At A t l as Cop Co p c o Exp Ex p l o r ati at i o n Pro Pr o d u c t s
CS40 CS4002 02 Core Drill Dri ll Rig Operator’s Instruction Manual (Pilot Operated Control)
Printed Matter No. 6991 1460 01
Operator's Operator's Instru ction Manual Manual for
CHRISTENSEN
CS4002 This instruction manual is intended for operators of the Christensen CS4002 high capacity diamond core drill. Instructions are given for set up, drilling, a nd 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 i s 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 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. ATL AS COPCO EXPLORATION PRODUCTS PRODUCTS NORTH BAY, CANADA 2006-10 Printed Matter No
6991 1424 01
Contents 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 Technical Specifications ___________20 5.3 Dimensions______________________22
6 Design Features _________________ 27 6.1 Mast and Feedframe ______________28 6.2 Rotation Unit ____________________29 6.3 Crown Block ____________________29 6.4 Control Console __________________30 6.5 Wireline Winch __________________30 6.6 Main Winch _____________________31 6.7 Hydraulic Tank __________________32 6.8 Mechanical Guards _______________33 6.9 Optional Rod Rack/Helper’s Platform ___________________________________33
Page
7.1 Main Control Panel (Pilot Operated) 35 7.2 Secondary Control Panel__________ 41
8 Diesel Engine Start-Up____________ 43 8.1 Pre-Start _______________________ 43 8.2 Engine Start ____________________ 45 8.3 Engine Shut-Down _______________ 45
9 Drill Set-Up _____________________ 47 9.1 Start-Up _______________________ 47 9.2 Secondary Controls ______________ 48 9.3 Levelling the Drill________________ 49 9.4 Operator’s Platform _____________ 50 9.5 Mast Slide ______________________ 50 9.6 Unfolding Mast Extension _________ 51 9.7 Mast Supports __________________ 51 9.8 Ground Support and Guy Wires ___ 56
10 Drilling _______________________ 61 10.1 Before Drilling Starts____________ 62 10.2 Start the Power Unit ____________ 62 10.4 Adjust the Flow of Mud/Water____ 63 10.5 Start Rotation __________________ 63 10.6 Start Drill Feed_________________ 64 10.7 Stop Drilling ___________________ 64 10.8 Controlled Wireline Lowering ____ 66 10.9 Controlled Wireline Winching ____ 66 10.10 Thread Compensation __________ 66 10.11 Adding a Drill Rod_____________ 67 10.12 Removing a Drill Rod __________ 67 10.13 Water Pressure Dump Valve ____ 67 10.14 Operating Main Winch _________ 68
6.10 Optional Spin-Out Tool __________34
10.15 Rod Handling _________________ 69
7 Controls ________________________ 35
10.16 Drill Rod Break-In Procedure ___ 71
Contents Page
Page
11 Maintenance And Servicing _______ 73
13.1 Electrical Fault Panel___________ 101
11.1 General________________________73
13.2 Safety Systems Description ______ 102
11.2 Periodic Maintenance and Service Schedule ___________________________73
14 Trouble-Shooting ______________ 103
11.3 Lubricant Recommendations ______75 11.4 Service Point Detailed Instructions _76 11.5 Periodic Inspections _____________85 11.6 Hydraulic Hoses & Fittings Inspection ___________________________________87
12 Hydraulic Circuit Description _____ 89 12.1 Hydraulic Pumps________________89 12.2 Filtration ______________________90 12.3 Main Pump Circuit ______________91 12.4 Auxiliary Pump Circuit __________95 12.5 Secondary Pump Circuit__________98 12.6 Return Oil Circuit and Hydraulic Tank ______________________________99 12.7 Hydraulic Oil Cooler____________100
13 Electrical Circuit Description_____ 101
14.1 Trouble-Shooting - General _____ 104 14.2 Trouble-Shooting Auxiliary Pump Circuit ___________________________ 106 14.3 Trouble-Shooting Main Pump Circuit _________________________________110 14.4 Trouble-Shooting Secondary Pump Circuit ___________________________ 113
15 Hydraulic Set-Up Procedure _____ 115 16 Spin-Out Tool Option ___________ 129 16.1 Safe-T-Spin Wireline Rod Make/Break Tool _____________________________ 129 16.2 Safe-T-Spin Operator’s Manual __ 130 16.3 Safe-T-Spin Maintenance _______ 137
17 Addendum Sheets ______________ 139
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Introduction
1 Introd uction Thank you for choosing the CS4002 as 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 CS4002 in the standard configuration. Some CS4002 drills have special cust omer ord ered features that differ from th e standard drill config uration. 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:
At las Cop co Exp lo rat io n Prod uc ts A Divisi on of At las Cop co Canad a Inc . 640 McKeown Avenue North Bay, Ontario P1B 8H2 Canada Telephone: Fax:
(1) 705 472-3320 (1) 705 472-6843
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Introduction
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2 Safety Instructions
Safety Instructio ns
2.1 Organization al Measures
Dear operato r, 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.
2.1.1
The CS4002 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 to the (optional) helper’s platform, working on the helper’s platform, or 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 inj ury 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.
Yours faithfully, Atlas Copco Exploration Products
Intended Use The CS4002 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 CS4002 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.
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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 l ift more than 25 kg (50 lb’s) 2.1.11 Do not operate the drill when the wind speed exceeds 20 m/sec (45 mph). Use guy wires when required (see section 9.8) to prevent upset of the machine. 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.
Safety Instructio ns
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.
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
Figure 2.1 If the drill is equipped with the optional 30 ft rod rack, the fall arrest and fall restraint kit Atlas Copco part 3760009042 is provided with the 30 ft rod rack components.
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Safety Instructio ns
2.2 Operatio n (General) 2.2.1
2.2.2
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.
2.2.6
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.
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
2.2.4
2.2.5
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. 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) 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
2.2.10 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.
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Safety Instructio ns
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.
alarm (beeper) similar to a truck backup warning device that is activated when hydraulic functions are used during setup 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.
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 CS4002 drill is provided with an audible
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Fig. 2.4 Use Only Genuine Atlas Copco Parts
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Safety Instructio ns
2.3 Movin g t he 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
2.3.8
2.3.9
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. 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. 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 i s recommended that a spill kit and absorbent be carried on the rig. 2.3.18 For long distance shipping, or in sensitive environmental areas, it is recommended to drain the hydraulic reservoir and fuel tank.
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Safety Instructio ns
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 sup port the drill. Where required use jacks pads or if necessary, timber or concrete pads. (See section 9.8.1 for details).
2.4.3
2.4.4
2.4.5
2.4.6
2.4.7
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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, mast fold). 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. 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. 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). 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 coul d move up, depending on the angle of drilling. Always secure the mast slide with the securing pins provided
2.4.8
Guy wires may be required to prevent tipping the drill in windy conditions. See section 9.8.2 for details. If wind speeds could exceed 30 m/sec (67 mph), then the rods should be taken out of the rod rack (if so equipped) and drilling stopped.
2.4.9
If there is a possibility of thunder or an electrical storm, a lightning conductor should be installed on the drill.
2.4.10 Ensure parking brakes are set and wheel chocks are used to prevent movement of truck mounted drills after the drill has located for drilling. 2.4.11 The cable restraint on the mast must be installed before operation of the drill – see section 9.7.1
For Drill s Equipped with Optional Rod Rack/Helper’s Platform 2.4.12 The rod rack should be set to the correct angle and position along the mast, before the mast is raised. This will ensure that the platform is horizontal and at the correct height when the mast is raised to the drilling angle. 2.4.13 The two backstay legs (one behind the mast, the other behind the rod rack) must be installed before operation of the drill. The cable restraint system is used only on drills without the optional rod rack/helper’s platform 2.4.14 The rod fallout guard (part 3760007966) in front of the rod rack must always be installed. This is a safety device to ensure the rods cannot fall out of the rod rack in windy conditions. 2.4.15 A safety chain or bar should be installed around the first row. This will prevent the rods being blown out of the rack if there are only a few steeply stacked rods in the rack. 2.4.16 Ensure personnel safety equipment is available and in good order for securing
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Safety Instructio ns
the helper when climbing the platform access ladder and securing the helper when working on the platform.
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 rod clamp or use the optional spi n-out tool.
2.4.17 Ensure that the emergency E-stop for use on the helper’s platform is plugged in and is operational. 2.4.18 Ensure that no loose tools are kept on the platform; that could fall from the platform.
2.5 Drillin g 2.5.1
2.5.2
2.5.2
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. 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. 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
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. Water swivel failure can cause hose whipping leading to injury or death 2.5.12 Ensure that the water swivel 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.
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Safety Instructio ns
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. 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 runaway of diesel engines. When drilling gaseous ground, use a B.O.P. (blow out preventer), if required.
Drills Equipped with Optional Rod Rack/Helper’s Platform 2.5.25 Check that the emergency E-stop on the helper’s platform is in good working order at the beginning of each shift. 2.5.26 Ensure that there are no loose tools on the helper’s platform that could fall and cause injury or damage. 2.5.27 Ensure that safety equipment is used for climbing to, and working on, the helper’s platform. Each time before using the safety equipment, check that it is in good working order. 2.5.28 Only one man equipped with small tools is allowed on the helper’s platform at any one time
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
2.5.23 Oily rags, bare conductors, spilled or leaking fuel or oil present a fire hazard and must be prevented
Be careful to avoid snagging or damaging any hose, winch rope or cable when moving the mast to the travel position.
2.6.4
2.5.24 The foot clamp can crush feet or hands. Keep feet and hands away from the foot clamp.
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 allowed the overall height limit.
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.
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2.6.7
Safety Instructio ns
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.
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.
2.7.8
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.
2.7.2
Any maintenance should be done using acceptable lockout procedures to ensure personal safety.
2.7.12 Welding near computer controlled engines can cause ECU damage. Disconnect batteries and ECU harness prior to welding.
2.7.3
Make sure the engine is stopped and hydraulic, air, and water circuits are properly depressurized before being worked on.
2.7.13 Use only certified welders for any welding repairs.
2.7.4
2.7.5
2.7.6
2.7.7
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. When replacing components, always purge air from the components prior to use to prevent uncontrolled movement. 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. 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.
