Atlas Copco Exploration Products

CS4002 Core Drill Rig

Operators Instruction Manual
(Pilot Operated Control)

Printed Matter No. 6991 1460 01

Operator's Instruction Manual for
CHRISTENSEN
CS4002

This instruction manual is intended for operators of the

Christensen CS4002 high capacity diamond core drill.

Instructions are given for set up, drilling, and maintenance

procedures to be carried out by the operator and
maintenance personnel. For further information concerning
service measures for the drill rig, please contact your
nearest Atlas Copco representative.

Safety instructions applicable to operating and maintaining

the drill are given in the section 2, Product Safety
Instructions. This section must be read carefully and fully
understood before starting to use the rig. Any questions
regarding these instructions should be referred to your
nearest Atlas Copco representative.

All rights reserved.

The owner of the equipment is granted the permission to

take copies of this publication solely for internal use.
It is recommended, however, to order additional copies from
your nearest Atlas Copco representative in order to benefit
from the latest revision.

Atlas Copco Exploration Products reserves the right to make

changes, without notice, in its products in order to improve
design or performance characteristics.

The information in this publication is assumed to be accurate

at the time of publication, but is subject to changes in order
to remedy detected deficiencies or to follow changes in the
product.

Users of this publication are requested to inform Atlas Copco

Exploration Products about deficiencies found, particularly in
matters concerning product safety.

ATLAS COPCO EXPLORATION PRODUCTS

NORTH BAY, CANADA 2006-10

Printed Matter No 6991 1424 01

Contents

Page Page

7.1 Main Control Panel (Pilot Operated) 35

1 Introduction______________________ 1
7.2 Secondary Control Panel__________ 41
2 Safety Instructions ________________ 3
8 Diesel Engine Start-Up ____________ 43
2.1 Organizational Measures ___________3
8.1 Pre-Start _______________________ 43
2.2 Operation (General) _______________5
8.2 Engine Start ____________________ 45
2.3 Moving the Drill __________________7
8.3 Engine Shut-Down _______________ 45
2.4 Set-Up of Drill ____________________8
9 Drill Set-Up _____________________ 47
2.5 Drilling __________________________9
9.1 Start-Up _______________________ 47
2.6 Tear-Down of Drill _______________10
9.2 Secondary Controls ______________ 48
2.7 Maintenance and Servicing ________11
9.3 Levelling the Drill________________ 49
2.8 Special Safety Signs _______________12
9.4 Operators Platform _____________ 50
2.9 Safety Decals ____________________13
9.5 Mast Slide ______________________ 50
2.10 Fire Extinguisher________________14
9.6 Unfolding Mast Extension _________ 51
3 Environmental Instructions ________ 15
9.7 Mast Supports __________________ 51
4 Hoisting the Drill ________________ 17
9.8 Ground Support and Guy Wires ___ 56
5 Specifications ___________________ 19
10 Drilling _______________________ 61
5.1 General _________________________19
10.1 Before Drilling Starts____________ 62
5.2 Technical Specifications ___________20
10.2 Start the Power Unit ____________ 62
5.3 Dimensions ______________________22
10.4 Adjust the Flow of Mud/Water____ 63
6 Design Features _________________ 27
10.5 Start Rotation __________________ 63
6.1 Mast and Feedframe ______________28
10.6 Start Drill Feed_________________ 64
6.2 Rotation Unit ____________________29
10.7 Stop Drilling ___________________ 64
6.3 Crown Block ____________________29
10.8 Controlled Wireline Lowering ____ 66
6.4 Control Console __________________30
10.9 Controlled Wireline Winching ____ 66
6.5 Wireline Winch __________________30
10.10 Thread Compensation __________ 66
6.6 Main Winch _____________________31
10.11 Adding a Drill Rod_____________ 67
6.7 Hydraulic Tank __________________32
10.12 Removing a Drill Rod __________ 67
6.8 Mechanical Guards _______________33
10.13 Water Pressure Dump Valve ____ 67
6.9 Optional Rod Rack/Helpers Platform
___________________________________33 10.14 Operating Main Winch _________ 68

6.10 Optional Spin-Out Tool __________34 10.15 Rod Handling _________________ 69

7 Controls ________________________ 35 10.16 Drill Rod Break-In Procedure ___ 71

Contents
Page
11 Maintenance And Servicing _______ 73
11.1 General ________________________73
11.2 Periodic Maintenance and Service
Schedule ___________________________73
11.3 Lubricant Recommendations ______75
11.4 Service Point Detailed Instructions _76
11.5 Periodic Inspections _____________85
11.6 Hydraulic Hoses & Fittings Inspection
___________________________________87
12 Hydraulic Circuit Description _____ 89
12.1 Hydraulic Pumps________________89
12.2 Filtration ______________________90
12.3 Main Pump Circuit ______________91
12.4 Auxiliary Pump Circuit __________95
12.5 Secondary Pump Circuit__________98
12.6 Return Oil Circuit and Hydraulic
Tank ______________________________99
12.7 Hydraulic Oil Cooler____________100
13 Electrical Circuit Description_____ 101
Page
13.1 Electrical Fault Panel___________ 101
13.2 Safety Systems Description ______ 102
14 Trouble-Shooting ______________ 103
14.1 Trouble-Shooting - General _____ 104
14.2 Trouble-Shooting Auxiliary Pump
Circuit ___________________________ 106
14.3 Trouble-Shooting Main Pump Circuit
_________________________________ 110
14.4 Trouble-Shooting Secondary Pump
Circuit ___________________________ 113
15 Hydraulic Set-Up Procedure _____ 115
16 Spin-Out Tool Option ___________ 129
16.1 Safe-T-Spin Wireline Rod Make/Break
Tool _____________________________ 129
16.2 Safe-T-Spin Operators Manual __ 130
16.3 Safe-T-Spin Maintenance _______ 137
17 Addendum Sheets ______________ 139
1 Introduction

1 Introduction
Thank you for choosing the CS4002 as your
next core drill. The team at Atlas Copco
Exploration Products is certain that it will provide
you with years of productive service.

This operators instruction manual contains

information and safety instructions to assist in
the safe operation and maintenance of the
CS4002 in the standard configuration. Some
CS4002 drills have special customer ordered
features that differ from the standard drill
configuration. These are described in
Section 18 Addendum Sheets

Core drilling by its nature can be dangerous

work. Care must be exercised when operating
and servicing this product. Never operate this
machine without all guards, pins and safety
devices in place and in good working order.

A safe and careful operator is the best insurance

against an accident.

If you require any assistance, or for Parts

ordering, please contact your nearest Atlas
Copco sales office or contact:

Atlas Copco Exploration Products

A Division of Atlas Copco Canada Inc.
640 McKeown Avenue
North Bay, Ontario
P1B 8H2
Canada

Telephone: (1) 705 472-3320

Fax: (1) 705 472-6843

1
1 Introduction

2
2 Safety Instructions
2 Safety Instructions
Dear operator,
Before putting your new equipment into use, we
would like to direct your attention to the safety
aspects. Drilling can be hazardous to you and to
the environment. Good order, training and well
maintained equipment are the key factors for
safe operation. This manual is no replacement
for thorough training, but will, as a training aid
and a reference book, help you to maintain a
safe working environment and keep the rig in
good operating condition.
Yours faithfully,
Atlas Copco Exploration Products
Intended Use
The CS4002 diamond core drill is intended for
Surface exploration and investigation drilling
within the published depth ratings of the drill.
Any use going beyond this shall be considered
"not intended use". The manufacturer is then not
liable for damage incurred as a result.
Unintentional use shall be at the owner's risk.
Proper use also includes observing the safety
instructions and procedures in the operation,
maintenance, and service manuals as described
by the manufacturer.
The CS4002 should be operated, serviced and
repaired by personnel properly trained for their
task. These personnel must have sound
knowledge about hazards in their respective
profession.
General safety regulations must be observed.
Personnel should be aware of dangers resulting
from abuse of drugs and alcohols as well as
effects of medicines legally prescribed, or
mixture of any of them.
No unauthorized alterations should be made to
the drill. The manufacturer is not liable for any
damage caused by unauthorized alterations.
2.1 Organizational Measures
2.1.1 The CS4002 core drill shall be operated
only by personnel who have been fully
trained on the rig. Particular emphasis
shall be put on the Safety Instructions
and proper maintenance of the drill.
2.1.2 Keep this instruction book available on
the rig at all times.
2.1.3 Always use personal protective
equipment as required by circumstances
or demanded by regulations. Always
use safety harnesses when climbing to
the (optional) helpers platform, working
on the helpers platform, or when
climbing the service ladder.
2.1.4 If, during operation of the unit, any
abnormal action in the safety or
operational systems is observed, the
unit should be stopped and the problem
investigated and rectified.
2.1.5 Warning signs must be kept legible at all
times. Damaged signs should be
replaced immediately.
2.1.6 Hydraulic and electrical systems are of a
complex nature, and can cause injury or
damage if not handled with care. Repair
and service shall be carried out by
personnel with documented experience
for these systems.
2.1.7 Welding repairs should only be carried
out by a qualified welder in order to
meet the high standards that apply to
Atlas Copco products. Special attention
must be given to components which
could cause injury or serious damage.
2.1.8 After repairs, make sure that the rig has
been inspected and approved by the
proper authorities before being brought
back to normal operation.
3
2 Safety Instructions
2.1.9 Never make alterations or modifications
to components of the unit, or alter
pressure settings, particularly to the
safety systems, which might result in
hazardous consequences. The
manufacturers approval should be
requested for any modification done to
the unit.
2.1.10 Mechanical aids should be used
whenever it is necessary to lift more
than 25 kg (50 lbs)
2.1.11 Do not operate the drill when the wind
speed exceeds 20 m/sec (45 mph). Use
guy wires when required (see section
9.8) to prevent upset of the machine.
2.1.12 Always practice good housekeeping.
Keep the drill deck clear and the
working area tidy. Prevent slippery
conditions underfoot on the deck, the
driller platform, the helpers platform (if
so equipped) and the area surrounding
the drill.
2.1.13 Do not store any flammable liquids or
gas bottles near the drill. Never store
any blasting caps or explosives near the
drill.
2.1.14 Always use the deck access ladder
when climbing onto the rig platform
4
2.1.15 Fall arrest and restraint equipment must
be used whenever the vertical drop
exceeds 3 m (10 ft) or as specified by
local safety regulations. When climbing
ladders (e.g. service ladder to the crown
block), it is recommended to use a
guided type of fall arrest system in
which a rope grab is attached to a body
harness (See Figure 2.1). Fall restraints
and a guided type of fall arrest system
are available, Atlas Copco part
3760009042. Follow instructions
supplied with the fall arrest and fall
restraint equipment. Do not alter or
misuse this equipment.
A body harness as shown in Figure 2.1
is available from Atlas Copco as part
3760008964. It should be used to climb
the service ladder to the crown block.
Figure 2.1
If the drill is equipped with the optional
30 ft rod rack, the fall arrest and fall
restraint kit Atlas Copco part
3760009042 is provided with the 30 ft
rod rack components.
2 Safety Instructions
2.2 Operation (General)
2.2.1 In addition to this manual you should
have a good knowledge of generally
recognized safety and accident
prevention regulations. If you follow the
regulations you stand a better chance of
accomplishing your task without harm to
either man or equipment.
2.2.2 Prior to starting up for the first time,
familiarize yourself with the rig's
features, its controls and their functions.
Fig 2.3 Read the Instruction Book before
Starting Up the drill
2.2.3 Various safety devices are built into the
system of the rig for your personal
safety. These devices must be checked
at least once at the beginning of each
shift to ensure that they are in proper
working order. The equipment should
not be used unless safety checks and
maintenance have been carried out.
2.2.4 The drill is equipped with a fire
extinguisher when shipped from the
factory. Always ensure that the fire
extinguisher is kept on the drill and is in
good working order (see section 2.10)
2.2.5 Operators and helpers should wear
helmets with ear protectors, safety
glasses, safety shoes, gloves and
suitable clothing. Loose fitting clothing
and jewellery can become caught in the
moving parts of the machinery, causing
serious injury or even death. Use
suitable respirators in dusty conditions
2.2.6 During drilling, no unauthorized
person(s) should be allowed near the
rig.
2.2.7 Set control levers and switches to the
neutral positions prior to starting up,
otherwise the rig could start
uncontrollably. Some of the levers are
spring-loaded so that the operation will
stop once released. This is part of the
safety system. Never lock these levers
into operating position using strings,
sticks or similar items. The drill should
always be started from the control
panel.
2.2.8 Shut the rig down for refuelling. Fuels
must be handled with care, at a safe
distance from fire, sparks or electrical
systems. Smoking is not allowed within
10 metres of the fuel! Do not fill the tank
in an enclosed space without ensuring
adequate ventilation. Fumes are
poisonous. Dispose of spilled fuel in
accordance with safety and
environmental regulations (Use
absorbents or dig out the contaminated
soil and transport it to an approved
storage). Do not overfill the fuel tank.
2.2.9 If you top up the fuel tank in the
morning, expansion of the fuel, as the
temperature increases later in the day,
may cause fuel to spill from the tank.
Tank breathers clog easily if the level of
fuel is too high.
2.2.10 Never leave the rig unattended with the
engine running. Carry the ignition key
with you.
2.2.11 Use extreme caution while handling
starter batteries. Wear gloves and
protective glasses when servicing
batteries. The batteries contain strong
acid which can seriously burn eyes, skin
and damage cloth, insulation and metal.
First aid in case of acid in the eyes:
wash with plenty of clean water and
seek medical help. Disconnect the
ground cable from the battery before
carrying out service in the electrical
system.
5
2 Safety Instructions

alarm (beeper) similar to a truck backup

The battery gas is explosive! Never use
matches when checking the acid level.
Be careful using iron tools near the
battery, a spark might set off an
explosion.
2.2.20 Obtain MSDS data sheets for the fluids
2.2.12 Hydraulic oils are poisonous. Use eye
protection and gloves. Hydraulic oils,
like fuel, must be treated in compliance
with safety and environmental
regulations.
warning device that is activated when
hydraulic functions are used during set-
up and tear-down. Stand clear of jacks
and mast when this device has been
activated.
that you use for the drill and follow the
instructions in the data sheets in case of
accidental ingestion, skin contact or
spills.

