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Operator's Instructions for

CHRISTENSEN

CT 14

2

Operator's Instructions for

CHRISTENSEN

CT 14 These instructions are intended for operators of the Atlas Copco diamond core drill CHRISTENSEN CT 14. Instructions are given for start and stop procedures, drilling, additional instructions, maintenance, and service schedule to be carried out by the operator. For further information concerning service measures for the drill rig, please contact your nearest Atlas Copco representative. Read carefully the INTRODUCTION- AND OPERATING SAFETY sections before starting to use the rig. All rights reserved. The owner of the equipment is granted the permission to take copies of this publication solely for internal use. It is recommended, however, to order additional copies from Atlas Copco representative in order to benefit from the latest revision. Atlas Copco Craelius AB reserves the right to make changes in its products in order to improve design or performance characteristict without notice. 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. Any user of this publication is requested to inform Atlas Copco Craelius AB about deficiencies found, particularly in matters concerning product safety.

ATLAS COPCO CRAELIUS AB MÄRSTA - SWEDEN 2006-02

Printed Matter No 6991 1433 01b 3

Contents Page

Page

Introduction ........................................................ 5

Thread compensation .......................................43 Adding a drill rod and making a joint..............44 Breaking the joint.............................................. 44 Water pressure dump valve..............................44

Operating safety ................................................ 6 Organizational measures ................................... 6 Operation and maintenace ................................ 7 Special safety device .......................................... 9 Following signs are used .................................. 9 Environmental Instructions ...............................11 General ............................................................... 13 Hoisting and transport .................................. 14 Hoisting the drill and power unit .................... 14 Technical specification.......................................15 Drilling positions............................................... 16 Transport .............................................................18 Characteristict .................................................. 22 Mast .................................................................. 22 Rod holder ......................................................... 22 Power units ....................................................... 23 Performance specifications .......................... 24 Rotation units .................................................... 24 Mast extension.................................................. 26 Wire line hoists ................................................. 26 Design features ................................................ 27 Drill module....................................................... 27 Power unit ......................................................... 27 Control panel..................................................... 27 Controls ............................................................. 28 Control panel functions.................................... 28 Maneuvring ....................................................... 30 Pre-start procedure .......................................... 30 Start-up Diesel power unit............................... 31 Stopping Diesel power unit ............................. 32 Setting up for drilling ..................................... 34 Leveling the drill ............................................... 34 Mast sections .................................................... 35 Mast raise procedure........................................ 36 Mast backstay legs............................................ 37 Drilling ................................................................. 38 Before drilling starts ..........................................40 Start the power unit.......................................... 40 Start the water pump ....................................... 40 Adjust the flow of flushing water.................... 40 Start rotation ..................................................... 40 Start drill feed.................................................... 41 Stop drilling....................................................... 41 Wireline ............................................................. 42 Controlled wireline lowering ............................42 Controlled wireline hoisting .............................42 4

Maintenance ...................................................... 45 General............................................................... 45 Cleaning the hydraulic system ........................ 45 Oil cooler .......................................................... 45 Hydraulic oil filters .......................................... 46 Changing hydraulic oil .................................... 47 Draining condensed water out of tank ........... 47 Periodic maintenance ....................................... 48 Lubricant recommendations ........................... 50 Daily safety check.............................................. 51 Hydraulic system ...............................................52 Drill head 3-1/2”, 4-5/8” spindle........................54 Oil filter ...............................................................55 Chuck bonnet......................................................56 Changing rod holder jaws and rod holder guide bushings.................................................. 57 Flush pump.........................................................58 Wireline hoist .....................................................59 Main hoist ...........................................................60 Mast/Hoist Frame...............................................62 Mud mixer ..........................................................63 Basic hydraulics................................................ 64 Basic hydraulics, Trouble-Shooting ..............72 Rotation unit “P head”....................................86 Trouble shooting............................................... 94 Hydraulic schematic ........................................ 98

Introduction This instruction book is part of the complete delivery of your new diamond core drill CHRISTENSEN CT 14. It offers basic information on features and handling of the unit and contains advice and measures necessary to keep the rig operational. It does not, though, replace thorough training of operator, helpers and service support.

The information is divided into the following chapters

It is the responsibility of the owner to make sure that all personnel assigned to this CHRISTENSEN CT 14 unit, have the skill necessary for the safe operation, service and maintenance of the unit before carring out any kind of work. Personnel must have been given adequate time to assimilate the information in this book. One copy of the manual should be kept available for reference on the rig at all times.

Section 1:

Operating safety

Section 2:

General and technical specification.

Section 3:

Operation

Section 4

Maintenance

The following information is available, and relevant for operating the CHRISTENSEN CT 14 drill rig. CHRISTENSEN CT 14 Operator’s manual Spare parts list

Printed Matter No. 6991 1433 01 6991 1432 50

Order from:

Atlas Copco Craelius AB S-195 82 Märsta Sweden

Fax:

+46 ( 8) 591 187 82

5

Operating safety Dear operator, Before putting your new equipment into use, we would like to direct your attention to the safety aspects. Drilling can be a hazard to you and to the environment. Good order, training and well maintained equipment are key factors to safe operation. This instruction book is no replacement for thorough training, but will, as a training aid and a reference book, help you maintain a safe working environment and keep the rig in good operational condition. Yours faithfully; Atlas Copco Craelius AB

Intended use The diamond core drill CHRISTENSEN CT 14 is intended for surface exploration and investigation drilling. 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 information in operation-, service-, and maintenance books as stipulated by the manufacturer. The CHRISTENSEN CT 14 should be run, 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. The manufacturer is not liable for any damage caused by unauthorized alterations made to the unit.

Fig.1 Read the instruction book carefully before starting up the drill rig. 1.3

Always use personal protective equipment, as required by circumstances or demanded by regulations.

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 be investigated and rectified.

1.5

Warning signs must be kept easily legible at all times. Damaged signs should be replaced immediately.

1.6

The daily safety check, as described in this instruction, must be carried out in addition to maintenance measures described in the periodic maintenance section.

1.7

Hydraulic and electrical systems are of a complex nature - and can cause injury or damage if not handled with care. Repair and service shall be carried out by personnel with documented experience for these systems.

1.8

Welding repairs should only be carried out by an authorized 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.

1.9

After repair make sure that the rig has been inspected and approved by the proper authorities before being brought back to normal operation.

1.0 Organizational measures: 1.1

1.2

6

The diamond core drill CHRISTENSEN CT 14 shall be operated only by personnel who have undergone theoretical and practical training on the rig. Particular emphasis shall be laid on safety precautions and maintenance. Keep this instruction book as well as other books related to the equipment available on the rig at all times.

Operating safety 1.10

Never make alterations or modifications to components of the unit, 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.

This is part of the safety system. Never lock these levers into operating position using strings, sticks or similar items. The unit should always be started from the control panel. On a Crawler mounted rig, the operator should ride on the rig during tramming. Any attempt to move the rig while walking beside it could result in injury.

2.0 Operation and maintenance. 2.1

In addition to this manual you should also have a good knowledge of generally recognized safety and accident prevention regulations. If you follow these regulations you stand a better chance of accomplishing your task without harm to either man or equipment.

2.2 Prior to starting up for the first time, familiarise yourself with the rig's features, its controls and their functions. Refer to "Controls, Manoeuvring and Setting up for drilling" pages for further information. 2.3 Various safety devices are built into the system of the rig for your personal safety. These devices must be checked at least once at the beginning of each shift to ensure that they are in full working order. The equipment should not be used unless safety checks and maintenance have been carried out according to the schedule. 2.4 Operators and helpers should wear helmets, (with ear protectors when called for), safety glasses, safety shoes, gloves and suitable clothing. Loose fitting clothing and jewellery can get caught in the moving parts of the machinery, causing serious injury or even death. 2.5 Check the surroundings. During drilling and tramming 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. Do not drive the rig into a dust cloud. Check the travel route if you are unsure of the safety of the ground. 2.6 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.

2.7 Avoid sharp turns when tramming on inclined ground. Take extreme care when moving on wet, slippery ground. Secure the rig with a suitable wire rope when operating on slopes in excess of 10° from horizontal. 2.8 Shut the rig down when refueling. Fuels must be handled with care, and 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 uot the contaminated soil and transport it to an approved storage) Do not overfill the fuel tank. If you top up the tank in the morning, the expansion of the fuel, as the temperature increases later in the day, may cause fuel to spill from the tank. Tank ventilation easily clogs if the level of fuel is too high. See the “Environmental instructions” chapter for further information. 2.9

Never leave the rig unattended with the engine running. Carry the ignition key with you.

2.10 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 earth cable from the battery before carrying out service on the electrical system. The battery gas is explosive! Never use matches when checking the acid level.

7

Operating safety Be careful using tools made of iron near the battery, a spark might set off an explosion. Read the battery manufacturer’s manual for further information as well as the “Environmental instructions” chapter. 2.11 Hydraulic oils are poisonous. Use eye protection and gloves. Hydraulic oils, like fuel, must be treated in compliance with safety and environmental regulations. See the “Environmental instructions” chapter for further information. 2.12 Before any repair or service is carried out on the rig's hydraulic or water systems, make sure the engine is stopped and that all systems are depressurized. 2.13 Be very careful while tracing leaks in the pressurized systems. Hydraulic oils, water or air under pressure can penetrate the skin and cause complicated injuries or infection. If this happens, see a doctor at once. 2.14 Dispose of engine oils, hydraulic oils, fuels, filters and acids in a safe manner according to environmental protection regulations 2.15 Avoid the use of cleaning agents containing solvents like carbon tetrachloride. There are environmentally better alternatives now available on the market. 2.16 Use only authorized parts (Atlas Copco parts). Any damage or malfunction caused by the use of unauthorized parts is not covered by warranty. 2.17 Any warranty for work performed, only covers Atlas Copco Products, Atlas Copco components and work performed by authorised personnel.

8

GENUINE PARTS

Fig. 2.16 Use only genuine Atlas Copco parts.

Operating safety 4.0 Special safety signs On the rig and in the manuals you will come across the following warning signs. 4.1

DANGER

The “DANGER” sign warns for immediate hazards, which, when ignored, will inevitably cause serious personal injury or death!

4.2

The “WARNING” sign warns for hazards or unsafe practices which, when ignored, could lead to serious personal injury or death.

4.3

ThE “CAUTION” sign indicates hazards or unsafe practice, which could lead to minor personal injury or damage to equipment.

4.4

The “IMPORTANT” sign is used for recommendations such as how to run the unit efficiently, economically and in compliance with environmental regulations.

Fig. 4.1

WARNING Fig. 4.2

CAUTION Fig. 4.3

IMPORTANT ! Fig. 4.4

5.0 Following signs are used on your CHRISTENSEN CT 14 Description and where the sign is located: 5.1

Lifting points. This sign is located where the sling is recommended to be attached. Location: Each corner of the crawler.

5.2

Ear protectors. Ear protectors should always be worn. 3716 5528 00

5.3

Risk of crush. Be aware of the risk from crushing.

5.4

Diesel fill. Location: On the diesel power unit.

5.5

ATTENTION Before starting, oil must be filled according to: Lubricant Recommendations

5.6

Drain water cooler. When there is a risk of freezing, especially during storage of the unit.

3716 5525 00

Fig. 5.1

Fig. 5.2

3716 5527 00

3716 5526 00

Fig. 5.3

Fig. 5.4

?

Fig. 5.5

-0°°C -0

Fig. 5.6 9

Operating safety

CAUTION! It is recommended that the drill operator checks that the mine disconnect system is equipped with a ground fault/ground check system. If the mine does not supply this type of disconnect system, such a system can be obtained through Atlas Copco.

WARNING! The ground fault protection system located in the mine disconnect system (and for CE marked drills in motor starter panel), trips at approximately 0.3 amp which is too high to provide personnel protection. The driller and helper should always use suitable electrically insulating boots when operating an electrically powered drill.

Fire protection! A fire extinguisher is placed on the lefthand side of the control panel The drill rig is equipped with a portable fire extinguisher. The fire extinguisher is located on the control panel at the left hand side. This fire extinguisher is suitable for fire in electrical cables, fuel and engines and lasts for approximately one minute when operated continuously. For use; remove the safety pin and press handle. Direct the jet towards the base of the fire. •

Check the function at least once a year.

This type of fire extinguisher puts out the fire by eliminating access to oxygen. Ember might start the fire again. Use water for fighting fire in wood, paper and similar materials.

10

Environmental Instructions Dear operator, Atlas Copco Craelius AB 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 Craelius product. These simple but important instructions will help to preserve the environment.

Chemicals Dispose of chemicals such as drilling additives, other additives, glycol etc. according to the manufacturer’s instructions. Avoid the use of cleaning agents containing solvents like carbon tetrachloride. There are environmentally better alternatives now available on the market. Follow national regulations regarding handling and disposal of wastes. Metals (steel, aluminum, etc.)

1.0 Operation, maintenance and disposal

These products are recyclable and should be taken care of according to national regulations. Plastict and rubber

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 threat to the environment. Collect all oil spills and waste (e.g. oil filter elements) contaminated with oil. Dispose of according to national regulations.

These products are often labeled according to different classes. In those cases they are recyclable and should be taken care of according to national regulations. Electrical components (cables, electronict, etc) Used components should be taken care of according to national regulations.

Use biologically decomposable hydraulic oils and lubricating oils for Atlas Copco products wherever possible. Contact your nearest Atlas Copco office for more information. Engine Engine emissions are toxic and pose an environmental threat. Always provide for fresh air when an engine is running. Well-maintained air filters help keep emissions at a low level. Fuel (Petrol/Gas, Diesel) Fuel spillage poses an environmental threat. Collect all wastes and fuel spillage and dispose of according to national regulations. Grease Lubricating grease poses a threat to the environment. Collect all wastes and spillage and dispose of according to national regulations. Batteries Batteries contain acids and heavy metals. Used batteries can therefore pose a threat to the environment and to your health. Avoid all contact with acids and dispose of used batteries according to national regulations. See also the “Operating safety” chapter for further information. Dust Rock dust can pose a health danger. Use dust binding oil. 11

General

Fig. 1 CHRISTENSEN CT 14 is an all-hydraulic operated diamond core drill. The CHRISTENSEN CT 14 is a complete, allhydraulic diamond core drill for surface exploration drilling. It is the perfect combination of the proven Christensen CT concept, combined with new and powerful components.

The CT14 is mounted on a frame to be mounted on a truck.

The CHRISTENSEN CT 14 uses well proven technology for diamond core drills combined with new improvements in order to get easy drill operation. Hydraulic jacks, mast dump, hinged top mast and all controls available at the new control panel provide the driller an easy set-up. Other features such as the strong main winch, powerful direct feed cylinder, modern diesel engine, long mast, new Rod Holder (option) and more gives the CT14 capacity to drill deeper than previous models.

Recommendations To achieve the best results with regard to: - high penetration - optimal core recovery - and low drilling costs it is of primary importance that drill rods, core barrels and coring bits are of the right type and quality, matched to the rock drill and to the prevailing rock conditions. Bearing in mind the core drill’s speed of rotation, its rating and chuck diameter, the CHRISTENSEN CT 14 is best suited to drill holes in diameter (60 - 123) using both conventional as well as wire line rods.

Revision. b 2006-02-20 12

Hoisting and transport 1.1 Hoisting the drill unit 1. Position the mast on the mast support. 2. Place the rotation unit above the main hoist to obtain the best possible point of balance and centre of gravity.