2.7.14 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 and max displacements on replacement
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Safety Instructio ns
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.
2.8 Special Safety Sign s 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!
Fig. 2.5 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.
Fig. 2.6
Fig. 2.7 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. 2.8
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Safety Instructio ns
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.
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
2.9.7
Fig 2.15 Foot Crushing hazard
Fig. 2.9
Fig. 2.10
Fig. 2.11
Fig. 2.12
Fig. 2.13
Check periodically that safety decals are legible and in place. Replace as required.
Fig. 2.14
See Parts Manual for safety decal location and part numbers.
Fig. 2.15
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Safety Instructio ns
2.10 Fire Extin gui sher 2.10.1 The drill rig is equipped with a portable fire extinguisher. The fire extinguisher is shipped with 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.
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3 Environ mental Instructio ns Dear op erator, 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.
Environmental Instructions
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, alumi niu m, etc.) These products are recyclable and should be taken care of according to national regulations and recycled where local programs exist.
Plastics and ru bber 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.
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.
Obtain MSDS data sheets for the flui ds that you use for the drill and follow the instructions in the data sheets to deal with accidental ingestion, skin contact or spills.
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Environmental Instructions
4
Hoisting the Drill
4 Hoistin Hoistin g th e Drill 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
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4
18
Hoisting the Drill
5
Specifications
5 Specifications 5.1 General
CHRISTENSEN CS4002 is an all-hydraulic operated diamond core drill.
The CHRISTENSEN CS4002 is an all-hydraulic diamond core drill for deep hole surface exploration drilling. The CS4002 is designed to be mounted on a truck and can also be mounted on tracks.
Recommendations To achieve the best results wi th regard to: high penetration optimal core recovery low drilling costs • • •
The CHRISTENSEN CS4002 uses well proven technology for diamond core drills together wi th safety improvements to provide a reliable, safe drill. An optional rod rack/helper’s platform capable of stacking rods from 90 to 45 degrees, give the operator flexibility in rod handling. An optional spin-out tool avoids the use of pipe wrenches for breaking rods
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 di ameter, the CHRISTENSEN CS4002 is best suited to drill N to P size holes using wire line rods.
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5.2 Techni cal Specificatio ns
Specifications
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 •
•
Drill Mast Feed stoke ...............................3.35 m (11 ft) Mast slide ..................................2.0 m (80 in) Rod pull ........................................ 9 m (30 ft) Mast style ......................................... Folding Feed pull..........................200 kN (45,000 lbf) Feed thrust ........................91 kN (20,400 lbf) Drill rod centerline location.... In front of mast Rod rack capacity (rods stacked on edge): .... 1,998 m (6,500 ft) capacity of N size rods ....................................vertical to 80 degrees Main Winch Main winch pull ................178 kN (40,000 lbf) Main winch speed: ... 0.6 m/sec (117 fpm) @ max displacement .. 1.17 m/sec (232 fpm) @ min displacement Rope size. .............................. 22 mm (7/8 in)
•
• • •
Fig. 5.1 Foot Clamp & Optional Spin-Out Tool
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 ........................................ 2:1 Drillhead spindle ID…..120.6 mm (4.75 in) Wireline Winch Drum Capacity: -4.7 mm (3/16 in) wire rope ... 4,600 m (15,000 ft) -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): …………………………13,388 kg (29,500 lbs)
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Fig.5.2 Control Console & Drillhead
5
Specifications
Diesel Engine - See Drill manual Section II for information on the Diesel Engine
CS4002 Drill head RPM and Torqu e Ratings at max. & min. disp lacements:
Diesel Fuel Reservoi r
- At rotation pressure of 3,500 psi - Max dis placement o f 145 cc - Min displacement of 100 cc
Capacity…………………….950 L (250 gal) Filling method………………By hand pump …………….connected to main return filter Hydraulic System
Gear
Hydraulic tank capacity ……500 litres (132 gal)
4
Max. operating pressure - Main pump................. 324 bar (4,700 psi) - Auxiliary pump ......... 172 bar (2,500 psi) - Secondary pump* … 207 bar (3,000 psi)
3 2
RPM Max Min Displacement Displacement
Torqu e Nm (ft lbf ) Max Min Displacement Displacement
th
892
1,300
1,003 (740)
689 (508)
rd
510
743
1,756 (1,295)
1,205 (889)
nd
286
417
3,130 (2,309)
2,149 (1,585)
st
142
207
6,291(4,640)
4,319 (3,185)
1
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 CS4002. 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 • Rod rack and helper’s platform for drilling angles 90 to 45 degrees. Rod rack capacity 1,998 m (6,500 ft) of N size rods, vertical to 80°, rods stacked on edge • Spin-Out Tool for mechanized rod make-up and break-out Depth Capacity Coring* N Wireline ............................2,450 m (8,030 ft) N Wireline – Upset Ends ...... 2,850 m (9,350 ft) H Wireline .............................1,600 m (5,250 ft) H Wireline – Upset Ends ...... 2,250 m (7,380 ft) P Wireline .............................1,050 m (3,440 ft) * For vertical, straight, water filled hole
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5
Specifications
5.3 Dimension s Dimensions are subject to change. If required, consult with factory to get dimensions certified. All dimension drawings shown are with 30 ft pull mast
3444
11063 Fig. 5.4 Shipping Dimensions – Elevation
2438
2767
4315
3976
Note: Optional Rod Rack/Helper’s Platform Shipped Loose Fig. 5.5 Ship ping Dimension s – Plan View
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5
Specifications
4.09 m (13' 5")
11.04 m (36' 2")
Fig. 5.6 Truck Mounted Drill in Transport Position - Elevation
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5
Specifications
14327
1010 400 Fig. 5.7 Truck Mounted Drill - Vertical Drilling
Fig. 5.8 Truck Mounted Drill - Vertical Drilling Plan View
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5
Specifications
Fig. 5.9 Truck Mounted Drill with Optional Rod Rack/Helper’s Platform - Vertical Drilling
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5
Specifications
3302
Fig. 5.10 Truck Mounted Drill with Optional Rod Rack/Helper’s Platform - Vertical Drilling Plan View
Fig. 5.11 Truck Mounted Drill with Optional Rod Rack/Helper’s Platform 45 Degree Drillin g
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6
Design Features
6 Design Features 1. 2. 3. 4. 5. 6. 7. 8. 9.
Mast and feed frame Rotation unit Crown block Control console Wireline winch (not shown) Main winch (not shown) Hydraulic tank Rod rack & helper’s platform (optional) Spin-out tool (optional)
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8
1
4 2 9
Mindoka, substitute picture from original source (before compression) to improve sharpness
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6
Design Features
6.1 Mast and Feedframe The 9 m (30 ft) pull mast consists of 2 parts – the main section which is 10.7 m (35 ft) long plus a 3 m (10 ft) long hydraulically folded section. The folding mast is locked in position before the mast is raised. This produces a very stable mast with a total length of 13.7 m (45 feet) for drilling as well as a shorter length of 10 m (33 ft) for transport. The main section 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 running on replaceable ways. This design gives maximum drillhead pulling efficiency (minimum friction) and well as allowing for replacement of worn ways. The mast is raised by two mast lift cylinders equipped wi th hard-plumber counterbalance valves. It is held in the drilling position by two short telescopic backstay legs which are pinned in position. A cable restraint system is used to limit the deflection of the mast. When equipped with the optional 30 ft rod rack and helper’s platform, the mast and rod rack are each supported in the drilling position by long telescopic backstay legs. The backstay legs are made of aluminum for light weight. It is recommended that the backstay legs are pinned at the right length to suit the drill angle before the mast is raised.
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6
Design Features
6.2 Rotation Unit The rotation unit slides sideways to clear the hole. It consists of a variable speed bent axis hydraulic motor for maximum efficiency, a heavy duty 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 4 speed transmission and transfer case are pressure lubricated. Note: Drillhead shown without standard “slam pan”
6.3 Crown Bloc k The crown block is equipped with large 30 inch sheaves (grooves for 7/8” rope) running on bearings which are remotely lubricated from the drill deck level. A block limit switch, that prevents the winch 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).
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6
Design Features
6.4 Contr ol 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) w ireline 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
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6
Design Features
6.6 Main Winch The main winch is designed to operate with single layer of 22 mm (7/8 inch) diameter rope. Two methods of handling 9 m rods (30 ft) can be used: -running rods out -stacking rods in mast with the optional rod rack/helper’s platform The main winch is equipped with 2 pressure rollers for improved rope management. The top pressure roller is equipped with 2 limit switches. One limit switch signals that three or less 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 90% 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.
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6
Design Features
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 b ack the rods, stop rotation and flush the cuttings out) before the engine stops. The indicator light (for the fault triggering 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 e ngine 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.
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Design Features
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 Rod Rack/Helper’s Platform An optional rod rack/helper’s platform is available for stacking rods in the mast. It can stack rods for drilling angles from 90 to 45 degrees. The helper’s platform angle and position along the mast is preset before raising the mast so the helper’s pl atform is in the right position when the mast is raised to the drilling angle. (See section 5.2 for rod rack stacking capacity). The rod rack and weight of the drill rods is supported by an adjustable telescopic backstay leg behind the rod rack (in addition to the backstay leg used to support the mast when not equipped with the rod rack/helper’s platform). Both backstay legs are made of aluminum for light weight. It is recommended that both backstay legs be pinned at the right length to suit the drill angle before the mast is raised (see section 9.7).
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6
Design Features
6.10 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
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7
Controls
7 Contro ls 7.1 Main Cont rol Panel (Pilo t Operated)
Figu re 7.1 CS4002 Main Con tro l Panel 7.1 CS4002 Main Con tro l Panel - Pilot Operated (co nt’d ) (Numbers refer to Balloon Numbers in Fig. 7.1)
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7
Controls
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.
5.
Head Opener Cylinder – Slides drillhead sideways.
6.
Hydraulic Chuck Control – 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. 4.
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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.
Main Winch Control – Controls the direction and speed of the main winch.
7
Controls
9.
Fast Travel Control – Controls the fast travel speed and direction of the drillhead.
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.
10. Wireline Winch Control – Controls the speed and direction of the wireline winch
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. 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.
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.