2.2.13 Before any repair or service is carried

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

2.2.14 Be very careful while tracing leaks in the

pressurized systems. Hydraulic oils,
water or air under pressure could
penetrate under the skin and cause
complicated injuries or infection. If this Fig. 2.4 Use Only Genuine Atlas Copco Parts
happens, see a doctor at once.

2.2.15 Dispose of engine oils, hydraulic oils,

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

2.2.16 Avoid the use of cleaning agents

containing solvents like carbon
tetrachloride. There are environmentally
better alternatives now available on the
market

2.2.17 Use only authorized parts (Atlas Copco

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

2.2.18 Any warranty, for work performed, only

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

2.2.19 Establish and use a standard means of

communication between all drill
personnel. Remain in eye contact with
each other where possible. The
CS4002 drill is provided with an audible

6
2 Safety Instructions
2.3 Moving the Drill
2.3.1 Always lower the mast to the transport
position and raise the jacks before
moving the drill. Ensure that the jacks
and mast slide securing pins are in
place. Driving with mast out of transport
position could cause rig upset.
2.3.2 Always safely stow and secure the
overshot and water swivel on the deck
before moving. Never move the drill with
loose items on the deck
2.3.3 Do not allow any personnel to ride on
the deck while the drill is moving.
Personnel must ride in cab of truck only
2.3.4 Always test brakes before descending a
ramp or steep incline.
2.3.5 For truck mounted drills, ensure that
trucks operators manual is supplied
and is kept in the truck.
2.3.6 Always check your surroundings before
moving the drill so you become aware of
any hazards.
2.3.7 While moving the rig, no unauthorized
person should be allowed near the rig.
Ask a supervisor for assistance when
moving the rig into dangerous positions
such as close to the edge of a quarry
bench. Make sure the visibility is good.
Don't drive the rig into a dust cloud.
2.3.8 When the drill is mounted on tracks and
is moved with the operator at the
console position, always use a spotter in
communication with the operator to
ensure that the drill is being safely
moved since visibility from the console
position is very limited.
2.3.9 Even with the mast down, the drill
when mounted on a truck or tracks has
a high center of gravity. To prevent
sideways tipping, never move the rig on
a side slope greater then 1 in 5.
2.3.10 If the drill is mounted on tracks or a
truck by the customer, the customer
must mount an inclinometer at the
driving position so the driver is aware of
the slope. An inclinometer is available
from Atlas Copco, Part # 3760005026
2.3.11 The driver must be aware of the
possibility of soft ground or soft road
shoulders at all times since sinking of
the wheels or tracks in soft ground can
rapidly increase the sideways slope of
the rig and lead to tipping of the rig and
personnel injury.
2.3.12 Always ensure there is sufficient
visibility when moving the rig. When
driving on poor roads, drive only in
daylight.
2.3.13 Take extreme precautions on rough
roads. Do not exceed posted speed
limits and match speeds to the road
conditions.
2.3.14 Before lowering the mast onto the front
support frame, ensure the mast is
located in its proper dumped position
(matching alignment arrows on mast
and saddle)
2.3.15 Ensure that the rig meets allowed
overall height limits
2.3.16 Always check the clearance of overhead
structures. When sufficient clearance is
in doubt, stop and check the clearance.
A common road accident with drills is a
collision with an overhead structure.
2.3.17 On trips, the driver should periodically
check for any leaks (hydraulic oil,
engine radiator, fuel tank and lines). It is
recommended that a spill kit and
absorbent be carried on the rig.
2.3.18 For long distance shipping, or in
sensitive environmental areas, it is
recommended to drain the hydraulic
reservoir and fuel tank.
7
2 Safety Instructions
2.4 Set-Up of Drill
2.4.1 When inspecting the site where the drill
is to be set up, ensure that there are no
underground utilities present (gas,
water, electric cables) and that there are
no overhead wires that can be
contacted.
2.4.2 Before setting up the drill (lowering the
jacks and raising the mast), ensure that
the ground is sufficiently firm to support
the drill. Where required use jacks pads
or if necessary, timber or concrete pads.
(See section 9.8.1 for details).
2.4.3 Check that the Set-up Audible Alarm is
working when any of the set-up controls
are moved (jacks, console extend, mast
raise, mast slide, mast fold). The
purpose of the alarm is to let personnel
know that a movement is taking place
and all personnel except the operator
should stand clear.
2.4.4 When lowering the jacks, never use
your finger to check the pin hole
alignment (several people have lost a
portion of their finger doing this!). Use a
visual check only, using a second
person if required. Always secure the
jacks with the locking pins provided.
2.4.5 When raising the mast, ensure that no
hoses, winch rope or cables are
snagged. Snagging of hoses could
damage them and lead to leaks, and
snagging of winch rope or cables could
damage them as well. Always secure
the mast with the safety pins in the
backstay leg(s).
2.4.6 It is important that the bottom of the
mast be supported and that the support
is robust enough to take the full force
exerted on the rod when pulling with the
main winch and/or the drillhead. If the
support moves while pulling on a stuck
rod, the front of the drill could move up,
depending on the angle of drilling.
2.4.7 Always secure the mast slide with the
securing pins provided
8
2.4.8 Guy wires may be required to prevent
tipping the drill in windy conditions. See
section 9.8.2 for details. If wind speeds
could exceed 30 m/sec (67 mph), then
the rods should be taken out of the rod
rack (if so equipped) and drilling
stopped.
2.4.9 If there is a possibility of thunder or an
electrical storm, a lightning conductor
should be installed on the drill.
2.4.10 Ensure parking brakes are set and
wheel chocks are used to prevent
movement of truck mounted drills after
the drill has located for drilling.
2.4.11 The cable restraint on the mast must be
installed before operation of the drill
see section 9.7.1
For Drills Equipped with Optional
Rod Rack/Helpers Platform
2.4.12 The rod rack should be set to the correct
angle and position along the mast,
before the mast is raised. This will
ensure that the platform is horizontal
and at the correct height when the mast
is raised to the drilling angle.
2.4.13 The two backstay legs (one behind the
mast, the other behind the rod rack)
must be installed before operation of the
drill. The cable restraint system is used
only on drills without the optional rod
rack/helpers platform
2.4.14 The rod fallout guard (part 3760007966)
in front of the rod rack must always be
installed. This is a safety device to
ensure the rods cannot fall out of the rod
rack in windy conditions.
2.4.15 A safety chain or bar should be installed
around the first row. This will prevent the
rods being blown out of the rack if there
are only a few steeply stacked rods in
the rack.
2.4.16 Ensure personnel safety equipment is
available and in good order for securing
2 Safety Instructions
the helper when climbing the platform
access ladder and securing the helper
when working on the platform.
2.4.17 Ensure that the emergency E-stop for
use on the helpers platform is plugged
in and is operational.
2.4.18 Ensure that no loose tools are kept on
the platform; that could fall from the
platform.
2.5 Drilling
2.5.1 Check that the emergency E-stops are
in good working order at the beginning
of each shift. Also check that the
drillhead guard and perimeter guards for
the main and wireline winches are in
place.
2.5.2 All controls should be in neutral before
starting engine. Check that neutral
switch for the rotation control lever is
working. It should not be possible to
start the engine if the rotation lever is
not in the neutral position. This is an
important safety device.
2.5.2 All main controls are live and dangerous
if accidentally activated. Do not wear
loose clothing. Do not stand on the
console or place tools or equipment that
can accidentally fall and operate the
controls. Use approved hand protection
that allows for positive and safe use of
all controls.
2.5.3 Use the wireline winch only for the
purpose intended, never for general
service. The wireline winch moves too
fast for any general service winching.
2.5.4 The main winch block limit switch,
located at the crown block, is meant for
emergency use only to prevent the
winching plug from being pulled into the
crown block. Do not use it for stopping
upward travel when winching the drill
rod.
2.5.5 Always keep a minimum of 3 wraps on
the main winch drum and the main
winch rope in a singe layer. Ensure that
the rope end is well anchored on the
drum flange.
2.5.6 Monitor the condition of the main winch
rope. At the first sign of wear or broken
strands, the main winch rope must be
replaced.
2.5.7 Whenever possible, do not use pipe
wrenches to break rod joints. Break the
rods between the drillhead and rod
clamp or use the optional spin-out tool.
2.5.10 Always protect your hearing with both
ear plugs and ear muffs (a total
attenuation rating of 15 dBA) when
working on the rig.
2.5.11 Grease and inspect the water swivel
every shift to avoid bearing failure and
seizure. Water swivel failure can cause
hose whipping leading to injury or death
2.5.12 Ensure that the water swivel is rated to
maximum load that can be applied to it.
2.5.13 Report excessive vibration to your
manager or foreman immediately when
it occurs. Excessive vibration will cause
machine damage and premature wear
2.5.14 Ensure that the operator and helper are
not exposed to continuous vibration
since this can cause white finger and
other disease
2.5.15 The audible alarm will sound on low
hydraulic oil level or high hydraulic oil
temperature (a light on the electrical
panel will show whether low level or
high temperature caused the alarm).
The engine will shut down in about 30
seconds after start of the alarm (time
period is adjustable). This gives the
driller time to stop drilling, pull the rods
back and secure the drill hole.
9
2 Safety Instructions
2.5.16 Ground conditions can deteriorate after
heavy rainfall. Inspect jack and mast
support areas daily.
2.5.17 Never operate the drill when the wind
speeds exceed 20 m/sec (45 mph) See
section 9.8.3 regarding guy wire
requirements
2.5.18 Do not operate the drill in lightning
storms. This could result in
electrocution.
2.5.19 Snow/ice/freezing rain can make the
work area hazardous. Take necessary
precautions prior to working. Provide
wind protection for personnel when
operating in cold and windy conditions.
Working in cold conditions can make it
difficult to work safely.
2.5.20 Take precautions when drilling in
gaseous deposits methane gas can
cause explosions and uncontrolled run-
away of diesel engines. When drilling
gaseous ground, use a B.O.P. (blow out
preventer), if required.
2.5.21 The operator should periodically check
for hydraulic oil, fuel and radiator
leakage. Any leaks found must be
rectified. It is recommended that a spill
kit and absorbent be available at the drill
site.
2.5.22 It is important to practice good
housekeeping and prevent slippery
underfoot conditions in the working
areas.
2.5.23 Oily rags, bare conductors, spilled or
leaking fuel or oil present a fire hazard
and must be prevented
2.5.24 The foot clamp can crush feet or hands.
Keep feet and hands away from the foot
clamp.
10
Drills Equipped with Optional Rod
Rack/Helpers Platform
2.5.25 Check that the emergency E-stop on the
helpers platform is in good working
order at the beginning of each shift.
2.5.26 Ensure that there are no loose tools on
the helpers platform that could fall and
cause injury or damage.
2.5.27 Ensure that safety equipment is used for
climbing to, and working on, the helpers
platform. Each time before using the
safety equipment, check that it is in
good working order.
2.5.28 Only one man equipped with small tools
is allowed on the helpers platform at
any one time
2.6 Tear-Down of Drill
2.6.1 Always put mast into transport position,
fully retract jacks, and retract the
console before moving the rig.
2.6.2 Before lowering the mast onto the front
support frame, ensure the mast is
located in its proper dumped position
(matching alignment arrows on mast
and saddle)
2.6.3 Be careful to avoid snagging or
damaging any hose, winch rope or cable
when moving the mast to the travel
position.
2.6.4 Always ensure that securing pins are in
place (jacks, backstay legs, mast slide,
and guards)
2.6.5 Always secure any loose items so they
cannot fall off the deck.
2.6.6 Ensure that the rig meets allowed the
overall height limit.
2 Safety Instructions
2.6.7 When preparing for a long trip, it is
recommended that the fuel tank and
hydraulic reservoir be drained. This will
prevent a major environmental problem
in case of any hydraulic hose/fuel line or
incident with the rig.
2.7 Maintenance and Servicing
2.7.1 Personnel must be properly trained and
have documented experience for the
type of maintenance/service work they
are doing in order to avoid injuries and
possible damage.
2.7.2 Any maintenance should be done using
acceptable lockout procedures to
ensure personal safety.
2.7.3 Make sure the engine is stopped and
hydraulic, air, and water circuits are
properly depressurized before being
worked on.
2.7.4 Make sure all components that can
move when hydraulic lines/components
are disconnected (e.g. drillhead, mast,
etc.) are in the lowest position or
supported by temporary means such as
blocks or chains before working on the
drill.
2.7.5 When replacing components, always
purge air from the components prior to
use to prevent uncontrolled movement.
2.7.6 Be very careful when tracing leaks in the
pressurized systems. Hydraulic oils,
water or air under pressure could
penetrate under the skin and cause
complicated injuries or infection. If this
happens, see a doctor at once.
2.7.7 Do not use pressure settings different
from factory settings without consulting
with the factory. Mechanical failures or
other dangerous situations resulting in
death or injuries could occur with
settings that are different from factory
settings.
2.7.8 Use safe lifting practices. Use power
assisted lifting wherever possible. Do
not lift more than 25 kg (56 lbs) per
person or as local regulations dictate.
2.7.9 Remove suspended loads on any winch
before commencing maintenance
2.7.10 When working on electrical circuits,
the battery ground cable should be
disconnected to prevent accidental
shorting.
2.7.11 Batteries contain corrosive acid.
Wear protective equipment before
doing any maintenance on batteries.
2.7.12 Welding near computer controlled
engines can cause ECU damage.
Disconnect batteries and ECU
harness prior to welding.
2.7.13 Use only certified welders for any
welding repairs.
2.7.14 Avoid hot areas of the rig such as the
engine exhaust system when
maintaining/servicing the rig. Allow
cool-down time prior to removing
heat shields and guards
2.7.15 A qualified person should inspect
high stress locations on a yearly
basis.
2.7.16 Never use oversize fuses or
breakers. These present a fire
hazard.
2.7.17 Periodically check that all danger and
warning labels, as specified in the
parts manual, are present and
legible. Any missing decals must be
replaced.
2.7.18 Never climb the mast using the
service ladder while the rig is
running.
2.7.19 Procedures in section 15 must be
used for setting min and max
displacements on replacement
11
2 Safety Instructions

hydraulic motors for rotation and the

main winch. Failure to do this can
cause over speeding and failure of
the motors and damage to the
drillhead or main winch.

