rotation motors. It is also useful for finding the procedures used to check/reset specific pressures/adjustments referenced in the troubleshooting section.

14 Trouble-Shooting

96

14.1 Trouble-Shooting - General Type of fault Possible cause Remedy

1. Noisy pump caused by

cavitation

A. Oil is too viscous B. Filter plugged C. Suction line plugged D. Suction line ball valve closed or not fully open E. Tank not sufficiently pressurized for high altitude

A. Change to proper viscosity B. Clean or replace C. Clean line D. Fully open valve, pumps

probably damaged, inspect. E. Check tank pressure, adjust pressure reducing valve from air tank to specification

2. Noisy pump caused by

aeration

A. Oil supply low B. Air leaking into suction line C. Foaming oil

A. Fill hydraulic tank, check low level switch mounted in tank B. Tighten fittings C. Drain hydraulic tank and fill

with non-foaming type oil. Check that return line oil is not mixing with air first

3. Hydraulic system overheating

A. Oil supply low B. Oil in system too light C. Fan speed too low D. Cooler fins dirty or plugged E. Excessive internal leakage in hydraulic pumps F. Aeration of oil

A. Fill hydraulic tank B. Drain hydraulic tank and refill

with proper viscosity oil C. Check RPM 1750 both fans D. Clean fins E. Connect a flow meter to the

pump pressure port. Connect the return to an adjustable needle valve and then run. If the pump shows less then 90% of the rated flow at 70% of max pressure, exchange the pump

F. Tighten suction fittings

14 Trouble-Shooting

97

Type of fault Possible cause Remedy 4. System not producing

necessary pressure

A. Excessive internal leakage B. Compensator spool stuck

open C. Compensator spring weak

or broken D. No flow to compensator

signal port E. Load sense line

disconnected or filled with air

A. Check amount of flow is

according to specification B. Disassemble, inspect, clean,

or replace compensator C. Check spring in compensator D. Check load sense line for

damage, size, and length E. Connect and bleed of the

system

5. System does not produce

proper flow

A. Excessive internal leakage B. Compensator spool stuck

open C. Compensator spring broken D. Pump cavitation E. No load sense signal to compensator F. Load sense line

disconnected or filled with air

G. Low pilot pressure

A. Check amount of flow

according to specification B. Disassemble, inspect, clean,

or replace compensator C. Check spring in compensator D. Check proper oil viscosity,

suction line, tank pressure E. Check load sense line and

ports at valve F. Connect and bleed the system G. Test pressure.

14 Trouble-Shooting

98

14.2 Trouble-Shooting Auxiliary Pump Circuit

Type of fault Possible cause Remedy 1. Little, erratic, or no feed

pressure

A. Hydraulic plumbing is not

according to schematic B. Pressure gauge defective (false

reading) C. Feed rate valve is not operating

properly D. Return line from manifold is

blocked E. Slow feed directional valve is not

operating properly F. Pressure reducing valve for

pulldown pressure is worn or damaged

G. Thru shaft from main pump is

broken or damaged H. Pump or compensator is bad or

out of adjustment I. Contamination in control valve or

auxiliary pump manifold ports. J. External problem such as main

winch brake or drillhead carriage parts are affecting the feed process.

K. Feed cylinder or feed cylinder

seal kit is defective or worn

A. Check schematic in Parts Manual and correct

plumbing if necessary. B. Check the face and needle in pressure gauge

for damage, replace if necessary C. Check needle valve and internal bypass

check valve D. Check oil flow back to tank E. Check for worn or damaged parts (slow feed

valve spool is detent) F. Check for worn or damaged parts G. If main pump is ok check where auxiliary and

secondary are piggybacked at thru shaft. H. Check auxiliary pump for excessive case

drain flow (more than 11 lpm or 3 gpm), pressure setting, and compensator for dirt and worn or broken parts. 1. position control levers in neutral. 2. start engine. 3. loosen jam nut on compensator adjustment

screw (inside screw). 4. while observing pressure on gauge turn

adjustment screw cw to increase and ccw to decrease auxiliary pressure. Retighten jam nut.

I. Disassemble, clean, and inspect for broken

parts J. Disconnect main winch rope and check

condition of carriage rollers and replaceable ways. Troubleshoot brake release system if necessary.

K. Check O-rings in block at rod end of cylinder.

Also check if oil is bypassing at piston seals. Check internal condition of feed cylinder.

14 Trouble-Shooting

99

14.2 Trouble-Shooting Auxiliary Pump Circuit (cont’d)

Type of fault Possible cause Remedy 2. Hydraulic chuck opens

partially, not at all, or leaking hydraulic oil (not grease) at chuck body.

A. Relief valve for chuck (located

below the control valve lever) is stuck, contains contamination, damaged, or pressure setting is not correct.

B. Control valve spool is damaged

or broken. C. Auxiliary pump or compensator

problem. D. Damage to internal sliding

parts of chuck. E. Seal kit, piston, or cylinder, is

worn or damaged.

A. Remove relief valve and inspect for

damage and dirt. Make sure relief valve was not over tightened into housing. Set pressure at 90 bar (1,300 psi)

B. Check for worn or damaged parts in

control valve. C. Check auxiliary pump for excessive

case drain flow (more than 11 lpm or 3 gpm), pressure setting, and compensator for contamination and worn or broken parts.

D. Disassemble chuck, clean all parts,

and inspect for galling, wear, or broken parts. Use caution when removing 7/16 in bolts at top plate. Remove evenly due to spring pressure below.

E. Remove piston from cylinder and

install new seal kit. Inspect piston and cylinder for wear or damage. Make sure relief setting is not too high if cylinder is bulged.

3. Chuck jaws not holding drill

rod or slipping.

A. Incorrect chuck jaw size, worn

jaws, or damaged. B. Hydraulic pressure entering

chuck cylinder when chuck control valve is in the closed position.

C. Internal parts of cylinder or

chuck are not moving properly.

D. Excessive contamination inside

chuck and jaws.

A. Inspect jaws and check for right part #.

Check the correct size of rod bushings (upper and lower) are being used if damage to carbide is occurring.

B. Install 206 bar (3,000 psi) gauge at

chuck and determine if pressure is entering chuck cylinder. If only a small amount is entering when chuck control valve is in closed position, check the valve for wear or damage.

C. Disassemble chuck, clean, and inspect

for damaged parts. D. Clean carbide inserts and sliding areas

of jaws.

14 Trouble-Shooting

100


Type of fault Possible cause Remedy 4. Mud mixer not rotating,

rotating slow, or erratic.

A. Quick disconnects not

connected properly or pilot inside is broken

B. Mud mixer control valve

(flow divider) is worn or damaged.

C. Drain port (port B) from

control valve not connected to tank or is line plugged.

D. Hydraulic motor at mixer

assembly is defective. E. Relief valve at flow divider

inlet is set too low or is leaking

F. Auxiliary pump or

compensator is bad or out of adjustment.

A. Check quick disconnects for

damage/broken parts or does not go together freely.