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7
Controls
18. Thread Compensation – Place lever in upper position to float drillhead downwards (when making joints), place lever in middle position for normal drilling operation and place lever in lower position to apply thread compensation (when breaking joints). The adjusting knob behind the directional valve adjusts the amount of lifting force.
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.
19. Mud Mixer Speed – Controls flow to the mud mixer. 24. Water Pressure Gauge – This gauge is connected to the mud/water pump outlet and indicates the mud/water pressure.
20. Mud/Water Pump Hi/Lo Speed – Sets mud/water pump motor to hi or low speed.
25. Main Pump Load Sense Pressure – Gives system pressure in the main pump function currently being used (main winch, fast travel, wireline or rotation). 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).
26. Engine Control Panel (not shown) Contains key switch, throttle control, tachometer, and other engine monitoring gauges.
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7
Controls
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.).
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).
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.
32. Holdback Pressure Gauge – Shows pressure on the holdback side of the feed cylinder. A movable calibrated decal ring can be used to indi cate the net bit force.
29. Spindle Tachometer – Provides the chuck rpm.
33. Circuit Breaker – Provides protection of main electrical control panel. 34. Spin-Out Tool (Optional) – Allows user to make or break rods
30. Flow meter – Provides mud/water pump flow by measuring mud/water pump rpm.
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7
Controls
35. Spin-Out Tool Torque Adjustment – Raises or lowers Spin-Out Tool (UDR Safe-T-Spin) make-up torque.
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
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7
Controls
7.2 Secondary Control Panel
1
9
8
7
6
5
4
3
2
Fig. 7.2 CS4002 Secondary Control Panel 1. Selector Valve – Directs hydraulic oil to either main control panel or secondary control panel (prevents inadvertent movement of set-up control while drilling) 2, 3, 4, 5 Hydraulic Jacks – Controls jacks. Locking pins must also be used. 6. Mast Raise – Raises and lowers mast 7. Mast Slide – Slides mast so mast bottom can be supported on ground. 8. Mast Folding – Folds mast extension 9. Console Extend – Extends/retracts console
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7
42
Controls
8
Diesel Engine Start-Up
8 Diesel Engine Start-Up Al way s f ol lo w t he Safety Ins tr uc ti on s in Sec ti on 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 CS4002 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 •
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8
Diesel Engine Start-Up
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
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Level Indicator for Fuel Tank.
8
8.1.6
Diesel Engine Start-Up
Activate Battery Disconnect switch Q1. Press in and turn in clockwise direction.
Q1
8.1.7
Starting instructions vary between the different engines. See Section 2. Engine Control Panel starting Instructions” in Section II of the Drill Manual.
8.2 Engin e Start 8.2.1.
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.
When starting up in cold weather, (below + 5°C ), run engine at 1000 rpm until the engine 8.3 Display Parameters temperature is about +10°C.
Hydraulic pumps will cavitate at high altitude if boost pressure fails.
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. 45
8
46
Diesel Engine Start-Up
9
Drill Set-up
9 Drill Set-Up Al way s fo ll ow th e Safety Ins tr uc ti on s in cl ud ed i n Sec ti on 2 and sp eci fic all y th os e in sectio n 2.3 for Movi ng The Drill and secti on 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 – CS4002 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).
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9
Drill Set-up
9.2 Secondary Control s The secondary controls operate the four jacks, mast raise, mast slide, folding of mast extension 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 CS4002 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
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9
Drill Set-Up
9.3 Levellin g th e Dril l 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 Ensure that drill is levelled on stable ground and pins are in place. Follow guidelines in section 9.8.1 – Precautions Required for Ground Conditions
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.
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9
Drill Set-Up
9.4 Operator’ s Platfor m 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, pi n 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 shippin g reasons. Pins are shipped with drill for cu stomer.)
Do not operate the drill without the mast lock pins in place
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9
Drill Set-Up
9.6 Unfol ding Mast Extensio n The mast extension should be unfolded and locked into place while the mast is in the lowered position. Take care that no snagging of hoses, ropes or cables occurs while the mast is being unfolded. Lock mast in position with locking pins before raising mast
Do not operate drill without folding mast locking pins in position and secured
9.7 Mast Supports 9.7.1 Drill wi thou t Option al Rod Rack/Helper’s Platform When the drill is not equipped with a rod rack/helper’s platform, short telescopic stifflegs, mounted in parallel with the mast raise cylinders, are used to support the mast. Pins are used to lock the stifflegs in the required length. In addition a cable restraint is required to reduce deflection of the top of the 30 ft pull to acceptable levels when pulling maximum load with the main winch.
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9
Drill Set-Up
The cable restraint system consists of the following components: -a fixed length of a 19 mm (¾ in) cable attached to the mast -a snatch block -a 12.7 mm (1/2 in) two part cable -a manual ratchet winch. The fixed length of cable is permanently attached to the mast. The two p art cable on the ratchet winch takes up the travel for mast positions between vertical and 45 degrees. The procedure for raising the mast is as follows: a) Ensure that the pawl is raised and locked in the open position so that the two part cable can spool off the ratchet winch when raising the mast. Ensure that no snagging of cable or hoses takes place. b) When the mast is in the drilling position, pin the short stifflegs legs in position. c) Release the spring loaded pawl and lower it to engage the ratchet wheel. Tension the cable by using a 600 mm (2 ft) long rod in the ratchet winch shaft and applying a maximum of about 22 daN (50 lbf) at the end of the 600 mm (2 ft) long pipe. d) When the cable has been tensioned, lock the pawl in the ratchet lock position. The procedure for lowering the mast is as follows: a) Release the tension in the cable b) Remove and store the locking pins in the stifflegs c) Lower the mast and at the same time spool the two part cable onto the ratchet d) Ensure no cable is pinched when lowering the mast to the transport position e) Secure the fixed cable on the deck.
Do not operate drill without cable restraint installed
Always lift the pawl and lock it in the raised position to free the manual ratchet before raising the mast
Do not apply more than 22daN (50 lbf) force at the end of 600mm (20 in) rod when tensioning the cable restraint
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9
Drill Set-Up
9.7.2 Drill Equipped w ith Optio nal Rod Rack/Helper’s Platform Two long telescopic backstay legs are used to support the rod rack and the mast. The short stifflegs mounted parallel to the mast raise cylinders are not used and must be removed if installed.
The recommended procedure for installing the rod rack/helper’s platform and 2 backstay legs is as follows: a. The rod rack is installed on the drill while the mast is in the transport position. Due to the weight of the components, this has to be done w ith a crane or forklift truck. b. Since the helper’s platform must be level in the raised position and the platform must be at a suitable height, the angle and locking position along the mast should be preset while the mast is in the lowered (transport) position and at deck level. Table 9.1 and figure 9.1 give the platform preset angle and position along the mast, so the helper’s platform is level and at a suitable height when the mast has been raised to the drilling angle.
Mast An gl e 0-4 5-9 10-14 15-19 20-24 25-30 30-34 35-39 40-44 45
Rod Rack Position See Fig 9.1 3 3 3 2 2 2 1 1 1 1
Short Leg Pin Position 21 19 17 16 13 10 12 8 5 1
Long Leg Pin Position 24 22 20 19 17 14 16 12 9 5
Table 9.1 Helper’s Platform Position and Backstay Leg Pin Positions
53
9
Drill Set-Up
c. The front safety guard (part # 3 760007966) for the platform should also be added while the mast is in the lowered position. d. The mast should be used to raise the backstay legs into position. The backstay legs should be adjusted to the correct length before installation so that locking pins between the telescoping sections do not have to be installed when the backstay legs have been raised. Table 9.1 gives the pin positions.
Figure 9.1 Rod Rack and Backstay Leg Pin Positions e. Once the backstay legs have been pinned into the required l ength, the mast complete with rod rack, should be raised high enough that the top end of the backstay legs can be connected to the mast and rod rack. f. The bottom end of the backstay legs should be supported with ropes by 2 people while the mast is raised and the mast bottom lowered to the ground. g. When the mast has been raised to the final position, the fine adjustment in the backstay legs is adjusted to align the bottom pin holes and the locking pins and locking wire installed. h. Connect the fall arrestor rope to the aluminum telescopic ladder for accessing the helper’s platform, before raising and securing the ladde r to the platform
54
9
Drill Set-Up
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 o f this equipment (instructions are supplied with the equipment). Do not alter or misuse this equipment.
55
9
Drill Set-Up
9.8 Grou nd Supp ort and Guy Wires Stability Precautions The CS4002 with a 30 foot 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.
9.8.1 Precautions Required For Groun d Condit ions - 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. 9.2, or a stronger support such as a timber or concrete pad must be used. The fabricated jack pads in Fig. 9.2 are available from Atlas Copco as part 3760012873. Also fabrication drawings for this part are available upon request.
Figu re 9.2 Jack Pad 3760012873 As a general guide, the cut-off ground soi l 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 3. The soil bearing ratings shown between the jack pads and a timber/concrete platform is 48,000 kN/m 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: Jacks with 0.5 m (2 ft) pads: Concrete/timber platforms:
56
hard, rocky ground, gravel, gravel clay, well graded sand uniformly or poorly graded sand, sandy clay compressible silts, clays and organics
9
Drill Set-Up
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.
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 i f 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.
9.8.2 Precaution s Required For Ground Conditio ns – 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 15 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. .
Diagonal Jack Braces may be required if can lose firm ground support under the mast base while angle drilling – See sect. 9.8.2 Figure 9.3 Diagonal Brace kit Installed on Truc k Mounted Drill
57
9
Drill Set-Up
9.8.3 Precautions Required For Windy Condi tion s Wind can exert very high forces on the drill, even upsetting the drill if the wind velocities are high enough. Other factors affecting the forces exerted by the wind are the presence of drill rods in the rod rack and the presence of wind screens on the helper’s platform. It is therefore recommended that guy wires be installed whenever the mast is raised for longer than a short duration and there is a risk of windy conditions.
Damage or injury due to environmental extremes such as earthquakes and hurricanes cannot be prevented by guy wires.