DANGER – The sling must be dimensioned for lifting 9 tons (Drill unit) to provide a safety margin. – Never use a damaged rope/sling.

3. Place a sling around the mast and mast support in the front of rig.

– Always make sure that nobody is under or anywhere near, a suspended load or within the swing radius of the rope/sling.

DANGER – The movement of the extention mast can cause injury or death.

Note. When lifting, make sure that the sling will not damage the hydraulic hoses, mechanical components etc. Use a spreader bar to lift the CT14.

Fig. 1.2 Hoisting the drill unit

13

Technical specifications

B

C

E

F

D

A

1.0 Drill unit Dimensions mm A B C D E F G

9816 4119 86 641 1100 1680 2280

in 386.4 162,1 3.4 25.2 43.3 66.1 89.7 G

Dimensions Length Width Height Lower Mast: 5150 mm (202”) 580/740 mm (22.8/29.1”) 457.5 mm (18”) Upper Mast: 4060 mm (159.8”) 560/730 mm (22.0/28.7”) 482 mm (18.9”) Assembled Mast: 9665 mm (31.8 ft) with Crown wheel (9215 mm 30.1 ft without Crown wheel) Drill Head: Horizontal view 787 mm (31”) x 1118 mm (44”) Vertical view 533 mm(21”) x 1118 mm (44”) Engine Component: 1740 mm (68.5”) x 822 mm (32.4”) x 1600 mm (62.9”) Weight: 9000 kg

14

Technical specifications

15

Technical specifications

16

Technical specifications

17

Technical specifications

18

Characteristics 1.1 Mast Feed Travel: . . . . . . . . . . 3.5 m (11,5 ft) Feed Speeds: . . . . . . . .fast and slow with . . . . . . . . . . . . . . . . . . . .variable control Thrust: . . . . . . . . . . . . . .59,6 kN (13,390 lb) Pull: . . . . . . . . . . . . . . . .138 kN (31 020 lb) Drilling Angle: . . . . . . . .45 to 90 degrees Rod pull length: . . . . . .6,09 m (20 ft)

1.2 Rod holder The rod holder is hydraulically operated, and closed by gas pressure.

Axial holding force: . . . . . . . . 133 kN (30000 lbf) Jaws . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ( TC set) Max. rod size: . . . . . . . . . . . . . . . . . . . . . 117,5 mm

Fig. 1.2 Hydraulically operated Rod holder

19

Characteristics 1.3 Power units

Fuel drain line maximum restriction . . . . 69 kPa Fuel inlet maximum temperature. . . . . . . . . 74°C

Power units with variable hydraulic pumps and independent hydraulic circuits for rotation and feed thrust. Prepared for auxiliary, hydraulically driven flush pump.

Engine minimum cranking speed . . . . . . 150rpm

Complete with hydraulic tank, filters, oil cooler and starter panel.

Low idle (minimum allowed). . . . . . . . . . 103 kPa

1.3.1 Diesel power unit Powered by a Cummins diesel engine Manufacture: Model: Power: RPM: Engine type: Cooling: Displacement

Cummins QSB5.0-C, 5.9 liter 6 cylinder 158 kW (212 hp) 1800 Diesel turbocharged/after cooled Water . . . . . . . . . . . . 5.9 liters [359 C.I.D]

Lubricating oil system Oil pressure: At rated speed (minimum allowed) . . . . 310 kPa Regulated pressure. . . . . . . . . . . . . . . . . . 414 kPa Oil capacity of standard engine Standard, total system . . . . . . . . . . . . . 16.4 liters Deep sump, total system . . . . . . . . . . . 18.3 liters Cooling system Coolant capacity (engine only) . . . . . . . 9.0 liters Std, modulating thermostat - range. . 84 to 91°C Max. allowed operating temperature . . . . 100 °C

Max operating pressure . . . . . . . . . . . . . . . . . . . . - Main pump . . . . . . . . . . . . . . . . . . . 280 bar - Service pump . . . . . . . . . . . . . . . . 200 bar - Auxiliary pump . . . . . . . . . . . . . . . . 215 bar

Min. recommended operating temperature

Max flow - Main pump. . . . . . . . . . . . . . . . . . 242 l/min - Service pump . . . . . . . . . . . . . . . 122 l/min - Auxiliary pump . . . . . . . . . . . . . . . 47 l/min

Air intake system

Engine weight . . . . . . . . . . . . . . . 458 kg [1010 lb] Fuel system Engine idle speed . . . . . . . . . . . 700 to 1000 rpm Max. fuel inlet restriction to lift pump . . . 20 kPa Max. fuel pressure at fuel filter outlet (engine cranking) . . . . . . . . . . . 28 to 55 kPa

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 °C Min. recommended pressure cap . . . . . . . 48 kPa Max. intake restriction (clean air filter element) . . . . . . . . . . . . . . . . . . . . . . . . . 254 mm H2O Max. intake restriction (dirty air filter element) . . . . . . . . . . . . . . . . . . . . . . . . . 635 mm H2O Exhaust system Maximum back pressure from pipeing and silencer (combined): Hg

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 mm Hg

Min. fuel pressure at fuel filter inlet (engine running) . . . . . . . . . . . 55 to 117 kPa

H2O . . . . . . . . . . . . . . . . . . . . . . . . . 1016 mm H2O Exhaust pipe size (normally acceptable inside

Max. pressure drop across fuel filter . . . . 34 kPa

diameter). . . . . . . . . . . . . . . . . . . . . . . . . . . 76 mm

Sound noise level Drill unit with diesel power unit Sound power emission . . . . . . . . . 100 dB (A)

Fig.1.3.1 Power Unit 20

Characteristics 1.4 CT 14 Performance Specifications Depth capacity coring (wire line or conventional) B wire line N wire line H wire line P wire line Depth are based

1 540 m (5 052 1 200 m (4 042 800 m (2 695 475 m (1 558 on vertical hole

ft) ft) ft) ft)

The above capacity values only serve as a guideline, and refer to vertical, downward drilling in homogeneus rock. Main hoist Capacity: Line speed: Cable size: Wire line Capacity:

Line pull: Line speed:

(Single line) Bare drum 80 kN (18 000 lb) Bare drum 44 m/min (148 ft/min) 35 m (118 ft) x 16 mm (10/16 in) 1 830 m (6 000 ft) of 4,76 mm (3/16 in) 975 m (3 200 ft) of 6,35 mm (1/4 in) bare drum: 11,9 kN (2665 lb) full drum: 3,0 kN (668 lb) bare drum 114 m/min (374 ft/min) full drum 453 m/min (1486 ft/min)

Mast and feed system Feed travel: 3,5 m (11,5 ft) Feed speeds: fast and slow with variable control Thrust: 59,6 kN (13 390 lb) Pull: 138 kN (31 020 lb) Drilling angle: 45 to 90 degrees Rod pull length: 6,09 m (20 ft) Drill head and spindle speeds Power: hydraulic motor – variable speed/reversible 4 in chain driven in oil bath – 2,5 ratio Spindle (inner diameter): 117 mm (4 5/8 in)

Range selection: manual control from operator’s station Hinged head: swing away Chuck assembly Type: hydraulic open, spring closed Maximum inside diameter: 117 mm (4 5/8 in) Holding capacity: 18 143 kg (40 000 lb) Drill base supports Frame mounted rig designed to be mounted on a truck Support: 4 hydraulic jacks Pad size: 210 x 210 mm (8,27x 8,27 in) Travel length: 900 mm (35,43 in) Weight Base drill:

approx. 8 000 kg (17 635 lb)

Dimensions (L – W – H) In transport position: L: 9 900 mm (32,48ft) W: 2 280 mm (7,48ft) H: 4 050 mm (13,29ft) Standard equipment -Hydraulic mast dump -Hydraulic mast raise -Mast in two sections -4 hydraulic levelling jacks -Large crown sheave wheel -Tier II engine -Towing package -Wear liners on lower mast -Fuel tank 200 l (53 gal) -Safety guards -Hydraulic oil reservoir fill -Fuel filter & water separator, pump & filtration -Mast lightening kit -Hydraulic P-size rod holder -Hydraulic mud mixer -Hydraulic mud pump, Trido 140: max flow: 140 l/min (37 gal/min) max pressure: 7 MPa (1 015 psi) -Water flow meter -RPM meter

Final drive:

Spindle speeds: Ratio Speed, rpm 1st 6,63:1 117-196

All weights and dimensions are approximations and are subject to change

Torque, Nm (ftlb) 5 113-3 011 (3 771-2 250)

2nd 3,17:1

245-410

2 445-1 459 (1 803-1 076)

3rd 1,72:1

451-756

1 326-792 (978-584)

4th 1,00:1

776-1300

771-460 (569-340)

Revision. b 2006-02-20 21

Characteristics

Fig.1.4.1 Torque diagram Revision. b 2006-02-20 22

Characteristics 1.0 Mast top section A mast extension (1) is mounted at the top of the mast. With the standard foldable mast extension , the total length of the mast extension is 4.5 m. With the crown block , the total length is 10 m. The crown block (2) is mounted on the extension mast.

2

1

To brace the mast, 3 metre aluminium tubes (3, Ø 49 mm) can be used.

3

1.1 Wire line hoist, 1800 m Mounted on the stand for the mast. Does not need to be moved when changing drilling angle.

5

Data Bare Drum: Full Drum:

264kg (580 lb) 995kg (2,190 lb)

Line Speeds: Bare Drum: Full Drum: Cable Size:

4 119 m/min (390 ft/min) 445 m/min (1,460 ft/min) 976 m(3,200ft) or 4.6 - 6 mm (3/16”)

Fig.1.0 CHRISTENSEN CT 14 equipped with mast and hoist. 1. Mast top section 2. Crown block 3. Backstay leg bracket 4. Wire line hoist 5. Water pump

Fig.1.1 Wire line hoist, 1800 m

23

CHRISTENSEN CT 14 Design Features 1.1 Drill module 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Feed frame Rotation unit Rod holder Foot bracket Control valves (panel) Platform Bracket for backstay legs Main hoist Wireline hoist Crown block

10

1

7

2 5

3

4 9 24

8

6

Controls 1.0 Control panel -Control functions, see Fig. 1.0 1)

Start panel with ignition Switch – To start engine.

2)

Gauge for hold back force (kN)

3)

Gauge for feed force (kN)

4)

Water Pressure – Indicates the pressure at the water pump outlet.

5)

Main pump pressure gauge (Bar)

6)

Rod holder gas pressure.

7)

Rotation speed – Digital tachometer - indicates engine speed in revolutions per minute. (Option)

8)

Flow meter - Indicates water flow (l/min) (Option)

9)

Emergency stop indicator

Read the safety instructions before start

9

3

2

4

5

6

1

8

7

Fig.1.0 Control panel 25

Controls 1

6

2

8

9

10

11

5 7

3

4 13 14

10 16

Fig.1.1.0 Drilling

1.1.0 Valve assembly (Drilling) 1. Rod kicker valve - moves rod kicker in and out 2. Break out tool and rod lifter (Option) 3. Rod holder (Option) 4. Chuck - Open and closes the chuck 5. Fine feed, rotation unit 6. Thread compensation, make/break 7. Throttle control (Diesel engine) 8. Rotation unit (Drilling) 9. Fast feed, rotation unit 10. Main hoist - Controls the direction of the main hoist up or down 11. Wire line - Controls the direction of the wireline up or down 13. Emergency stop 14. Pressure knobs 15. Hold back force 16. Rotation speed - Controls rotation speed from low to high speed. Must be at low speed for rod breaking 17. Feed rate - Allows for adjustment of the feed speed during slow feed operation 18. Water flow lever - Controls operation of the water pump (on/off)

15

18

26

17

Maneuvering 1.0 Pre-start procedure 1. Check hydraulic oil level in the oil tank. Refill if oil level is too low Fig. 1.2. 2. Before starting motor, carry out instructions given in Periodic Maintenance pages.

1

DANGER

Fig. 1.2. 1.

Hydraulic oil tank Level indicator & Temp gauge

Special care and attention should be paid to damaged or worn components, which could cause structural fatique, cracks or even fracture in materials or welded joints.

27

Maneuvering 2.0 Start-up Diesel power pack 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 preventive maintenance schedule. Pre-Start

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

A1

A2

Check that all controls are in neutral position. Check that the emergency stop button on the control panel is not depressed. 4.1 Check the oil level in the diesel engine, (A1, fig. 4.1) and fill when necessary. (A2, fig. 4.1). Oil viscosity and quality according to engine manufacturer manual. 4.2 Check cooler fluid level

Fig. 4.1. Check level /A1). Fill when required (A2)

4.3 Check the engine air intake filter. Clean or replace cartridge. (X, Fig. 4.2) 4.4 Check oil level in hydraulic oil tank (C1, fig. 4.3) Add when required. 4.5 Check fuel level (D2, fig. 4.4) Top up before beginning of each shift. X D1

D2

Fig. 4.2. Engine air intake filter. Remove coarse particles daily at (X). C2 C3

C1

Fig. 4.4. Filler cap D1, level indicator D2 fuel tank. Fill when required. 28

Fig. 4.3. Check hyd. oil level C1: Gauge: Temperature and level C2: Hyd. oil filters C3: Filler cap

Maneuvering H0 H1 4.6 Activate master circuit switch Q1 (fig. 4.5). Press and turn in clockwise direction. 4.7 Turn the starter key (S1, fig. 4.5) to position and press button (S2, fig. 4.5. Lamp functions H0 to H1 should light up.

F1 F2

S1 S2

Start 1

Move speed control lever to 1/2 speed position.

2

Check that none of the indicator lamps ( H0 - H1) is lit when the engine is running. If any lamp remains on, switch off the engine, investigate and remedy

Q1

3

Check the oil temperature on the combined temperature and level indicator mounted to 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. Verify that hydraulic oil return line filter warning lamp is off after the warming period.

Fig. 4.5

Startbox for diesel power unit.

S1 S2

Starter key. : Positions 0, 1, 2 Start button

F1 F2

Fuse Fuse

H0 H1

Check lamp: Fuse tripped Check lamp: Fuse tripped

Display Parameters

Stopping the diesel engine 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.

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

The following are some of the engine and transmission parameters displayed by the PowerView in English or Metric units (when applicable), consult engine or transmission manufacturer for SAE J1939 supported parameters. • Engine RPM • Engine Hours • Machine Hours • System Voltage • % Engine Load at the Current RPM • Coolant Temperature • Oil Pressure • Fuel Economy • Throttle Position • Engine Manifold Air Temperature • Current Fuel Consumption • Transmission Gear Oil Pressure • Transmission Gear Oil Temperature • Transmission Gear Position • Active Service Codes • Stored Service Codes from the Engine • Set Units for Display (English or Metric) • View Engine Configuration Parameters 29

Setting Up for Drilling 1.0

Set Up - Start Up CHRISTENSEN CT 14: Engine Start Up The Engine is equipped with a Murphy high temperature, low oil pressure and a manual emergency shut down. If any of these conditions exist, the engine will not run. The manual emergency shut down switch is located on the instrument panel – pull out to run – push in to stop. Before start up of the CT 14 the following pre start checks should be made: * Engine Oil Level – Check at the start of every 8-hour shift. Keep oil to the full level on the dip stick. * Coolant Level – Check radiator at the start of every 8-hour shift. Maintain level at bottom of filler neck. * Hydraulic Oil Level – Check hydraulic tank sight glass at the start of every 8-hour shift. Maintain level at or near full level. When adding oil, use the transfer pump. * Hydraulic Filters – Check hydraulic filter indicators every 8-hour shift after system is warmed to operating temperature. * Gear Box Oil Levels – Check oil levels at the start of every 8-hour shift. * Grease Fittings – Grease all fittings for components that are in daily use. * Fuel check

Before engine start up, check that all controls are in the neutral position. The engine and all systems are designed to operate from 1800 RPM to 2000 RPM for best efficiency.