B. Check the spool and housing of

control valve for wear or damage C. Connect tank line or clean line D. Troubleshoot hydraulic motor for

damage or internal leakage. E. Check relief valve setting of 138

bar (2,000 psi). Reset if necessary. F. Troubleshoot pump for proper

settings, excessive internal wear, and compensator problem.

5. Hydraulic jacks, mast raise,

etc. will not operate at all or erratic.

A. Selection valve in “main

console” position B. Hydraulic cylinder leaking

internally or damaged. C. Control valve is worn or

damaged. D. Auxiliary pump or

compensator is bad or out of adjustment.

E. Selection valve not working

properly

A. Move valve to “secondary console’

position B. Troubleshoot the cylinder. C. Inspect control valve spool and

housing for wear or damage. D. Check auxiliary pump for

excessive case drain flow (more than 11 lpm or 3 gpm), pressure setting, and compensator for contamination and worn or broken parts.

E. Check selector valve

14 Trouble-Shooting

101


Type of fault Possible cause Remedy 6. Rotation speed (high to low)

is erratic or not changing rpm when turning rotary control valve in or out.

A. Main pump or compensator

problem. B. No pressure from rotary

control valve C. Swivel angle adjustment

screws are not properly set (located on both sides of hydraulic motor).

D. Rotary valve cartridge is

worn, damaged, or contamination inside.

E. Hydraulic control valve at

hydraulic motor is worn, damaged, not adjusted properly, or contains contamination

F. Internal wear or damage to

displacement parts inside hydraulic motor.

G. Erratic rpm can be caused

by problems beyond the hydraulic system such as problems in the drilling process, transmission, or the drillhead.

A. Check the other functions on main

valve for correct operation. If they are working properly continue troubleshooting B thru J. If some problem persists, troubleshoot the main valve or main pump circuit.

B. Check the auxiliary pump and

compensator C. See set-up procedure, section 15,

for setting min and max displacement or simply try turning the adjustment screw slightly and observe if rpm changes. Check the set-up procedure for correct rpm setting procedure and using a hand photo-tachometer, set the engine speed and head rotation to specification. The engine speed is set at 2100 rpm and the head high speed is 1300 rpm. It is not recommended to overspeed either.

D. Remove the rotary control valve

cartridge from housing and check for wear, damage, or contamination.

E. Carefully disassemble valve and

check for wear, broken parts, or contamination. Use caution when disassembling as some parts may be spring loaded.

F. Troubleshoot the hydraulic motor

according to Rexroth troubleshooting guide manual.

G. Disconnect the drillhead from drill

string and observe if rotation improves.

14 Trouble-Shooting

102

14.3 Trouble-Shooting Main Pump Circuit

Type of fault Possible cause Remedy 1. Rotation section in

main valve bank producing slow rpm, no revolutions, or lack of pressure.

A. Main pump or compensator problem B. Problem in primary or secondary shuttles C. Relief valve in main valve is stuck or damaged D. Main valve spool in rotation section is worn or damaged E. Incorrect pilot pressures for shifting main valve spool F. Flow compensator spool in rotation section blocked or stuck G. No load sense signal from main valve to pump

A. Troubleshoot main pump and compensator.

Check for proper suction, contamination, compensator pressure setting, standby pressure setting, and excessive case drain leakage -more than 20 lpm (6 gpm) is excessive for this pump. Check compensator spools for wear, damage, and contamination. Compensator setting is 324 bar (4,700 psi). For the Rexroth 4M22 main valve, the standby pressure is 26.2 bar (380 psi).

If compensator and standby pressure settings

are correct and problem persists, do a flow/pressure check on the main pump with a flow meter. See Rexroth manual located in Parts Manual

for more information.

B. Check/remove, clean, and inspect primary and secondary shuttles in rotation section. If ok, check the shuttles in remaining valve sections as they may affect this function.

C. Remove and inspect main relief valve for

contamination, wear, damage, and proper pressure setting. Pressure setting for the main relief is 362 bar (5,260 psi).

D. Check main valve spool and housing for wear,

contamination, or damage. E. Check pilot pressures produced by pilot control

valve. For the Rexroth 4M22 main valve, the pilot pressures should be in range of 6 to 25 bar (87 to 363 psi)

F. Carefully remove compensator spool and check

for wear, damage, or contamination. G. Check the load sense line from valve to main

pump for obstruction in hose

14 Trouble-Shooting

103

14.3 Trouble-Shooting Main Pump Circuit (cont’d)

Type of fault Possible cause Remedy 2. Rotation section in

main valve bank producing slow rpm, no revolutions, or lack of pressure (cont’d).

H. Problem in hydraulic

motor on drillhead. I. Load sense relief valve

settings in main valve not to specification

J. Problem in transmission

or drillhead housing.

H. Try turning the min and max displacement

adjusting screws slightly in 3rd gear and observe if rpm changes. Check the drill setup procedure, section 15, for correct min and max rpm settings and reset if required. Drillhead maximum allowed rpm is 1300 rpm. This rpm must not be exceeded in high gear (the RPM counter is programmed to sound the audible alarm if 1300 rpm is exceeded)

I. Lock chuck on rod held in foot clamp and check

max pump pressure - should be at 297 bar (4,300 psi)

J. Disconnect hydraulic motor from transmission

and see if problem still exists.

3. Fast feed section

in main valve bank does not move feed cylinder, too slow, or erratic.

A. Similar problems as in

rotation section: main pump, main valve, pilot pressure or load sense line

B. Load sense relief valve


C. Problem in feed cylinder. D. Problem in the drillhead

carriage rollers or the replaceable ways

A. Perform same checks as for rotation section

B. Check the load sense limiting valve by running

the cylinder into end position and read system pressure gauge - should be 193 bar (2,800 psi) in both directions

C. Troubleshoot the feed cylinder checking for

worn seal kit or damage to cylinder. D. Do inspection of rollers, and ways

14 Trouble-Shooting

104

14.3 Trouble-Shooting Main Pump Circuit (cont’d)

Type of fault Possible cause Remedy 4. Main winch section

in main valve bank producing slow winch, no winching, erratic, or winch not holding load.





C. No pressure from manual

brake release valve when valve is in brake release position

D. Problem in Braden winch E. Problem in structural or

mounting parts of Braden winch


B. Check the load sense relief valve by disconnecting

and capping lines to main winch motor. Activate winch control - system pressure gauge should be 324 bar (4,700 psi) in both directions

C. Check brake release valve. D. Troubleshoot Braden winch according to installation,

maintenance, and service manual located in Part Manual

E. Check structural area where winch is mounted.

Make sure mounting platform is strong and mounting surface is even

5. Wireline section in

main valve bank producing slow, erratic, or no rotation of the wireline winch drum.





C. Brake does not release H. Problem in hydraulic motor

mounted to winch drum. I. Damage to structural or

mounting parts on winch.


B. Check the load sense relief valve by disconnecting

and capping lines to wireline winch motor. Activate winch control - system pressure gauge should be 207 bar (3,000 psi) in both directions

C. Check automatic brake release valve, shuttle valve

and pressure line from auxiliary pump circuit

H. Troubleshoot hydraulic motor and counterbalance valve mounted on the winch

I. Check assembly and mounting area of winch to main frame and condition of sheave wheels and crown block.

14 Trouble-Shooting

105

14.4 Trouble-Shooting Secondary Pump Circuit Type of fault Possible cause Remedy 6. The mud/water

pump will not turn or stalls at low pressure.