The following guidelines should be followed in regards to wind conditions: For All Drills -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 even when guy wires have been installed. (This is a requirement of EN 791, the European Safety Standard for Drilling Equipment). For Drills without Rod Racks: -If there is a possibility of wind speeds greater 36 m/sec (80 mph), the mast should be lowered. For Drills with Rod Racks: -If there is a possibility of wind speeds greater than 20 m/sec (45 mph) , guy wires must be installed on drills with drill rods in the rod rack or wind screens (which can act like sails) installed on the helper’s platform. -If there is a possibility of wind speeds greater than 30 m/sec (67 mph), drill rods should be taken out of the rod rack and the mast lowered.
9.8.4 Guy Wire Inst allation Use guy wires rated at 4 tonnes breaking strength firmly anchored to develop a minimum of 38 kN (4,200 lbf) pull out force. Place 4 such ropes at 90° to each other in plan view and at 45 to the gro un d. As the drilling angle changes from 90 to 45 degrees, keep at least 30 degrees between the rear guy wires and the mast. This is necessary to keep the necessary leverage on the mast.
58
9
Drill Set-Up
9.8.5 Other Conditi ons Requiri ng Guy Wires For Drills without Rod Racks: A truck mounted or stand alone drill is stable without guy wires for drilling angles between vertical and 45 degrees provided wind speeds are not more than indicated in the section 9.8.2. For Drills with Rod Racks: Provided that the drill is set up as described in this section, it is stable in the verti cal posi tion and for mast angles up to 3 5° fr om t he v ert ica l. Over 3 5 ° from the vertical, guy wires are required. This rule must be followed for bo th the truck m ounted and stand alone conditio n.
59
9
60
Drill Set-Up
10
Drilling
10 Drilling Al way s fo ll ow th e Safety Ins tr uc ti on s in cl ud ed i n Sec ti on 2 and sp eci fic all y th os e 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 CS4002 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 wi th a total rating of 15 dBA when working on this drill.
Report excessive vibration to your manager or foreman immediately when it occurs.
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Drilling
10.1 Befor e Drillin g 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. Fig. 10.1 Q1 Master Disconnect switch
Keep all guards in place and in good working condition.
10.2 Start t he Power Unit (Fig 10.1) a. b.
2
Activate master disconnect switch (Q1) Start the engine as described in Section II of Drill Manual - Diesel Engine Unit
• •
Fig. 10.2 Start Mud/Water Pump
10.3 Start th e Mud/Water Pump 10.3.1 Water flow control knob. Controls oil flow to mud/water pu mp 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.
62
1
Fig. 10.3 Select Hi or Lo Mud/Water Pump
10
Drilling
3
2
10.4 Adju st th e Flow o f 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.
1 Fig 10.4 Adjusting Mud/Water Flow
10.5 Start Rot ation 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 low er as the hole deepens and the drilling torque increases so the maximum rotation pressure remains at 240 bars (3500 psi). (Fig 10.5, pos 2)
2
1
Fig 10.5 Start Rotation
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Drilling
10.6 Start Dri ll Feed 10.7 Stop Drillin g 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 ring 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.
64
Continue drilling to the end of the feed stroke, fill the inner tube, or until you get core blockage.
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
Figure 10.6 Main Console Controls
65
10
Drilling
10.8 Contr olled 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.
b.
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.
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. 1
10.9 Contr olled 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 stops automatically.
10.10 Thread Compens ation 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
66
Fig. 10.7 Adjusting Thread Compensation
10
Drilling
10.11 Adding a Drill Rod 10.12 Remov ing a Dril l Rod Note: If the drill is equipped with the optional Spin-Out Tool, see section 17.1 for
a.
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
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.
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.
Use caution when making or breaking rod joints and handling the rods.
10.13 Water Pressu re 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.
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10
Drilling
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 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
Use a hoisting plug that is heavy enough to pull the rope down the rod slide when lowering
Monitor the condition of the main winch rope. At the first sign of wear, such as broken strands, replace the winch rope.
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Drilling
10.15 Rod Handlin g 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 proc edure is not recommended and is not permitted in som e jurisdiction s) 10.15.1 Rod Handli ng Usin g Drillh ead – Tripp ing 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 i n optional rod rack.
f.
Move drillhead back to starting position and lower/guide hoisting plug extension through chuck and repeat.
10.15.2 Rod Handl ing Usi ng Drill head – Trip ping 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), and 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.
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10
Drilling f.
Close foot clamp and repeat
Gear
Gear Ratio
BT
Recommended Make Up Torque Recommended Make UP Pressure In Various Gears
1
6.27
2
3.12
3
1.75
4
1
1,016 Nm 750 ft lbf 39 bar 570 psi 78 bar 1,140 psi 140 bar 2,030 psi
Rod size NT HT 1,360 Nm 1,000 ft lbf 52 bar 750 psi 105 bar 1,520 psi 186 2,700
PT
1,490 Nm 1,100 ft lbf 57 bar 830 psi 115 bar 1,670psi 205 bar 2,970 psi
2,030 Nm 1,500 ft lbf 78 bar 1,130 psi 157 2,270
Table 10.1 CS4002 Recommended Make-Up Torq ue And Correspon din g Rotation Pressur e Based On: -Rotation mo tor s et at max displacement of 145 cc -Total mechanical efficiency o f 90% for dr illhead -No allowance for inertial effects
Rotation Pressure PSI 3500 3400 3200 3000 2800 2600 2400 2200 2000 1800 1600 1400 1200 1000 800 600 400
Spindle Torque – Ft LBF 4th gear Min Disp
508 494 464 435 406 377 348 319 290 261 232 203 174 145 116 87 58
3rdh gear
Max Displ
740 719 677 634 592 550 507 465 423 381 338 296 254 211 169 127 85
Min Disp
889 849 799 749 699 649 599 549 499 449 399 350 300 250 200 150 100
2nd gear
Max Displ
1,295 1,236 1,164 1,091 1,018 946 873 800 727 655 582 509 436 364 291 218 145
Min Disp
1,585 1,564 1,472 1,380 1,288 1,196 1,104 1,012 920 828 736 644 552 460 368 276 184
1st gear
Max Displ
2,309 2,279 2,145 2,011 1,877 1,743 1,609 1,475 1,341 1,206 1,072 938 804 670 536 402 268
Min Disp
3,185 3,272 3,080 2,887 2,695 2,502 2,310 2,117 1,925 1,732 1,540 1,347 1,155 962 770 577 385
Max Displ
4,640 4,766 4,486 4,206 3,925 3,645 3,364 3,084 2,804 2,523 2,243 1,963 1,682 1,402 1,121 841 561
Table 10.2 CS4002 Spin dle Torqu e (ft lbf) For Range Of Rotation Pressures (ps i) Based On: -Rotation mo tor d isplacement at: -minimum at 100 cc, displacement control screwed in -maximum at 145 cc, displacement control screwed out -Total mechanical efficiency o f 90% for dr illhead -No allowance for inertial effects
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Drilling
10.15.3 Rod Handl ing Usi ng Opti onal 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 Proc edure 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.
Pi e wrenches and breakout tools can cause serious in uries. Take extreme recautions.
71
10
72
Drilling
11.1
General
Al way s fo ll ow th e Safety Ins tr uc ti on s in cl ud ed i n Sec ti on 2 and sp eci fi cal ly th os e in sectio n 2.7 for Maintenance and Servic ing The performance and reliability of the Christensen CS4002 is largely dependent on the amount of care and attention shown to it. Re gular 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 •
• • • •
11-1
11.2
Perio dic Maintenance & Service Schedule
The maintenance and service schedule specifies periodic lubrication and servicing instructions following a certain number of operating hours. Use this schedul e to get the most reliable service from your equipment.
Table 11.1 CS4002 Maintenance Schedule Check & Service Points
8
250
11.4.1
Engine oil level
Check
11.4.2
Engine oil filter
Change oil 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 if applicable & check cooling system
11.4.5
Engine air intake filter
Remove coarse particles
Check filters
11.4.6
RACOR engine fuel filter/water separator
Drain water at separator
11.4.7
Hydraulic tank level and oil condition
Check level, drain water as required
Ref #
11.4.9 11.4.1 0
Hydraulic oil cooler High pressure filters (3) : -main pump -auxiliary pump -secondary pump
11.4.1 1
Hydraulic tank return filter
11.4.1 2 11.4.8, 11.4.1 3
Case drain filters (2) Compressed air tank & charge air filter (if equipped) Hydraulic tank breathers (2) Electric oil transfer pump (if equipped)
11.4.8
11.4.1 5
Drillhead oil level and filter
11.4.1 5
Rotation unit chain tension
11.4.1 6
Hydraulic chuck
11-2
Service Interval In Hours Of Operation 500
1000
2000
Notes
Drain cooling system, flush, replace coolant Change filters as required
Change filters more often in dusty conditions
Replace Filter Element Change oil or a minimum of once per year
Water may have to be drained daily if humidity high & tank cools between shifts
Clean fins Replace filter elements
Or earlier if pop-up indicator remains up with oil at operating temp.
Replace filter element
Or earlier if pop-up indicator remains up with oil at operating temp.