30

Setting Up for Drilling 1.1 Set Up – Leveling the Drill

WARNING

Controls for hydraulic jacks 1. Start the power unit and check that all hydraulic connections are tightened and that no leakage appears.

•

Always stabilize / anchor the rig in a proper way before drilling commences.

2. Stabilize the rig with the hydraulic jacks (1). Assemble mast and legs. Lower down dump mast to the ground. Insert lock pins.

•

MAST MUST BE IN CONTACT WITH FIRM GROUND OR TIMBERS. Hydraulic jacks must be grounded and stabilized, the feed cylinder creates enough force to tip the rig.

•

Make sure that no loose pieces of equipment or objects are lying on the feed.

•

Before raising the mast look up to check for overhead obstructions. When overhead electrical power lines exist at, or near a drilling site, consider all wires to be alive and dangerous.

•

Always make sure no unauthorized persons are within the working area of the drill rig in use.

•

Lock out positioning valve bank before pins are removed from dump plate.

3. Raise the mast to the desired angle. Anchor mast to the ground. 4. Anchor the support legs to the brackets on the power unit frame.

1

Fig. 1.0 1. 2. 3. 4. 5.

6. 7. 8.

1

Control levers - Driving panel Rear left jack Rear right jack Front left jack Front right jack Mast raise - Raises or lowers the mast from the resting position to drilling position Dump cylinder Panel - In / out from the rig Platform - Raise and lower

2

3

4

5

6

7

8

31

Setting Up for Drilling WARNING ENSURE THAT DRILL IS LEVELED ON STABLE GROUND.

In order to prevent accidents, caused by overturning the rig, strictly stabilize the rig / crawler before starting to drill.

WARNING • Mast must be horizontal before attempting to fold. • Make sure that no loose pieces of equipment or objects are lying on the feed.

1.1 Set Up – Mast Sections Bolt top mast section to mid section using (6) M36 Grade 8 bolts and nuts. Torque nuts to 2.2 kNm.

32

• Before raising the feed (mast) look up to check for overhead obstructions. When overhead electrical power lines exist at, or near a drilling site, consider all wires to be alive and dangerous.

Setting Up for Drilling 1.5 Set Up – Mast Raise Procedure 1. Using mast lift valve in up position, raise mast to desired position, lock mast stiffening legs with the lock jaw bolts ¾-10 NC x 3” LG. Torque bolts to 376 ft/lbs.

STAND CLEAR OF UNDER MAST AREA UNTIL MAST IS RAISED TO THE DESIRED ANGLE AND STIFFENING LEGS ARE LOCKED IN PLACE.

MAST DUMP PROCEDURE

MAST MUST BE IN CONTACT WITH FIRM GROUND OR TIMBERS.

DUMP PLATE PINS MUST BE IN PLACE.

SPECIAL NOTES FOR FOLDING MAST. - FOR SHORT TRAMMING DISTANCE ONLY - MUST BE LEVEL - BEWARE OF CRUSHING DANGER BETWEEN SECTIONS

33

Setting Up for Drilling 1.7 Set Up – Mast Backstay Legs 1. Raise mast to desired position (45 degrees to 90 degrees) and pin stiffening legs with (4) 3/4”-10 x 2” grade 8 bolts and nuts (pin part number 150270-179). Torque nuts to 376 ft/lbs.

34

DO NOT OPERATE THIS DRILL WITHOUT STIFFENING LEGS AND PINS IN PLACE.

Drilling Drilling methods The CHRISTENSEN CT 14 is an all-hydraulic diamond core drill with a wide range of options and accessories. The drill unit with power pack and a control console gives the operator a good view over the rig from the working platform in front of the control panel. It is suitable for a variety of drilling methods in surface operations such as core drilling, probing etc. The drill unit is powered by a diesel engine. The drill rig is mounted on a platform suited for truck carrier. The CHRISTENSEN CT 14 uses the best technology available for diamond core drills. All tube jointing, thread breaking with adjustable thread compensation, feeding, wireline hoist sequences, are controlled from a control console. Feed is by direct cylinder, eliminating the need for chains. This results in smoother feed and reduced maintenance. Recommendations To achieve the best results with regard to: - high penetration - optimal core recovery - less deviation - and low drilling costs it is of primary importance that drill rods, core barrels and coring bits are of the right type and quality, matched to the rock drill and to the prevailing rock conditions. Reaming shell, back and stabilizer. Bearing in mind the core drill’s speed of rotation, its rating and chuck diameter, the CHRISTENSEN CT 14 is best suited to drill holes in diameter (B - P, 60 mm-123 mm).

IMPORTANT IMPORTANT: Never try to remove the drill rod until the rotation unit has passed over the open rod joint and stopped.

Always make sure the counter pressure valve has been correctly adjusted and set before rod breaking starts. If this valve is set too high, this will result in much shorter life span for the rod threads and consequential leakage. When rod threads leak, it is difficult to judge how much flushing water is reaching the drill bit. It is also necessary to occasionally check the condition and diameter of the rods being used. Worn rods can slide back and forth inside the jaws.

35

Drilling

CT 14 Working platform 36

Drilling 1.0 Before drilling starts Make sure that the supply of water is adequate. See to that the suction hose to the water pump in good condition. Strainer clean and not clogged

Q1

1.1 Start the power unit Activate master circuit switch (Q1, fig. 1.1). Turn the starter key (S1, fig 1.1) clock-wise direction. Push the start button (S2, fig 1.1).

S1 S2

1.2 Start water pump Water flow lever - Controls operation of the water pump (on/off) (Fig 1.2 pos 2.)

1.3 Adjust the flow of the flushing water

Fig. 1.1 S1 S2 Q1

Startbox for diesel power unit. Starter key. : Positions 0, 1, 2 Start button Master circuit switch

1. Start the water pump with the control lever (Fig 1.2 pos 2) at the front on the panel. 2. Read the water flow rate on the flow meter (Fig 1.3 pos 1) on the control panel.

2

2. Read the water pressure on the gauge (Fig 1.3 pos 2) in the control panel.

1.4 Start rotation

Fig.1.2 Start the water pump

Before starting the rotation select gear on the rotation gear box that gives you the right rpm range for the ITH equipment. 1. Position the drill string with the corebarrel and the drill bit about 50 cm above the bottom of the drill hole. 2. Open the rod holder

2

1 0000

0000 0000

3. Start the drill rotation with rotation lever. 4. Adjust the rotation speed to the desired RPM control on the display. The rotation speed must be adjusted as the hole deepens so the maximum rotation pressure remains at 240 bars.

Fig.1.3 Adjusting the water flow

37

Drilling 1.5 Start the drill feed 6

4

1. Before the drilling operation can be started, the rod weight must be compensated so the actual feed force can be read.

3

2. Adjust rpm and flow, with the fine feed (Fig 1.6 pos 5) in the neutral position. The feed pressure should be zero. The feed force can be read on the gauge (Fig 1.5 pos 4) on the control panel. 3. Turn the hold back force knob (Fig 1.6 pos 14.1) clockwise. The holdback force can be read on the gauge (Fig 1.5 pos 3) in the control panel. 4. Regulate the holdback knob so that the cradle is stationary - not moving up or down. Now the rod weight is balanced.

Fig.1.5 Control panel

5. When the feed is balanced, the drill feed can be activated with lever (Fig 1.6 pos 5) without any danger that the drill string will rush to the bottom of the drill hole and damage the drill bit.

3) Gauge for hold back force (kN) 4) Gauge for feed force (kN) 6) Main circuit pressure

6. Increase the fine feed force slowly using the fine feed knob (Fig. 1.6 pos 14:3) until the drill string reaches bottom of the hole or the face. 7. Continue to increase the feed force in order to reach desired penetration rate for chosen drill bit and formation. 8. Do not apply more feed force than is recommended for the drill bit. 9. Continue drilling to the end of the feed stroke, fill the inner tube, or until you get coreblockage.

1.6 Stop drilling 1. Stop the drill feed by moving the drill feed lever (Fig 1.6 pos 5) to the neutral position. 2. Stop the rotation by moving the drill rotation lever (Fig 1.6 pos 8) to neutral. 3. It is recommended to flush the drill hole for some minutes after stopping drilling to avoid problems with cuttings and sludge specially at the end of the work shift.

38

2

1

6 8

5 3

4

9

10

11

7

13 14 Fig.1.6 Controls 1. Rod kicker valve - moves rod kicker in and out 2. Break out tool and rod lifter (Option) 3. Rod holder (option) 4. Chuck - Open and closes the chuck 5. Fine feed, rotation unit 6. Thread compensation, make/break 7. Throttle control (Diesel engine) 8. Rotation unit (Drilling) 9. Fast feed, rotation unit 10. Main hoist - Controls the direction of the main hoist up or down 11. Wire line - Controls the direction of the wireline up or down 13. Emergency stop 14. Pressure knobs 1. Hold back force 2. Rotation speed - Controls rotation speed from low to high speed. Must be at low speed for rod breaking 3. Feed rate - Allows for adjustment of the feed speed during slow feed operation

Drilling Wireline Operation 2.0 Controlled wireline lowering 1. To spool out cable from the wireline drum with the hydraulic motor, push the lever slowly forward (away from you). The drum will start to rotate. 2. To increase the speed, push the lever further forward. 3. When the lever is dropped, the spring force will move it back to neutral 2.2 Controlled wireline hoisting 1. To spool in cable rope from the wireline drum with the hydraulic motor, move it slowly backwards (towards you). The drum will start to rotate. 2. To increase the speed, pull the lever further backward. 3. Stop the winch smoothly. If the winch comes to a sudden stop it can cause a jump and the core can make the core lifter to loosen it´s grip and go down the hole. 4. When the lever is dropped, the spring force will move it back to neutral, where it locks automatically.

Fig.2.0 Wire line

39

Drilling 3.0 Thread compensation 1. 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 for downhole drilling. The amount of thread compensation should be adjusted when starting with new drill rod size or large change in drilling angle. Whenmaking the joint, the feed cylinder is moving downwards according to the setting. It is recommended that the helper turns the rod in at least one full turn before the rest of the joint is made with the rotation unit. 2. Turn the thread compensation adjustment screw clockwise to increase the thread compensation force or counterclockwise to decrease the thread compensation force. Tighten the lock screw after making the adjustment.

40

Drilling 3.1 Adding a drill rod and making the joint 1. 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.

4.0 Water pressure dump valve Dump valve relieves the water pressure in the drill string. Push the lever down to open the valve.

2. To make the joint close the chuck and start the rotation head to rotate clockwise. At the same time the feed cylinder disengages so the rod ends can screw together without damage to the threads.

3.2 Breaking the joint 1. To break the joint with the rod holder closed, start the rotation unit to rotate counter- clockwise. 2. 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.

41

Maintenance 1.0 General The performance and reliability of the CHRISTENSEN CT 14 is largely dependent on the amount of care and attention shown to it. Regular checks and inspection of wearprone components prevent breakdowns and costly downtime. Dirt is a primary cause for most malfunctions in a hydraulic system. Therefore: - Always try and keep the core drill clean and free from dirt and other pollutants. It is much easier to detect faults or oil leakage on clean equipment.

4 Use the rotation control to set the drill location lever (10) in drilling position to circulate the hydraulic system for about 5 minutes. 5. Disconnect the two main hoses from the fitting and reconnect them to their correct points on the hydraulic motor.

1.2 Oil cooler - air type When required, clean the air oil cooler by flushing dust out of the fins. Do not damage the fins by using excessive water pressure.

- Never leave any part of the hydraulic system open or exposed to external influence. - Always attach tight-fitting plugs to disconnected hose ends and couplings. - Always perform oil refills into the hydraulic oil tank by using the hand pump supplied. - Always store fresh oil stocks in sealed containers. - Always use TREDO-type seals for sealing threads. Use of Teflon tape, oakum or similar, could damage sensitive components in the system if fragments dislodge and enter the system.

1.1 Cleaning the hydraulic system Following any major intervention in the hydraulic system, systematic and through cleaning of the system should be performed, before drilling is allowed to continue. Cleaning procedure 1. Disconnect the two main hoses on the hydraulic motor and put caps on the fittings. 2. Reconnect the loose ends to the fittings included in the tool kit. 3. Start up the power unit.

42

WARNING Do not carry out any service and repair on hydraulic equipment being under hydraulic pressure. Stop the power unit, then operate valves until pressure is relieved. Escaping pressurized hydraulic oil can penetrate skin which can cause serious inflammations. Seek medical attention if injured. Small leaks are practically invisible, so when searching for them, Do not expose your face or hands but use a piece of cardboard or wood.

Maintenance 1.3 Hydraulic oil filters 5

There are in total three filters on the CHRISTENSEN CT 14 drill. Two returnfilters and one breathing filter.

1,2,3

Power unit Of the three on the power unit, one is a breathing filter mounted on top of the tank, and two are return filter mounted from the lid inside the hydraulic tank. The breathing filter is all in one piece, unscrew the filter and replace with a new one. Replace once per year and more often in dusty conditions. The return filter is equipped with a clogging indicator. The filter contains a bowl that holds two filter elements. To change those elements, unscrew the four hexagon nuts on top of the filter and lift the bowl straight out. Once you have have the bowl in your hand, push down the lid, turn 90 degrees counter clockwise and lift the lid out. Inside the bowl you see two filter elements stacked on each other. Pull them out, rinse the bowl if necessary and replace the elements with fresh ones. Then put the lid back on the bowl and reinstall the the bowl.

4 Fig. 1.3 1. 2. 3. 4. 5.

Filter change Filter housing Filter cartridge (inside the container) Filter container (inside the housing) Lid Clogging indicator

All filters in contact with oil on CHRISTENSEN CT 14 drill have filter elements that are lifted from a bowl. The advantage of this is that there is no leakage when replacing the filter elements. Even if the clogging indicators have not called for a cartridge change, the cartridges should be changed once every year.

IMPORTANT If the oil temperature is normal (+50 to +60°C) and the indicator (5) reactives a couple of times, the filter cartridge has to be replaced at once. Otherwise there is a high risk of the oil bypassing the filter and dirt contained in the oil being transported further into the hydraulic system with the ultimate breakdown or serious malfunction of hydraulic components as the result. When the oil temperature is low, the indicator will activate through the pressure drop caused by the high viscosity of the oil. 43

Maintenance 1.4 Changing the hydraulic oil. The hydraulic oil should be changed after 2000 operating hours in normal worksite conditions, or at least once a year. If the quality of the oil has deteriorated for some reason, either through extremely high temperatures or contamination for example, then it should be changed as soon as possible. In such cases, the top part of the tank should also be removed and the entire interior of the tank cleaned thoroughly. Oil change. 1. Drain off all the hydraulic oil by opening the drain valve (1) underneath the tank. 2. Refill new oil (about 250 litres) using the hand pump. As the oil is pumped into the tank it passes through the filter so that any impurities are strained out. Fig. 1.3 Hydraulic oil tank

1.5 Draining condensed water out of tank The tank drain valve (1) is used to drain condensed water out of the tank. Condensed water can collect at the bottom of the tank. The amount of water collected depends on the humidity levels and the number of times the drill is shut down and the oil tank cools down. The tank drain should be checked regularly for the presence of condensed water. In conditions of high humidity and tank cool down each shift, condensed water may have to be drained out at the beginning of each shift. If the power unit is not level, try and position the drain on the low side.