2.8 Special Safety Signs

The following warning signs are used on the rig
and in the manual:

2.8.1 Fig. 2.5 warns for immediate hazards,

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

Fig. 2.5
2.8.2 Fig 2.6 warns for hazards or unsafe
practices which, when ignored, could
lead to serious personal injury or death

Fig. 2.6
2.8.3 Fig 2.7 indicates hazards or unsafe
practice, which could lead to minor
personal injury or damage to equipment.

Fig. 2.7
2.8.4 Fig.2.8 is used for recommendations
such as how to run the unit efficiently,
economically and in compliance with
environmental regulations.

Fig. 2.8

12
2 Safety Instructions

2.9 Safety Decals

The following safety decals are used:

2.9.1 Fig. 2.9 Lifting points. This sign is

located where it is recommended that
slings be attached.

2.9.2 Fig 2.10 Ear protectors. Ear protectors

should always be worn.

2.9.3 Fig. 2.11 Risk of crush. Be aware of the

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

2.9.5 Fig 2.13 ATTENTION: Before starting,

oil must be filled according to Lubricant
Recommendations

2.9.6 Fig 2.14 Electrical hazard

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

Fig. 2.13

Check periodically that safety decals are

legible and in place. Replace as required. Fig. 2.14

See Parts Manual for safety decal location

and part numbers.

Fig. 2.15

13
2 Safety Instructions

2.10 Fire Extinguisher

2.10.1 The drill rig is equipped with a portable
fire extinguisher. The fire extinguisher is
shipped with drill.

This fire extinguisher is suitable for fire

in electrical cables, fuel and engines
and lasts for approximately one minute
when operated continuously.

To use, remove the safety pin and press

handle. Direct the jet towards the base
of the fire.

This type of fire extinguisher puts out

the fire by eliminating access to oxygen.
Embers might start the fire again. Use
water for fighting fire in wood, paper and
similar materials.

2.10.2 If the fire extinguisher has to be

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

14
3 Environmental Instructions
3 Environmental Instructions
Dear operator,
Atlas Copco Exploration Products recognizes
the importance of environmental issues. As part
of our commitment to a better environment, we
want to inform you, the customer, of how you
can minimize the effect on the environment
when using an Atlas Copco product. These
simple but important instructions will help to
preserve the environment.
Oil
Leaks of hydraulic and lubrication oils pose an
environmental threat. Changing lubricating and
hydraulic oils, hydraulic hoses and hydraulic
filter elements also pose a potential threat to the
environment.
Collect all oil spills and waste (e.g. oil filter
elements) contaminated with oil. Dispose of
according to national regulations.
Use biologically decomposable hydraulic oils
and lubricating oils for Atlas Copco products
wherever possible. Contact your nearest Atlas
Copco office for more information.
Engine
Engine emissions are toxic and pose an
environmental threat. Always provide for fresh
air when an engine is running. Well-maintained
air filters help keep emissions at a low level.
Fuel (Petrol/Gas, Diesel): Fuel spillage poses
an environmental threat. Collect all wastes and
fuel spillage and dispose of according to national
regulations.
Grease
Lubricating grease poses a threat to the
environment. Collect all wastes and spillage and
dispose of according to national regulations.
Batteries
Batteries contain acids and heavy metals. Used
batteries can therefore pose a threat to the
environment and to your health. Avoid all
contact with acids and dispose of used batteries
according to national regulations. See also
section 2.2 for further information.
Chemicals
Dispose of chemicals such as drilling additives,
other additives, glycol etc. according to the
manufacturers instructions and local
regulations. Avoid the use of cleaning agents
containing chlorinated solvents. There are
environmentally better alternatives now available
on the market. Follow national regulations
regarding handling and disposal of wastes.
Metals (steel, aluminium, etc.)
These products are recyclable and should be
taken care of according to national regulations
and recycled where local programs exist.
Plastics and rubber
These products are often labelled according to
different classes. In those cases they are
recyclable and should be disposed of according
to national regulations and recycled where local
programs exist.
Electrical components (cables, electronics,
etc)
Used components should be disposed of
according to national regulations and recycled
where local programs exist.
Spill Kit and Absorbent
Always carry a spill kit and suitable absorbent
for hydraulic oil and anti freeze.
Daily Inspection
Inspect fuel tank, hydraulic tank, radiator and
cooler for leaks daily.
Obtain MSDS data sheets for the fluids that
you use for the drill and follow the instructions
in the data sheets to deal with accidental
ingestion, skin contact or spills.
15
3 Environmental Instructions

16
4 Hoisting the Drill
4 Hoisting the Drill
4.1 Ensure that mast is in the transport position
on the mast support.
4.2 Locate the rotation unit above the main
winch to obtain a good point of balance and
centre of gravity.
4.3 Lift the drill using the lifting points at the 4
jacks and spreader bars (see Fig. 4.1 & 4.2)
to ensure that the forces on the jacks are
vertical only.
4.4 If spreader bars are not available, use slings
at least 7m (23 ft) in length to prevent high
side forces on the jacks and ensure that no
hoses or mechanical components are
touched by the slings.
Fig 4.1 Spreader Bars For Hoisting the Drill
The sling must be sized for lifting 16
tons (Drill unit) to provide a safety
margin.
Never use a damaged rope/sling.
Always make sure that nobody is
under or anywhere near, a suspended
load or within the swing radius of the
rope/sling.
Failure to use spreader bars, or long
enough slings (see section 4.4), can cause
damage and permanent distortion of the
deck
Fig. 4.2 Lifting Point on Drill Jack
17
4 Hoisting the Drill

18
 5 Specifications
5 Specifications
5.1 General
CHRISTENSEN CS4002 is an all-hydraulic operated diamond core drill.
The CHRISTENSEN CS4002 is an all-hydraulic
diamond core drill for deep hole surface
exploration drilling. The CS4002 is designed to
be mounted on a truck and can also be mounted
on tracks.
The CHRISTENSEN CS4002 uses well proven
technology for diamond core drills together with
safety improvements to provide a reliable, safe
drill. An optional rod rack/helpers platform
capable of stacking rods from 90 to 45 degrees,
give the operator flexibility in rod handling. An
optional spin-out tool avoids the use of pipe
wrenches for breaking rods
Recommendations
To achieve the best results with regard to:
high penetration
optimal core recovery
low drilling costs
It is of primary importance that drill rods, core
barrels and coring bits are of the right type and
quality, matched to the drill and to the prevailing
rock conditions.
Bearing in mind the core drills speed of rotation,
its depth rating and chuck diameter, the
CHRISTENSEN CS4002 is best suited to drill N
to P size holes using wire line rods.
19
 5 Specifications

Foot Clamp
5.2 Technical Specifications Hydraulically operated, self energizing foot
clamp
Easy-to-remove jaws
Drill Mast Common jaws from 44.5 mm (1.75 in) to
Feed stoke ...............................3.35 m (11 ft) 177.8 mm (7 in)
Mast slide .................................. 2.0 m (80 in) Casing and rod jaws for all popular sizes
Rod pull ........................................ 9 m (30 ft) 224 mm (8.8 in) foot clamp opening
Mast style ......................................... Folding
320 mm (12.5 in) mast bottom opening
Feed pull..........................200 kN (45,000 lbf)
Feed thrust ........................91 kN (20,400 lbf)
Drill rod centerline location.... In front of mast
Rod rack capacity (rods stacked on edge):
.... 1,998 m (6,500 ft) capacity of N size rods
....................................vertical to 80 degrees

Main Winch
Main winch pull................178 kN (40,000 lbf)
Main winch speed:
... 0.6 m/sec (117 fpm) @ max displacement
.. 1.17 m/sec (232 fpm) @ min displacement
Rope size. .............................. 22 mm (7/8 in)
Fig. 5.1 Foot Clamp & Optional Spin-Out Tool
Drillhead
Chuck axial holding capacity:
.178 kN (40,000 lbf)
Actuation ......Spring apply, hydraulic release
Number of jaws ........................................... 5
Drillhead ........Chain final drive plus 4 speed
.................................................. transmission
Chuck mounting ................................. Bolt on
Final drive ratio ........................................ 2:1
Drillhead spindle ID..120.6 mm (4.75 in)

Wireline Winch
Drum Capacity:
-4.7 mm (3/16 in) wire rope ... 4,600 m (15,000 ft)
-6.3 mm ( in) wire rope ......... 2,600 m (8,530 ft)
Levelwind for even spooling ...........Standard
Parking brake ..................................Standard
Winch position..................... Raised on stand

Control Console
Console movement ....... Hydraulic in and out

Weight (less truck):

13,388 kg (29,500 lbs) Fig.5.2 Control Console & Drillhead

20
 5 Specifications

Diesel Engine - See Drill manual Section II for CS4002 Drillhead RPM and Torque Ratings at
information on the Diesel Engine max. & min. displacements:

Diesel Fuel Reservoir - At rotation pressure of 3,500 psi

- Max displacement of 145 cc
Capacity.950 L (250 gal) - Min displacement of 100 cc
Filling methodBy hand pump
.connected to main return filter
RPM Torque Nm (ft lbf)
Hydraulic System Max Min Max Min
Gear
Displacement Displacement Displacement Displacement
Hydraulic tank capacity 500 litres (132 gal) 4
th
892 1,300 1,003 (740) 689 (508)
rd
3 510 743 1,756 (1,295) 1,205 (889)
Max. operating pressure
nd
- Main pump................. 324 bar (4,700 psi) 2 286 417 3,130 (2,309) 2,149 (1,585)
- Auxiliary pump ......... 172 bar (2,500 psi) 1
st
142 207 6,291(4,640) 4,319 (3,185)
- Secondary pump* 207 bar (3,000 psi)
Max. flow
- Main pump................. 272 l/min (72 gpm)
- Auxiliary pump .......... 125 l/min (33 gpm)
- Secondary pump*........ 95 l/min (25 gpm)

*Note: This is the secondary pump pressure and

flow on the standard CS4002. The drill may
have a different secondary pump if the
mud/water pump is different than the standard
FMC W1122BCD. See the addenda sheets
(section 18), parts list and hydraulic schematic
for the drill.

Options

Rod rack and helpers platform for drilling

angles 90 to 45 degrees. Rod rack capacity
1,998 m (6,500 ft) of N size rods, vertical to 80,
rods stacked on edge

Spin-Out Tool for mechanized rod make-up

and break-out

Depth Capacity Coring*

N Wireline ............................ 2,450 m (8,030 ft)

N Wireline Upset Ends ...... 2,850 m (9,350 ft)
H Wireline............................. 1,600 m (5,250 ft)
H Wireline Upset Ends ...... 2,250 m (7,380 ft)
P Wireline ............................. 1,050 m (3,440 ft)
* For vertical, straight, water filled hole

21
 5 Specifications

5.3 Dimensions
Dimensions are subject to change. If required, consult with factory to get dimensions certified.
All dimension drawings shown are with 30 ft pull mast

3444

11063

Fig. 5.4 Shipping Dimensions Elevation

2438

2767 4315 3976

Note: Optional Rod Rack/Helpers Platform Shipped Loose

Fig. 5.5 Shipping Dimensions Plan View

22
5 Specifications

4.09 m
(13' 5")

11.04 m
(36' 2")

Fig. 5.6 Truck Mounted Drill in Transport Position - Elevation

23
 5 Specifications

14327

1010
400

Fig. 5.7 Truck Mounted Drill - Vertical Drilling

Fig. 5.8 Truck Mounted Drill - Vertical Drilling

Plan View

24
5 Specifications

Fig. 5.9 Truck Mounted Drill with Optional Rod Rack/Helpers Platform - Vertical Drilling

25
 5 Specifications

3302

Fig. 5.10 Truck Mounted Drill with Optional Rod Rack/Helpers Platform - Vertical Drilling
Plan View

Fig. 5.11 Truck Mounted Drill with Optional Rod Rack/Helpers Platform
45 Degree Drilling

26
6 Design Features

6 Design Features
1. Mast and feed frame
2. Rotation unit
3. Crown block
4. Control console
5. Wireline winch (not shown)
6. Main winch (not shown)
7. Hydraulic tank
8. Rod rack & helpers platform (optional)
9. Spin-out tool (optional)

2
9

Mindoka, substitute picture from original source (before compression) to improve sharpness

27
6 Design Features

6.1 Mast and Feedframe

The 9 m (30 ft) pull mast consists of 2 parts the main section which is 10.7 m (35 ft) long plus a 3 m
(10 ft) long hydraulically folded section. The folding mast is locked in position before the mast is
raised. This produces a very stable mast with a total length of 13.7 m (45 feet) for drilling as well as a
shorter length of 10 m (33 ft) for transport. The main section is stress relieved and straightened after
welding. The feedframe section of the mast uses a 3.3 m (11 ft) stroke, direct acting feed cylinder.
The drillhead carriage is guided by rollers running on replaceable ways. This design gives maximum
drillhead pulling efficiency (minimum friction) and well as allowing for replacement of worn ways.