Replace filters Drain water at air tank
Replace filter Replace breathers
Every 500 hours in dusty conditions Replace filter
Check level
Change oil and filter, clean strainer Check tension
Grease 3 fittings
Replace oil & filter, clean strainer of new drill or rebuilt drillhead at 100 Hrs. Check tension of new drill or rebuilt drillhead at 100 Hrs
11.2
Ref #
Perio dic Maintenance & Service Schedule Check & Service Points
Service Interval In Hours Of Operation 8
250
11.4.17
Mud/water pump
11.4.18
Main winch
Check oil level
11.4.19
Wireline hoist
Grease levelwind screw
11.4..20
Foot clamp
Grease hinge pins
11.4.20
Carriage rollers
Grease 8 rollers
11.4.21
Mast pivot pins (2), mast raise cylinder pins (4), mast hinge cylinder pins (4)
Grease
Chuck jaws
Inspect inserts and clean if necessary
11.6
Hydraulic hose and elastomeric seal replacement
1000
Change oil & clean magnetic plug
Check oil level
Main hoist rope
500
Change oil
Notes
2000 Replace oil & clean magnetic plug after first 100 Hrs for new or rebuilt pump Change oil after 100 hrs for new or rebuilt hoist
Grease bearings, oil levelwind chain
Stop greasing when grease escapes around roller seal
Lubricate main cable
Cable should be lubricated at first use of a new cable See section 11.6 for recommendations
11-3
11.3
Lub ricant Recomm endations Table 11.2 Recommended Lubricants
Lubricant Hydraulic oil
Service Point 11.4.7
Recommendation Use mineral-based hydraulic oil with good anti-wear , rust (oxidation) and foam inhibiting proper ties, as well as ef fective 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
+25 to +40 C (77 to 104 F) 0 to +25 C (32 to 77 F) -30 to 0 C (-22 to +32 F)
Viscosity Index Min. 150 Min. 150 Min. 150
ISO VG 68 ISO VG 46 ISO VG 32
Examples of oil grades in the temperature range 0 to + 25°C: Shell Tellus T46 Bartran HV 46 BP Castrol Hyspin T 46 DTE 15M Texaco Mobil Rando HDZ 46 Exxon Univis HP 46
For use of f lame pr oof or biodegradable hydraulic oil, please contact nearest Atlas Copco representativ e f or inf ormation
Drillhead transmission & gearcase oil Transmission oil (mud/water pump & main hoist Grease
11.4.15
11.4.17, 11.4.18
11.4.20
Summer operation: 80w90 weight API Classification GL5 Winter operation: hydraulic oil ISO VG 46
80W90 weight API Classification GL5 “For main winch use: Mobilgear 600XP 150 or equivalent” Univer sal 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 Esso BP
Engine oil and Coolant Main Hoist Rope
11.4.1, 11.4.4
Retinax AM
MP Grease Energrease LS-EP 2
Use engine oil and coolant according to diesel engine Instruction Manual 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 )
These instructions provide Atlas Copco and manufacturer’s part numbers for filters/filter elements, pictures and other information of interest. 11.4.1 Engin e Oil L evel - See section 4.1 in Diesel Power Unit (Drill Manual Section II) 11.4.2 Engine Oil An d Coolant Filters - See section 4.2 in Diesel Power Unit (Drill Manual Section II)
11-4
11.4
Service Point Detailed Instru ctio ns
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 Engi ne 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
11-5
11.4
Service Point Detailed Instru ctio ns
11.4.7 Hydraulic Tank Oil Level, Draining Water and Cleanin g •
• •
•
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 gl ass. 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 Hydrauli c Tank Breathers and Charge Air filt er • • •
•
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
11-6
Charge Air Filter
11.4
Service Point Detailed Instru ctio ns
11.4.9 High Pressure Filt er (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 (Aux iliary & Secon dary Pump s) 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.
11-7
11.4
Service Point Detailed Instru ctio ns
11.4.11 Hydraulic Tank Main Return Filt er •
•
•
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
Do not substitute filter element. Warranty void if specified filter element is not used.
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
Do not substitute filter element. Warranty void if specified filter element is not used.
11-8
11.4 11.4
Servi Service ce Point Detailed Detailed Instru ctio ns
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. 4.1 bar (60 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 Drills equipp ed with Joh n Deere Deere Engines use a small compressor (not sh own) and the Diesel Diesel engine turbo to pressurize the hydraulic tank (not sh own)
11.4.1 11.4.14 4 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 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.
11-9
11.4 11.4
Servi Service ce Point Detailed Detailed Instru ctio ns
11.4.1 11.4.15 5 Drill Head 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 transmission and the drill drill head chain case use the same oil. Chain case housing is checked in the vertical position on right side of casing through plug located behind adjuster plate. The transmission oil level is also checked/filled in the vertical position, on back side of transmission through ¾ NPT plug. 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.
Oil Filter
Remove plug to check chain tension
Oil Pump
Strainer
Check vertical level here, behind adjuster plate.
11.4.1 11.4.16 6 Hydraulic Chu ck Grease Fitti Fitti ngs •
•
On the drill head there are 3 grease fittings, two on the chuck bonnet, and one on the bearing retainer. Grease these these fittings fittings per schedule in Table 11.1using good quality multi purpose E.P. grease. grease.
Grease here plus one on opposite side
Grease here 11-10
Clean grease fittings before adding grease to prevent contamination
11.4 11.4
Servi Service ce Point Detailed Detailed Instru ctio ns
11.4.17 Mud/Water Pump • •
Check the mud/water pump oil level daily. Refer to to the FMC Operator’s Operator’s Manual located in the Parts Manual Manual for maintenance, startup and shut-down procedures.
Model Shown FMC W1122 BCD
11.4.18 Main Winch • •
Check the main winch oil level daily. See the Braden Winch insert insert in the the Parts 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
11-11
11.4
Service Point Detailed Instru ctio ns
11.4.19 Wirelin e Winc h • •
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) (Guard shown removed)
Grease hose into fitting (2 locations)
Grease crown block here
11-12
11.4
Service Point Detailed Instru ctio ns
Carriage rollers grease fittings (4 on o ther side, 8 in total)
Lift cylinder clevis pins (4 locations)
Mast pivot pins (2 locations)
11-13
11.5
Perio dic 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 personnel fall protection devices are serviceable 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.
11-14
11.5
Perio dic Inspections Table 11.3 Periodic Inspections and Intervals Inspection Frequency Inspection Point
y l i a D
Emergency Devices & Alarms: -E-stop buttons -Main winch block limit switch -Audible alarm
X X
Guards
X
Main winch rope
X
y l k e e W
Crown block sheave for main winch Tightness of Bolts: -rope clamps on main hoist drum -crown block to mast -jacks to deck -main hoist to deck -bolts retaining mast in saddle -drillhead slide plate -angle adjustment plate on platform -feed cylinder anchor plate to mast -carriage rollers (8) -roller mounting plates -replaceable ways -hose end anchors Pin retainers in place: -hoisting plug -waters swivel -hoist block limit switch -mast raise cylinders -mast backstay leg -rod rack backstay leg -folding mast securing pin Weld and Material Cracks -rod clamp table to mast -saddle weldment -backstay legs -cylinder ends Oil leakage from tank, fittings, hoses and components Personnel fall protection devices Hoisting plug, water swivel
y l h t n o M
X
X X X X X X X X X X X X
y l r a e y f l a H
y l r a e Y
Comments
-Audible alarm test button is located on console -Check audible alarm sounds when using secondary control panel Ensure guards are in place and are functioning Replace rope if rope is kinked, has broken strands, or is worn Check for wear & surface cracks Inspect all bolts for tightness every month but pay special attention to the bolts listed. Re-torque as required
Ensure pin retainers are in place and secured
X X X X X X X X X X X X X X
Ensure that devices are in serviceable condition Inspect these load carrying items for damage and condition
11-15
11.6
Hydraulic Hoses & Fitting s Inspection
Hose and Fitting Maintenance and Replacement Instruct ions 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. 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
11-16
11.6
Hydraulic Hoses & Fitting s Inspection
eliminate the pressure in the hose assembly. Many times check valves, etc., are employed in a system and can cause pressure to remain i n 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 i f a failure has occurred. Never a ttempt 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.
11-17
11.6
Hydraulic Hoses & Fitting s Inspection Page Intentio nally Left Bl ank
11-18
12
Hydraulic Circuit Description
12 Hydraulic Circuit Descript ion 12.1 Hydrauli c 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.
20 µ 87 psi
20 µ 87 psi
20 µ 87 psi
30 psi Max
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.
89
12
Hydraulic Circuit Description
12.1.2 Auxi liary 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 172 bar (2,500 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 CS4002 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 CS4002 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 CS4002 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 p rotects 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 i s designed to have the 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
90
12
Hydraulic Circuit Description
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 Charg e Air filt er (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.
12.3 Main Pump Circuit
Premature and repeated failure of hydraulic components has occurred when customer substituted wrong type of filter elements.
91
12
Hydraulic Circuit Description
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 counterbalance valve item 89. The counterbalance 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. 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 hydraul ic 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, to prevent overspeed conditions and damage to the winch and winch motor. Also see Braden service manual in the part manual for installation, maintenance, and service instructions.
92
12
Hydraulic Circuit Description
12.3.2 Rotatio n Mot or (Item 4) Maximum flow to the rotation motor is 272 lpm (72 gpm); max pressure is 241 bar (3,500 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 hydraul ic 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 w inch 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. A 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.
93
12
Hydraulic Circuit Description
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, 136 lpm (36 gpm) in the down direction. Max pressure is 165 bar (2,400 psi ). The cylinder ID is 127 mm (5 in) and the rod diameter is 88.9 mm (3.5 in). The differences in area and flow produce approximately the same speed in the down and up direction. The fast travel section directs maximum volume (0-272 l pm) to the feed cylinder for rapid movement up. 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
94
12
Hydraulic Circuit Description
12.4 Auxi liary Pump Circu it 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. An audible alarm sounds when any of the positioning valves are activated to w arn personnel of the cylinder movements. The auxiliary pump compensator setting sets the max circuit pressure at 2500 PSI 1. 2. 3. 4. 5. 6. 7. 8.
Control panel slide Mast fold (used with optional folding mast) Mast dump Mast raise (a relief valve limits the pressure in the mast lowering direction) Valve for front right jack Valve for front left jack Valve for rear right jack Valve for rear left jack
i s p 0 8
P
2 6 x 0 3 . 0 i 0 s 1 p
T
95
12
Hydraulic Circuit Description
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 Item 28 Item 17 Item 18A Item 24A Item 20 Item 18B Item 24B Item 19 Item 47 Item 23A Item 23B Item 15
Slow feed directional valve Pulldown pressure cartridge Feed rate valve Chuck open/close Head opener Hi/lo water pump Main winch brake release Rod kicker Foot clamp open/close Thread compensation (adjustable setting) Main winch motor displacement (speed/torque) control (not shown) Rotation motor displacement (rpm/torque) control (not shown) Mud mixer (placed in series with air/oil cooler fan motors
12.4.3 Other functi ons p owered by auxiliary p ump Item 63A/B Item 81 Item 96 Item 50
96
Fans motors on air/oil cooler Pilot controllers for main valve Wireline hoist brake release Optional Spin-Out tool
12
Hydraulic Circuit Description
3000
3000 Max PSI
Fig 12.1 Functions Powered By Auxiliary Pump
97
12
Hydraulic Circuit Description
12.5 Secondary Pump Circuit The standard CS4002 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 CS4002 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
2000 Max PSI
98
12
Hydraulic Circuit Description
12.6 Retur n Oil Circ uit 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). Th is allows the hydraulic oi l 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 h ydraulic 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 6.2 bar (90 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.