1.6 Hydraulic tank oil level The oil level in the tank should be kept in the sight glass at all times (2 on Fig. 1.3). There is a low oil level guard which will trip the motor when the oil level is about 50 mm below the lowest sight glass level. This will prevent damage to the hydraulic pumps.

44

1. Drain valve 2.

Sight glass

IMPORTANT The useful service life of the hydraulic oil can be seriously reduced at high temperture. High temperature can cause: – Leaky gaskets – Serious internal leakage in pumps and valves, due to decreased viscosity and lubricating properties of the oil.

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45

Maintenance 2.1 Periodic maintenance with Service schedule for CHRISTENSEN CT 14 The Service Schedule gives instructions to lubrication, inspection procedures and measures to take, following a specific number of operating hours. Use this schedule to get the most out of your equipment and always follow the instructions given.

1

6

7

8,9

12

4 3

5 5a

11

46

10

Maintenance 2.1 Periodic maintenance with Service schedule for CHRISTENSEN CT 14

Ref. No.

Check points

Procedure

Service interval in hours of operation 8

40

Notes

once/ month

1

Feed frame holder

Tightening

x

2

Slide shoes

Lubrication

x

More often in bad conditions

3

Chuck jaw inserts

Cleaning

x

Inspect and clean if necessary

4

Rotation unit

Lubrication

4

Rotation unit and gear case

Check level and temperature

5

Rod holder (Bearing)

Lubrication

5

Rod guide

Cleaning Lubrication

5a

Rod jaws

Cleaning

Jaw holder

Check, Clean

Gas spring

Check, Clean Adjustment

x

See Lubr. Recommendations x

See Rotation unit

x

See Lubr. Recommendations x x

See Lubr. Recommendations

x x

Check for wear Grease behind jaws

x x

6

Hydraulic oil tank

Level check Oil temperature

7

Hydraulic oil filters

Inspection

x

See Hydraulic oil filters

8

Oil leakage

Inspection

x

Continuous inspection of hydraulic fittings, hoses and components

9

Complete drill rig

Cleaning

x

When necessary

Wireline hoist

Lubrication

x

Apply, on lube nipple.

Main hoist

Lubrication

x

Apply, on lube nipple.

11

Oil cooler

Cleaning

x

See Oil cooler

12

Emergency devices

Test of function

10

x x

Adjust pressure

x

Fill oil when necessary (clean the tank once a year)

On control panel, power unit and rig

47

Maintenance 2.2 Lubricant recommendations

Lubricant 1. Hydraulic oil

Check point No. Recommendation 11

Use mineral-based hydraulic oil with good anti-wear, rust (oxidation) and foam inhibiting properties, as well as effective air and water separation abilities. The viscosity grade should correspond to the ambient temperature and ISO 3448, as follows: Ambient temp. °C (°F) 0 to +25 (32 to 77) -30 to 0 (-22 to +32)

Viscosity grade +25 to +40 (77 to 104) ISO VG 46 ISO VG 32

Viscosity index ISO VG 68 Min. 150 Min. 150 Min. 150

Examples of oil grades in the temperature range 0 to + 25°C Shell Tellus T46 BP Bartran HV 46 Castrol Hyspin T 46 Mobil DTE 15M Texaco Rando HDZ 46 Exxon UNIVIS HP 46 Use of flame proof or biodegradable hydraulic oil, please contact nearest Atlas Copco representative for information.

2. Grease

2,4,5,6,8,9,10

Universal grease NLG12....................Operating temperature °C (°F) lithium/molybdenum ..................................Max. 100 (212) additive Synthetic sodium or Max. 140 (284) calcium grease Example of grease grades Shell Esso BP

3. Engine oil

Retinax AM MP Grease Energrease LS-EP 2

Use engine oil according to diesel engine Instruction Manual Example of grade 15W 40 Turbo oil

4. Transmission oil

4

Use transmission oil according to API Example of grade 80-90 weight API Classification GL5

48

Maintenance 3.0 Daily safety check Before each shift commences, an extra and thorough safetey check shall be carried out to detect: — emergency stop failure

(On panel and rig)

— cracks or fractures in materials or at welded points.

1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11

— damage, which could cause structural weakness or fracture

1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11

— wear, which could cause structural weakness or fracture

5, 6, 8, 9, 10, 11

— loose junctions, loose threaded unions

1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11

From the safety aspects therefore, the following check points are particularly important (see illustration below)

6

1. Mast 2. Mast holder 3. Platform 4. Rotation unit, cradle & slides

10

5. Rod holder 6. Crown block 7. Wireline hoist, wire rope

1

8. Main hoist, wire shown

2 11

9. Water pump 10. Mast extension

4

11. Hydraulic tank Fig. 3.0

5

9

8,7

3 49

Maintenance Maintenance – Hydraulic System 1) Hydraulic Tank Oil Level

50

Maintenance 2) Hydraulic Filters Pos

Designation

1

Cover assy

1a

Cover with magnetic system

2

By-pass assy

3

Filter elements

4

Filter bowl

5

O-ring

6

O-ring

7

Flat gasket

8

Clip

9

Mesh screen element

10

O-ring

2

1 Oil Filter Change: every 500 hours or when indicators show change. One breathing filter mounted on top of the tank, and two return filter mounted from the lid - inside the hydraulic tank. The breathing filter is all in one piece, unscrew the filter and replace with a new one. Replace once per year and more often in dusty conditions. The return filter is equipped with a mechanical clogging indicator. The filter contains a bowl that holds two filter elements. To change those elements, unscrew the four hexagon nuts on top of the filter and lift the bowl straight out. Once you have have the bowl in your hand, push down the lid, turn 90 degrees counter clockwise and lift the lid out. Inside the bowl you see two filter elements stacked on each other. Pull them out, rinse the bowl if necessary and replace the elements with fresh ones. Then put the lid back on the bowl and reinstall the the bowl.

3 1 Main Return Filters 2 Secondary Return Filters 3 Clogging indicator

51

Maintenance Maintenance – Drill Head 3-1/2” Spindle Maintenance – Drill Head 4-5/8” Spindle 1) Oil Level

1

2

2.2 2.1

1.2

TWO Oil Levels 1) Funk Transmission – Filler Plug 1.2) Funk Transmission - Drain plug 2) Transmission – Filler Plug 2.1) Transmission - Drain plug 2.2) Transmission - Level check (place the rotation unit in vertical position) Recommended Oil Change: 500 hours (250 hours preferred) Recommended Oil: 80-90 weight API Classification GL5 1.

Total amount is approx. 12 liter for complete unit. The Funk Transmission (1) holds about 4 liter and housing (2) with chain about 8 liter.

2.

Transmission is filled half the box until oil comes from plug on front cover near shift lever or from clear plastic on left side near chuck.

3.

Main housing with chain is filled to plug on right side of housing. This plug is located just to right and bottom of round access cover for adjusting chain tension. After the housings have been filled, the head should be rotated in low gear and lube pump should be checked to see oil is moving thru 1/4 inch lines by cracking them open. Most times the suction on pump needs to be opened to get air out and oil to pump. Suggest head is then run until oil is returning from clear plastic line on side of transmission. Next to the chuck.

You can also fill spin on lube filter with oil which speeds up circulation when you start rotation. NOTE; Make sure the case drain on drillhead hydraulic motor has been filled with clean hyd. oil before rotation. 52

Maintenance Maintenance – Drill Head 3-1/2” Spindle Maintenance – Drill Head 4-5/8” Spindle 2) Oil Filter

Oil Filter Change: every 500 hours Filter: CBC# 155841-55, Fleetguard# HF 6510

WHEN HEAD IS ROTATING, OIL FLOW MUST BE PRESENT IN LOWER CLEAR RETURN LINE. GEAR BOX DAMAGE WILL RESULT IF NO OIL FLOW IS PRESENT.

53

Maintenance 3) Grease Fittings

(2) Fittings on Chuck Bonnet (1) Fitting on Chuck Bearing Retainer Grease Daily Recommended Grease: Multipurpose E.P. Grease

54

Maintenance 1

4

3 5 2

7

6

10

9

8

Changing Rod Holder Jaws And Rod Holder Guide Bushings Changing Jaws Remove the two bolts holding the rod holder insert (2) in the rod holder housing. Pull out the insert so the jaws (3) are clear of the housing, taking care not to damage or stretch the hydraulic hose. The jaws can now be pulled out and replaced. Important: The jaws have a flange on one side. Ensure that the jaws are put in so that the flange keeps the jaws from falling out of the jaw holders and down the drill hole when the rod holder insert is pulled out.

Rod Holder Guide Bushing

11

Fig. 11.0-11.2 1 2 3 4 5 6 7 8 9 10 11

Rod holder jaws and guide bushing RH Housing Rod holder insert Liner Front cover Back cover Retainer Socket holder Ball bearing Circlip Guide socket Jaw

For A and B size reainer, the bearing (8) is held and centered in the back cover (5) by retainer (6). For N and H size bushings, the bushing (10) is centered directly in the bearing (8) .

The diameter of the bushing (10) and retainer (7) must be chosen to suit the drilling equipment to be used (See spare parts list). The retainer is replaced by prying it out of the bearing (8). The new bushing is knocked into the bearing (snap fit). There are two sizes of bearings – one for A and B size bushings, the other for N and H size bushings. 55

Maintenance Maintenance – Water Pump 1) Oil Level 1.1 Level plug 1.2 Drainage plug 1.3 Oil cap 2) Grease Fittings

1.3

1.2

1.1

Oil Level: Check Daily Recommended Oil: 30 weight API Service SB. Grease Fittings: Check Monthly Recommended Grease: Multipurpose E.P. Grease

56

Maintenance Maintenance – Wireline Hoist 1) Grease Fittings - (both sides of the drum)

Grease Daily.

Recommended Grease: Multipurpose E.P. Grease

57

Maintenance Maintenance – Main Hoist 1) Oil Level Check Oil Level Weekly.

Recommended Oil: 80 – 90 weight API Classification GL5

Preventive maintenance A regular program od preventive maintenance for your planetory winch is strongly recommended to minimize the need for emergency servicing and promote safe, reliable winch operation. Field experience, supported by engineering tests, indicate the three (3) service procedures listed below are the MOST critical to safe, reliable winch operation and must be observed. * Regular Gear Oil Changes - every 1000 hours or six (6) months * Use of Proper Gear Oil - recommended type for prevailingambient temperature * Annual Dissassembly and Inspection of All Wear Item - in compliance with American National Standards Institute (ANSI) specification B30.5c 1987 and American Petroleum Institute (API) recommended practice RP 2D section 3. The following minimum service intervals are specified for operating hours of the prime mover.

1. Oil level The gear oli level should be checked every 500 operating hours or three (3) months, whichever occurs first. To check the oil level, remove the large plug located in the center of the drum support. The oil should be level with the bottom of this opening. If additional oil is needed, refer to “Recommended Planetory Gear Oil”

58

2. Oil change The gear oil should be changed after the first one hundred (100) hours of operation, then every 1,000 operating hours or six (6) months, whichever occurs first. The gear oil must be changed to remove wear particles that impede the reliable and safe operation of the brake clutch and erode bearings, gears and seals. Failure to change gear oil at these suggested minimum intervals may contribute to intemittent brake slippage which could result in property damage, severe personal injury or death. The gear oil should also be changed whenever the ambient temperature changes significantly and an oil from a different temperature range would be more appropriate. Oil viscosity with regard to ambient temperature is critical to reliable brake clutch operation.

Maintenance Our tests indicate that excessively heavy or thick gear oil may contribute to intermittent brake clutch slippage. Make certain that the gear oil viscosity used in your winch is correct for your prevailing ambient temperature. Failure to use the proper type and viscosity of planetary gear oil may contibute to brake clutch slippage wich could result in property damage, severe personal injury or death. Refer to “Recommended Planetory Gear Oil” for additinal information. 3. Vent plug The vent plug is located in the drum support as shown. It is very important to keep this vent clean and unobstructed. Whenever gear oil is changed, remove vent plug, clean in solvent and reinstall. Do not paint over the vent or replace with a solid plug. 4. Hydraulic system The original filter element should be replaced after the first fifty (50) hours of operation, then every 500 operating hours or three (3) months, or in accordance with the equipment manufacturer´s recommendations. 5. Wire rope Inspect entire length of wire rope according to wire rope manufacturer´s recommendations. 6. Mounting Bolts Tighten all winch base mounting bolts to recommended torque after the fisrt one hundred (100) hours of operation, then every 1000 operating hours or six (6) months, whichever occurs first. 7. Warm-up Procedures A warm-up procedure is recommended at each start-up and is essential at ambient temperatures below +40ºF (4ºC) The prime mover should be run at its lowest recommended RPM with the hydraulic winch control valve in neutral allowing sufficient time to warm up the system. The winch should then be operated at low speeds, forward and reverse, several times to prime all lines with warm hydraulic oil and to circulate gear lubricant through the planetary gear sets.

WARNING Failure to properly warm up the winch, particularly under low ambient temperature conditions, may result in temporary brake slippage due to high back pressures attempting to release the brake, which could result in property damage, severe personal injury or death. 8. Recommended Planetory Gear Oil Field experience, supported by extensive engineering tests, indicates the use of proper planetary gear oil is essential to reliable and safe operation of the brake clutch and obtaining long gear train life.

WARNING Failure to use the proper type and viscosity of planetary gear oil may contribute to intermittent brake clutch slippage which could result in property damage, severe personal injury or death. Some gear lubricants contain large amounts of EP (extreme pressure) and antifriction additives which may contribute to brake clutch slippage and damage to brake friction disct or seals. Oil viscosity with regard to ambient temperature is also critical to reliable brake clutch operation. Our tests indicate that excessively heavy or thick gear oil may contribute to intermittent brake clutch slippage. Make certain that the gear oil viscosity used in your winch is correct for your prevailing ambient temperature. For simplicity, BRADEN has listed one (1) readily available product in each temperature range which has been tested and found to meet our specifications. This is not to say that other lubricant brands would not perform equally as well. If the following lubricant brands are not available in your are, make certain your lubricant vendor supplies you with oil that is equivalent to those products listed below. BRADEN planetary winches are factory filled with Texaco Meropa 150 or equivalent AGMA No. 4EP gear oil. 9. Inspection In compliance with ANSI specification number B30.5c1987 and API recommended practice RP 2D section 3, we recommend that the winch be disassembled for a thorough inspection of all wear items every 2,000 hours of operation or twelve (12) months, whichever occurs first. 59

Maintenance Maintenance – Mast/Hoist Frame 1) Grease Fittings

(1) Fittings on both sides of mast/hoist frame. Grease weekly. Recommended Grease: Multipurpose E.P. Grease

60

Maintenance Maintenance – Mud Mixer

Factory sealed, self contained, hydraulic propeller type mixer.