A. Wrong rotation direction

of pump. B. Check pump 2 speed motor is for Lo speed (high pressure, lower flow) when drilling C. Problem with 2 speed motor D. Secondary pump problem E. Pump suction or relief valve problem F. Problem beyond hydraulic motor

A. The motor on the mud/water pump is designed

to turn in one direction only (ccw when viewed from the shaft end of the motor). If the direction is reversed, hydraulic pump and motor damage will occur.

B. Check Hi/Lo speed control is set in Lo speed

(high pressure, low flow) when drilling. High flow ,lower pressure is used for flushing the hole

C. Check for proper hose plumbing. Troubleshoot

two-speed pilot line on auxiliary circuit. Refer to Eaton service manual for more information.

D. Check the secondary pump pressure – should

be 207 bar (3,000 psi) E. Troubleshoot the pump for suction problem,

water/mud pump relief valve stuck or damaged F. Inspect hydraulic motor adapter and mud pump

for damage.

14 Trouble-Shooting

106

15 Hydraulic Set-Up Procedure

107

15 Hydraulic Set-Up Procedure The Hydraulic Set-Up procedure is added to the manual to provide the mechanic with detailed procedures to set the hydraulic adjustments on the machine. This will be useful when adding new components such as variable hydraulic motors, hydraulic pumps, cartridges etc. which generally will not have been preset pressures, volume stops etc. at the factory or vendor. This will prevent damage to components due to over-speeding, over-pressure etc. Also the procedure will be useful when making hydraulic adjustments after a general overhaul. General Commissioning Notes: -if some settings appear to be difficult to do, there may be air in the applicable hydraulic lines and bleeding of the lines may be required to remove the air. -Pressure and flow adj. (adj.) screws in valves typically increase pressure/flow when the adjustment is turned clockwise and reduce pressure/flow when the adjustment is counter clockwise. For some valves, the adjustment direction is reversed and is noted in the procedure. Acronyms: adj. = adjustment min. = minimum max. = maximum 1. PREPARATIONS FOR COMMISSIONING OPERATIONS

RESULTS

COMMENTS

-Fill all fluid levels (radiator, engine, main hoist, hydraulic tank, drill head and mud pump)

-Prime all pumps and motors

-Prime rotation head lubrication system

-Lock ball valves open -Back out flow control valve for cooling fan flow , and main valve load sense relief valves

2. HYDRAULIC PUMP ADJUSTMENTS PRIOR TO STARTING ENGINE OPERATIONS RESULTS COMMENTS Main Pump (1st pump after engine) -Loosen high pressure compensator lock nut (inside adj. screw) -Turn adj. screw counter clockwise until the spring pressure is released, then turn clockwise until a slight spring pressure is felt


108

against it. -Loosen stand-by compensator lock nut (outside adj. screw) and turn adj. screw counter clockwise to release spring pressure. Auxiliary Pump -Loosen high pressure compensator lock nut (inside adj. screw) -Turn adj. screw counter clockwise until the spring pressure is released, then turn clockwise until a slight spring pressure is felt against it. -Loosen stand by compensator lock nut (outside adj. screw) and turn adj. screw clockwise it bottoms out. Tighten lock nut. (Auxiliary pump only) Secondary ( Powers Mud/Water Pump) -Loosen high pressure compensator lock nut (inside adj. screw) -Turn adj. screw counter clockwise until the spring pressure is released, then turn clockwise until a slight spring pressure is felt against it. -Loosen stand-by compensator lock nut (outside adj. screw) and turn adj. screw counter clockwise to release spring pressure. 3. ENGINE STARTUP AND HYDRAULIC OIL TANK PRESSURE SETTING OPERATIONS RESULTS COMMENTS -Start engine. See Section II of Drill Manual – Diesel Power Unit for instruction for the model of engine used. AFTER ENGINE IS WARMED UP, increase engine R.P.M. to 2100 R.P.M. -Back out pressure reducing valve on air tank. -Set unloader valve on engine mounted air compressor (screw clockwise to reduce pressure) to 60 PSI (pressure gauge on tank) -Set pressure reducing valve feeding hydraulic tank to 8 PSI (gauge mounted on valve) and push in plastic locking cap. -Shut engine off. Monitor tank pressure and check that pressure stays constant. If pressure leaks off, find source of air leak and correct.

4. AUXILIARY PUMP HIGH PRESSURE COMPENSATOR SETTING OPERATIONS RESULTS COMMENTS -Prior to setting auxiliary pump, back out adj. screw on pressure reducing valve feeding valve manifold with 4 x D03 valves. Also back out adj. screw on flow control valve controlling flow to cooler fan motors -Pump pressure is indicated on auxiliary system gauge in control


109

console -Adjust compensator (inside adj. screw) to 2800 PSI. Tighten lock nut. 5. PRESSURE REDUCING VALVE FEEDING 4 X D03 MANIFOLD AND PRESSURE REDUCING RELIEVING VALVE LOCATED IN 4 X D03 MAIFOLD OPERATIONS RESULTS COMMENTS 5.1 Pressure reducing valve feeding 4 x D03 manifold (for head opening valve) -Connect 3000 PSI gauge to test fitting in pressure reducing valve feeding the 4 x D03 manifold -Loosen lock nut and adjust PRV to 2,200 PSI. -Tighten lock nut and remove gauge 5.2 Pressure reducing relieving valve in 4 x D03 manifold -Connect 2000 PSI gauge to test fitting on the 4xD03 manifold -Loosen lock nut and adjust pressure reducing relieving valve mounted in manifold to 1450 PSI. (feeds main winch brake release valve, Hi/Lo control on water pump motor, tray lifter, foot clamp, main valve pilot pressure and mud mixer) -Tighten lock nut and remove gauge Main Control valves can now be operated

6. COOLING FAN RPM OPERATIONS RESULTS COMMENTS -Adjust flow control valve for cooling fan flow so speed of upper fan increases to 1725 rpm. Lock flow control valve -Measure and record rpm of lower cooling fan

7. MAIN PUMP AND MAIN VALVE PRESSURE RELIEF SET UP OPERATIONS RESULTS COMMENTS 7.1 Main pump stand by pressure -Start and run engine at low idle. -Connect 1000 PSI test gauge to test fitting in main pump -Adjust this pressure to 380 PSI and tighten lock nut 7.2 Main valve pressure relief (2 persons required for rest of

this section) -Turn main relief valve adj. screw (located in main valve) fully in and back ½ turn -Install flow meter in main hoist lines. -Start engine and hold control lever for main hoist in raise position. -Let oil circulate for a minute. -Close needle valve on the flow meter. -Adjust main pump high pressure compensator to 5260 PSI


110

-Adjust main valve relief opening to 5260 PSI (adj. reached when main pump pressure gauge moves & engine start to work). -Open needle valve fully and return main hoist lever to neutral 7.3 Main pump high pressure compensator -Close needle valve on flow meter and hold control lever for main hoist in raise position. -Lower high pressure compensator setting (inside adj. screw) to 4700 PSI and tighten lock nut. - Put lever in neutral and open needle valve. 7.4 Check main pump flow -Increase engine speed to 2100 rpm, open flow meter needle valve and put main hoist control in raise position. Pump flow should be about 72 gpm. -Start turning the flow meter needle valve in until the high pressure compensator starts to de-stroke the pump (approximately 4,300.S.I.). Pump flow should be about 63 G.P.M. -Open needle valve, return main hoist control to neutral. Idle the engine for a few minutes to cool down then shut off. - Disconnect test equipment & re-connect main hoist hoses. 8. CHUCK PRESSURE OPERATIONS RESULTS COMMENTS -Back out adj. screw of pressure reducing relieving valve located under chuck control valve and connect 2000 psi gauge to test fitting located there. -Place chuck control lever in open position. Adjust pressure reducing relieving valve to 1300 PSI. -Tighten lock nut, place control lever in neutral, remove gauge.