99
12
Hydraulic Circuit Description
TEMP 130 °F
65 psi
1725 MAX RPM 6 GPM 6000 Max PSI
10 µ 25 psi
25 µ 3 psi
10 µ
10 µ
10 psi
10 psi
125 psi
60 psi
25 µ 3 psi
10 µ
30 psi Max
8 psi
TEMP SETTING 176 °F
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.
100
13
Electrical Circuit Description
13 Electrical Circuit Description 13.1 Electri cal 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 plus an additional one if drill is equipped with optional rod rack and helper’s platform) 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. 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 Condit ion 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. • •
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• •
•
•
•
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13
Electrical Circuit Description
13.2 Safety Systems Description The CS4002 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 of the emergency stops cuts power to the normally open solenoid valve connected to the main pump load sense li ne, and at the same time, ini tiates engine shut-down. Cutting power to the solenoid valve connects the l oad sense line to tank and therefore reduces pressure and flow from the main pump functions (rotation, main winch, wireli ne 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) For drills equipped with the optional rod rack/helper’s platform, there is a plug-in E-stop connection accessible from the helper’s platform. The helper can then locate the portable E-stop at a suitable location on the platform. A jumper is used when the helper’s E-stop is not plugged into the receptacle.
13.2.2 Rotatio n Pilot Cont roll er Neutral Switc h •
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 Audibl e Alarm When Operating Secondary Cont rol Cons ole •
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.
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Trouble Shooti ng
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 t he procedures used by the factory to set up the hydraulic sys tem pressures, adjustments etc. It is inc luded to aid the mechanic with detailed instructi ons when parts of the hydraulic syst em are out of adjustment and have to be reset, and to reset minimum and maximum dis placement settings on replacement main winc h and rotation moto rs. It is also useful for finding the procedures used t o c heck/reset specific pressures/adjustments referenced in the troubleshooting section.
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Trouble Shooti ng
14.1 Trouble-Shooting - General Type of fault 1. Noisy pump caused by cavitation
2. Noisy pump caused by aeration
3. Hydraulic system overheating
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Possible cause
Remedy
A. Oil is too viscous
A. Change to proper viscosity
B. Filter plugged
B. Clean or replace
C. Suction line plugged
C. Clean line
D. Suction line ball valve closed or not fully open
D. Fully open valve, pumps probably damaged, inspect.
E. Tank not sufficiently pressurized for high altitude
E. Check tank pressure, adjust pressure reducing valve from air tank to specification
A. Oil supply low
A. Fill hydraulic tank, check low level switch mounted in tank
B. Air leaking into suction line
B. Tighten fittings
C. Foaming oil
C. Drain hydraulic tank and fill with non-foaming type oil. Check that return line oil is not mixing with air first
A. Oil supply low
A. Fill hydraulic tank
B. Oil in system too light
B. Drain hydraulic tank and refill with proper viscosity oil
C. Fan speed too low
C. Check RPM 1750 both fans
D. Cooler fins dirty or plugged
D. Clean fins
E. Excessive internal leakage in hydraulic pumps
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. Aeration of oil
F. Tighten suction fittings
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Trouble Shooti ng
Type of fault 4. System not producing necessary pressure
5. System does not produce proper flow
Possib le cause A. Excessive internal leakage
Remedy A. Check amount of flow is according to specification
B. Compensator spool stuck open
B. Disassemble, inspect, clean, or replace compensator
C. Compensator spring weak or broken
C. Check spring in compensator
D. No flow to compensator signal port
D. Check load sense line for damage, size, and length
E. Load sense line disconnected or filled with air
E. Connect and bleed of the system
A. Excessive internal leakage
A. Check amount of flow according to specification
B. Compensator spool stuck open
B. Disassemble, inspect, clean, or replace compensator
C. Compensator spring broken
C. Check spring in compensator
D. Pump cavitation
D. Check proper oil viscosity, suction line, tank pressure
E. No load sense signal to compensator
E. Check load sense line and ports at valve
F. Load sense line disconnected or filled with air
F. Connect and bleed the system
G. Low pilot pressure
G. Test pressure.
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Trouble Shooti ng
14.2 Troubl e-Shootin g Auxi liary Pump Circuit Type of fault 1. Little, erratic, or no feed pressure
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Possible cause A. Hydraulic plumbing is not according to schematic
Remedy A. Check schematic in Parts Manual and correct plumbing if necessary.
B. Pressure gauge defective (false reading)
B. Check the face and needle in pressure gauge for damage, replace if necessary
C. Feed rate valve is not operating properly
C. Check needle valve and internal bypass check valve
D. Return line from manifold is blocked
D. Check oil flow back to tank
E. Slow feed directional valve is not operating properly
E. Check for worn or damaged parts (slow feed valve spool is detent)
F. Pressure reducing valve for pulldown pressure is worn or damaged
F. Check for worn or damaged parts
G. Thru shaft from main pump is broken or damaged
G. If main pump is ok check where auxiliary and secondary are piggybacked at thru shaft.
H. Pump or compensator is bad or out of adjustment
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. Contamination in control valve or auxiliary pump manifold ports.
I. Disassemble, clean, and inspect for broken parts
J. External problem such as main winch brake or drillhead carriage parts are affecting the feed process.
J. Disconnect main winch rope and check condition of carriage rollers and replaceable ways. Troubleshoot brake release system if necessary.
K. Feed cylinder or feed cylinder seal kit is defective or worn
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.
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Trouble Shooti ng
14.2 Trouble-Shooting Auxiliary Pump Circuit (cont’d) Type of fault 2. Hydraulic chuck opens partially, not at all, or leaking hydraulic oil (not grease) at chuck body.
3. Chuck jaws not holding drill rod or slipping.
Possib le cause
Remedy
A. Relief valve for chuck (located below the control valve lever) is stuck, contains contamination, damaged, or pressure setting is not correct.
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. Control valve spool is damaged or broken.
B. Check for worn or damaged parts in control valve.
C. Auxiliary pump or compensator problem.
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. Damage to internal sliding parts of chuck.
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. Seal kit, piston, or cylinder, is worn or damaged.
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.
A. Incorrect chuck jaw size, worn jaws, or damaged.
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. Hydraulic pressure entering chuck cylinder when chuck control valve is in the closed position.
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. Internal parts of cylinder or chuck are not moving properly.
C. Disassemble chuck, clean, and inspect for damaged parts.
D. Excessive contamination inside chuck and jaws.
D. Clean carbide inserts and sliding areas of jaws.
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Trouble Shooti ng
14.2 Trouble-Shooting Auxiliary Pump Circuit (cont’d) Type of fault 4. Mud mixer not rotating, rotating slow, or erratic.
5. Hydraulic jacks, mast raise, etc. will not operate at all or erratic.
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Possib le cause A. Quick disconnects not connected properly or pilot inside is broken
Remedy A. Check quick disconnects for damage/broken parts or does not go together freely.
B. Mud mixer control valve (flow divider) is worn or damaged.
B. Check the spool and housing of control valve for wear or damage
C. Drain port (port B) from control valve not connected to tank or is line plugged.
C. Connect tank line or clean line
D. Hydraulic motor at mixer assembly is defective.
D. Troubleshoot hydraulic motor for damage or internal leakage.
E. Relief valve at flow divider inlet is set too low or is leaking
E. Check relief valve setting of 138 bar (2,000 psi). Reset if necessary.
F. Auxiliary pump or compensator is bad or out of adjustment.
F. Troubleshoot pump for proper settings, excessive internal wear, and compensator problem.
A. Selection valve in “main console” position
A. Move valve to “secondary console’ position
B. Hydraulic cylinder leaking internally or damaged.
B. Troubleshoot the cylinder.
C. Control valve is worn or damaged.
C. Inspect control valve spool and housing for wear or damage.
D. Auxiliary pump or compensator is bad or out of adjustment.
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. Selection valve not working properly
E. Check selector valve
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Trouble Shooti ng
14.2 Trouble-Shooting Auxiliary Pump Circuit (cont’d) Type of fault
Possib le cause
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.
Remedy 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 ci rcuit.
B. No pressure from rotary control valve
B. Check the auxiliary pump and compensator
C. Swivel angle adjustment screws are not properly set (located on both sides of hydraulic motor).
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. Rotary valve cartridge is worn, damaged, or contamination inside.
D. Remove the rotary control valve cartridge from housing and check for wear, damage, or contamination.
E. Hydraulic control valve at hydraulic motor is worn, damaged, not adjusted properly, or contains 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. Internal wear or damage to displacement parts inside hydraulic motor.
F. Troubleshoot the hydraulic motor according to Rexroth troubleshooting guide manual.
G. Erratic rpm can be caused by problems beyond the hydraulic system such as problems in the drilling process, transmission, or the drillhead.
G. Disconnect the drillhead from drill string and observe if rotation improves.
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Trouble Shooti ng
14.3 Trouble-Shoo ting Main Pump Circui t Type of fault 1. Rotation section in main valve bank producing slow rpm, no revolutions, or lack of pressure.
Possib le cause A. Main pump or compensator problem
Remedy 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. Problem in primary or secondary shuttles
C. Relief valve in main valve is stuck or damaged
B. Check/remove, clean, and inspect the shuttle in the 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.
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
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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
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Trouble Troub le Shooti ng
14.3 14.3 Trouble-Shoo Trouble-Shoo ting Main Main Pump Circu it (cont ’d) Type of fault 2. Rotation section in main valve bank producing slow rpm, no revolutions, or lack of pressure (cont’d).