Check quick couplers periodically for leakage.

61

Basic hydraulics 1.0 Operation of hydraulic system The system consists of three separate hydraulic circuits. The three pumps (main, water/mud* pump and auxiliary) are driven directly from the power unit flywheel.

The pump is connected directly to the engine flywheel by a synthetic adapter and hub. The pump is an axial piston load sense type. Suction oil comes directly from the reservoir. The pressure side of pump is directed to the main valve block which control 4 functions-- drillhead rotation, fast feed, main hoist, and wireline hoist. All hydraulic pressure from these 4 functions can be observed on the control panel.

The rotation section directs oil to the rotation motor on top of the drillhead. The rotation motor is a variable displacement bent axis design with min. to max. displacement controled by a rotary hydraulic control on the control panel. The fast feed section directs maximum volume (0-190 l/min) to the feed cylinder for rapid movement up or down. The main hoist section controls the hydraulic winch. Incorporated in this circuit is an automatic brake release which is activated from the fine feed pressure. This allows the winch cable to unspool as the drillhead is feeding down. The brake system can also be unlocked by a diversion valve located at the front of the control panel. See Braden service manual for complete installation, maintenance, and service.

The wireline section controls the raising and lowering speed of wireline cable hoist. The hydraulic section is similar on both hoists. The hydraulic motor has a counter-balance valve mounted directly to the exhaust port to protect against overruns and act as a brake when stopping.

The water / mud* pump is piggybacked to the main pump and driven by a thru shaft. The pump is an axial piston load sense type. Suction oil to this pump comes directly from the reservoir.

The auxiliary hydraulic pump is piggybacked to the water/mud* pump and driven by a thru shaft. The pump is an axial piston pressure compensated type. This pressure can be observed constantly on pressure gauge at the control panel. Suction oil to this pump comes directly from the reservoir. Pressure oil is directed to the positioner valves (3VB) for the hydraulic jacks, the auxilliary valves (3VA) that controls the water pump, rod kick cylinder, break out tool, and the rod lifter. The auxilliary valves also control the hold back, feed and drilling valves.

The auxilliary pump controls the rod holder, chuck, feed cylinder (when drilling), rotation motor displacement and thread compensation.

62

Basic hydraulics Diesel engine: Powered by a Cummins diesel engine QSB5.9-C Motor rating . . . . . 158 kW / 212 Hp at 1800 rpm Displacement . . . . . . . . . . . . 5.9 liters [359 C.I.D] Hydraulic Main Pump (0P1) Data: Bosch Rexroth GMBH A1OVO 140 cc Automatic adjusted by actuators, maximum; Pressure: 280 bar Flow (@1800 rpm): 242 l/min Stand by setting: 25 bar Hydraulic Secondary Pump (0P2) Data: Bosch Rexroth GMBH A1OVO 71 cc Automatic adjusted by actuators, maximum; Pressure: 200 bar Flow (@1800 rpm): 122 l/min Stand by setting: 20 bar

Fig.1.1 CT 14 Diesel engine

Hydraulic Auxilliary Pump (0P3) Data: Bosch Rexroth GMBH A1OVO 28 cc Automatic adjusted by actuators, maximum; Pressure: 215 bar Flow (@1800 rpm): 47 l/min

OP1

OP2

OP3

Fig.1.2 CT 14 Hydraulic pumps

0P3P1

T9

8

0P3P2 6 POWERUNIT 158 kW

0P1LS2 Main Pump 280 bar, 20 bar st-by 242 l/min @ 1800 rpm

0P2LS Water/Mud Pump 200 bar, 20 bar st-by 122 l/min @ 1800 rpm

Auxilliary Pump 215 bar 47 l/min @ 1800 rpm

T7 T5 T4B 3V19

13 l

T6 T3

B

X

16

X

12

0P1P

X

F 4

0P2P1

3C1DR

M

3C1

T8

8

0P4 Hand Pump

B

B 0P1

T1

B 0P2

T2

0P4S

20

20

0P4P

0P3

12

0M1

0S1

0F1

M S T1

12

L1

L1

S

L

L

S

L1

0F2

0Z2

0F3

L

48

16

32

12

20

12

0P1S

0P1DR

0P2S

0P2DR

0P3S

0P3DR

0Z4

Drain box

Fig.1.3 CT 14 Power Unit circuit 63

Basic hydraulics Cooler (0Z1) (Fig 1.4) On the CT 14 a air/oil cooler is mounted as standard. A hydraulic motor drives the air/oil cooler. Filters (0F1, 0F2 and OF3) (Fig 1.5) There are three filters in the hydraulic system; they are Return filter with filter indicators for clogging (Fig 1.6) (0F1, OF2 placed on the hydraulic tank) Air filter (0F3, placed on the hydraulic tank). Recommended change interval on all filters is one year. The rig is equipped with 10 micron filter inserts from factory in return filter.

OZ1 Fig.1.4 CT 14 Air/Oil cooler OF1, OF2

OS1

OF3

Hydraulic oil tank (TI) (Fig 1.5) The tank size is 250 liter of oil; it is equipped with a sight glass and thermometer (Fig 1.8). It is equipped with air filters and has a combined temperature and level guard sticking down from the lid (0S1) (Fig. 1.5). On the front side there is a drain box, this in order to get a controlled drain oil flow into the tank. The drain box is filled with oil, before disconnecting any drain hose please empty the box. The drain box also has a magnetic plug for indication and removal of metal particles in the oil (0Z4)(Not shown). T1 Filling of hydraulic oil (OP4) (Fig 1.6) When filling oil into the system please fill through the filter by using the handpump (OP4, fig 1.6) or some equivalent pump in the service shop.

Fig.1.5 CT 14 Oil tank OS1 = indicators on the control panel with two lamps for temperature and level in tank.

OP4

Fig.1.7 CT 14 Visual filter indicators

Fig.1.6 CT 14 Hand pump 64

Fig.1.8 CT 14 Sight glass and thermometer

Basic hydraulics 0P2P1 MAST DUMP CYL

3A1F

3A1E2

MAST RAISE CYL

4

T4A T4B

REAR LEFT JACK

REAR RIGHT JACK

3A1A

3A1B

FRONT LEFT JACK

FRONT RIGHT JACK

3A1C

3V1EA2 4

3A1D

6

0P1LS1

4

3V1FB

3V1FA

3A1E1

Optional

4

CONTROL PANEL SLIDE

0P3P12

PLATFORM TILT

3A1G

4

4

6

0P1LS2

250

250

250

250

3V1EA1

3A1H

3V1EB2

0P3P6 4

3N5 Ø0,7

3N4 Ø0,7

B

3V1A 8

4

A

4

3V1CA

3V1BB B

A

3V1B

4

3V1DA

3V1CB B

A

3V1C

3V1D

3V1GA

4

3V1DB B

4

250

3V1BA

3V1AB

3V2

8

4

4

3V1AA

0P3P4

250

0P3P5 4

4

4

4

A

B

3V1E

4

A

3V1GB 4

3V1EB1 B

A

3V1F

B

3V1G

4

3V1HA B

A

3V1H

P2

3V1HB 4

A S

P3B X

1V2

P1

T

P

T1

T5

235

3V1I

T3B

T2 3V1 Positioner valve

0P3P1

Fig.2.0 CT 14 Positioner valves for hydraulic jacks

1

2

3

4

5

6

7

8

3VB Positioner valves - Hydraulic Jacks The system consists of a separate hydraulic circuit for manuovering of the hydraulic jacks driven by the auxilliary pump circuit. Valve (3V11) - Pressure relieving valve maximises the pressure in the circuit to 235 bar 1.

Valve (3V1D) - Valve for rear left jack

2.

Valve (3V1C) - Valve for rear right jack

3.

Valve (3V1B) - Valve for front left jack

4.

Valve (3V1A) - Valve for front right jack

5.

Valve (3V1E) - Mast raise, raises and lowers the mast from resting position to drilling position

6.

Valve (3V1F) - Dump cylinder

7.

Valve (3V1G) - Control panel slide

8.

Valve (3V1H) - Platform tilt

65

Basic hydraulics Optional GWP

Optional

70

MUD MIXER

WPREL

Flow Meter

WPD

WPP2

2MM

WPWD

A

2MMBP

4

Ø0,7 Optional 3N4 3V13A2

4

3V12A2 3V12B

2V5 4

3V12B1

P

6

3N3

Ø0,7

3N2 Ø0,7

100 bar

6

6

0P2MMP 4

2MMLS

3V17DR

1

4

Optional

2

2

3V17

3V13B1 3V13B1

R

A Out

B

T5A12

R

A Out

3GRH

4

4

T5A13

4

3V11

B

R

A Out

4

GFD

4

3GFD 3V3FD1

3V3DM1

4

G Hold

3V16B In

P

3V3DR1

G Drill

3V3C

Hold B.

3V16A

A

B

R

P

Drill

G Feed

3V3D

Feed

20-30 bar knob

4

Rot. Speed

4

3V3A

DR2

3V3B

3V3DR2

120 bar

2V1

P

4

0P3P12

R

In B

4

R

In B

P R

A

A

Hold b.

T5A16

3V10 3V7

3V6

E

R

4

3N1

knob

Feed

0-300 bar

P

110 bar

4

3V3 Drill ctrl. valve

P

3V7A

knob

0-180 bar

Ø1

2V3

6

16

C

P

0P2P2

16

1VDDMA2

3GHB

3V18

3V16 GRH

4

0P3P16 4

1DMDR1

4

4

3V13A1

In

P

3V3HB1

15-30 bar 2

In

12

1VDDMB2

Out

2WPP

4

B

GHB

1 3

0-30 bar

4

4

0P2LS

4

3

30 bar

4

3V13 In

P

3V3FD3

3V18DR

1

4

3

3V15

3V12A

12

4

3V3DM2

4

Optional

Optional

B

1DMDR2

6

B

4

0P3P13

2V4 F 20 l

4

B DR 4

Z

3V12A1

T6

3V15 3V14

In

A

3V3FD2

3V15DR

3N5 Ø0,7

4

A FD

1CVDR 12

3V10CH2

6

IN A IN

1CV

1DM

6

3V12B2 T7 12

2WPLS

B

3A14 ROD LIFT CYLINDER 3A12 BREAK OUT GRIPPER 3A15 ROD KICK CYLINDER CYLINDER Optional

2WP WATER PUMP

FEED CYLINDER

B HB 250 bar

DRILL MOTOR

2WPDR

1FD

OUT B OUT

4

Water Swivel

3V10CH1

2V2

3CH 3V3HB2

V DR

3V8RH

R

CHUCK

WPP1

WPS

3000 rpm 7,4 cc

ROD HOLDER 3RH

WPG

DR1

0P3P5

4

4

0P3P6

4

T5A6

4

0P3P7 T5A7

T9C

4

T9

3V11DR

6

3V2 Auxilliary valves The system consists of a separate hydraulic circuit for manuovering of feed cylinder, chuck, rod holder, rod kick cylinder and break out cylinder / rod lift cylinder.

Valve (3V7) - Valve for chuck open / close Valve (3V6) - Valve for rod holder open/close Valve (3V12A) - Valve for rod kick cylinder Valve (3V13) - Valve for break out cylinder Valve (3V13) - Valve for rod lift cylinder

Pressure relieving valve keeps the pressure in the circuit to 235 bar Valve for feed thread compensation when breaking and making rod joints

66

Basic hydraulics

GHB

3V3HB1

3V3DR1

4

GFD

4

3GHB

3GFD 3V3FD1

3V3DM1

4

4

G Hold

G Drill

In

A

B

R

P

G Feed

3V3D

Out

3V3C

Hold B.

Drill

Feed

20-30 bar knob Rot. Speed

3V3A

knob

3N1

Ø1

Hold b.

DR2

3V3B

0-180 bar

knob

3V3DR2

4

Feed

0-300 bar

P 4

3V3 Drill ctrl. valve

DR1

0P3P5

3V3 Drill ctrl. valves The system consists of a separate hydraulic circuit for manuovering of feed/hold back pressure and speed of rotation motor.

Valve (3V3B) - Knob for pressure adjustment, feed pressure range 30 - 300 Bar Valve (3V3A) - Knob for pressure adjustment, hold back force range 30 - 180 Bar Valve (3V3C) - Valve for enablying fine feed pressure to reach feed cylinder Valve (3V3D) - Knob for pressure adjustment, rotation speed range 0-50 Bar Valve (3GHB) - Pressure gauge for hold back force Valve (3GFB) - Pressure gauge for feed force

67

Basic hydraulics 8

1MH 2

1BV3A

(BRAKE) MAIN HOIST

3A

1MHDR

1WL WIRE LINE

1BV

1

2

175 bar

VA

7

1AV

VB

260 bar

3V3FD3

4

4

16

1VBMHB2

1VDDMA1

4

16

1VCFDA

9

16

1VDDMB1

1VCFDB

16

16

1VBMHA

12

1VAWLA 1VAWLB

1VBMHB1

12

16

GP1 A B

A B

Z

A B

A B

1GP

A: 75 L/MIN A, B: 115L/MIN

A, B: 190 L/MIN

B: 190 L/MIN

A, B: 180 L/MIN

M

1V1D

1V1C

b

1V1B

1V1A

b

b

P3=220bar

P4=180bar

b

P3

P4

1V1E

P2=140bar

P1=300bar

P2

P1

a

T

LS Z P R

a

a

a

DW

LS T Z P R

R

1V1

LS

P

T3 20

0P1P 0P1LS1

6

Main valves The system consists of a separate hydraulic circuit for manuovering of rotation unit, fast feed, Main hoist and wire line.

Valve (1V1D) - Rotation unit circuit flow = 190 l/min Valve (1V1C) - Fast feed circuit flow = 90 l/min, 190 l/min, pressure P4 = 180 bar Valve (1V1B) - Main hoist circuit flow = 190 l/min, pressure P3= 220 bar Valve (1V1A) - Wire line circuit flow = 115 l/min, pressure P2 = 140 bar

68

Basic hydraulics RETURN OIL CIRCUIT Oil which has been circulated by the hyd. pumps through the directional valves, to motors, hyd. cylinders and valves is returned to the hydraulic oil tank. On its way back it passes through a air/oil cooler (OZ1 ). In order to avoid damage to the cooling ducts a check valve set at 5 bar permits oil to by-pass the cooler when the flow of oil creates too high pressure (when cold). A hydraulic filter (OF1, OF2) with two easily replaceable cartridge removes impurities and metal chips from the hydraulic oil. An indicator connected to the control panel alerts the operator when the function of the filter is unsatisfactory.When the resistance in the filter increases further, check valves will open and the oil will by-pass the filter, however now without being cleaned. Replace cartridges as soon as the indicator gauges alerts for clogging filter.

OP3 . . . . . . . . . . . . . . . . . . . . . .Auxilliary pump OP4 . . . . . . . . . . . . . . . . . . . . . .Hand pump OZ1 . . . . . . . . . . . . . . . . . . . . . .Air/Oil Cooler OZ2 . . . . . . . . . . . . . . . . . . . . . .Temp / oil level OF1 . . . . . . . . . . . . . . . . . . . . . .Oil filter OF2 . . . . . . . . . . . . . . . . . . . . . .Oil filter OF3 . . . . . . . . . . . . . . . . . . . . . .Air Breathter

The system includes a hand operated pump (OP4) for filling of the hyd. oil tank. This pump is permanently connected to the system and supplies oil into the system ahead of the filter (OF2) in order to prevent ingress of impurities while adding or replacing hydraulic oil.