9. HEAD OPENING OPERATIONS RESULTS COMMENTS -Test head opening with pressure for this function set to 2200 psi in section 5.1. Drillhead should just start to move when mast is down and resting on headache rack. Drillhead will need to open when mast is in 45 to 90 degree mast position. -If drillhead does not open, pressure in section 5.1 will have to be reset. Record new pressure.


111

10. MUD MIXER RELIEF VALVE SETTING AND MUD MIXER FLOW CHECK (Flow Divider Control) OPERATIONS

RESULTS

COMMENTS

-Back out mud mixer relief valve adj. screw. -Connect 3000 PSI pressure gauge into hydraulic pressure line to mud mixer (line dead headed) -Open mud mixer line fully and set relief valve to 2000 PSI. Lock adjusting screw. -Disconnect pressure gauge and connect flow meter into hydraulic pressure hose line to mud mixer. -Connect hydraulic lines to mud mixer and place mud mixer in a barrel of water. -Open mud mixer valve fully and record flow - should be about 6 GPM. -Check that flow shuts fully off. -Rotation of mud mixer should be counter clockwise (viewed from hose end) If not correct swap hoses at the mud mixer motor. -Disconnect pressure line to mud mixer and open mud mixer control valve. Check fan speed remains constant. Flow from fan motors should flow over relief valve.

11. WIRELINE HOIST SETTINGS OPERATIONS RESULTS COMMENTS 11.1 Preparation -Disconnect hoses from manifold mounted on wireline winch motor and cap. -Back out adj. screw on pressure reducing valve to wireline brake release (port 3A) -Fully back out adj. screw on 3-way directional valve (port 5A), turn in ½ turn, and tighten lock nut -Screw in volume stops on wireline winch main valve section to limit max flow on ports A & B -Back out W/L winch load sense relief valve setting on ports A & B 11.2 Wireline Load Sense Pressure -Place wireline winch lever in the raise position. -Adjust wireline load sense relief valve (raise side) to 3000 PSI using the main pump pressure gauge -Repeat for wireline load sense relief in lowering position 11.3 Wireline Brake Release Valve Setting -Hold wireline winch lever in raise position


112

-Using test port and 1000 psi gauge, set pressure reducing valve (port 3A) to wireline brake release to 300 PSI 11.4 Wireline Counterbalance Valve setting -Turn adj. screw fully counter clockwise (screw will remain stationary or may move in and C/B valve relief will be a max. setting). Then turn adj. screw ¾ turn counter clockwise and tighten locknut. (Setting will be approx. 3900 PSI). 11.5 Wireline flow -Connect flow meter into hoses -Operate wireline winch control and adjust main valve section volume stops to give 30 gpm in both directions (screw volume stops out to increase flow) -Lock volume stops, remove flow meter and reconnect hoses -Operate wireline hoist and check drum rpm for correct rotation. Should be about 180 rpm. 11.6 Wireline Brake Holding -Disconnect wireline winch brake line and cap -Gently move wireline control in lower position. If wireline drum turns (parking brake slips), record pressure on main pump pressure gauge. -Reconnect brake line 12. FEED CYLINDER COUNTERBALANCE (C/B) VALVE OPERATIONS RESULTS COMMENTS -Disconnect fast travel hose ( 1 ¼ “ hose) feeding pull down side of feed cylinder and cap -Operate fast travel lever in down direction. -Set pull down load sense relief to 2330 PSI (temporary adjustment, to be reset in section 13) -Reconnect fast travel hose and disconnect pilot line to counterbalance valve and cap -Screw out (counter clockwise) counterbalance adj. screw to increase C/B valve relief setting -While operating fast travel lever in down position, screw in C/B valve screw until feed cylinder start to move (C/B relief valve has opened at 3650 PSI) -Reconnect C/B pilot line


113

13. FAST TRAVEL LOAD SENSE PRESSURES OPERATIONS RESULTS COMMENTS -Back out fast travel load sense relief valves -Run fast travel up and down to clear any air from feed cylinder (if required, increase load sense pressure to move feed cylinder) -Run fast travel up until cylinder bottoms out -While holding fast travel lever in up position, adjust fast travel load sense relief valve for travel up to 2800 PSI using the main pump pressure gauge. -Repeat for fast travel down and set load sense for travel down at 1400 psi.

14. PROGRAMMING OF DRILLHEAD DIGITAL RPM DISPLAY AND WATER PUMP FLOW RATE DISPLAY OPERATIONS RESULTS COMMENTS Reference Red Lion Bulletin CUB5-D, Drawing No. LP0584 Found in OEM Parts Manual 14.1 Setting Drillhead Digital RPM Display -Per section 6.2 Module 2 -Rate Setup Parameters, enter DSP=60 for rate scaling display value INP =12 for Rate Scaling Input Value 14.2 Setting Spindle Overspeed Audible Alarm -Per section 6.4 Module 4 – Setpoint Output Parameters, enter SPt ASN = rAtE SPt Act = bOUNd SPt Val = 1300 Ch-COLOr = YES (changes display colour when 1300 rpm is reached) 14.3 Setting Mud Pump Flow Rate Based On Mud Pump RPM -Per section 6.2 Module 2 -Rate Setup Parameters, enter DSP=60 for rate scaling display value (converts pulses per seconds into pulses per minute) INP =102 for Rate Scaling Input Value for display in GPM (1 GPM=6x630/37 with 6 pulses per pump revolution) INP= 27 for Rate Scaling Input Value for display in LPM (1 LPM = 6x630/140 with 6 pulses per pump revolution)


114

15. ROTATION PRESSURE LOAD SENSE PRESSURE OPERATIONS RESULTS COMMENTS -Disconnect rotation hose (reverse rotation direction). -While holding rotation lever in reverse direction, adjust rotation load sense relief valve to 4300 PSI using the main pump pressure gauge. -Disconnect rotation hose in forward direction and repeat procedure to set load sense relief for forward direction to 4300 PSI -Reconnect both rotation hoses

16. ROTATION MOTOR - DISPLACEMENT ADJUSTMENT OPERATIONS RESULTS COMMENTS

Procedure to set the 80 cc rotation motor at 62 cc minimum displacement

-Spray paint bottom spindle adapter with flat black paint, install reflective tape for R.P.M. photo tachometer. -Remove the min displacement adjustment screw from the Rexroth rotation motor and check that length is 90 mm long. If it isn’t, replace screw 3760008986 (90 mm). Re-install with 1/4" of threads showing above the lock nut and tighten the lock nut. (initial adjustment only) -Make sure head lubrication system (oil pump, filter, hoses, etc.) is primed and full of 90-weight oil. -Set engine R.P.M. at 1700. -Place transmission in 3rd gear. -Turn rotation speed control clockwise to high speed. -Place rotation control lever in forward position. DO NOT ROTATE CHUCK IN OPEN POSITION DO NOT ROTATE IN CLOSED POSITION WITHOUT JAWS AND LIFTING BAIL INSTALLED -Check lubrication oil flow by loosening fittings where the oil enters the rotation head

DO NOT ROTATE HEAD WITHOUT LUBRICATION OIL FLOW.