The mast is raised by two mast lift cylinders equipped with hard-plumber counterbalance valves. It is
held in the drilling position by two short telescopic backstay legs which are pinned in position. A cable
restraint system is used to limit the deflection of the mast.

When equipped with the optional 30 ft rod rack and helpers platform, the mast and rod rack are each
supported in the drilling position by long telescopic backstay legs. The backstay legs are made of
aluminum for light weight. It is recommended that the backstay legs are pinned at the right length to
suit the drill angle before the mast is raised.

28
6 Design Features

6.2 Rotation Unit

The rotation unit slides sideways to clear the hole. It consists of a variable speed bent axis hydraulic
motor for maximum efficiency, a heavy duty four speed transmission, a transfer case with a heavy
duty chain and a P size hydraulic chuck. The drive chain in the transfer case can be adjusted if
required. The 4 speed transmission and transfer case are pressure lubricated.

Note: Drillhead shown without standard slam pan

6.3 Crown Block

The crown block is equipped with large 30 inch sheaves (grooves for 7/8 rope) running on bearings
which are remotely lubricated from the drill deck level. A block limit switch, that prevents the winch
plug from being pulled into the crown block, is standard. Use fall arrest and fall restraint equipment
when accessing the crown block.

Fall arrest and fall restraint equipment must be

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

29
6 Design Features

6.4 Control Console

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

6.5 Wireline Winch

The high capacity wireline winch is equipped with a direct drive hydraulic motor, levelwind and parking
brake. The winch is equipped with a load holding counterbalance valve. The parking brake is a wet type
using case drain fluid from the motor.

It is necessary to use different drive chain kits for the levelwind drive depending on whether 4.7 mm
(3/16 in) or 6.3 mm (1/4 in) wireline rope is used.
4.7 mm (3/16) cable: Drive sprocket A/C # 3760009249 (11T), chain A/C # 3760008617
6.3 mm (1/4 kit) cable: Drive sprocket A/C # 3760009210 (14T), chain A/C # 3760009128

30
6 Design Features

6.6 Main Winch

The main winch is designed to operate with single layer of 22 mm (7/8 inch) diameter rope. Two
methods of handling 9 m rods (30 ft) can be used:
-running rods out
-stacking rods in mast with the optional rod rack/helpers platform

The main winch is equipped with 2 pressure rollers for improved rope management. The top
pressure roller is equipped with 2 limit switches. One limit switch signals that three or less wraps are
left on the drum (there should always be a minimum of 3 wraps on the drum). The other limit switch
signals that the pressure roller is higher than for a single layer of rope). This informs the operator that
the rope is crossing which can kink and/or damage the rope. Both limit switches sound the audible
alarm and a winch indicator light lights up in the control console to let the operator know that one of
the main winch limit switches is triggering the audible alarm.

The winch is equipped with a continuously variable, bent axis, piston motor. This allows the main
winch speed to be increased by up to 90% when the rod string load is reduced as the rod string is
pulled out of the hole. The winch motor displacement control should be adjusted so the main winch
hydraulic pressure is maintained at 297 bar (4,300 psi) as long is there sufficient load on the hoist.

31
6 Design Features

6.7 Hydraulic Tank

The hydraulic tank is equipped with a combination sight glass/thermometer and a combination low oil
level/high oil temperature switch.

If the oil level drops below the level of the sight glass or the temperature increases to over 80C
(176 F), the audible alarm will sound and the oil level or oil temperature indicator light in the electrical
panel will light up. An adjustable timer will then shut the engine down in about 30 seconds (time is
adjustable). This will prevent hydraulic system damage and give the operator time to safeguard the
drill hole (e.g. pull back the rods, stop rotation and flush the cuttings out) before the engine stops.

The indicator light (for the fault triggering the alarm) will stay lit to tell the operator which fault
occurred. The indicator light can then be cancelled with the reset button (see section 13.1)

The tank is pressurized with 0.55 bar (8 psi) air from the engine mounted compressor for high altitude
operation. Two breathers mounted on the tank filter incoming air and limit max tank gauge pressure
to 0.68 bar (10 psig).

The main return filter is mounted in the top of the tank.

32
6 Design Features

6.8 Mechanical Guards

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

6.9 Optional Rod Rack/Helpers Platform

An optional rod rack/helpers platform is available for stacking rods in the mast. It can stack rods for
drilling angles from 90 to 45 degrees. The helpers platform angle and position along the mast is
preset before raising the mast so the helpers platform is in the right position when the mast is raised
to the drilling angle. (See section 5.2 for rod rack stacking capacity).

The rod rack and weight of the drill rods is supported by an adjustable telescopic backstay leg behind
the rod rack (in addition to the backstay leg used to support the mast when not equipped with the rod
rack/helpers platform). Both backstay legs are made of aluminum for light weight. It is recommended
that both backstay legs be pinned at the right length to suit the drill angle before the mast is raised
(see section 9.7).

33
6 Design Features

6.10 Optional Spin-Out Tool

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

34
7 Controls

7 Controls
7.1 Main Control Panel (Pilot Operated)

Figure 7.1 CS4002 Main Control Panel

7.1 CS4002 Main Control Panel - Pilot Operated (contd)
(Numbers refer to Balloon Numbers in Fig. 7.1)

35
7 Controls

The following acronyms are used in this section:

CCW or ccw means counterclockwise
CW or cw means clockwise
5. Head Opener Cylinder Slides drillhead
sideways.
1. Light Switches- Control console and deck
lighting.

6. Hydraulic Chuck Control Opens the

2. Pull Down Pressure Controls pressure hydraulic chuck when the lever is lowered.
on pulldown side of feed cylinder. CW When the lever is returned to the central
rotation increases pull down pressure. position, the chuck is closed and grips the
drill rod.

3. Feed Rate Controls feed rate. CCW

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

8. Main Winch Control Controls the

direction and speed of the main winch.
4. Slow Feed Direction When the lever is
lowered, the drill head will feed into the
hole. When the lever is raised, the drill
head will raise.

36
7 Controls

9. Fast Travel Control Controls the fast 13. Water Pressure Release Allows water
travel speed and direction of the drillhead. pressure in the drill string to be released.

14. Main Winch Motor Control Controls the

main winch motor displacement. Turning
the knob counter cw decreases motor
displacement (torque) and therefore
increases speed.

10. Wireline Winch Control Controls the

speed and direction of the wireline winch

15. Engine Speed Control For Tier I Diesel

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

Do not use wireline hoist for general

service since speed is too high.
16. Winch Brake Release Move up to apply
brake and down to release brake on main
11. Rotation Control Controls the speed and
winch.
direction of the rotation motor. This control
must be returned to neutral before the
engine can be started

12. Mud/Water Pump Speed Control

17. Foot clamp Opens and closes the
Controls the speed of the mud/water
hydraulic foot clamp.
pump.

37
7 Controls

18. Thread Compensation Place lever in 22. Hydraulic Tank Pressure Gauge
upper position to float drillhead Indicates hydraulic tank charge pressure.
downwards (when making joints), place Do not operate the drill when pressure is
lever in middle position for normal drilling below 0.3 bat (4 psi).
operation and place lever in lower position
to apply thread compensation (when
breaking joints). The adjusting knob
behind the directional valve adjusts the
amount of lifting force.

23. Auxiliary Pump Pressure Gauge

Indicates the system pressure in the
auxiliary pump circuit.

19. Mud Mixer Speed Controls flow to the

mud mixer.

24. Water Pressure Gauge This gauge is

connected to the mud/water pump outlet
and indicates the mud/water pressure.

20. Mud/Water Pump Hi/Lo Speed Sets

mud/water pump motor to hi or low speed.

25. Main Pump Load Sense Pressure Gives

system pressure in the main pump
function currently being used (main winch,
fast travel, wireline or rotation).
21. Make /Drill Pressure Selects max
rotation pressure as pump compensator
(drill setting) or a preset pressure for rod
joint make-up (adjustable at the back of
the console to suit rod size).

26. Engine Control Panel (not shown) -

Contains key switch, throttle control,
tachometer, and other engine monitoring
gauges.

38
7 Controls

27. Audible Alarm (not shown) - Provides
audible warning for low oil level & high oil
temperature, main winch rope
management (see section 6.6), operation
of secondary console controls (hyd jack
movements, mast raising etc.).
31. Pulldown Pressure Gauge Shows
pressure on the pulldown side of the feed
cylinder. A calibrated decal ring is
translates the pressure to feed cylinder
pulldown force (in pounds).

28. Rotation Motor Displacement Control

Controls the rotation motor displacement,
and is continuously variable during drilling.
Turning the knob cw decreases motor
displacement and therefore increases
motor speed. For given rod torque, the
rotation pressure will be increased.
Turning the knob ccw increases the motor 32. Holdback Pressure Gauge Shows
displacement and therefore decreases pressure on the holdback side of the feed
motor speed. For a given rod torque, the cylinder. A movable calibrated decal ring
rotation pressure will be decreased. can be used to indicate the net bit force.

29. Spindle Tachometer Provides the chuck 33. Circuit Breaker Provides protection of
rpm. main electrical control panel.

34. Spin-Out Tool (Optional) Allows user to

make or break rods

30. Flow meter Provides mud/water pump

flow by measuring mud/water pump rpm.

39
7 Controls

35. Spin-Out Tool Torque Adjustment

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

36. Pressure Gauge Shows make-up

pressure applied to the Spin-Out Tool

37. Rod Lifter Lifts the rod to lineup with the

chuck centerline.

38. Test Button for Audible Alarm (not shown)

Used to test audible alarm

40
7 Controls

7.2 Secondary Control Panel

1 9 8 7 6 5 4 3 2

Fig. 7.2 CS4002 Secondary Control Panel

1. Selector Valve Directs hydraulic oil to either

main control panel or secondary control panel
(prevents inadvertent movement of set-up
control while drilling)

2, 3, 4, 5 Hydraulic Jacks Controls jacks.

Locking pins must also be used.

6. Mast Raise Raises and lowers mast

7. Mast Slide Slides mast so mast bottom can

be supported on ground.

8. Mast Folding Folds mast extension

9. Console Extend Extends/retracts console

41
7 Controls

42
8 Diesel Engine Start-Up

8 Diesel Engine Start-Up

Always follow the Safety Instructions in Section 2.

Before starting the diesel engine, certain checks and measures must be carried out to prevent accidents,
unnecessary stops or breakdown. Some of these measures must be carried out regularly as a part of the
CS4002 Maintenance Schedule - see Table 11.1

The following start-up information applies to all diesel engines however the pictures are for the
Cummins QSC 8.3 litre engine and will be only representative for the other engines. Specific Information
on the engine installed on the drill is included in Section II of the Drill Manual Diesel Power Unit

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

8.1.1 Check the oil level in the diesel engine

fill when necessary

8.1.2 Check coolant level

fill when necessary

43
8 Diesel Engine Start-Up

8.1.3 Check the engine air intake filter.

Clean or replace cartridge. Remove coarse particles daily at X

8.1.4 Check oil level in hydraulic oil tank.

Use only hand pump to add hydraulic oil when required

Temperature And Level gauge Hand Pump For filling

8.1.5 Check fuel level.

Top up before beginning of each shift.

Filler Cap Level Indicator for Fuel Tank.

44
8 Diesel Engine Start-Up

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

Q1

8.1.7 Starting instructions vary between the different engines. See Section 2. Engine Control Panel
starting Instructions in Section II of the Drill Manual.

8.2 Engine Start

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

8.2.2 Check the oil temperature on the combined temperature and level indicator mounted on the oil
tank. If the temperature is below +20C, let the engine run a few minutes until this value is
reached before activating any control levers.

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

When starting up in cold weather, (below Hydraulic pumps will cavitate at high
+ 5C ), run engine at 1000 rpm until the engine altitude if boost pressure fails.
8.3 Display Parameters
temperature is about +10C.

8.3 Engine Shut-Down

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

The diesel engine should only be shut

down directly from its operating rpm in
the case of emergency.

45
8 Diesel Engine Start-Up

46
9 Drill Set-up

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

It is the responsibility of the owners,

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

9.1 Start-Up

Before engine start, ensure that the checks to be done each shift in Table 11.1 CS4002 Maintenance
Schedule, have been completed and that all controls are in the neutral position.