3. Fast feed section in main valve bank does not move feed cylinder, too slow, or erratic.
Possib le cause
Remedy
H. Problem in hydraulic motor on drillhead.
H. Try turning the min and max displacement adjusting screws slightly and observe if rpm changes. Check the drill setup procedure, section 15, for correct min and max rpm settings and reset if required. Drillhead high speed is 1300 rpm and it is not recommended to overspeed
I. Load sense relief valve settings in main valve not to specification
I. Lock chuck on rod held in foot clamp and check max pump pressure - should be at 240 bar (3,500 psi)
J. Problem in transmission or drillhead housing.
J. Disconnect hydraulic motor from transmission and see if problem still exists.
A. Similar problems as in rotation section: main pump, main valve, pilot pressure or load sense line
A. Perform same checks as for rotation section
B. Load sense relief valve settings in main valve not to specification
B. Check the load sense limiting valve by running the cylinder into end position and read system pressure gauge - should be 165 bar (2,400 psi) in both directions
C. Problem in feed cylinder.
C. Troubleshoot the feed cylinder checking for worn seal kit or damage to cylinder.
D. Problem in the drillhead carriage rollers or the replaceable ways
D. Do inspection inspection of rollers, and ways
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Trouble Troub le Shooti ng
14.3 14.3 Trouble-Shoo Trouble-Shoo ting Main Main Pump Circu it (cont ’d) Type of fault 4. Main winch winch section in main valve bank producing slow winch, no winching, erratic, or winch not holding load.
5. Wireline section in in main valve bank producing slow, erratic, or no rotation of the wireline winch drum.
Possib le cause A. Similar problems as in rotation section: main pump, main valve, pilot pressure or load sense line
A. Perform same checks as for rotation rotation section
B. Load sense relief valve settings in main valve not to specification
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 b oth directions
C. No pressure from manual brake release valve when valve is in brake release position
C. Check brake release valve.
D. Problem in Braden winch
D. Troubleshoot Braden winch according to installation, maintenance, and service manual located in Part Manual
E. Problem in structural or mounting parts of Braden winch
E. Check structural area where winch is mounted. Make sure mounting platform is strong and mounting surface is even
A. Similar problems as in rotation section: main pump, main valve, pilot pressure or load sense line
A. Perform same checks as for rotation rotation section
B. Load sense relief valve settings in main valve not to specification
B. Check the load sense relief valve by disconnecting and capping lines to wireline winch m otor. Activate winch control - system pressure gauge should be 207 bar (3,000 psi) in b oth directions
C. Brake does not release
C. Check automatic brake release valve, shuttle valve and pressure line from auxiliary pump circuit
H. Problem in hydraulic motor mounted to winch drum.
H. Troubleshoot hydraulic motor and counterbalance valve mounted on the winch
I. Damage to structural or mounting parts on winch.
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Remedy
I. Check assembly and mounting mounting area of winch winch to main frame and condition of sheave wheels and crown block.
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Trouble Troub le Shooti ng
14.4 14.4 Trouble-Shoo Trouble-Shoo ting Second Second ary Pump Circu it Type of fault
Possib le cause
Remedy
6. The mud/water pump will not turn or stalls at low pressure.
A. Wrong rotation direction of pump.
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 pump 2 speed motor is for Lo speed (high pressure, lower flow) when drilling
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. Problem with 2 speed motor
C. Check for proper hose plumbing. Troubleshoot two-speed pilot line on auxiliary circuit. Refer to Eaton service manual for more information.
D. Secondary pump problem
D. Check the secondary pump pressure – should be 207 bar (3,000 psi)
E. Pump suction or relief valve problem
E. Troubleshoot the pump for suction problem, water/mud pump relief valve stuck or damaged
F. Problem beyond hydraulic motor
F. Inspect hydraulic motor adapter and mud pump for damage.
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Trouble Shooti ng
15
Hydraulic Set-up Procedure
15 Hydraulic Set-Up Procedure The Hydraulic Set-Up procedure is added to the manual to provide the mechanic with d etailed procedures to set the hydraulic adjustm ents on the machine. This will be useful when adding new comp onents such as variable hydraulic mot ors, hydraulic pumps, cartridg es etc. which generally will not have been preset pressures, volume stops etc. at the factory or vendor. This will pr event damage to compon ents due to ov er-speeding, over-pressure etc. Also th e 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. Ac ro ny ms : 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
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Hydraulic Set-up Procedure
2. HYDRAULIC PUMP ADJUSTMENTS PRIOR TO STARTING ENGINE OPERATIONS
RESULTS
COMMENTS
st
Main Pump (1 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 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. CUMMINS ENGINE STARTUP AND HYDRAULIC OIL TANK PRESSURE SETTING OPERATIONS
-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.
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RESULTS
COMMENTS
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Hydraulic Set-up Procedure
4. AUXILIARY PUMP HIGH PRESSURE COMPENSATOR SETTING OPERATIONS -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
RESULTS
COMMENTS
-Pump pressure is indicated on auxiliary system gauge in control console -Adjust compensator (inside adj. screw) to 2500 PSI. Tighten lock nut.
5. PRESSURE REDUCING RELIEVING VALVE FEEDING 4 X D03 MANIFOLD (HEAD OPENER, PILOT PRESSURE,MAIN WINCH BRAKE RELEASE, TRAY LIFTER AND FOOT CLAMP) OPERATIONS -Connect 3000 PSI gauge to test fitting in pressure reducing valve feeding Hi/Lo water pump speed control and valve manifold with 4 x D03 valves.
RESULTS
COMMENTS
RESULTS
COMMENTS
-Loosen lock nut and adjust PRV to 1450 PSI. -Tighten lock nut and remove gauge Main Control valves can now be operated
6. COOLING FAN RPM OPERATIONS -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
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Hydraulic Set-up Procedure
7. MAIN PUMP AND MAIN VALVE PRESSURE RELIEF SET UP OPERATIONS 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
RESULTS
COMMENTS
RESULTS
COMMENTS
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 -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 67 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
-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 -
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Hydraulic Set-up Procedure
9. HEAD OPENER PRESSURE OPERATIONS
RESULTS
COMMENTS
-Tee a 3000 PSI gauge into port of pressure reducing relieving valve set in section 5. - Move drill head to side and back again while observing the pressure required to slide the drillhead. Record the maximum pressure to move drillhead.
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.
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Hydraulic Set-up Procedure
11. WIRELINE HOIST SETTINGS OPERATIONS 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 -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
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RESULTS
COMMENTS
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Hydraulic Set-up Procedure
12. FEED CYLINDER COUNTERBALANCE (C/B) VALVE OPERATIONS
RESULTS
COMMENTS
RESULTS
COMMENTS
-Run fast travel down until cylinder bottoms out. Select "Make" setting at drill/make control (position 21 in Fig. 7.1). Hold fast travel lever in down position while adjusting "Make" pressure until main pump load sense pressure gauge reads 570 psi. (The "Make" pressure setting controls main pump load sense pressure so this is effective for all main pump functions). -Close feed rate valve and screw out (counter clockwise) the C/B adj. screw to increase C/B relief valve setting (valve located in port 2A on feed block) -Raise drillhead to mid stroke with fast travel up. -Put fast travel in down direction. Load sense pressure gauge should read 570 psi and drillhead should not move. - Screw in C/B valve screw (reduces C/B relief valve setting) until drillhead just starts to move (C/B valve relief has opened at 3120 PSI which is 30% above 2400 PSI max pullback pressure. The pilot pressure signal from the fast travel down is calculated from formula: Pilot pressure= C/B set pressure/(pilot ratio + 0.51) when load induced pressure is zero With pilot ratio of 5, pilot pressure is about 570 psi -Reset drill/make control to drill position
13. FAST TRAVEL LOAD SENSE PRESSURES OPERATIONS -Back out fast travel load sense relief valves far enough to enable drillhead to move up and down
-Run fast travel up and down to clear any air from feed cylinder (if required, increase load sense pressure to move feed cylinder) -Screw in fast travel volume stop screw for down direction in main valve to position that gives approximately same speed in down direction as the up direction (about 3.5 ft in 3 seconds) -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 2400 PSI using the main pump pressure gauge. -Repeat for fast travel down and set load sense for travel down at 2400 psi. -check fast travel speed in down direction is same as for up
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direction, should be approx 3.5 ft in 3 seconds. If necessary adjust down direction volume stop screw in main valve. -Record speed in up and down direction.
14. PROGRAMMING OF DRILLHEAD DIGITAL RPM DISPLAY AND WATER PUMP FLOW RATE DISPLAY OPERATIONS Reference Red Lion Bulletin CUB5-D, Drawing No. LP0584 Found in OEM Parts Manual
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14.1 Setting 4002 Drillhead Digital RPM Display -Per section 6.2 Module 2 -Rate Setup Parameters, enter DSP=60 for rate scaling display value INP =6 for Rate Scaling Input Value 14.2 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)
15. ROTATION PRESSURE LOAD SENSE PRESSURE OPERATIONS
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-Disconnect rotation hose (reverse rotation direction). -While holding rotation lever in reverse direction, adjust rotation load sense relief valve to 3500 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 3500 PSI -Reconnect both rotation hoses
16. ROTATION MOTOR - DISPLACEMENT ADJUSTMENT OPERATIONS Procedure to set the 160 cc rotation motor at 145 cc max displacement and 105 cc min displacement
-Spray paint bottom spindle adapter with flat black paint, install reflective tape for R.P.M. photo tachometer. -Remove the min displacement adj. screw from the 160 cc Rexroth rotation motor and check that length is 110 mm long. If it isn’t,
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replace screw with part # 3760008988 (110 mm). Re-install with ¼ in. of threads showing above the lock nut and tighten the lock nut. (initial adj. only) -Remove the max displacement adj. screw from the 160 cc Rexroth rotation motor and check that length is 80 mm long. If it isn’t, replace screw with part # 3760009055 (80 mm). Re-install with ¾ in. of threads showing above the lock nut and tighten the lock nut. (initial adj. only) -Make sure head lubrication system (oil pump, filter, hoses, etc.) is primed and full of 90-weight oil and chuck bearings are greased. DO NOT ROTATE CHUCK IN OPEN POSITION DO NOT ROTATE IN CLOSED POSITION WITHOUT JAWS AND LIFTING BAIL INSTALLED
-Set engine R.P.M. at 1700. -Place transmission in 3rd gear. -Turn rotation speed control clockwise to high speed (minimum motor displacement). -Place rotation control lever in forward position.