-Rotate head 15 minutes to warm the lubrication oil, note oil flow in clear return line. Transmission return line should have flow within a few minutes. Top adapter case return line may or may not have oil flow when the oil is cold, and will probably not have oil flow when oil is at operating temperature, this is normal. Place rotation control lever in neutral position.


115

-Verify that transmission in 3rd gear (shift lever position out and up ) -Place rotation control lever in the forward position and set engine speed at maximum RPM. Make sure rotation speed control is at maximum displacement (screwed out). Check rotation speed on reflective tape with photo tachometer. RPM should be 795 rpm -Adjust rotation speed control in control console to max rpm. Then loosen minimum displacement adj. screw on motor and slowly screw out until spindle rpm reaches 980 rpm. Tighten lock nut and reinstall plastic cap. -Check rotation speed control. Turn rotation speed control counter clockwise. Rotation should slow to about 795 R.P.M. -Check the digital display on the console with the photo tachometer 17. MAIN WINCH LOAD SENSE PRESSURES OPERATIONS RESULTS COMMENTS -Fully screw in load sense reliefs for both A and B ports. (maximum pressure limited to 4700 psi main pump compensator).

18. MAIN WINCH MOTOR – MINIMUM & MAXIMUM DISPLACEMENT ADJUSTMENT OPERATIONS RESULTS COMMENTS 18.1 Procedure For Rexroth Motor -107 cc max displacement and set to 75 cc minimum displacement -Remove the minimum displacement adj. screw from the 107 cc Rexroth rotation motor and check that length is 100 mm long. If it isn’t, replace screw with part # 3760008987 (100 mm). Re-install with ¼" of threads showing above the lock nut and tighten the lock nut. (initial adj. only) -Screw out maximum displacement adjusting screw --Turn main hoist speed control out (counter clockwise) so motor is a maximum displacement -Set engine rpm at 2100 rpm -Hold winch rotation control lever in the fully raise position -Check drum rpm with photo tach. Drum rpm should be about 37 rpm. Adjust maximum displacement screw as required -Screw in winch speed control (motor at minimum displacement). -Check drum rpm with photo tachometer. Should be approx 43 rpm. -Loosen minimum displacement adj. screw on motor and slowly screw out until drum rpm reaches 55 rpm. Tighten lock nut and


116

reinstall plastic cap. -Check winch speed control. Drum rpm should change from 36 to 55 rpm as winch speed adjustment is turned from fully out to fully in. -Record rpm range. 19. MAST PULLDOWN RELIEF VALVE AND COUNTERBALANCE VALVES ON MAST RAISE AND MAST DUMP CYLINDERS OPERATIONS RESULTS COMMENTS -Remove hose from “pulldown” side of mast raise cylinders and attach 3000 PSI gauge. Check that maximum pressure (controlled by adjustable relief valve on pulldown side of mast raise valve section) is 2,500 PSI. Adjust if necessary. Remove gauge and re-connect hose -If the counterbalance valves on mast raise and mast dump cylinders need to be set or reset, the adj. screws on the valves should be turned fully counter clockwise (screw will remain stationary or may move in and C/B valve relief will be a maximum setting). Then turn adj. screw ½ turn clockwise and tighten locknut. -Record mast raise pressure with mast dumped back and rotation head at bottom of stroke. -Record mast raise pressure with mast dumped forward and rotation head at top of stroke.

20. SECONDARY HYDRAULIC PUMP SETUP FOR FMC W1122BCD MUD PUMP, WATER PUMP RELIEF VALVE SETTING AND WATER PUMP TEST OPERATIONS RESULTS COMMENTS

21.1 Hydraulic Pump Standby Pressure: -Connect hoses to FMC mud pump. (pressure, return, case drain) and install reflective tape on rotation indicator wheel. -Plumb mud pump into a barrel of water. (2 ½” suction hose 1” discharge hose).

DO NOT TURN F.M.C. PUMP WITHOUT WATER IN CYLINDERS; IT WILL DAMAGE THE PISTON CUPS.

-Run engine at 2100 rpm R.P.M and fully open mud pump control valve. -Set two-speed motor at high speed (pull out speed control knob) -Adjust secondary pump stand-by pressure (outside adj. screw) until FMC W1122BCD input speed is 650 rpm (gives 38 gpm water


117

flow) using photo tach. -Turn stand-by pressure adjustment clockwise to increase flow/speed and counter clockwise to decrease flow/speed.

CHECK MUD PUMP CRANK TURNS IN DIRECTION SPECIFIED BY FMC.

-Check the console digital mud pump flow meter – should read 34 gpm at 630 mud pump input rpm 21.2 Mud Pump Relief Valve (water side) Setting And Secondary Pump High Pressure Compensator Setting -Connect 5000 psi gauge into secondary pump outlet line -Reduce secondary pump high pressure compensator setting (inside adjusting screw) -Screw in mud pump relief valve adjustment screw -Install throttle valve on mud pump outlet line and open throttle valve. -Set pump speed selector to low speed (push in speed control knob) -Run engine at 1200 rpm and operate mud pump control fully open. -Increase pump high pressure compensator setting (inside adjusting screw) and adjust water side throttle valve until water pressure reaches 1100 psi. -Turn water side relief valve adjusting screw counter clockwise until water comes out of relief valve. -Lock relief valve setting and record pump compensator pressure. -Reduce pump high pressure compensator setting until water pressure reaches 1000 psi. -Lock pump compensator adjustment screw and record compensator pressure. -Check and record maximum pump rpm and water pressure obtained in high speed mode -Check and record max pump rpm and water pressure obtained in low speed mode -Turn off water flow and remove test equipment

21. OPERATION CHECK ALL FUNCTIONS OPERATIONS RESULTS COMMENTS Thermostatic valve setting of 130 F – when testing drill at low power, reservoir temperature should increase to 130 F and then level off

All functions controlled in console operate in direct indicated in console decals (as applicable)

Slow feed down

Drillhead power float

Drillhead overspeed alarm


118

Main hoist and brake release

Wireline hoist and brake release

Make pressure operation

Hydraulic jacks

Mast dump

Mast raise & lower, stiff leg pinning

Water pressure release valve at console

Lighting system

Water Pump Hi/Lo Speed Control

Hydraulic tank pressure not leaking off through relief valves

Rod tray lifter

Special equipment 1: UDR spin out tool. Check flow from pressure compensated flow control valve with flow meter and record.