With all checks made and systems warmed up, move throttle to high engine speed to begin operation.
The engine and all systems are designed to operate at 2100 rpm.

Check Hydraulic tank pressure. Pressure should be 0.55 bar (8 psi).

Do not operate this drill if this pressure is

below 0.3 bar (4 psi).

47
9 Drill Set-up

9.2 Secondary Controls

The secondary controls operate the four jacks, mast raise, mast slide, folding of mast
extension and console retraction. The selector valve at the left side of the secondary control
console directs hydraulic oil to either the secondary controls or the main control console. This
feature prevents accidental movement of the secondary controls when operating the main
control console.

Establish and use a standard means of communication between all drill personnel. Remain
in eye contact with each other where possible. The CS4002 drill is provided with an audible
alarm (beeper similar to a truck backup warning device) that is activated when secondary
controls are operated. Stand clear of jacks, mast and main console when the audible alarm
sounds when operating the secondary controls.

Selector Valve A/C # 3760009862

48
9 Drill Set-Up

9.3 Levelling the Drill

Level the drill using the 4 levelling jacks located
at each corner of the machine. Controls for
these jacks are located in the secondary control
panel, at the left rear corner of the drill deck. Pin
all 4 legs with the safety pins provided - safety
pin A/C # 3760010587
Ensure that drill is levelled on stable
ground and pins are in place. Follow
guidelines in section 9.8.1 Precautions
Required for Ground Conditions

Check hole alignment visually only. Do not

check for hole alignment using a finger
(fingers have been lost doing this!).

Inspect footings every shift. Watch for

changing conditions due to weather /
environment.

49
9 Drill Set-Up

9.4 Operators Platform

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

9.5 Mast Slide

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

Do not operate the drill without the

mast lock pins in place

50
9 Drill Set-Up

9.6 Unfolding Mast Extension

The mast extension should be unfolded and locked into place while the mast is in the lowered position.
Take care that no snagging of hoses, ropes or cables occurs while the mast is being unfolded. Lock mast
in position with locking pins before raising mast

Do not operate drill without folding mast

locking pins in position and secured

9.7 Mast Supports

9.7.1 Drill without Optional Rod Rack/Helpers Platform

When the drill is not equipped with a rod rack/helpers platform, short telescopic stifflegs, mounted in
parallel with the mast raise cylinders, are used to support the mast. Pins are used to lock the stifflegs in
the required length. In addition a cable restraint is required to reduce deflection of the top of the 30 ft pull
to acceptable levels when pulling maximum load with the main winch.

51
9 Drill Set-Up

The cable restraint system consists of the following components:

-a fixed length of a 19 mm ( in) cable attached to the mast
-a snatch block
-a 12.7 mm (1/2 in) two part cable
-a manual ratchet winch.

The fixed length of cable is permanently attached to the mast. The two part cable on the ratchet winch
takes up the travel for mast positions between vertical and 45 degrees.

The procedure for raising the mast is as follows:

a) Ensure that the pawl is raised and locked in the open position so that the two part cable can spool
off the ratchet winch when raising the mast. Ensure that no snagging of cable or hoses takes
place.
b) When the mast is in the drilling position, pin the short stifflegs legs in position.
c) Release the spring loaded pawl and lower it to engage the ratchet wheel. Tension the cable by
using a 600 mm (2 ft) long rod in the ratchet winch shaft and applying a maximum of about 22
daN (50 lbf) at the end of the 600 mm (2 ft) long pipe.
d) When the cable has been tensioned, lock the pawl in the ratchet lock position.

The procedure for lowering the mast is as follows:

a) Release the tension in the cable
b) Remove and store the locking pins in the stifflegs
c) Lower the mast and at the same time spool the two part cable onto the ratchet
d) Ensure no cable is pinched when lowering the mast to the transport position
e) Secure the fixed cable on the deck.

Do not operate drill without cable restraint Always lift the pawl and lock it in the raised
installed position to free the manual ratchet before raising
the mast

Do not apply more than 22daN (50 lbf) force at

the end of 600mm (20 in) rod when tensioning
the cable restraint

52
9 Drill Set-Up

9.7.2 Drill Equipped with Optional Rod Rack/Helpers Platform

Two long telescopic backstay legs are used to support the rod rack and the mast. The short stifflegs
mounted parallel to the mast raise cylinders are not used and must be removed if installed.

The recommended procedure for installing the rod rack/helpers platform and 2 backstay legs is as
follows:

a. The rod rack is installed on the drill while the mast is in the transport position. Due to the weight of the
components, this has to be done with a crane or forklift truck.

b. Since the helpers platform must be level in the raised position and the platform must be at a suitable
height, the angle and locking position along the mast should be preset while the mast is in the lowered
(transport) position and at deck level. Table 9.1 and figure 9.1 give the platform preset angle and position
along the mast, so the helpers platform is level and at a suitable height when the mast has been raised to
the drilling angle.

Rod Rack
Mast Position Short Leg Pin Long Leg Pin
Angle See Fig 9.1 Position Position
0-4 3 21 24
5-9 3 19 22
10-14 3 17 20
15-19 2 16 19
20-24 2 13 17
25-30 2 10 14
30-34 1 12 16
35-39 1 8 12
40-44 1 5 9
45 1 1 5

Table 9.1 Helpers Platform Position and Backstay Leg Pin Positions

53
9 Drill Set-Up

c. The front safety guard (part # 3760007966) for the platform should also be added while the mast is in
the lowered position.

d. The mast should be used to raise the backstay legs into position. The backstay legs should be
adjusted to the correct length before installation so that locking pins between the telescoping sections do
not have to be installed when the backstay legs have been raised. Table 9.1 gives the pin positions.

Figure 9.1 Rod Rack and Backstay Leg Pin Positions

e. Once the backstay legs have been pinned into the required length, the mast complete with rod rack,
should be raised high enough that the top end of the backstay legs can be connected to the mast and rod
rack.

f. The bottom end of the backstay legs should be supported with ropes by 2 people while the mast is
raised and the mast bottom lowered to the ground.

g. When the mast has been raised to the final position, the fine adjustment in the backstay legs is
adjusted to align the bottom pin holes and the locking pins and locking wire installed.

h. Connect the fall arrestor rope to the aluminum telescopic ladder for accessing the helpers platform,
before raising and securing the ladder to the platform

54
9 Drill Set-Up

Fall arrest and fall restraint equipment must be used

whenever the vertical drop exceeds 3 m (10 ft.). Follow
instructions for the proper use and maintenance of this
equipment (instructions are supplied with the
equipment). Do not alter or misuse this equipment.

55
9 Drill Set-Up

9.8 Ground Support and Guy Wires

Stability Precautions

The CS4002 with a 30 foot mast in the raised position is stable under most operating and
environmental conditions. This section describes some environmental and abnormal operating
conditions which can cause sudden motion or upset of the drill and what the operator can do to
safeguard against this and reduce the risk of personal injury or property damage. The environmental
conditions considered are ground conditions and wind. Earthquakes and hurricanes can also cause
sudden motion or upset of the drill but these are not considered here.

9.8.1 Precautions Required For Ground Conditions - Jacks

Before setting up the drill, check the ground conditions. If the ground is soft enough, it can yield under
the jack and cause misalignment of the drill or in extreme cases tilting and upset of the drill. Also the
ground should not be sloped more than 1 in 10 in any direction.

Where the ground is not hard enough to support the standard jack foot, jack pads, shown in Fig. 9.2, or
a stronger support such as a timber or concrete pad must be used. The fabricated jack pads in Fig. 9.2
are available from Atlas Copco as part 3760012873. Also fabrication drawings for this part are available
upon request.

Figure 9.2 Jack Pad 3760012873

As a general guide, the cut-off ground soil strength between using the standard jacks and 0.5 m (2 ft)
diameter jacks pads is a sub grade modulus reaction of 80,000 kN/m3, and the cut-off soil strength
3.
between the jack pads and a timber/concrete platform is 48,000 kN/m The soil bearing ratings shown
here are based on a standard 76 cm (30 in) disc test. A civil engineer or geologist can do a soil test to
obtain the ground rating. Suitable soils are typically as follows:

Standard jacks: hard, rocky ground, gravel, gravel clay, well

graded sand
Jacks with 0.5 m (2 ft) pads: uniformly or poorly graded sand, sandy clay
Concrete/timber platforms: compressible silts, clays and organics

56
9 Drill Set-Up

If expert advice is not available, a simple test of the soil strength can be done with a 13 cm
(5 in) diameter, 5 cm (2 in) thick test disc:

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

Check after 6 hours:

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

The mast should always be lowered so that it is supported on the ground, using blocking if required.
This will prevent the deck from lifting at the front during angle drilling if the operator pulls with both the
winch and drillhead. This is an abnormal operating condition, but could be done by an operator trying to
free a stuck drill rod. The closer the drilling angle is to 45 degrees, the more important a solid support
of the end of the mast becomes.

The operator must also be aware that ground conditions can change in the case of prolonged rainfall or
improper drainage of drilling fluid return. Support of the jacks and the mast base should be checked
each shift.

9.8.2 Precautions Required For Ground Conditions Mast Support

When setting up the drill, the dumped mast must always be supported on the ground by setting on a
firm support and blocking as required. If the ground becomes soft enough from rain or drilling fluids to
yield under the dumped mast so the mast is no longer fully supported on the ground, shear forces can
be generated in the bolted connection between the deck and the jack leg.

If pulling with maximum forces (drillhead and main winch) on drilling angles between 15 and 45
degrees off vertical, and under conditions where the ground can yield under the mast base, then two
optional diagonal braces (2 x kit part # 3760012851) should be installed between the jack and the deck
This will prevent excessive shear forces in the bolted connection and possible mechanical damage. Fig
9.2 shows the diagonal brace installed. For a truck mounted drill, the outer rear tires must be removed
to install the diagonal brace.
.

Diagonal Jack Braces may be

required if can lose firm ground
support under the mast base
while angle drilling See sect.
9.8.2

Figure 9.3 Diagonal Brace kit Installed on Truck Mounted Drill

57
9 Drill Set-Up

9.8.3 Precautions Required For Windy Conditions

Wind can exert very high forces on the drill, even upsetting the drill if the wind velocities are high enough.
Other factors affecting the forces exerted by the wind are the presence of drill rods in the rod rack and the
presence of wind screens on the helpers platform. It is therefore recommended that guy wires be
installed whenever the mast is raised for longer than a short duration and there is a risk of windy
conditions.

Damage or injury due to environmental extremes

such as earthquakes and hurricanes cannot be
prevented by guy wires.

The following guidelines should be followed in regards to wind conditions:

For All Drills

-The maximum wind speed for safe operation is 20 m/sec (45 mph). Do not operate the drill if wind speed
exceeds 20 m/sec even when guy wires have been installed. (This is a requirement of EN 791, the
European Safety Standard for Drilling Equipment).

For Drills without Rod Racks:

-If there is a possibility of wind speeds greater 36 m/sec (80 mph), the mast should be lowered.

For Drills with Rod Racks:

-If there is a possibility of wind speeds greater than 20 m/sec (45 mph) , guy wires must be installed on
drills with drill rods in the rod rack or wind screens (which can act like sails) installed on the helpers
platform.
-If there is a possibility of wind speeds greater than 30 m/sec (67 mph), drill rods should be taken out of
the rod rack and the mast lowered.

9.8.4 Guy Wire Installation

Use guy wires rated at 4 tonnes breaking strength firmly anchored to develop a minimum of 38 kN (4,200
lbf) pull out force. Place 4 such ropes at 90 to each other in plan view and at 45 to the ground. As the
drilling angle changes from 90 to 45 degrees, keep at least 30 degrees between the rear guy
wires and the mast. This is necessary to keep the necessary leverage on the mast.

58
9 Drill Set-Up

9.8.5 Other Conditions Requiring Guy Wires

For Drills without Rod Racks:

A truck mounted or stand alone drill is stable without guy wires for drilling angles between vertical and 45
degrees provided wind speeds are not more than indicated in the section 9.8.2.

For Drills with Rod Racks:

Provided that the drill is set up as described in this section, it is stable in the vertical position and
for mast angles up to 35 from the vertical. Over 3 5 from the vertical, guy wires are required. This
rule must be followed for both the truck mounted and stand alone condition.

59
9 Drill Set-Up

60
10 Drilling

10 Drilling
Always follow the Safety Instructions included in Section 2 and specifically those in
section 2.5 for Drilling

To achieve the best results with regard to:

high penetration
optimal core recovery
less deviation
low drilling costs

It is of primary importance that drill rods, core barrels, reaming shells and coring bits are of the right type
and quality, matched to the drill and to the prevailing rock conditions. Core barrels should have the right
type of stabilization.

Based on the core drills speed of rotation and chuck diameter, the CHRISTENSEN CS4002 is best
suited to drill holes in diameter N to P (76 mm-123 mm).

Familiarize yourself with the location and

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

Always protect your hearing with both

ear plugs and ear muffs with a total
rating of 15 dBA when working on this
drill.

Report excessive vibration to your

manager or foreman immediately when it
occurs.

61
10 Drilling

10.1 Before Drilling Starts

Make sure that the supply of water is adequate.

Ensure that the suction hose to the mud/water

pump in good condition, strainer clean and not
clogged.

Fig. 10.1 Q1 Master Disconnect switch

Keep all guards in place and in good

working condition.