0P3P1

T9

8

0P3P2

6

Auxilliary Pump 215 bar 47 l/min @ 1800 rpm

T7 T5 T4B 3V19

13 l

T6 T3

B

X

F 4

3C1DR

M

3C1

T8

8

0P4 Hand Pump

T1

B

T2

0P4S

20

20

12

0P4P

0P3

12

0F2

0F1

S 0P2DR

L1

0Z2

0F3

L

20

12

0P3S

0P3DR

0Z4

Drain box

69

Basic hydraulics, TroubleShooting INFORMATION Potential problems and solutions

•

The following guide is designed to help you organize your solutions of hydraulic problems. The explanations may not provide all the answers but may direct your train of thought toward solving the problem. Saftey first

•

Remember to observe saftey practices when performing troubleshooting on equipment make sure to support heavy objects, hydraulic oil under pressure is dangerous, and be careful around rotating parts.

Type of fault 1. Noisy pump caused by cavitation

Possible cause A. Oil is too heavy

Remedy A. Change to proper viscosity

B. Filter plugged B. Clean or replace C. Suction line plugged C. Clean line

2. Noisy pump caused by aeration

3. Hydraulic system overheating

70

A. Oil supply low

A. Fill reservior

B. Air leaking into suction line

B. Tighten fittings

C. Foaming oil

C. Drain reservoir and fill with non-foaming type oil. check that return line oil is directed into tank properly and not mixing with air first.

A. Oil supply low

A. Fill reservoir

B. Oil in system too light

B. Drain reservoir and refill with proper viscosity oil

Basic hydraulics, TroubleShooting Type of fault 3. Hydraulic system overheating

4. System not producing necessary pressure

5. System does not produce proper flow

Possible cause

Remedy

C. Excessive internal leakage

C. Connect a flow meter to the pump pressure port. Connect the return to a adjustable nozzle valve and then run, if the valve shown less then 90% of the flow at 70% pressure exchange the pump.

D. Aeration of oil

D. Tighten fittings

A. Excessive internal leakage

A. Check amount of flow according to spec.

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 signal 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 spec.

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 strainer, and suction line

E. No signal to compensator

E. Check signal line and ports at valve

F. Load sense line disconnected or filled with air

F. Connect and bleed of the system

71

TroubleShooting (specific functions), Auxiliary pump circuit

Type of fault 1. Little, erratic, or no feed pressure

Possible cause

Remedy

A. Hydraulic plumbing is not according to schematic

A. Check schematic in parts book 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. Quick disconnect fitting not connected or pilot inside is broken.

C. Make sure quick disconnects go together freely and no broken parts. D. Check oil flow back to tank

D. Return line from manifold is blocked E. Check for worn or damaged parts E. Spool in lever assy is worn or damaged F. Check for worn or damaged parts F. Rotary control valve for feed pressure is worn or damaged G. Thru shaft from main pump is broken or damaged H. Pump or compensator is bad or out of adjustment

72

G. If main pump is ok check where water/mud and auxiliary pump is piggybacked at thru shaft. H. Check auxiliary pump for excessive case drain flow (more than 2.5 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 located at the rear of pump.

4.

while observing pressure on gauge turn adjustment screw clockwise to increase and counterclockwise to decrease auxiliary pressure. Retighten jam nut.

I. Contamination in control valve or auxiliary manifold ports.

I. Disassemble, clean, and inspect for broken parts

J. External problem such as winch brake or structural parts are affecting the feed process.

J. Disconnect winch cable and check condition of sliding parts and structure. troubleshoot automatic brake release system if necessary.

K. Feed cylinder or feed cylinder seal kit is defective or worn

K. Check o-rings in block at ram end of cylinder (p4 and p6. also check if oil is bypassing at piston cups. check internal condition of cylinder.

TroubleShooting (specific functions), Auxiliary pump circuit

Type of fault 2. Automatic-chuck opens partially, not at all, or leaking hydraulic oil (not grease) at chuck body.

3. Automatic-chuck jaws not holding drillrod or slipping.

Possible cause

Remedy

A. Relief valve for autochuck (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 overtightened into housing. set pressure at 90 bar.

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 10 liters), pressure setting, and compensator for contamination and worn or broken parts.

D. Damage to internal sliding parts of autochuck.

D. Disassemble chuck, clean all parts, and inspect for galling, wear, or broken parts. use caution when removing 7/16 bolts at top plate. remove evenly due to spring pressure below.

E. Seal kit, cylinder ram, or cylinder, is worn or damaged.

E. Remove piston ram from cylinder and install new seal kit. Inspect piston ram 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 part numbers according to parts book if possible. make sure the correct size rod bushings (upper an lower) are being used if damage to carbide is ocurring.

B. Hydraulic pressure entering chuck cylinder when chuck control valve is in the closed position.

B. Install 250 bar gauge at chuck and determine when pressure is entering chuck cylinder. if only a small amount is enterning when auto-chuck control valve is in closed position then 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.

73

TroubleShooting (specific functions), Water/Mud pump circuit

Type of fault 1. Mud mixer not rotating, rotating slow, or erratic.

Possible cause

Remedy

A. Quick disconnect not connected properly.

A. Check quick disconnect for damage or does not go together freely.

B. Auxiliary valve cartridge on auxiliary manifold is mounted incorrectly.

B. Check the drawing in parts book for correct mounting according to lettering on valve.

C. Auxiliary control valve is worn or damaged.

C. Check the spool and housing at control valve for wear or damage.

D. Hydraulic motor at mixer assembly is defective.

D. Troubleshoot hydraulic motor for damage or internal leakage.

E. Sequence valve (located below control valve on back side of manifold) is out of adjustment.

E. Make proper ajustment to sequence valve. install a 250 bar gauge in the " a" port hose. move the mud mixer valve to the on position. the adjustment is under the valve inside the operators panel. loosen the locknut and turn the screw clockwise to lower and counterclockwise to raise the pressure. the pressure should be set at 100 bar.

F. Water/Mud pump or compensator is bad or out of adjustment.

F. Troubleshoot pump for proper settings, excessive internal wear, and compensator problem.

TroubleShooting (specific functions), Additional auxiliary control valve circuits Type of fault 1. Hydraulic jacks, rod kicker, mast lift, etc. will not operate at all or erratic.

74

Possible cause

Remedy

A. Auxiliary valve cartridge is mounted incorrectly.

A. Check the drawing in parts book for correct mounting according to lettering on valve.

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. Pump or compensator is bad or out of adjustment.

D. Check auxiliary pump for excessive case drain flow (more than 10 liters), pressure setting, and compensator for contamination and worn or broken parts.

TroubleShooting (specific functions), Auxiliary pump circuit

Type of fault 1. Rotation speed (hi to low) is erratic or not changing r.p.m. when turning rotory control valve in or out.

Possible cause

Remedy

A. Main pump or compensator problem.

A. check the other functions on main valve bank for correct operation. If they are working properly continue troubleshooting b thru i. If some problem exists troubleshoot the main valve or main pump circuit.

B. No pressure from rotory control valve

B. Check the auxiliary pump and compensator

C. Swivel angle adjustment screw is not properly set (located at the top of drillhead on the front side of hydraulic motor).

C. See rexroth service manual procedure for setting min. to max. displacement or simply try turning the adjustment screw slightly and observe if r.p.m. changes. check the parts book for correct r.p.m. setting and using hand photo-tachometer set the engine speed and head rotation to spec.the engine speed is set at 2500 r.p.m. and the head high speed is 1250 r.p.m. its .not recommended to overspeed either.

D. Rotory valve cartridge is worn, damaged, or contamination inside.

D. Remove the rotory control valve cartridge from housing and check for wear, damage, or contamination.

E. Hydraulic controlvalve at hydraulic motor is worn, damaged, contains contamination, or not adjusted properly.

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 r.p.m. 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.

75

TroubleShooting (specific functions), Main pump circuit

Type of fault 1. Rotation section in main valve bank producing slow r.p.m., no revolutions, or lack of pressure.

Possible cause A. Main pump or compensator problem.

Remedy A. Troubleshoot main pump and compensator. check for proper suction, contamination, pressure settings, and excessive case drain leakage (more than 10 l/min is excessive for this pump). Check compensator spools for wear, damage, and contamination. High pressure setting for main pump is 280 bar. The standby pressure is 2o to 30 bar. these are set at the compensator on the main pump. The adjustment closest to the pump housing is standby. The larger adjustment and furthest from the pump is the maximum pressure adjustment. The high pressure can be seen on the rotation gauge. Procedure for checking or setting the compensator low pressure standby requires the following: 1.

stop engine.

2.

install 50 bar gauge in the high pressure line from the main pump before the high pressure filter.

3.

make sure all controls are in the neutral position and restart the engine.

4.

if standby requires adjustment - loosen the jam nut on the compensator and turn the screw clockwise to increase and counterclockwise to decrease pressure.

5.

after adjustment is completed, stop engine, retighten jam nut, remove test gauge, and tighten all fittings.

Procedure for checking or setting the compensator high pressure requires the following:

76

1.

stop engine.

2.

disconnect quick-coupler fittings going to the drillhead motor. (if quick couplers are not used, disconnect male and female hose ends and install steel plugs and caps).

3.

engage the rotory control lever in forward or reverse and observe the pressure on gauge..

4.

if adjustment is necessary, loosen the jam nut on the compensator and turn the screw clockwise to increase and counterclockwise to decrease pressure.

5.

after adjustment is completed, stop engine, retighten the jam nut on compensator, and reconnect pressure lines to drillhead. See eaton manual located in parts book for more information.

TroubleShooting (specific functions), Main pump circuit

Type of fault 1. Rotation section in main valve bank producing slow r.p.m., no revolutions, or lack of pressure.

Possible cause

Remedy

B. Problem in primary or secondary shuttles.

B. Remove, clean, and inspect primary and secondary shuttles in rotation section. If their ok check the shuttles in remaining valve sections as they may affect this function. Use caution when removing secondary shuttle due to loose ball behind shuttle. Install proper o-rings and backups. note primary and secondary shuttles are located in each valve section of the main valve bank. See the main control valve manual for description.

C. Main relief valve in mp-18 is stuck or damaged. (located at the top left side of valve bank under control panelcover.)

C. Remove and inspect main relief valve for contamination, wear, damage, and proper pressure setting. early model units did not have a main relief in main valve bank. the later models do. (the main relief is located at the top left side of valve bank under the control panel cover). pressure setting for the main relief is 280 bar. Follow the procedure in this section solution c for setting high pressure on compensator. After setting this, loosen the jam nut on main relief and turn the adjusting screw counterclockwise until the pressure falls slightly below 250 bar, stop and turn the screw clockwise half a turn.this will set the main relief at approximately 280 psi.

D. Manual control valve spool is worn or damaged.

D. Check manual spool and housing for wear, contamination,or damage.

E. Rotory control valve (for two speed head) on auxiliary circuit is not working properly.

E. Troubleshoot rotory control valve (for two speed) at the control panel and the auxiliary circuit. See solution a thrud under problem 1 rotation speed (hi to low) is erratic or not changing r.p.m. when turning rotory control valve in or out.

F. Flow compensator spool in rotory valve section blocked or stuck.

F . Carefully remove compensator spool and check for wear, damage, or contamination.

G. No signal to ls port on pump from main valve bank.

G. Check the ls signal line from mp-18 valve to main pump for obstruction in hose or blocked orfice fittings.

H. Problem in hydraulic motor on drillhead.

H. See rexroth service manual procedure for setting min. to max. displacement or simply try turning the adjustment screw slightly and observe if r.p.m. changes. Check the parts book for correct r.p.m. setting and using hand photo tachometer set the engine speed and head rotation to spec. the engine speed is set at 3250 r.p.m. and the drillhead high speed is 1300 r.p.m. its not recommended to overspeed either.

I.

Problem in transmission or drillhead housing.

I. disconnect hydraulic motor from transmission and see if problem still exists.

77

TroubleShooting (specific functions), Main pump circuit

Type of fault 2. Fast feed section in main valve bank does not move feed cylinder, too slow, or erratic.

Possible cause A. Main pump or compensator problem.

Remedy A. Troubleshoot main pump and compensator. check for proper suction, contamination, pressure settings,and excessive case drain leakage (more than 1,5 g.p.m. is excessive for this pump). Check compensator spools for wear, damage, and contamination. Check metallic gasket and o-ring between compensator and pump for wear. high pressure setting for main pump is 280 bar. The standby pressure is 20 to 30 bar. these are set at the compensator on the main pump. the adjustment closest to the pump housing is standby. The larger adjustment and furthest from the pump is the maximum pressure adjustment. see previous section solution c for procedure on setting and checking high pressure and low pressure standby on compensator. see eaton manual located in parts book for more information.

B. Problem in primary or secondary shuttle.

C. Main relief valve in main or the two relief valves located in the fast feed section are stuck or damaged.

B. Remove, clean, and inspect primary and secondary shuttlesin fast feed section. if their ok check the shuttles in remaining valve sections as they may affect this functionuse caution when removing secondary shuttle due to loose ball behind shuttle. Install proper o-rings and backups. note primary and secondary shuttles are located in each valve section of the main valve bank. see the main control valve manual for description. C. Remove and inspect main relief for contamination, wear, damage, and proper pressure setting. ( the main relief is located on the inlet section. Check the load sense limiting valve by running the cylinder intoend position and read system pressure gauge

78

D. Manual control valve spool is worn or damaged.

D. Remove and check spool for wear or damage.

E. Flow compensator spool in fast feed section is blocked or stuck.

E. Carefully remove compensator spool and check for wear, damage, or contamination.

F. No signal to ls port on pump from the main valve bank.

F. Check the ls signal line from the main valve to the main pump for obstruction in hose or blocked orfice fittings.

G. Problem in feed cylinder.

G. Troubleshoot the feed cylinder checking for worn seal kit or damage to cylinder.

H. Problem in the sliding parts of the drillhead mounting plate, roller parts, or lift chain.

H. Do inspection of slides, rollers, and lift chain.

TroubleShooting (specific functions), Main pump circuit

Type of fault 3. Main winch section in main valve bank producing slow hoist, no hoisting, erratic, or winch not holding load.

Possible cause

Remedy

A. Quick disconnect fittings are not connected.

A. Make sure quick disconnect fittings go together freely and no broken parts inside.

B. High pressure filter between pump and main valve is blocked.

B. Remove and inspect high pressure filter. install the proper filter element.

C. Main pump or compensator problem.

C. Troubleshoot main pump and compensator. check for proper suction, contamination, pressure setting, and excessive case drain leakage ( more than 10 l/min is excessive for this pump). Check compensator spools for wear, damage, and contamination. Check metallic gasket and o-ring between compensator and pump for wear. high pressure setting for main pump is 280 bar. the standby pressure is 20 to 30 bar. The adjustment closest to the pump housing is standby. the larger adjustment and furthest from the pump is the maximum pressure adjustment. See previous section solution c for procedure on setting and checking high pressure and low pressure standby on compensator.

D. Problem in primary or secondary shuttles.

D. Remove, clean, and inspect primary and secondary shuttles in winch section. If their ok check the shuttles in remaining valve sections as they may affect this function.use caution when removing secondary shuttle due to looseball behind shuttle. Install proper o-rings and backups.note primary and secondary shuttles are located in each valve section of the main valve bank.