22. OPERATION CHECK OF SAFETY DEVICES OPERATIONS RESULTS COMMENTS E-stop operation – all e-stop buttons

Neutral switch on rotation pilot controller

Crown block limit switch

Audible alarm (horn) on console control panel

Perimeter guard on main winch and wireline winch

Drillhead guard

Commissioning & Testing Signoff Mechanics name (print & sign):

Date:

16 Spin-Out Tool Option

119


16.1 Safe-T-Spin Wireline Rod Make/Break Tool Safe-T-Spin is a trademark of UDR. The attached information is a copy of UDR documentation. 16.1.1 Introduction Safe-T-Spin Specifications CAPACITY: BO, NO, HO Wireline Drill Rods and HW Casing MAX TORQUE - Break out: 3,000 Nm MAX TORQUE - Make Up: 2,100 Nm CONTROLS: All Hydraulic RECOMMENDED OIL FLOW: 100 lpm MAX SUPPLY PRESSURE: 180 bar WEIGHT: Safe-T-Spin 91 kg Mounting Arm 25 kg General Information This manual describes the complete modifications for fitting a Safe-T-Spin to UDR1000 drill rigs from 1000-44 onwards, for rigs prior to 1000-44 details will be furnished on request from UDR. Fitting of the Safe-T-Spin on UDR1000 drill rigs will directly influence the available headroom required in the mast to safely trip rods. As a result and depending on the model and configuration of the drill rig, some update modifications are mandatory, while another update modification is strongly recommended. A brief description of each update modification is given below. The requirement for each rig is shown in the table in Section 1.7. UM 68 - Safe-T-Spin This update modification contains all the components and information required to fit the support structure to the mast, modify the control cabinet and modify the hydraulic circuit, including installing components. Details are contained in Section 5. UM65 – Foot Clamp Modification This update modification is MANDATORY. As the Safe-T-Spin is mounted as low as possible in the mast, the travel of the foot clamp lever arms must be limited so they do not interfere with the travel of the Safe-T-Spin. This update modification contains all the components and information required to fit the foot clamp lever arm limiter. Details are contained in section 4.9.


120

16.2 Safe-T-Spin Operator’s Manual 16.2.1 Installation for Operation The following procedures can be used to fit the safe-t-spin to the mast for a 650 rig. 16.2.1.1 Mast Vertical Where possible the safe-t-spin should be fitted to the mast with the mast vertical and prior to the mast being set up for the final drill angle. A. Reeve the main winch rope through the snatch block with the mast in the transport position. B. Attach the Lifting Base, Lifting Socket and Lifting Connecting Pin to the safe-t-spin assembly. Pin the

lifting connecting pin with a grip clip. Fit the locking pins of the lifting base to the holes provided in the safe-t-spin housing.

C. Connect the main winch rope, using a suitable D shackle, to the hole on the lifting socket for a 90-degree mast. The lifting socket has five holes in it; each hole is hard stamped for a particular mast angle.

D. Swing the vertical support out of the mast. Using a combination of rod boom movements and operation of the main winch lift the safe-t-spin into the mast, until the cam followers of the support and the roller brackets touch the mast.

WARNING: CHECK THE SAFE-T-SPIN AS IT IS LIFTED INTO THE MAST AND LOWERED DOWN THE MAST. THE SAFE-T-SPIN BRACKETS CAN FOUL WITH THE GUARDS COVERING THE LOWER TRAVERSE SHEAVES. ALSO CHECK THE POSITION ON THE LOCKING HOOK IN CASE IT ALSO CATCHES THE LOWER TRAVERSE GUARDS.

E. Lower the safe-t-spin to a position where the vertical support bracket for either the left-hand or right-hand mount can be swung into the mast. Align the pins of the vertical support and the bushed holes of the support bracket, slowly lower the safe-t-spin onto the pins of the vertical support. Pin the safe-t-spin assembly to the vertical support.

F. Remove the main winch rope and the lifting base and socket from the safe-t-spin assembly. G. Adjust the height of the safe-t-spin until it is 535mm above the mast base to the top of the safe-t-spin.

If necessary adjust the height of the safe-t-spin by turning the shaft adjustment hexagon (24mm across the flats) at top of the support structure.

H. Plug the hydraulic oil supply and drain hoses for the safe-t-spin into their respective quick release couplings and secure the hook to lock the safe-t-spin into the mast. The engine of the rig may have to be shut down to allow the quick release couplings to be assembled. The safe-t-spin is now ready for operation.

I. The mast can be set up for the required drill angle if required to do so.

WARNING: THE SAFE-T- SPIN MUST NOT BE SWUNG OUT OF THE MAST UNTIL THE MAST IS IN THE FINAL SET UP POSITION. THE SAFE-T-SPIN WILL FOUL WITH THE ROD TRAY DURING MAST SET UP IF IT IS SWUNG OUT OF THE MAST DURING SET UP.


121

16.2.1.2 Mast Set Up at any angle between 90 and 45 Degrees. A. Reeve the main winch rope through the snatch block with the mast in the drilling position.

WARNING: ANY PERSONNEL REQUIRED TO CLIMB THE MAST WHEN IT IS SET UP FOR DRILLING MUST WEAR AN APPROVED SAFETY HARNESS.

B. Attach the Lifting Base, Lifting Socket and Lifting Connecting Pin to the safe-t-spin assembly. Pin the lifting connecting pin with a grip clip. Fit the locking pins of the lifting base to the holes provided in the safe-t-spin housing.

C. Connect the main winch rope, using a suitable D shackle, to the hole on the lifting socket for the particular mast angle. The lifting socket has five holes in it; each hole is hard stamped for a particular mast angle.

NOTE: For mast angles between 60 and 45 degrees only one lifting hole in the socket is provided.

D. Swing the vertical support out of the mast. Using a combination of rod boom movements and operation of the main winch lift the safe-t-spin into the mast, until the cam followers of the support and the roller brackets touch the mast.

WARNING: CHECK THE SAFE-T-SPIN AS IT IS LIFTED INTO THE MAST AND LOWERED DOWN THE MAST. THE SAFE-T-SPIN BRACKETS CAN FOUL WITH THE GUARDS COVERING THE LOWER TRAVERSE SHEAVES. ALSO CHECK THE POSITION ON THE LOCKING HOOK IN CASE IT ALSO CATCHES THE LOWER TRAVERSE GUARDS.

FOR MAST ANGLES BETWEEN 60 AND 45 DEGREES, TWO MEN MUST HOLD BACK THE SAFE-T-SPIN UNTIL THE ROLLERS CONTACT THE MAST. THIS IS DUE TO THE LENGTH OF THE FULLY EXTENDED ROD BOOM.

E. Lower the safe-t-spin to a position where the vertical support bracket for either the left-hand or right-hand mount can be swung into the mast. Align the pins of the vertical support and the bushed holes of the support bracket, slowly lower the safe-t-spin onto the pins of the vertical support. Pin the safe-t-spin assembly to the vertical support.