-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. rd -Verify that transmission in 3 gear (shift lever position out and up )
-Place rotation control lever in the fully forward position and set engine speed at 2100 RPM. -Screw out rotation speed control (motor at max displacement). -Check rotation speed on reflective tape with photo tachometer. RPM’s should be 480 rpm -Loosen max. displacement adj. screw on motor and slowly screw in until spindle rpm reaches 535 rpm. Tighten lock nut and reinstall plastic cap. -Screw in rotation speed control (motor at min. displacement). -Check rotation speed on reflective tape with photo tachometer. RPM’s should be 660 rpm
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-Loosen min. displacement adj. screw on motor and slowly screw out until spindle rpm reaches 745 rpm. Tighten lock nut and reinstall plastic cap. -Put transmission in high gear, Check rotation speed control. Rotation speed should change from 940 to 1300 rpm as rotation speed adjustment is turned from fully out to fully in. -Check the digital display on the console with the photo tachometer.
17. MAIN WINCH LOAD SENSE PRESSURES OPERATIONS
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-Fully screw in load sense reliefs for both A and B ports. (Max pressure limited to 4700 psi main pump compensator).
18. MAIN WINCH MOTOR – MIN. & MAX. DISPLACEMENT ADJUSTMENT OPERATIONS Procedure to set the 160 cc winch motor at 135 cc max displacement and 75 cc min displacement
-Install reflective tape for R.P.M. photo tachometer on drum. -Remove the min displacement adj. screw from the 160 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 in. of threads showing above the lock nut and tighten the lock nut. (initial adj. only) -Remove the max displacement adj. screw from the 160 cc Rexroth rotation motor and check that length is 90 mm long. If it isn’t, replace screw with part # 3760008986 (90 mm). Re-install with 7/8 in. of threads showing above the lock nut and tighten the lock nut. (initial adj. only) -Screw out winch speed control (motor at max displacement). -Hold winch rotation control lever in the fully raise position and set engine speed at 2100 RPM. -Check spindle rpm on reflective tape with photo tachometer. Should be about 25 rpm -Loosen max. displacement adj. screw on motor and slowly screw in until spindle rpm reaches 28 rpm. Tighten lock nut and re-install plastic cap. -Screw in winch speed control (motor at min. displacement). -Check drum rpm with photo tachometer. Should be approx 43 rpm.
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-Loosen min. displacement adj. screw on motor and slowly screw out until drum rpm reaches 55 rpm. Tighten lock nut and reinstall plastic cap. -Check winch speed control. Drum rpm should change from 28 to 55 rpm as winch speed adjustment is turned from fully out to fully in. Record rpm range.
19. MAIN HOIST COUNTERBALANCE VALVE (TYPE SUN CAIG) OPERATIONS
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19.1 Cartridge Setting -Ensure C/B valve adj. screw is fully turned out counter clockwise (gives max set pressure setting of 6,000 psi) 19.2 C/B Cartridge Opening Check When main hoist is connected to water swivel, the manual hoist brake release control releases the brake and pilots open the counterbalance valve. Check correct function of brake release as follows: -Rotate main hoist slowly in raise direction and note pressure on main pump pressure gauge – should be about 150 to 500 PSI depending on rpm. -Rotate main hoist slowly down (brake not released) and note pressure on main pump pressure gauge - should be about 1500 PSI -Engage main hoist brake release and rotate hoist slowly down. Note pressure on main pump pressure gauge - should be about 150 to 500 PSI. This indicates that counterbalance valve is being piloted open by the hoist brake release valve.
20. MAST PULLDOWN RELIEF VALVE AND COUNTERBALANCE VALVES ON MAST RAISE AND MAST DUMP CYLINDERS OPERATIONS
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-Remove hose from “pulldown” side of mast raise cylinders and attach 3000 PSI gauge. Check that max 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 ccw (screw will remain stationary or may move in and C/B valve relief will be a max. setting). Then turn adj. screw ½ turn cw and tighten locknut. -Record mast raise pressure with top section folded out, mast dumped back and rotation head at bottom of stroke. -Record mast raise pressure with top section folded out, mast
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dumped forward and rotation head at top of stroke.
21. SECONDARY HYDRAULIC PUMP SETUP FOR FMC W1122BCD MUD PUMP, WATER PUMP RELIEF VALVE SETTING AND WATER PUMP TEST OPERATIONS 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 flow) using photo tach. -Turn stand-by pressure adjustment cw to increase flow/speed and ccw 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 ccw until water comes out of relief valve. -Lock relief valve setting and record pump compensator pressure. -Reduce pump high p ressure compensator setting until water pressure reaches 1000 psi. -Lock pump compensator adjustment screw and record compensator
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pressure. -Check and record max 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
22. OPERATION CHECK ALL FUNCTIONS OPERATIONS 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
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Drillhead power float Main hoist brake and release Wireline hoist and brake Make pressure operation Hydraulic jacks Mast dump Mast raise & lower, stiff leg pinning (no rod rack) Water pressure release valve at console Lighting system Water Pump Hi/Lo Speed Control Limit switch on main hoist for minimum 3 wraps Limit switch on main hoist for rope crossing/second layer Hydraulic tank pressure not leaking off through relief valves Special equipment 1: folding mast operation Special equipment 2: UDR spin out tool. Check flow from pressure compensated flow control valve with flow meter and record.
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23. OPERATION CHECK OF SAFETY DEVICES OPERATIONS All E stop operations: console, auxiliary valve position, rod stacking area, plug-in E stop on helper’s platform outlet (if drill equipped with helper’s platform option)
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Crown block limit switch Neutral switch on rotation pilot controller Audible alarm (beeper) on console control panel Audible alarm (beeper) when operate secondary panel controls Perimeter guard on main winch and wireline winch Drillhead guard If Equipped With Helper’s Platform
-Fall arrestor for climbing platform access ladder -Intermediate tie off when transitioning from ladder to body harness on platform (tie off point marked) -Operation of body harness for helper on platform (tie off point marked) -Operation of fall arrestor for climbing service ladder to crown -Portable E-stop and plug-in accessible from helper’s platform
Commissioning & Testing Signoff Mechanics name (print & sign): Date:
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16 Spin-Out Tool Option 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: MAX TORQUE - Break out: MAX TORQUE - Make Up: CONTROLS: RECOMMENDED OIL FLOW: MAX SUPPLY PRESSURE: WEIGHT:
BO, NO, HO Wireline Drill Rods and HW Casing 3,000 Nm 2,100 Nm All Hydraulic 100 lpm 180 bar 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 i nstalling components. Details are contained in Section 5.
UM65 – Foot Clamp Mod ific ation 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 SafeT-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.
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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 90degree 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 li ft 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 po sition where the vertical support bracket for either the left-hand or righthand 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-tspin 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 S WUNG OUT OF THE MAST DURING SET UP.
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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 foll owers 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 T O THE LENGTH OF THE FULLY EXTENDED ROD BOOM. E. Lower the safe-t-spin to a po sition where the vertical support bracket for either the left-hand or righthand 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-tspin 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 eng ine 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.
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16.2.1.3 Procedure t o sw ing the SAFE-T-SPIN out of the m ast. Right-hand m ount. 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 Proc edure to swin g th e Safe-T-Spin int o th e mast. Right-hand m ount. 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 m ount. 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 sw ing 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 w arning above re grip and footing conditions.
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16.2.1.5 Proc edure to remove th e Safe-T-Spin f rom 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 Operation al 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 Torqu e Control Pressure Settin g 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.
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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 BO NO HO HW Casin g
MAKE UP TORQUE ( Nm) 1250 1650 2100 1250
SAFE-T-SPIN MAKE TORQUE PRESSURE ( BAR ) 88 116 147 88
CAUTION: SLOWLY ENGAGE THE SAFE-T-SPIN CONTROL LEVER TO MAKE THE JOINT. IF THE CONTROL LEVER IS SUDDENLY ENGAGED, THE ROD J OINT 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 Str ing 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 Sa fe-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 da mage. E. Operate the Safe-T-Spin to ensure that the jaw s 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
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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.
16.2.3.2 Make Up o f Dril l Stri ng Changing the operation of the Sa fe-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 S afe-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 i n the foot clamp. Take the wei ght 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 gau ge 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 t he Drill String - General Notes Before making up the rod joi nts 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
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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. 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 w ear 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 Troubl e Shoo ting Guide PROBLEM No functions operate
PROBAB LE CAUSES Hydraulic power supply not connected Quick couplers damaged or dirty. Pilot pressure to the "make break" pilot control is low
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PROBLEM Safe-T-Spin will not Operate
PROBAB LE CAUSES Hydraulic hoses not connected Quick couplers damaged or dirty Broken chain / sprockets Hydraulic motor failure Safe-T-Spin torque control set too low
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RECOMMENDED SOLUTIONS 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. RECOMMENDED SOLUTIONS 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.
16
Spin-Out Tool Option
16.3 Safe-T-Spin Maintenance 16.3.1 Maintenan ce Sch edule
Weekly
3 Monthly An nu al
Bi-Annual General
Planned Maintenance Schedule 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 ) Lid off, Hose out thoroughly and Grease, including light grease of top bronze bush and chain. 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 list ed below. Carry out all servicing listed above; fit new upper and low er bronze thrust rings. Part nu mbers listed b elow. 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 Sectio n 4.1.1 SP8150-3. Items 6a & 23
Minor Overhaul Kit Contents. Reference Section 4.1 Drawing SP8150-3 for exploded view, Item No. 21 16 23 25 27
Part No. PD22873AG WU8151 PD22923Z PD22923AE PM28605E8
Descript ion. Stainless Balls Outrigger Bush Bush Permalube Thrust Washer Skt/Hd C/Sunk Capscrew
Quantity . 58 1 6 6 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. 9 36
Part No. WU7449 WU9278
Descript ion. Thrust Ring Top Thrust Ring Bottom
Quantity . 1 1
Ad di ti on al Misc ell aneo us Part s 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 1-2
Part No PD22923AK
Descript ion Bush Permaglide
Quantity 2
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138
Spin-Out Tool Option
17
Add endum Sheets
17 Add endum Sheets This section contains addendum sheets with Operator’s Instruction Manual information for those CS4002 drills that do not use the standard engines, water pumps, water pump circuits etc. Also see the hydraulic schematic specific to the customer’s drill included in the Parts Manual.
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