10.2 Start the Power Unit

(Fig 10.1)
2
a. Activate master disconnect switch (Q1)
b. Start the engine as described in
Section II of Drill Manual - Diesel Engine
Unit Fig. 10.2 Start Mud/Water Pump

10.3 Start the Mud/Water Pump

10.3.1 Water flow control knob.
Controls oil flow to mud/water pump motor and
therefore water flow. CCW rotation increases
pump speed, CW rotation decreases pump 1
speed (Fig 10.2, pos 2.)

10.3.2 Hi/Lo mud/water pump control knob.

Controls speed of mud/water pump motor Fig. 10.3 Select Hi or Lo Mud/Water Pump
between Lo speed position (used for drilling with
lower flow, higher pressure) and Hi speed
position (used for washing the hole with higher
flow, lower pressure). (Fig. 10.3, pos 1)
Turn knob cw for Hi speed position.
Turn knob ccw for Lo speed.

62
10 Drilling

3 2

10.4 Adjust the Flow of

Mud/Water
a. Set the Hi/Lo knob in the Lo speed
position for drilling
b. Start the mud/water pump with the
control knob (Fig 10.4, pos 1) at the
front on the panel.
c. Read the water flow rate on the flow
meter (Fig 10.4, pos 2) on the control
panel.
d. Read the water pressure on the gauge
(Fig 10.4 pos 3) in the control panel.

Fig 10.4 Adjusting Mud/Water Flow

10.5 Start Rotation
Before starting rotation, select gear on the
rotation gear box that gives you the right rpm
range for the ITH equipment. 2 1
a. Position the drill string with the core
barrel and the drill bit about 50 cm (20
in) above the bottom of the drill hole.
b. Open the foot clamp
c. Start the drill rotation with rotation lever.
d. Adjust the rotation speed to the desired
RPM on the display.(Fig 10.5, pos 1)

The rotation speed must be adjusted lower

as the hole deepens and the drilling torque
increases so the maximum rotation pressure
remains at 240 bars (3500 psi). (Fig 10.5,
pos 2)
Fig 10.5 Start Rotation

63
10 Drilling

10.6 Start Drill Feed

10.7 Stop Drilling
a. Before the drilling operation can be
started, the rod weight must be a. Stop the drill feed by moving the fine
compensated for so the actual bit force feed lever (Fig 10.6, pos 5) to the
can be read. neutral position.
b. Adjust rpm and mud/water flow, with the
fine feed directional valve (Fig 10.6, pos b. Stop the rotation by moving the drill
4) in the neutral position. The pulldown rotation lever (Fig.10.6, pos 11) to
pressure can be read on the gauge (Fig neutral
10.6, pos 31) and should be zero. The
pulldown force can be read on the c. It is recommended to flush the drill hole
calibrated ring located around the for some minutes after stopping drilling
gauge. to avoid problems with cuttings and
c. Turn the feed rate valve knob (Fig 10.6, sludge especially at the end of the work
pos 3) clockwise (zero feed rate shift.
position). The holdback pressure can be
read on the gauge (Fig 10.6, pos 32).
d. Adjust the calibrated ring for reading the
bit force (located around the holdback
gauge) to zero at the point of the
holdback gauge needle.
e. When the rod weight has been
balanced, the drill feed can be activated
with lever (Fig 10.6, pos 4) without any
danger that the drill string will plunge to
the bottom of the drill hole and damage
the drill bit.
f. Increase the fine feed rate knob slowly
ccw until the drill bit reaches the
bottom of the hole and the bit force
reaches the desired value for the
chosen drill bit and formation. The
pulldown pressure may have to be
increased, depending on the current rod
string weight.
g. Do not apply more bit weight than is
recommended for the drill bit.
h. Continue drilling to the end of the feed
stroke, fill the inner tube, or until you get
core blockage.

64
10 Drilling

Figure 10.6 Main Console Controls

65
10 Drilling

before the rest of the joint is made with

10.8 Controlled Wireline the rotation unit.

Lowering c. Turn the thread compensation

a. To spool out rope from the wireline
drum, push the lever slowly forward
(away from you). The drum will start to
rotate.
b. To increase the speed, push the lever
further forward.
adjustment screw (Fig. 10.7, pos 1) cw
to increase the thread compensation
force or ccw to decrease the thread
compensation force. Tighten the lock
screw after making the adjustment.
1

c. Always stop the winch smoothly. If the

lever is dropped, the spring force will
move it back to neutral.

10.9 Controlled Wireline

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

b. To increase the speed, pull the lever

further backward.
Fig. 10.7 Adjusting Thread Compensation
c. Always stop the winch smoothly. If the
winch comes to a sudden stop it can
cause a jump. This in turn can cause the
core lifter to loosen its grip on the core
and lose the core.

d. When the lever is dropped, the spring

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

10.10 Thread Compensation

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

b. When making the joint, the feed cylinder

is disengaged through the slow feed
lines. It is recommended that the helper
turns the rod in at least one full turn

66
10 Drilling

10.11 Adding a Drill Rod

10.12 Removing a Drill Rod
Note: If the drill is equipped with the optional
a. Move the thread compensation control
Spin-Out Tool, see section 17.1 for (Fig 10.6, pos 18) into joint breaking
instructions on how to use this tool. position. Rod ends can screw apart
without damage to the threads (drillhead
weight is compensated for)
a. Move the thread compensation control
b. Move the make/drill pressure control
(Fig 10.6, pos 18) into joint making
(Fig. 10.6, pos 21) to drill position.
position. Rod ends can screw together
Screw out rotation motor displacement
without damage to the threads (feed
control (Fig.10.6, pos 28) so motor is at
cylinder is disengaged through the slow
max displacement. Shift the
feed lines).
transmission to a suitable gear to break
the joint.
b. Ensure the preset makeup torque
pressure is set to the desired value for
c. To break the joint with the rod holder
the drill rod being used (select pressure
closed, start the rotation unit to rotate
from Tables 10.1 & 10.2). Move the
ccw
make/drill pressure control (Fig. 10.6,
pos 21) to joint making position.
d. Do not unscrew the joint fully. Leave at
least one turn of the thread engaged.
c. Screw out the rotation motor
When the rod is lifted out, the last thread
displacement control (Fig.10.6, pos 28)
is screwed out by hand.
so motor is at max displacement

d. When adding a drill rod, ensure that the

threads are properly engaged, by
spinning the rod in one full turn by hand,
before making the remainder of the joint
with the machine.
Use caution when making or breaking rod
e. To make the joint, close the chuck and
joints and handling the rods.
start the rotation head to rotate
clockwise.

10.13 Water Pressure Dump

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

67
10 Drilling

10.14 Operating Main Winch

(See section 6.6 for a description of the main
winch features)

a. To spool in rope onto the main winch

drum, pull the lever slowly backwards
(towards you). The drum will start to
rotate.

b. To increase the speed, pull the lever

fully backward (main valve passes max Use the main winch for raising, lowering
flow). If winching pressure is less than and handling drill rods only. Do not use for
297 bar (4300 psi), increase winch general service or pulling off line except
speed by decreasing winch motor when handling drill rods.
displacement by turning in winch speed
control (Fig.10.6, pos 14). Periodically
adjust this control to maintain winching
pressure at 297 bar (4300 psi).

c. Always start and stop the winch

smoothly.

d. Always leave at least 3 wraps on the

winch drum and keep the rope in a
single layer. The audible alarm will The block limit switch is a safety device to
sound if there is less than 3 wraps on prevent the winching plug from being
the drum or the rope climbs on a second pulled into the crown block. Do not use it to
layer. stop upward movement of the winching
plug
e. Use a hoisting plug that is heavy
enough to pull the rope down the rod
slide when lowering

Monitor the condition of the main winch

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

68
10 Drilling

10.15 Rod Handling

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

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

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

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

10.15.1 Rod Handling Using Drillhead Tripping Out

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

a. Attach main winch hoisting plug and plug extension to rod string (rod joint is located
between drillhead and foot clamp). Remove any slack in the main winch rope until slack
is removed and rope is slightly tensioned.

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

c. Close foot clamp and then chuck

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

e. When joint has separated, take up the rope slack, lift drill rod through drillhead and run
out to horizontal position or stack in optional rod rack.

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

10.15.2 Rod Handling Using Drillhead Tripping In

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

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

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

d. Pre-torque rod joint using drillhead (ref Table 10.1). Note that rotation motor
displacement control (Fig. 10.6, pos 28) must be turned fully ccw

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

69
10 Drilling

f. Close foot clamp and repeat

Rod size
Gear Gear BT NT HT PT
Ratio
Recommended 1,016 Nm 1,360 Nm 1,490 Nm 2,030 Nm
Make Up Torque 750 ft lbf 1,000 ft lbf 1,100 ft lbf 1,500 ft lbf
1 6.27 39 bar 52 bar 57 bar 78 bar
Recommended 570 psi 750 psi 830 psi 1,130 psi
Make UP Pressure 2 3.12 78 bar 105 bar 115 bar 157
In Various Gears 1,140 psi 1,520 psi 1,670psi 2,270
3 1.75 140 bar 186 205 bar
2,030 psi 2,700 2,970 psi
4 1

Table 10.1 CS4002 Recommended Make-Up Torque And Corresponding Rotation Pressure Based
On:
-Rotation motor set at max displacement of 145 cc
-Total mechanical efficiency of 90% for drillhead
-No allowance for inertial effects

Rotation Spindle Torque Ft LBF

Pressure 4th gear 3rdh gear 2nd gear 1st gear
PSI Min Disp Max Displ Min Disp Max Displ Min Disp Max Displ Min Disp Max Displ
3500 508 740 889 1,295 1,585 2,309 3,185 4,640
3400 494 719 849 1,236 1,564 2,279 3,272 4,766
3200 464 677 799 1,164 1,472 2,145 3,080 4,486
3000 435 634 749 1,091 1,380 2,011 2,887 4,206
2800 406 592 699 1,018 1,288 1,877 2,695 3,925
2600 377 550 649 946 1,196 1,743 2,502 3,645
2400 348 507 599 873 1,104 1,609 2,310 3,364
2200 319 465 549 800 1,012 1,475 2,117 3,084
2000 290 423 499 727 920 1,341 1,925 2,804
1800 261 381 449 655 828 1,206 1,732 2,523
1600 232 338 399 582 736 1,072 1,540 2,243
1400 203 296 350 509 644 938 1,347 1,963
1200 174 254 300 436 552 804 1,155 1,682
1000 145 211 250 364 460 670 962 1,402
800 116 169 200 291 368 536 770 1,121
600 87 127 150 218 276 402 577 841
400 58 85 100 145 184 268 385 561

Table 10.2 CS4002 Spindle Torque (ft lbf) For Range Of Rotation Pressures (psi) Based On:
-Rotation motor displacement at:
-minimum at 100 cc, displacement control screwed in
-maximum at 145 cc, displacement control screwed out
-Total mechanical efficiency of 90% for drillhead
-No allowance for inertial effects

70
10 Drilling

10.15.3 Rod Handling Using Optional Spin-Out Tool

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

10.16 Drill Rod Break-In Procedure

It is recommended that rod joints of exploration drilling rods be pre-torque to the recommended values.

Wireline drill rods are typically manufactured using conical threads, and in such a manner to allow for a
stand-off between box and pin when hand tightened. Because these threads are intended to be in a state
of tension while in use, closing the standoff and further pre-loading of the joint through adequate
mechanical pre-torque accomplishes this.

A properly made up and lubricated tool joint reduces the likelihood of galling and wear through movement
between mating surfaces. A properly made-up joint also reduces the likelihood of service failure from
fatigue due to cyclic bending, (tension/compression/tension).

ACEP Platinum Series wireline drill rods are surface treated on the pin thread to provide a low friction
surface that absorbs lubricant and promotes a smooth break in and conditioning of the new rod joint,
particularly during the critical first make-ups and break-outs. Proper break-in practices promote long
service life and joint integrity.

Particular attention to proper joint make-up should be exercised where one or more conditions could
contribute to a joint running loose. Hole depth, deviation, dry holes, spin-outs from rapid deceleration,
and vibration as examples.

The recommended pre-torque values for Platinum wireline drill rods are given in Table 10.1. For more
information, please contact your nearest ACEP representative.

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

71
10 Drilling

72
11.1 General

Always follow the Safety Instructions included in Section 2 and specifically those in
section 2.7 for Maintenance and Servicing

The performance and reliability of the Christensen CS4002 is largely dependent on the amount of care
and attention shown to it. Regular checks and inspection of wear prone components prevent breakdowns
and costly downtime.

Dirt is the primary cause for most malfunctions in a hydraulic system.