F. Remove the main winch rope and the lifting base and socket from the safe-t-spin assembly. G. Adjust the height of the safe-t-spin until it is 535mm above the mast base to the top of the safe-t-spin.

If necessary adjust the height of the safe-t-spin by turning the shaft adjustment hexagon (24mm across the flats) at top of the support structure.

H. Plug the hydraulic oil supply and drain hoses for the safe-t-spin into their respective quick release couplings and secure the hook to lock the safe-t-spin into the mast. The engine of the rig may have to be shut down to allow the quick release couplings to be assembled. The safe-t-spin is now ready for operation.


122

16.2.1.3 Procedure to swing the SAFE-T-SPIN out of the mast.

Right-hand mount. For mast angles between 90 and 60 degrees, release the hook assembly, take hold of the handles provided on the support arm and the roller brackets and swing the safe-t-spin out of the mast.

WARNING: ENSURE YOU HAVE A SECURE GRIP OF THE SAFE-T-SPIN AND THAT YOU HAVE SECURE FOOTING DURING THIS OPERATION. THE SAFE-T-SPIN COULD SWING OVER CENTRE SUDDENLY AND CAUSE YOU TO LOOSE YOUR GRIP OR FOOTING.

For mast angles between 60 and 45 degrees, two men are required to swing the safe-t-spin out of the mast. One man must fit the swing arm to the left-hand roller bracket and the second must grip the handle of the support bracket. Refer to the warning above re grip and footing conditions. 16.2.1.4 Procedure to swing the Safe-T-Spin into the mast.

Right-hand mount.

A. Check that the safe-t-spin support arm is secured to the vertical support with lynch pins. B. Check the safe-t-spin is 535 mm above the mast base to the top of the safe-t-spin; if necessary adjust

the height of the safe-t-spin by turning the shaft adjustment hexagon (24mm across the flats) at top of the support structure.

C. Check that the foot clamp is closed and that the box end of the rod does not protrude more than 120 mm above the rod jaws, before swinging the safe-t-spin into the mast.

WARNING: THE SAFE-T-SPIN COULD COLLIDE WITH THE ROD CLAMPED IN THE ROD CLAMPS, IF THE SAFE-T-SPIN IS IN THE LOWEST POSITION ON THE VERTICAL SUPPORT.

D. Carefully swing the safe-t-spin into the mast and secure the safe-t-spin with the hook on the left-hand side of the safe-t-spin support arm. Right-hand mount. For mast angles between 90 and 60 degrees, take hold of the handles provided on the support arm and the roller brackets and swing the safe-t-spin into of the mast.

WARNING: ENSURE YOU HAVE A SECURE GRIP OF THE SAFE-T-SPIN AND THAT YOU HAVE SECURE FOOTING DURING THIS OPERATION. THE SAFE-T-SPIN COULD SWING OVER CENTRE SUDDENLY AND CAUSE YOU TO LOOSE YOUR GRIP OR FOOTING.

For mast angles between 60 and 45 degrees, two men are required to swing the safe-t-spin into of the mast. One man must fit the swing arm to the left-hand roller bracket and the second must grip the handle of the support bracket. Refer to the warning above re grip and footing conditions.


123

16.2.1.5 Procedure to remove the Safe-T-Spin from the mast. A. To remove the safe-t-spin from the mast is a reversal of the procedure of sections 16.2.1.1. 16.2.2 Operational Checks A. Check the conditions of the inserts in the jaws of the Safe-T- Spinner for wear and check for any

foreign matter that may stop the jaws from rotating. B. Check the hoses for the Safe-T-Spinner motor have been correctly connected and the operation is as

per the name tags on the control cabinet C. Check the Safe-T-Spin attachment bolts are tight. D. Check the Safe-T-Spin pivot bushes float spring and linear bearings are in good working order. E. Check the Safe-T-Spin torque control is at the minimum setting before operating. Adjust this setting

when using the Safe-T-Spin. F. Check the Safe-T-Spin is 535 mm above the mast base to the top of the spinner; if necessary adjust

the height of the spinner by turning the shaft adjustment hexagon nut (24mm across the flats) at top of the support structure.

G. Check that the foot clamp stop pin has been fitted to the foot clamp base.

WARNING: THE FOOT CLAMP STOP PIN MUST BE USED WITH THE SAFE-T-SPIN. THE FOOT CLAMP JAWS WILL CONTACT THE SAFE-T-SPIN HOUSING, WHEN THE FOOT CLAMP IS OPEN, IF THE STOP IS NOT FITTED.

16.2.2.1 Pre Torque Control Pressure Setting Make: To set or adjust the hydraulic pressure to the Safe-T-Spin and to obtain an accurate pre-torque, when making up the drill rods the following procedure is used: A. Set the Safe-T-Spin torque control to the minimum setting. B. Stall the Safe-T-Spin against a foot clamped in the foot clamp, the same size as the rod size you will

drill with. The diesel engine should be 1600- 1800 rpm and the hydraulic oil temperature should be at 60 degrees C. The Safe-T-Spin control lever should be fully engaged in the "make" position.

C. Using the table below as a guide, adjust the Safe-T-Spin torque control until the required pressure can

be read on the Safe-T-Spin make torque gauge.

ROD SIZE MAKE UP TORQUE ( Nm)

SAFE-T-SPIN MAKE TORQUE PRESSURE ( BAR )

BO 1250 88 NO 1650 116 HO 2100 147

HW Casing 1250 88


124

CAUTION: SLOWLY ENGAGE THE SAFE-T-SPIN CONTROL LEVER TO MAKE THE JOINT. IF THE CONTROL LEVER IS SUDDENLY ENGAGED, THE ROD JOINT COULD OVER TIGHTEN DUE TO INERTIA OF THE SAFE-T-SPIN JAWS SUDDENLY GRIPPING THE ROD.

BREAK: There is no torque setting adjustment for breaking the rod joint. 16.2.3 OPERATION 16.2.3.1 Break Out of Drill String The Safe-T-Spin is now ready to break apart the drill string according to the following instructions: A. Support the drill string in the foot clamp with the box end of the rod beneath the rod driver assembly.

The box end of the drill rod must be located between 80 and 100 mm above the foot clamp jaws when the jaws are closed.

B. Fit the foot clamp stop pin to the foot clamp base. The stop pin is required to keep the foot clamp jaws and lever arms from hitting the Safe-T-Spin base

C. Swing the Safe-T-Spin into place as described earlier. D. Check the Safe-T-Spin is 535 mm above the mast base to the top of the Safe-T-Spinner, if necessary

adjust the height of the spinner by turning the shaft adjustment hexagon nut (24mm across the flats) at top of the support structure. The 535mm will allow the Safe-T-Spin to float up or down as required to break the joint.

Note: A coil spring in the vertical support allows the Safe-T-Spin to float up and down as the rod joint is broken apart in order to eliminate rod thread damage.