E. Main relief valve or relief valve in winch section is stuck, damaged, or setting is incorrect. (the winch section contains only one relief valve located on the hoist side of the work port).

E. Remove and inspect main relief valve for contamination,wear, damage, and proper pressure setting.

79

TroubleShooting (specific functions), Main pump circuit

Type of fault 3. Main winch section in main valve bank producing slow hoist, no hoisting, erratic, or winch not holding load.

Possible cause E. Main relief valve or relief valve in winch section is stuck, damaged, or setting is incorrect. (the winch section contains only one relief valve located on the hoist side of the work port).

E. The main relief valve setting is 280 bar and the one relief valve in the winch section is set at 2800 psi on p4. the p6l with 12000 lb. winch requires the one relief to be set at 3250 psi.

F. Manual control valve is worn or damaged.

F. Check manual spool and housing for wear, contamination, or damage.

G. Flow compensator spool in the winch is blocked or stuck.

G. Carefully remove compensator spool and check for wear, damage, or contamination.

H. No signal to ls port on pump from the mp-18 valve.

H. Check the ls signal line from main valve to the main pump for obstruction in hose or blocked orfice fittings.

I.

I.

Problem with automatic brake release signal.

J. Problem in braden winch. K. Problem in structural or mounting parts of braden winch

80

Remedy

Load sense limiting and plugging

If any pressure signal is evident at hoist and if not check that diversion valve at control panel is receiving pressure from feed circuit.

J. Troubleshoot braden winch according to installation, maintenance, and service manual located in parts book K. Check structural area where winch is mounted. make sure mounting platform is strong and mounting surface is even.

TroubleShooting (specific functions), Main pump circuit

Type of fault 4. Wireline section in main valve bank producing slow, erratic, or no rotation of the wireline hoist drum.

Possible cause A. Quick disconnect fittings are not connected properly or pilot is damaged inside. B. Main pump or compensator problem.

Remedy A. Make sure quick disconnect fittings go togther freely and no broken parts inside. B. Troubleshoot main pump and compensator.. check for proper suction, contamination, and excessive case drain leakage (more than 10 liters is excessive for this pump). Check compensator spools for wear, damage, contamination. Check metallic gasket and o-ring between compensator and pump for wear. High pressure setting for main pump is 280 bar. The standby pressure is 20 to 30 bar. The adjustment closest to the pump housing is standby. The larger and furthest from the pump is the maximum pressure adjustment. see previous section solution c for procedure on setting and checking high pressure and low pressure standby on compensator.

C. Problem in primary or secondary shuttles.

C. Remove, clean, and inspect primary and secondary shuttles in wireline section. If their ok check the shuttles in remaining valve sections as they may affect this function. use caution when removing secondary shuttle due to loose ball behind shuttle. Install proper o-rings and backups. note primary and secondary shuttles are located in each valve section of the main valve bank.

D. Main relief valve in main valve bank or the two relief valves located in the wireline section are stuck or damaged.

D. Remove and inspect main relief valve and the two relief valves located in wireline valve section for contamination, wear damage, and proper pressure settings.

E. Manual control valve spool is worn damaged. F. Flow compensator spool in wireline section is blocked or stuck. G. No signal to ls port on pump from main valve bank. H. problem in hydraulic motor mounted to hoist drum. I. check wireline speed control valve located on the right side of the control panel J. damage to structural or mounting parts on hoist.

The load sense limiting valve in the wireline section can be set by completely closing the speed control valve for wireline hoist and engaging the control lever up or down. The quick couplers can also be disconnected to set this pressure. E. Check spool and housing for wear, contamination, or damage. F. Carefully remove compensator spool and check for contamination. wear, or damage.

G. Check the ls signal line from main valve to main pump for obstruction in hose or blocked orfice fittings. H. Troubleshoot hydraulic motor and counterbalance valve mounted on the hoist drum. see eaton manual in parts book for information. I.

Inspect internal parts of speed control valve for contamination or broken parts.

J. Check assembly and mounting area of hoist to main frame and condition of sheave wheels and crown block.

81

TroubleShooting (specific functions), Secondary unit

Type of fault

Possible cause

Remedy

1. The water pump will not turn or stalls at low pressure.

A. Hydraulic hose plumbing is incorrect.

A. Check the parts book hydraulic schematic for correct plumbing. important the motor on the mud pump is designed to turn in one direction only. (counterclockwise when viewed from the shaft end of the motor). if the direction is reversed, hydraulic pump and motor damage will occur.

B. Hydraulic pump problem.

B. Check the pump pressure. Remove both the pressure and the return hoses going to the mud pump motor and plug them. Connect load sense signal to the hose before the plug and a 400 bar gauge. The pressure should read 175 bar. This is nonadjustable and if the pump cannot build 175 bar either the pump or the pump drive is bad. Troubleshoot the pump for suction problem, excessive case drain leakage, charge pressure low, charge relief problem, or high pressure relief is stuck or damaged. see Rexroth pump manual for more information.

82

F. Hydraulic motor problem.

F. Check for proper hose plumbing. troubleshoot two-speed pilot line on auxiliary circuit. refer to eaton service manual for more information.

G. Problem beyond hydraulic motor.

G. Inspect hydraulic motor adapter and mud pump for damage.

83

Rotation Unit ”P head” 1.1 DRILLHEAD ASSY. P HEAD Part # 025161-104 4 "CHAIN ASSEMBLY PROCEDURE REFER TO DRAWING # 025161-105" #1 Thoroughly inspect housing (Part # 362926-0) Remove all burrs and weld spatter. Check tapped holes for proper size and thread quality . #2 Wash housing with clean solvent and blow dry. Make sure all tapped holes are free of chips. #3 Lay housing (Part # 362926-0) on work bench, back side down, with spindle opening on the left. #4 Install the race for bearing (Part # 0915781) in the bottom spindle opening. (Tapered side in first.) #5 Inspect and clean cap. (Part # 162843-0) Plug both lube oil holes, bottom hole with a 1/4" NPT socket head plug, (Part # 0901233-02) and the side hole with a 1/8" NPT socket head plug, (Part # 0901233-01) Apply hydraulic sealant on threads. #6 Install thin section roller bearing (Part # 162764-2) in cap, (Part # 162843-0) #7 Apply a thin bead of silicone sealant on cap, Lay 1 each 151174-110 gasket (.062'') on cap and apply a thin bead of silicone on gasket. Attach cap (Part # 162843-0) to bottom of housing (Part #362926-0) with 8 each (Part # 090214-214) ½" 13 X 2 ¼" bolts and ½" lock washers (Part #090343-7) Lubricate threads and torque bolts to 85 foot pounds.

#14 Line up keys and install spacer (Part # 150035-500) Split ring groove down on spindle. Make sure split ring seats COMPLETELY into groove on spacer. THIS IS IMPORTANT, IF THE SPACER IS NOT SEATED COMPLETELY, THE SPINDLE END PLAY WILL LOOSEN UP AFTER THE HEAD HAS BEEN RUN. #15 Apply a generous amount of anti-seize on the spindle and inside the spindle sprocket (Part # 150040-223) Install spindle sprocket chamfered end up, on spindle and push it on until it bottoms COMPLETELY against the spacer (Part # 150035-00) THIS IS IMPORTANT, IF THE SPROCKET IS NOT SEATED COMPLETELY, THE SPINDLE END PLAY WILL LOOSEN UP AFTER THE HEAD HAS BEEN RUN. #16 Install spindle bearings, 2 each, (Part # 091578-1) tapered side toward end of spindle, 1 on each end of spindle. MAKE SURE THE SPINDLE BEARINGS ARE SEATED COMPLETELY AGAINST THE SPINDLE SPROCKET, IF THEY ARE NOT, THE SPINDLE END PLAY WILL LOOSEN UP AFTER THE HEAD HAS BEEN RUN. #17 Install retaining rings, 2 each, (Part # 0900202-600) in groove above spindle bearing 1 on each end of spindle.

ASSEMBLY INSTRUCTIONS

#8 Set housing upright on work bench stand with inspection hole facing out. #9 Inspect and clean spindle (Part # 162838-0) #10 Place spindle (Part # 162838-0) on work bench with split ring groove on lower side. #11 Apply a generous amount of anti-seize to split ring groove, split ring, spacer, key ways and keys during assembly procedure. #12 Install split ring (Part # 162840-0) into split ring groove in spindle. Make sure the split ring bottoms completely in the groove. #13 Install 2 Each keys (Part # 142614-4) into key ways in spindle.

84

•

Drillhead must be assembled in a clean area free of any contaminants that can accidently get into this assembly.

•

All parts must be clean and free of any dust, dirt, paint, metal chips, burrs, weld slag, weld splatter, or any foreign material before assembly.

•

After assembly is completed and before installing front cover, inspect inside of box to insure that no foreign materials have entered the box during assembly.

Rotation Unit ”P head” 51

4"

REF.

15

MOUNT

43

AS SHOWN

VIEW A-A

16

(1/2 SCALE)

162839-1 (REF.) 2 PLACES INSTALL WITH LOCTITE #609

1-9/16 TYP. BOTH ENDS

162838-1 (REF.)

1/2 SCALE

REMOVE INSTALLATION LIP.

MAKE SURE THERE ARE NO SHARP EDGES. LUBRICATE MOTOR AND TRANSMISSION SPLINED SHAFTS WITH HIGH QUALITY GREASE BEFORE ASSEMBLY. 47

46

55 14

B

**

39

38

18

13

62 68

2 REQD.

6 REQD.

41

42

2 REQD.

***

34 28

A

*** 31

23

7

40

2 REQD.

22

19 2 REQD.

25

4 4" HV CHAIN

24

23 T.

57 T. 9 2 REQD.

12

21

15/16

8 48 44 28

REF. 47 32

49

59 66

43

2 REQD.

8 REQD.

72 17

60 66 16 REQD.

53

NOT SHOWN FOR CLARITY PURPOSES

2 REQD.

** *** A

INSTALL

GUARD 4-5/8 CHUCK

20

18

BEFORE MOUNTING CAP

5

49

4 REQD. ADDITIONAL SHIMS MAY BE REQUIRED ON TOP CAP

A

151174-118

.002 RED

A

151174-118

.005 BLUE

A

151174-118

.010 BROWN

A

SERVICE IN SEAL KIT 041040-42

DRILLHEAD ASSY. NO.

HOUSING PART. NO.

TRANSMISSION PART. NO.

HYD. MOTOR PART. NO.

REMARKS

025161-104

362926-0

025001-65

025052-110

CT-3000 VOLVO MOTOR

025161-105

362926-0

025001-65

025052-104

CT-1000 REXROTH MOTOR

025161-

363028-0

025001-46

LESS MOTOR (025052-29 REF.)

CT-2000 HYD. HINGE

025161-

362926-0

LESS TRANS.

LESS MOTOR

025161-

363028-0

LESS TRANS.

LESS MOTOR

025161-

363028-0

025001-65

025052-104

CT-1000 MANUAL HINGE CT-1000 HYD. HINGE CT-1000 - REXROTH MOTOR, HYD. HINGE

85

Rotation Unit ”P head” #18 Install speedy sleeve, 2 each, (Part # 162839-1) 1 each on each end of spindle as per manufactures instructions, supplied with the speedy sleeve. Apply red Locktite 262 to the inside of the speedy sleeves before installation. Using special installation tool (Part # 163692-6), Position the top of the speedy sleeve 1 9/16'' from the end of the spindle. Remove the installation lip from the speedy sleeves. REMOVE ALL SHARP EDGES, IF ANY, FROM THE SPEEDY - SLEEVES. ANY SHARP EDGES WILL CAUSE SEAL DAMAGE. #19 Before installing the chain, count the number of links in the chain. (There should be 96 links only) Check to see if there is a painted link on the chain, if so, its installed painted side up during chain installation. #20 Install chain (Part # 025287-8) in housing. Position the chain so the spindle assembly can be lowered into the housing coming to rest on the bottom cap. #21 Apply a generous amount of assembly lube to each of the bearings. Lubriplate 105 or equivalent. THIS IS IMPORTANT, THE HEAD WILL ROTATE FOR A SHORT TIME BEFORE LUBE OIL WILL GET TO THE BEARINGS. #22 Lower spindle assembly through top opening in housing, through chain and into bottom cap assembly. MAKE SURE THE SPINDLE IS COMPLETELY SEATED IN THE BOTTOM CAP, IF IT IS NOT, THE SPINDLE END PLAY WILL LOOSEN UP AFTER THE HEAD HAS BEEN RUN. #23 Apply assembly lube (Lubriplate 105 or equivalent) on bearing surface of outer race. Install the outer race for spindle bearing (Part # 091578-1) into top of housing (Tapered end in first.) #24 Install thin section roller bearing (Part # 162764-2) on spindle, make sure it is seated against the snap ring.

#25 Clean and inspect top cap (Part # 162843-0) apply hydraulic thread sealant on threads and install 1 each (Part # 0901233-01) 1/8'' pipe plug, in side lubrication oil hole, and 1 each (Part # 91124-604) JIC fitting in the top lubrication oil hole. Apply a thin bead of silicone on top cap (Part # 162843-0) place 1 each shim (Part #151174-110 .062" thick) and any combination of shims, (Part #'s 151178-118 .002'' 151174-118 .005" 151174-118 .101") to achieve a total shim pack thickness of .085" to .095". Apply a thin bead of silicone to the last shim and install the top cap, positioned on the housing with the lubrication oil port positioned at 4:00 o'clock using 8 each (Part # 090214-214) ½''13 X 1 ½'' bolts and 8 each (Part # 090343-7) ½'' lock washer. Lubricate threads and torque bolts to 87 foot pounds. MAKE SURE ALL THE BOLTS ARE INSTALLED AND TORQUED, SPINDLE END PLAY WILL NOT BE SET CORRECTLY IF THEY ARE NOT. #26 Spindle end play must be established at this time. Spindle end play set up procedure: Attach Special tool (Part # 163692-2) on top of spindle. With 2 each 7/16'' 20 x 1 1/2'' bolts. Torque bolts to 40 foot pounds. Install 2 each ½'' 20 x 9'' all thread bolts through tool with 1 nut below tool and 1 nut above tool. Screw ½'' all thread bolts into the jacking holes in the top cap. Back the lower ½'' nuts away from the tool. Tighten the upper ½'' nuts until the spindle is bottomed tightly in the lower cap. Hit the top of the tool with a large soft faced hammer a few times and retighten the top ½'' nuts. (This will assure that all the end play is out of the spindle.) Install a dial indicator on the top cap with the indicator shaft resting on the top of the spindle. Zero the dial indicator. Loosen the top ½'' nuts a few turns and tighten the bottom ½'' nuts against the tool until the dial indicator quits moving. This is the spindle end play. It must be .010'' to .015''. If the end play is not correct, add or remove shims from under top cap until the correct end play is achieved. THIS IS IMPORTANT, THE LIFE OF THE DRILL HEAD DEPENDS IN THIS BEING CORRECT.

86

Rotation Unit ”P head”

MINIMUM DISPLACEMENT SCREW STEP # 64

3

6

63 69

SILICONE SEALANT

2 REQD.

1

52 74 10

LOCTITE TWO (2) BEARINGS INTO TRANSMISSION HOUSING BEFORE ASSEMBLY WITH DRILLHEAD USE LOCTITE #680

2 REQ D.

71

61 67 4 REQD.