Therefore:
Always try and keep the drill clean and free from dirt and other pollutants. It is much easier to
detect faults or oil leakage on clean equipment
Never leave any part of the hydraulic system open or exposed to external influence
Always attach tight fitting plugs to disconnected hose ends
Always refill oil into the hydraulic system by using the fill pump
Never use Teflon tape or similar material for sealing threads fragments can dislodge , enter the
system and damage sensitive components or plug orifices

11-1
11.2 Periodic Maintenance & Service Schedule

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

Table 11.1 CS4002 Maintenance Schedule

Check &
Ref # Service Service Interval In Hours Of Operation
Notes
Points 8 250 500 1000 2000
11.4.1 Engine oil level Check Change oil
Replace
11.4.2 Engine oil filter
filter
Primary &
Replace
11.4.3 Secondary Fuel
filters (2)
Filters
Replace
coolant filter Drain cooling
11.4.4
if applicable system, flush,
& Engine Radiator Check level Clean fins
& check replace
11.4.2
cooling coolant
system
Remove Change Change filters more
Engine air intake Check
11.4.5 coarse filters as often in dusty
filter filters
particles required conditions
RACOR engine Replace
Drain water
11.4.6 fuel filter/water Filter
at separator
separator Element
Water may have to be
Hydraulic tank Check level, Change oil or
drained daily if
11.4.7 level and oil drain water a minimum of
humidity high & tank
condition as required once per year
cools between shifts
Hydraulic oil
Clean fins
cooler
High pressure
Or earlier if pop-up
11.4.9 filters (3) : Replace
indicator remains up
11.4.1 -main pump filter
with oil at operating
0 -auxiliary pump elements
temp.
-secondary pump
Or earlier if pop-up
Replace
11.4.1 Hydraulic tank indicator remains up
filter
1 return filter with oil at operating
element
temp.
11.4.1 Case drain filters Replace
2 (2) filters
11.4.8, Compressed air
Drain water Replace
11.4.1 tank & charge air
at air tank filter
3 filter (if equipped)
Hydraulic tank Replace Every 500 hours in
11.4.8
breathers (2) breathers dusty conditions
Electric oil transfer
pump (if Replace filter
equipped)
Change oil Replace oil & filter,
11.4.1 Drillhead oil level and filter, clean strainer of new
Check level
5 and filter clean drill or rebuilt drillhead
strainer at 100 Hrs.
Check tension of new
11.4.1 Rotation unit Check
drill or rebuilt drillhead
5 chain tension tension
at 100 Hrs
11.4.1 Grease 3
Hydraulic chuck
6 fittings

11-2
11.2 Periodic Maintenance & Service Schedule

Check &
Ref # Notes
Service Points Service Interval In Hours Of Operation
8 250 500 1000 2000
Change oil Replace oil & clean
Check oil & clean magnetic plug after
11.4.17 Mud/water pump
level magnetic first 100 Hrs for new
plug or rebuilt pump
Change oil after 100
Check oil
11.4.18 Main winch Change oil hrs for new or rebuilt
level
hoist
Grease
Grease
bearings, oil
11.4.19 Wireline hoist levelwind
levelwind
screw
chain
Grease
11.4..20 Foot clamp hinge
pins
Stop greasing when
Grease 8
11.4.20 Carriage rollers grease escapes
rollers
around roller seal
Mast pivot pins (2), mast
raise cylinder pins (4),
11.4.21 Grease
mast hinge cylinder pins
(4)
Inspect
inserts and
Chuck jaws
clean if
necessary
Cable should be
Lubricate
Main hoist rope lubricated at first use
main cable
of a new cable
Hydraulic hose and
See section 11.6 for
11.6 elastomeric seal
recommendations
replacement

11-3
11.3 Lubricant Recommendations

Table 11.2 Recommended Lubricants

Lubricant Service Point Recommendation
Hydraulic oil 11.4.7 Use mineral-based hydraulic oil with good anti-wear, rust
(oxidation) and foam inhibiting properties, as well as effective air and
water separation abilities. The viscosity grade should correspond to the
ambient temperature and ISO 3448, as follows:

Ambient temp. C (F) Viscosity grade Viscosity

Index
+25 to +40 C (77 to 104 F) ISO VG 68 Min. 150
0 to +25 C (32 to 77 F) ISO VG 46 Min. 150
-30 to 0 C (-22 to +32 F) ISO VG 32 Min. 150

Examples of oil grades in the temperature range 0 to + 25C:

Shell Tellus T46
BP Bartran HV 46
Castrol Hyspin T 46
Mobil DTE 15M Texaco
Rando HDZ 46
Exxon Univis HP 46

For use of flame proof or biodegradable

hydraulic oil, please contact nearest Atlas
Copco representative for information

Drillhead 11.4.15 Summer operation: 80w90 weight API Classification GL5

transmission & Winter operation: hydraulic oil ISO VG 46
gearcase oil
Transmission 11.4.17,
oil (mud/water 11.4.18 80W90 weight API Classification GL5
pump & main For main winch use: Mobilgear 600XP 150 or equivalent
hoist
Grease 11.4.20 Universal grease NLG12..........Operating temperature C (F)
-Lithium/molybdenum ..................................Max. 100 C (212 F)
additive
-Synthetic sodium or calcium grease Max. 140 C (284 F)

Example of grease grades:

Shell Retinax AM
Esso MP Grease
BP Energrease LS-EP 2

Engine oil and 11.4.1,

Coolant 11.4.4 Use engine oil and coolant according to diesel engine
Instruction Manual

Main Hoist Brilube 30 or Brilube 35 (light oils with anticorrosion additives

Rope that can be applied by spray or brush. Will penetrate cable and
not build up on surface to inhibit inspection)
These instructions provide Atlas Copco and manufacturers part numbers for filters/filter elements,
pictures and other information of interest.

11.4.1 Engine Oil Level - See section 4.1 in Diesel Power Unit (Drill Manual Section II)

11.4.2 Engine Oil And Coolant Filters - See section 4.2 in Diesel Power Unit (Drill Manual
Section II)

11-4
11.4 Service Point Detailed Instructions

11.4.3 Fuel Filters - See section 4.3 in Diesel Power Unit (Drill Manual Section II)

11.4.4 Engine Radiator - See section 4.4 in Diesel Power Unit (Drill Manual Section II)

11.4.5 Engine Air Filter - See section 4.5 in Diesel Power Unit (Drill Manual Section II)

11.4.6 Engine Fuel Filter/Water Separator

In addition to the fuel filters supplied by the engine manufacturer, the drill is equipped
with a RACOR model 1000FH fuel filter system. See the RACOR Fuel Filter owners
manual in the parts manual for information regarding this system.

Replacement Element 3760008961

11-5
11.4 Service Point Detailed Instructions

11.4.7 Hydraulic Tank Oil Level, Draining Water and Cleaning

Maintain the hydraulic oil level by inspecting the sight glass. The recommended operating
level of hydraulic fluid is 2/3rds of the way up the sight glass. The tank should be topped
up if the level drops to the bottom of the sight glass.
Hydraulic tank capacity 500 liters (132 U.S. gallons)
Drain water from tank as required. Water may have to be drained daily in humid conditions
and if tank cools down between shifts
When cleaning out the tank, it is important to remove and clean the permanent magnets
located in the tanks

11.4.8 Hydraulic Tank Breathers and Charge Air filter

Replacement charge air filter element 3760007158

Replacement breathers 3760009018
Use only A/C approved breathers since they must meet the following requirements: filter rating of
10 micron and relief pressure setting of 10 psig to limit max tank pressure to 10 psig
Schedule calls for replacement every 500 hours but replace more frequently in dusty conditions

Breathers Charge Air Filter

11-6
11.4 Service Point Detailed Instructions

11.4.9 High Pressure Filter (Main Pump)

Replacement element 3760004888, HYDAC model # 5.03.27D20BN HYDAC material #
02065006 (20 micron absolute, 685 mm (27 inch) long version, collapse pressure of 17 bar
(250 psi) differential pressure
A pop-up indicator with automatic reset (located at the base of the filter) indicates when the
pressure drop exceeds 1.9 bar (27 psi). The bypass valve is set at 6 bar (87 psi) differential
pressure
Schedule calls for replacement every 1,000 hours but replace earlier if pop-up indicator stays up
when hydraulic oil is at operating temperature

Do not substitute filter element.

Warranty void if specified filter element is
not used.

11.4.10 High Pressure Filters (Auxiliary & Secondary Pumps)

Replacement element 3760004890 , HYDAC model # 0240D020BN3HC (20 micron absolute,
size 240, collapse pressure of 17 bar (250 psi) differential pressure
A pop-up indicator with automatic reset (located in the top of the filter) indicates when the
pressure drop exceeds 1.9 bar (27 psi). The bypass valve is set at 6 bar (87 psi) differential
pressure
Schedule calls for replacement every 1,000 hours but replace earlier when pop-up indicator stays
up when hydraulic oil is at operating temperature

Do not substitute filters element.

Warranty void if specified filter element is
not used.

11-7
11.4 Service Point Detailed Instructions

11.4.11 Hydraulic Tank Main Return Filter

Replacement element 3760004894, HYDAC 0660R010BN3HC (size 660, 10 micron

absolute)
A pop-up indicator with automatic reset (located at the top of the filter) indicates when the
pressure drop exceeds 1.9 bar (27 psi). The bypass valve is set at 6 bar (87 psi) differential
pressure
Schedule calls for replacement every 1,000 hours but replace earlier if pop-up indicator stays up
when hydraulic oil is at operating temperature

Do not substitute filter element.

Warranty void if specified filter
element is not used.

11.4.12 Case Drain Filters (2)

The case drain filters are located on opposite sides of the hydraulic tank
Replacement element (same for both filters) - 3760005230, MP Filtri Inc. # CSG100A25A
(25 Micron), or Fleetguard # HF6725
The bypass valve is set at 0.2 bar (3 psi) differential pressure to limit case pressure in the
auxiliary and secondary pumps

Do not substitute filter element.

Warranty void if specified filter
element is not used.

11-8
11.4 Service Point Detailed Instructions

11.4.13 Compressed Air Tank System (Drills with Cummins Diesel Engines)
The air tank is fed air from the engine compressor to a pressure of approx. 4.1 bar (60
psi). It is equipped with an auxiliary Quick Disconnect for a customer supplied air hose. It
is also equipped with a drain plug.
The air is used to charge the hydraulic tank to 0.55 bar (8 psi) through a pressure
reducing valve and charge air filter (filter also referenced in section 11.4.8)
Refer to Parts Manual for complete parts, fittings & hose information.
Water should be drained from the tank daily

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

11.4.14 Hydraulic Oil Fill Pump

Hydraulic oil is added to the hydraulic system by use of the fill pump located on the side of the
drill. The hydraulic oil is filtered through the main return filter before being added to the tank.
Replacement pump - 3760003200
Manufacturer Tuthill Transfer Systems # Fill Rite FR-110

Do not add hydraulic oil to the

hydraulic system using any other
method. Hydraulic system
contamination and hydraulic
system damage may result.

11-9
11.4 Service Point Detailed Instructions

11.4.15 Drill Head Oil Level and Filter

Replacement oil filter element 3760007158, LHA # SPE-15-10 or Fleetguard # HF6510

When the drill head is rotating, oil flow must be present in the clear line on the side of the
drill head. Without this flow, damage will result.
The transmission and the drill head chain case use the same oil. Chain case housing is
checked in the vertical position on right side of casing through plug located behind adjuster
plate. The transmission oil level is also checked/filled in the vertical position, on back side
of transmission through NPT plug.
Check level when oil is warm or has had time to drain down if checked cold. The method of
checking the oil level is the same for drilling angles 45 to 90 degrees.
See service schedule (Table 11.1) for change intervals and lubricant recommendations
section 11.3, for oil recommendations. Change oil more frequently if visibly dirty or
discolored, also change at 100 hours after putting a new or rebuilt drillhead into operation.

Oil Filter
Remove plug to check
chain tension Check
vertical level
here, behind
adjuster
plate.
Oil Pump Strainer

11.4.16 Hydraulic Chuck Grease Fittings

On the drill head there are 3 grease fittings, two on the chuck bonnet, and one on the bearing
retainer.
Grease these fittings per schedule in Table 11.1using good quality multi purpose E.P. grease.

Grease here
plus one on
opposite
side
Clean grease fittings before adding
grease to prevent contamination

Grease here

11-10
11.4 Service Point Detailed Instructions

11.4.17 Mud/Water Pump

Check the mud/water pump oil level daily.

Refer to the FMC Operators Manual located in the Parts Manual for maintenance, start-
up and shut-down procedures.

Model Shown FMC W1122 BCD

11.4.18 Main Winch

Check the main winch oil level daily.

See the Braden Winch insert in the Parts Manual for service information.

Inspect entire winch rope weekly.

Do not use rope if it is kinked or
has broken strands.

Poor rope condition can lead to

instant failure causing death. Do
not use drill with damaged rope.