E. Operate the Safe-T-Spin to ensure that the jaws are in the fully "open" position. F. Insert the winch plug extension through the Safe-T-Spin. G. Screw the winch plug extension pin into the drill string box end and tighten. H. Take the weight of the rod string with the main winch rope. I. Open the foot clamp. J. winch the drill string until the next rod joint to break is between the foot clamp and Safe-T-Spin and the

stop winch indicator light (if fitted) has illuminated. Stop winching. K. Close the foot clamp. L. Lower the main winch rope slightly to relieve any tension on the main winch rope. M. Break the rod joint apart by engaging "Make-Break" control lever to the "Break" position. Continue

depressing this lever until rod joint is unscrewed. Release the control lever to neutral

NOTE: ENGAGE THE LEVER SLOWLY TO BREAK THE JOINT.

N. Winch the drill string until the rod pin end clears the Safety-T-Spin housing. Lower the rod string with the main winch and place the rod in the rod rack.

O. Remove the winch plug from the rod string. Raise the winch plug and reconnect it back into the drill string clamped in the foot clamp.

P. Repeat steps E to O for the remainder of the drill string.


125

16.2.3.2 Make Up of Drill String Changing the operation of the Safe-T-Spin from the break out mode to the make up mode requires that the direction of the control lever is changed and that the Safe-T-Spin torque control be set.

NOTE: REFER TO THE PRE-TORQUE CONTROL PRESSURE SETTING SECTION FOR THE PROCEDURE TO SET THE SPINNER.

A. Fit the foot clamp stop pin to the foot clamp base. The stop pin is required to keep the foot clamp jaws

and lever arms from hitting the Safe-T-Spin base B. Operate the Safe-T-Spin to ensure the jaws are in the "Open" position. C. Attach the winching plug to core barrel locking coupling. D. Open the foot clamps. Raise the core barrel assembly. E. Lower the core barrel assembly through the Safe-T-Spin and the foot clamps. F. Close the foot clamp. Take the weight off the winch rope by lowering the main winch slightly. G. Remove the winch plug extension from the core barrel locking coupling by operating the control lever

to "break". This will spin the winch plug extension out of the box thread. H. Attach the winch plug to the next rod in the rod rack. I. Raise the drill rod from the rod rack J. Connect the drill rod to the rod / core barrel supported in the foot clamp. Take the weight off the winch

rope by lowering the main winch slightly. Engage the Safe-T-Spin into the "break" slightly, this will allow the rod thread to line up and drop into the box thread.

K. Make up the rod joint by engaging the "Make-Break" control lever to "Make" function. Continue engaging this control lever until rotation stops and the Safe-T-Spin make torque gauge reads the correct setting.

NOTE: ENGAGE THE LEVER SLOWLY TO MAKE THE JOINT.

L. Take the weight of rod string with the main winch. M. Open the foot clamp. N. Lower the drill rods into the drill hole. O. Close the foot clamp. Take the weight off the winch rope by lowering the main winch slightly. P. Remove the winch plug extension from the drill rod box thread by operating the control lever to "break".

This will spin the winch plug extension "out" of the box thread. Q. Repeat the steps from "F" to "P" for the remainder of the drill string. 16.2.3.3 Making up the Drill String - General Notes Before making up the rod joints for the first time, examine the rods carefully for damage that may have occurred during transport to the drilling site. Remove any accumulated dirt from both the box and pin threads and apply thread lubricant. Make up the joint. There will be a slight "stand-off" when the joint is hand tight. In order to make the shoulders butt; it is necessary to torque the joint to the recommended torque.

CAUTION: DO NOT USE WICKING. THE TAPER THREAD DESIGN WHEN TORQUED TO THE CORRECT PRESSURE WILL MAKE UP WITH NO LEAKS. A RECOMMENDED THREAD LUBRICANT SHOULD ALWAYS BE USED.


126

Avoid stabbing the pin end of the rods when making them up, lower the pin end slowly into the box end and engage the thread by hand. During tripping of the drill string, the threads of the winch plug should be checked on a regular basis for wear and dirt accumulation and cleaned when necessary. It is important that the rods be made up with a 20% greater torque than the torque at which the rods will be operated. 16.2.4 Trouble Shooting Guide

PROBLEM PROBABLE CAUSES RECOMMENDED SOLUTIONS No functions operate • Hydraulic power supply not

connected • Quick couplers damaged or

dirty. • Pilot pressure to the "make -

break" pilot control is low

Connect hoses to drill hydraulic supply. Clean or replace quick couplers. Check the pilot pressure at the pressure test point at Valve No 9 at Pump 10d on the hydraulic circuit for the rig.

PROBLEM PROBABLE CAUSES RECOMMENDED SOLUTIONS Safe-T-Spin will not Operate

• Hydraulic hoses not connected

• Quick couplers damaged or dirty

• Broken chain / sprockets • Hydraulic motor failure • Safe-T-Spin torque control

set too low

Connect hoses. Clean or replace couplers. Inspect gearbox and replace chain / sprockets as required. Replace hydraulic motor. Reset Safe-T-Spin torque as per instructions. Replace the cartridge in the spinner torque control valve on the panel.


127

16.3 Safe-T-Spin Maintenance 16.3.1 Maintenance Schedule

Planned Maintenance Schedule Weekly Wash-out and grease Spinner box.( 1 to 2 pumps )

Grease linear bearings on mounting arm. (1 pump) Grease cam followers on mounting arm.(1 pump )

3 Monthly Lid off, Hose out thoroughly and Grease, including light grease of top bronze bush and chain.

Annual Same as 3 Monthly, shim to reduce chain slack, renew chain where necessary. Fit minor overhaul kit. Orientate ring gear and cam at 45 deg to allow even wear. Kit contents listed below.

Bi-Annual Carry out all servicing listed above; fit new upper and lower bronze thrust rings. Part numbers listed below. Tungsten inserts in the jaws should be changed at drillers / rig fitter's discretion.

Note: Bushes must be replaced in the jaws once they are heated!

Refer Section 4.1.1 SP8150-3. Items 6a & 23

General

Minor Overhaul Kit Contents. Reference Section 4.1 Drawing SP8150-3 for exploded view,

Item No. Part No. Description. Quantity. 21 PD22873AG Stainless Balls 58 16 WU8151 Outrigger Bush 1 23 PD22923Z Bush Permalube 6 25 PD22923AE Thrust Washer 6 27 PM28605E8 Skt/Hd C/Sunk Cap screw 12

Major Overhaul Kit Contents. These parts should be replaced as part of the bi-annual service in addition to the parts in the minor overhaul kit.

Item No. Part No. Description. Quantity. 9 WU7449 Thrust Ring Top 1 36 WU9278 Thrust Ring Bottom 1

Additional Miscellaneous Parts Reference section 4.2.1 and 4.3.1 drawing SP8155 and SP8154. The flanged permaglide bushes in the Support Arm WU8352 should be replaced whenever noticeable clearance exists.

Item No Part No Description Quantity 1-2 PD22923AK Bush Permaglide 2


128

17 Addendum Sheets

129

17 Addendum Sheets This section contains addendum sheets with Operator’s Instruction Manual information for those CS3001 drills that do not use the standard water pumps, water pump circuits etc. Also see the hydraulic schematic specific to the customer’s drill included in the Parts Manual.

17 Addendum Sheets

130

1. cs3001 u-deck operator's instructions

Documents