1/8 NPT LUBE PORT REF.

30

54

57 65 6 REQD.

45

70 OIL LEVEL PLUG

50

33

58 65 12 REQD.

56 64 3 REQD.

11

29

2

8 REQD.

SERVICE IN SEAL KIT 041040-42

87

Rotation Unit ”P head” See attached drawing for detailed end play tool set up. This completes the set up procedure portion on the spindle. The following steps detail the set up procedure of the pinion shaft. #27 Clean and inspect the pinion sprocket (Part # 150040-223) Check the lubrication oil pump (Part # 025014-107) drive shaft in the bottom of the pinion sprocket. Lubricate the pump shaft with gear oil, it should slide freely in the pinion sprocket. Bearing surface to spline concentricity must be checked at this time. This is accomplished by installing a spline plug, (Part # 1636925) in the input spline , then place the sprocket in a two point live center fixture, (Part # 163692-7) set up a dial indicator in the bearing surface nearest the oil pump drive end, then on the bearing surface on the input splined end, then on the spline plug. The run out on any of these surfaces must be .003'' or less (see drawing # 150040222) IF THE RUN OUT EXCEEDS .003'' DO NOT USE THE PINION SHAFT. (Pinion shafts have been through quality assurance, but they need to be rechecked before installation.) Remove pinion shaft from live center fixture and remove spline plug . Lubricate the input spline, (top of pinion sprocket) with (Optimol grease Part # 08464-215 or equivalent.) Insert the out put shaft from the Funk transmission (Part # 025001-65) into the input spline in the pinion sprocket . It must slide free without any binding. Check the bearing fit (Part # 090013-221) 4 each on the pinion sprocket. (The fit needs to be a tap fit. This is necessary for ease of installation.) If bearing fit is not correct, polish the shaft area until it fits right. When bearing fit is correct, hand pack each bearing with assembly lube, (Lubriplate 105 or equivalent.) THIS IS IMPORTANT AS THE PINION SPROCKET WILL TURN FOR A SHORT TIME BEFORE LUBRICATION OIL FLOW IS ESTABLISHED. Install 1 bearing, 1 spacer (Part # 150035-481) and 1 bearing on each end of pinion sprocket. Set the sprocket aside, it will be installed later. #28 Install tensioner pin (Part # 050270-180) with key (Part # 16614-4) Into tensioner housing. Secure tensioner pin with retaining ring. (Part # 090203-98) 88

#29 Install tensioner assembly into the housing. (the tensioner assembly pin is offset from center, install the tensioner assembly with the shorter offset down.) #30 The next 5 steps are necessary to determine the correct width of the stop spacer. (Part # 150035-505) The stop spacer has to be fit to each individual case because of variances in the housing manufacturing. The stop spacer is installed to prevent excessive pinion bearing side loading in the event the adjuster nut is over tightened. #31 Install Lubrication pump mount (Part # 162830-0) as shown in view A-A drawing # 025161-105, with 8 each ½'' 13 x 1 ½'' bolts, (Part # 090214-144) without a gasket on the bottom of the housing. Bolts need to be looseenough so mount can slide freely. #32 Install pinion sprocket assembly into the tensioner housing assembly and seat lower pinion sprocket bearing into lubricationpump mount. (The chain is not on the pinion sprocket at this time.) #33 Install transmission mount (Part # 1628290) with 6 each 5/8'' 11 x 1 ¾'' bolts, (Part # 090214-173) without a gasket on the top of the housing. Bolts need to be loose enough so mount can slide freely. #34 Move tensioner assembly to the right (away from spindle) until the mounting bolts bottom in the adjusting slots on the transmission and lubrication pump mount plates. Measure the distance between the tensioner housing and the weldment plate that the tensioner pin goes through. This dimension plus .030'' is the width that the spacer, (Part #150035-505) needs to be. #35 Check the width of the spacer (Part # 150035-505) Machine it to the dimension that has been determined in step 36. #36 Disassemble transmission and lubrication pump mount, remove the pinion sprocket assembly from the tensioner housing, remove the tensioner housing assembly. #37 Reinstall tensioner housing with the spacer (Part # 150035-505) on the tensioner pin. (The spacer goes on the tensioner pin between the out side of the tensioner housing and the weldment plate, make sure the recessedend of the spacer is towards the snap ring) Install lock nut 1'' 8 NC

Rotation Unit ”P head” (Part # 090356-9) on tensioner pin. (Leave this nut as loose as possible.) #38 Position the chain (Part # 025287-8) in the tensioner housing so the pinion assembly will fit past it. Install pinion sprocket assembly into tensioner housing. #39 Turn the housing so it is laying on it's back on the work bench.

#44 Tighten the transmission mount bolts to 175 foot pounds of torque, and the lubrication pump mount bolts to 87 foot pounds of torque. Wipe away excess silicone and Hylomar from assembled parts. #45 Pinion sprocket end play must be established at this time. Pinion sprocket end play procedure:

#40 Apply a thin bead of silicone to the inside face of the lubrication pump mount (Part # 162830-0) and install gasket (Part # 151174114) Apply a thin coat of Hylomar gasket maker (Part # 710xx264 medium) to gasket and mating surface on housing. Install lubrication pump mount to the housing with 8 each ½'' 13 x 1 ½'' bolts (Part # 090214-144) 8 each ½'' lock washer (Part # 090343-7) and 8 each ½'' flat washers (part # 090347-20) Snug the bolts up hand tight so the lubrication pump mount can slide for chain adjustment. (Hylomar gasket maker is the preferred sealant to be used between the gasket and the housing because it stays pliable and wont leak when chain is adjusted if it is not available silicone is the next best thing to use.) #41 Apply a thin bead of silicone to the inside face of the transmission mount (Part # 162829-0) and install steel gasket (Part # 151174-117). Apply a thin bead of silicone to the face of the steel gasket, and install plastic transmission mount gasket (part # 151174-122). Apply a thin coat of Hylomar gasket maker to the face of the plastic transmission mount gasket and the mating surface on the housing. NOTE: APPLY HYLOMAR GASKET MAKER SPARINGLY SO IT WONT GET INTO THE HOUSING AND CONTAMINATE THE LUBRICATION SYSTEM. #42 Install transmission mount on housing with 6 each 5/8'' 11 x 1 ¾'' bolts (part # 090214-173) 6 each 5/8'' lock washers (Part # 090343-8) and 6 each 5/8'' flat washers (part # 090347-23) Snug these bolts up hand tight so the transmission mount can slide for chain adjustment. #43 Adjust the chain. Tighten 1''8 NC self locking nut (1 ½'' socket) until the chain has 1" of deflection from front to back . (see chain adjusting procedure drawing # 163963-8)

Install special tool (Part # 163639-2) to the top of the transmission mount with 2 each 5/8'' 18 x 6 ½'' all thread bolts with nuts. Tighten 5/8 nuts against tool. (This will push the pinion sprocket to the lower limit of it's travel.) Remove the tool and install a dial indicator with the pointer resting on the top of the pinion sprocket. Install special tool (Part # 163692-3) to the bottom of the lube pump mount with 2 each 1/2'' 16 x 4 ½'' all thread bolts with nuts. Tighten the 1/2'' nuts against tool until the pinion sprocket is pushed to the upper limit of it's travel. The dial indicator should read .030'' minimum. If the end play is more than .035 this is acceptable, if it is less than .030'' this is unacceptable. Add 1 each steel transmission mount gasket (Part # 151174-117) to transmission mount to achieve the correct pinion sprocket end play. THIS END PLAY IS CRITICAL, PINION SPROCKET BEARINGS WILL FAIL IF IT'S NOT RIGHT. #46

Install key (part # 090796-3) in shaft of lubrication pump

CAUTION LUBRICATION OIL FLOW IS ABSOLUTELY NECESSARY AT ALL TIMES WHEN THE HEAD IS ROTATING. FAILURE TO MAINTAIN LUBE OIL FLOW WILL CAUSE CATASTROPHIC DAMAGE TO THE HEAD AND OR THE TRANSMISSION.

DO NOT OVER TIGHTEN CHAIN. THE LIFE OF THE ROTATION HEAD DEPENDS ON THIS ADJUSTMENT BEING CORRECT. 89

Rotation Unit ”P head” (Part # 025014-107) Put a thin layer of silicone on lubrication pump gasket (part #151174-115) and install gasket to face of lubrication pump. Apply a thin layer of silicone on mating surface of lubrication pump mount (part # 162830-0) Install lubrication pump into mount with 3 each ¼'' 20 x ¾'' bolts (part # 090214-85) with ¼'' lock washers (part # 090343-4) Tighten bolts to 7 foot pounds of torque. Lubrication pump relief valve adjustment procedure. Remove the acorn nut (5/8'' wrench) from the relief valve, loosen the lock nut (7/16'' wrench) and turn the adjusting screw clockwise until three threads are showing above the lock nut . Tighten lock nut and reinstall acorn nut. This adjustment will assure lubrication oil flow during warm up. The lube system depends more on oil volume, than oil pressure to lubricate the bearings. #47 Install lower spindle oil seal (part # 090363424) lip up as shown in drawing (# 025161105) Apply a thin layer of silicone to the inside mating surfaces of the seal. Install seal with special tool (part # 163692-1) #48 Install oil tube (part # 364286-0) in the ¼'' NPT hole in the center bottom of the housing. Make sure the oil spray holes in the tube face the rear side of the pinion sprocket. #49 Reposition housing upright on bench with chain opening facing forward. #50 Install the spindle top seal (part # 090363424) in the top cap with the lip up. (view A of drawing # 025161-105) Apply a thin layer of silicone in the inside mating surfaces of the seal. Install seal with special tool (part # 163296-1) This seal is installed up side down to prevent contaminates from entering the housing from the top of the spindle. #51 Install seal excluder (part # 155971-9) (wide side down) over spindle and on top of top seal. #52 Install speedy sleeve (part # 162839-2) on top section of pinion shaft. (splined end) Coat mating surfaces with red loctite (Part # 262) Tap speedy sleeve into place with the installation tool provided in the speedy sleeve kit. Leave the installation lip in place, there is no need to remove it.

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#53 Install oil seal (part # 090365-203) Apply a thin layer of silicone on the mating surfaces of the seal, install seal with the lip up, in the transmission mount plate. Install seal with special tool (part # 163692-4) MAKE SURE THE SEAL IS INSTALLED LIP UP, AS SHOWN IN (DRAWING # 025161105.) THIS SEAL HOLDS THE LUBRICATING OIL IN THE TRANSMISSION. IF IT IS NOT INSTALLED CORRECTLY, THE LUBRICATION OIL WILL DRAIN FROM THE TRANSMISSION INTO THE CHAIN CASE, CAUSING PREMATURE TRANSMISSION FAILURE AND CHAIN CASE OVERHEATING. #55 Recheck pinion sprocket run out one last time at this point. Install spline plug (part # 163692-5) into female spline in pinion sprocket. Check the run out on the side of the spline plug with a dial indicator. It should be .003'' to .005'' or less. #56 Apply a thin film of silicone to both sides of side cover gasket (part # 151174-112) install gasket and side cover (part # 162833-0) with 6 each (part # 090214-59) 3/8'' 16 x ¾'' bolt and 6 each (part # 090343-6) 3/8'' lock washers. Tighten bolts to 36 foot pounds of torque. #57 Apply a thin bead of silicone to both sides of transmission gasket (part # 151174-122). #58 Transmission installation procedure. Make sure the transmission has been reworked from a (part # 025001-43) into a (part # 025001-65) Rework consists of: Transmission adapter modified as shown on (drawing # 160303-5.) Transmission to motor coupler modified as shown on (drawing # 164356-0.) Transmission input shaft bearing (part # 90017-210) shown in (drawing # 02500165.) The input shaft must be removed from the transmission and the oil shields removed from both sides of the input bearing. THIS IS DONE TO ALLOW FOR LUBRICATION OIL FLOW THROUGH THE TRANSMISSION. Transmission out put shaft, (part # 15896-6) shown in (drawing # 025001-65) must be removed and reworked as shown in (drawing # 163692-9.) THE SNAP RING IS ADDED TO THE OUT PUT SHAFT TO MAINTAIN CLEARANCE BETWEEN THE INPUT AND OUT PUT SHAFT TO PROVIDE LUBRICATION OIL FLOW TO

Rotation Unit ”P head” THE POCKET BEARING BETWEEN THE TWO SHAFTS. #59 Apply a liberal coating of Optimol grease # 08464-215 to transmission out put shaft. Install transmission into pinion sprocket. Attach transmission to transmission mount with 4 each (part # 090214-154) 9/16'' 12 x 1 ½'' bolts and 4 each (part # 090343-19) 9/16'' lock washers. Tighten bolts to 125 foot pounds of torque. #60 Apply a liberal coating of Optimol grease on the splines of motor to transmission coupling (part # 164356-0) and install on transmission input shaft. Make sure the coupling has been reworked as shown on (drawing # 164356-0) The top of the coupling has a recess cut in to it, to create an oil dam to cut down on coupler and shaft fretting.

#66 Install lubrication system. There are basically two types of lubrication systems used on this head assembly. One with an oil cooler (drawing # 025282-13) and one without an oil cooler (drawing # 02528311). Refer to the drawing that applies to your application. ALWAYS PRIME THE FILTER AND THE ENTIRE LUBRICATION SYSTEM BEFORE START UP. THE LOWER TRANSMISSION TO CHAIN CASE DRAIN LINE (CLEAR PLASTIC LINE) WILL SHOW OIL FLOW AFTER THE HEAD HAS BEEN ROTATED FOE A MINUTE OR SO. IF NO OIL FLOW IS ESTABLISHED, CHECK THE LUBE SYSTEM TO DETERMINE THE CAUSE. THE UPPER DRAIN LINE WILL ONLY SHOW LUBRICATION OIL FLOW IN COLD WEATHER START UP.

#61 Install oil tube (part # 364335-0) in top left side hole in transmission adapter (part # 160303-5) as shown in view B-B (drawing # 025282-13.) #62 Install O ring (part # 090108-104) with a little assembly lube on mating flange of hydraulic motor (part # 025052-104). #63 Install hydraulic motor onto transmission adapter with 2 each (part # 090214-215) 5/8'' 11 x 2 bolts and 2 each (part # 0903438) 5/8'' lock washers. Tighten bolts to 175 foot pounds of torque. #64

Check the length of the minimum displacement screw on the hydraulic motor. See (drawing # 025161-105) . The screw should be 3 ¼'' long overall. IF IT IS NOT THE CORRECT LENGTH, MODIFY IT, REASON BEING, THAT THERE IS A POSSIBILITY OF MOTOR OVER SPEED WITH THE FACTORY LENGTH BOLT THAT COMES IN THE MOTOR. THE INITIAL SETTING OF THIS SCREW IS 3 THREADS SHOWING ABOVE THE LOCK NUT. THE FINAL SPEED WILL HAVE TO BE FINE TUNED TO EACH INDIVIDUAL DRILL DURING START UP.

#65 Apply a thin bead if silicone to both sides of front cover gasket (Part # 151174-111) and install on mating surface of front cover (part # 162847-0) Install front cover on housing with 12 each (part # 090214-87) 3/8'' 16 x 1'' bolts and 12 each (part # 090343-6) 3/8'' lock washer . Tighten bolts to 36 foot pounds of torque. 91