Check level here

Drain oil here

11-11
11.4 Service Point Detailed Instructions

11.4.19 Wireline Winch

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

Levelwind screw

Levelwind
chain
located
under cover

11.4.20 Grease Fittings

Follow the schedule in Table 1.1 for greasing these components

Foot clamp grease fittings (4 fittings) Grease hose into fitting

(Guard shown removed) (2 locations)

Grease crown block here

11-12
11.4 Service Point Detailed Instructions

Carriage rollers grease fittings (4 on other side, 8 in total)

Lift cylinder
clevis pins
(4 locations)

Mast pivot pins

(2 locations)

11-13
11.5 Periodic Inspections

Periodic inspections are recommended to ensure that the machine is in a safe and serviceable condition.
The inspections should check the following:
emergency devices are functioning
all mechanical guards are in place
condition of the main winch cable
bolts are tight and have not worked loose
pin retainers are in place and secured
no cracks have developed in welds or parent material
there is no oil leakage from tank, fittings, hoses and components
personnel fall protection devices are serviceable
Lifting components (water swivel and hoisting plugs) are in good condition
audible alarm is functioning

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

Use extreme caution when checking hoses

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

11-14
11.5 Periodic Inspections

Table 11.3 Periodic Inspections and Intervals

Inspection Frequency

Half - yearly
Monthly
Weekly
Inspection Point Comments

Yearly
Daily
Emergency Devices & Alarms: -Audible alarm test button is
-E-stop buttons X located on console
-Main winch block limit switch X -Check audible alarm
-Audible alarm sounds when using
secondary control panel
Guards X Ensure guards are in place
and are functioning
Main winch rope X Replace rope if rope is
kinked, has broken strands,
or is worn
Crown block sheave for main winch X Check for wear & surface
cracks
Tightness of Bolts: Inspect all bolts for
-rope clamps on main hoist drum X tightness every month but
-crown block to mast X pay special attention to the
-jacks to deck X bolts listed.
-main hoist to deck X
-bolts retaining mast in saddle X Re-torque as required
-drillhead slide plate X
-angle adjustment plate on platform X
-feed cylinder anchor plate to mast X
-carriage rollers (8) X
-roller mounting plates X
-replaceable ways X
-hose end anchors X
Pin retainers in place: Ensure pin retainers are in
-hoisting plug X place and secured
-waters swivel X
-hoist block limit switch X
-mast raise cylinders X
-mast backstay leg X
-rod rack backstay leg X
-folding mast securing pin X
Weld and Material Cracks
-rod clamp table to mast X
-saddle weldment X
-backstay legs X
-cylinder ends X
Oil leakage from tank, fittings, X
hoses and components
Personnel fall protection devices X Ensure that devices are in
serviceable condition
Hoisting plug, water swivel X Inspect these load carrying
items for damage and
condition

11-15
11.6 Hydraulic Hoses & Fittings Inspection

Hose and Fitting Maintenance and Replacement Instructions

Even with proper selection and installation, hose life may be significantly reduced without a continuing
maintenance program. The severity of the application, risk potential from a possible hose failure, and
experience with any hose failures in the application or in similar applications should determine the
frequency of the inspection and the replacement for the products so that products are replaced before
any failure occurs. A maintenance program must be established and followed by the user.

Visual Inspection Hose/Fitting: Any of the following conditions require immediate shut down and
replacement of the hose assembly:

Fitting slippage on hose,

Damaged, cracked, cut or abraded cover (any reinforcement exposed);
Hard, stiff, heat cracked, or charred hose;
Cracked, damaged, or badly corroded fittings;
Leaks at fitting or in hose;
Kinked, crushed, flattened or twisted hose; and
Blistered, soft, degraded, or loose cover.

Visual Inspection Other Items: The following items must be tightened, repaired, corrected or replaced
as required:

Leaking connections;
Excess dirt build up;
Worn clamps, guards or shields; and
System fluid level, fluid type, and any air entrapment.

Functional Test: Operate the system at maximum operating pressure and visually check for possible
malfunctions and leaks. Personnel must avoid potential hazardous areas while testing and using the
system.

Replacement Intervals: Hose assemblies and elastomeric seals used on hose fittings and adapters will
eventually age, harden, wear and deteriorate under thermal cycling and compression set. Hose
assemblies and elastomeric seals should be inspected and replaced at specific replacement intervals,
based on previous service life, government or industry recommendations, or when failures could result in
unacceptable downtime, damage, or injury risk.

Hose Inspection and Failure: Hydraulic power is accomplished by utilizing high-pressure fluids to
transfer energy and do work. Hoses, fittings, and hose assemblies all contribute to this by transmitting
fluids at high pressures. Fluids under pressure can be dangerous and potentially lethal and, therefore,
extreme caution must be exercised when working with fluids under pressure and handling the hoses
transporting the fluids. From time to time, hose assemblies will fail if they are not replaced at proper time
intervals. Usually these failures are the result of some form of misapplication, abuse, wear, or failure to
perform proper maintenance.

When hoses fail, the high-pressure fluids inside can escape in a stream which may or may not be visible
to the user. Under no circumstances should the user attempt to locate the leak by feeling with their
hands or any other part of their body. High-pressure fluids can and will penetrate the skin and cause
severe tissue damage and possibly loss of limb. Even seemingly minor hydraulic fluid injection injuries
must be treated immediately by a physician with knowledge of the tissue damaging properties of hydraulic
fluid.
If a hose failure occurs, immediately shut down the equipment and leave the area until pressure has been
completely released from the hose assembly. Simply shutting down the hydraulic pump may or may not

11-16
11.6 Hydraulic Hoses & Fittings Inspection

eliminate the pressure in the hose assembly. Many times check valves, etc., are employed in a system
and can cause pressure to remain in a hose assembly even when pumps or equipment are not operating.
Tiny holes in the hose, commonly known as pinholes, can eject small, dangerously powerful but hard to
see streams of hydraulic fluid. It may take several minutes or even hours for the pressure to be relieved
so that the hose assembly may be examined safely.

Once the pressure has been reduced to zero, the hose assembly may be taken off the equipment and
examined. It must always be replaced if a failure has occurred. Never attempt to patch or repair a hose
assembly that has failed. Never touch or examine a failed hose assembly unless it is obvious that the
hose no longer contains fluid under pressure. The high-pressure fluid is extremely dangerous and can
cause serious and potentially fatal injury.

Elastomeric seals: Elastomeric seals will eventually age, harden, wear and deteriorate under thermal
cycling and compression set. Elastomeric seals should be inspected and replaced.

Caution: Matches, candles, open flame or other sources of ignition shall not be used for hose inspection.
Leak check solutions should be rinsed off after use.

11-17
11.6 Hydraulic Hoses & Fittings Inspection

Page Intentionally Left Blank

11-18
12 Hydraulic Circuit Description

12 Hydraulic Circuit Description

12.1 Hydraulic Pumps

The system consists of three separate hydraulic circuits. The three pumps (main, secondary, and
auxiliary) are driven directly from the power unit flywheel.

The three pumps are mounted in tandem and are connected directly to the engine flywheel by a steel
adapter and hub. The main and secondary pumps are an axial piston load sense type. The auxiliary is an
axial piston pressure compensated type. There are full bore, lockable shut off valves in the suction lines
from the hydraulic tank.

20
87 psi 20
87 psi 20
87 psi

30
psi
Max

12.1.1 Main Pump (Item 1)

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

89
12 Hydraulic Circuit Description

12.1.2 Auxiliary Pump (Item 2)

The auxiliary pump is a pressure compensated pump. It produces 125 lpm (33 gpm) at 2100 rpm and has
a compensator setting of 172 bar (2,500 psi). The pressure side of the auxiliary pump is directed to the
either the main control console or the secondary control console be means of a selector valve. This
prevents the two control panels from being active at the same time.

The auxiliary pump connection to the main console powers all controls required for drilling (see section
12.4) as well as the hydraulic driven air/oil cooler and mud pump. The auxiliary pump connection to the
secondary console powers all positioning cylinders required for drill set up.

12.1.3 Secondary Pump (Item 3)

The standard CS4002 secondary pump is a load sensing pump with a compensator setting of 206 bar
(3,000 psi). It produces 87 lpm (23 gpm) at 2,100 rpm. The secondary pump powers only the mud/water
pump through a control valve. A two-speed hydraulic motor is used on the water/mud pump.

Note: The manual describes the standard CS4002 secondary pump, standard mud/ water pump
(FMCW1122BCD) and the standard control components. If another mud/water pump has
been specified by the customer, the secondary hydraulic pump and control components may
vary. Details on the non-standard components are available in Addendum Sheets in section
18 and the specific drill schematic in the Parts Manual.

12.2 Filtration
The main factor affecting problem free operation and long life of hydraulic system components is the
cleanliness of the hydraulic oil. Experience shows that most hydraulic problems are due to hydraulic oil
contamination. To eliminate contamination, the CS4002 uses five types of filters to protect the hydraulic
system: pressure filters, main return filter, case drain filters, hydraulic tank breathers and charge air filter

12.2.1 Pressure Filters (Items 30, 31A and 31B)

The pressure filters are located downstream of each of the three hydraulic pumps. This protects the
valves and components that receive oil from the pumps, from contamination caused by failure of the
pumps. The pressure filters use a 20 Micron absolute element (ISO level 20/18/15). A pop-up indicator
signals a differential pressure of 1.9 bar (27 psi) across the element and has an automatic reset. All three
pressure filters use an internal bypass valve cracking pressure of 6 bar (87 psi) differential pressure.

12.2.2 Case Drain Filters (Item 33A and 33B)

The case drain filters are located at the hydraulic tank in the case drain return of the hydraulic pumps and
motors. This protects the hydraulic tank from contamination in case of hydraulic pump or motor failures
which can generate particles in the case drain connections. The case drain filters use a 25 micron
absolute element and have low bypass pressures of 0.2 bar (3 psi) to avoid exceeding max differential
pressure allowed between suction and case drain for the auxiliary and secondary pumps.

12.2.3 Return Filter (Item 32)

All hydraulic oil returns to tank through the main return filter located in the top of the tank. The return filter
uses a 10 micron absolute element (ISO 19/17/14). Because this filter retains the smallest particles of any
of the hydraulic fluid filters, it collects most of the contamination particles and is designed to have the
highest dirt holding capacity. A pop-up indicator signals a differential pressure of 1.9 bar (27 psi) across
the element and has an automatic reset. The bypass valve is set at 6 bar (87 psi) differential pressure

90
12 Hydraulic Circuit Description

12.2.4 Hydraulic Tank Breathers (Item 74A and 74B)

The hydraulic tank breathers have a built in 10 micron filters and prevent dust/dirt from entering the
hydraulic tank when the tank temperature and pressure decrease after shutdown. The breathers also act
as relief valves to limit the hydraulic tank pressure to a maximum of 0.69 bar gauge (10 psi) pressure.

12.2.5 Charge Air filter (Item 79)

The charge air filter, with a 10 micron rating, cleans the air coming from the compressor to pressurize the
tank to 0.55 bar (8 psi) for high altitude operation.

Do not substitute filter elements. Warranty void if

specified filter element are not used.

Premature and repeated failure of hydraulic

components has occurred when customer
substituted wrong type of filter elements.
12.3 Main Pump Circuit

91
12 Hydraulic Circuit Description

The pressure output of the main pump passes through a pressure filter to the main valve, item 80. The
main valve is pressure compensated, has a built-in relief valve set at 362 bar (5260 psi), and is hydraulic
pilot operated. The pilot controllers get the supply pressure from the auxiliary pump.

The main valve powers the main winch, drillhead rotation, wireline winch and drillhead fast travel.
Maximum flows and pressures vary for the various functions as shown.

12.3.1 Main Winch (Item 5)

Maximum flow to the main winch is 272 lpm (72 gpm); max pressure is 324 bar (4,700 psi)

Load lowering is controlled by a counterbalance valve item 89. The counterbalance valve is direct
mounted on the winch motor to prevent load dropping in case of hose failure. A manual brake control is
used to release the winch brake and pilot open the counterbalance valve when drilling, so the winch rope
can unspool as the drillhead is feeding down.

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

Also see Braden service manual in the part manual for installation, maintenance, and service instructions.

92
12 Hydraulic Circuit Description

12.3.2 Rotation Motor (Item 4)

Maximum flow to the rotation motor is 272 lpm (72 gpm); max pressure is 241 bar (3,500 psi)

The rotation motor is a variable displacement bent axis design with motor displacement continuously
variable between min and max displacement settings by means of a rotary hydraulic control on the control
panel. This allows the operator to change the rotation speed/torque as required. Note that the min and
max displacement adjusting screws must be set up on a new motor using the set-up procedure in section
15, to prevent overspeed conditions and damage to the drillhead and rotation winch motor.

12.3.3 Wireline Winch (Item 6)

Maximum flow to the wireline winch is 113 lpm (30 gpm); max pressure is 207 bar (3,000 psi).

Load lowering is controlled by a counterbalance valve item 102. A direct mounted parking brake is
automatically released when the hoist is activated in either direction. The parking brake prevents
downward creeping of the overshot due to weight and hydraulic motor leakage when the control valve is
in the neutral position. Brake release valve item 96 uses pressure from the auxiliary pump which is then
reduced to 20.6 bar (300 psi) by pressure reducing valve item 97, to release the brake even when motor
port pressures are less than the 20.6 bar (300 psi) brake release pressure.

93
12 Hydraulic Circuit Description

12.3.4 Fast Travel of Feed Cylinder (Item 7)

Maximum flow to the feed cylinder is 272 lpm (72 gpm), in the up direction, 136 lpm (36 gpm) in the down
direction. Max pressure is 165 bar (2,400 psi). The cylinder ID is 127 mm (5 in) and the rod diameter is
88.9 mm (3.5 in). The differences in area and flow produce approximately the same speed in the down
and up direction.

The fast travel section directs maximum volume (0-272 lpm) to the feed cylinder for rapid movement up.
Load lowering is controlled by a counterbalance valve item 84. The counterbalance valve is direct
mounted on the feed cylinder to prevent load dropping in case of hose failure.

A pilot operated check valve item 85 isolates the fast travel circuit from the slow feed circuit on the rod
end of the cylinder

94
12 Hydraulic Circuit Description

12.4 Auxiliary Pump Circuit

The auxiliary pump pressure is connected to the air cooler fan motors and a selector valve item 100
which directs oil from the auxiliary pump to either the secondary control console item 93 or the main
control console. This selector valve prevents inadvertent movement of the positioning cylinders when
using the main control console for the drilling operation

12.4.1 Positioning Valves (Secondary Control console)

When the selector valve directs oil to the secondary control console, the positioning cylinders used for
setting up the drill in the drilling position can be activated. An audible alarm sounds when any of the
positioning valves are activated to warn personnel of the cylinder movements.
The auxiliary pump compensator setting sets the max circuit pressure at 2500 PSI
1. Control panel slide
2. Mast fold (used with optional folding mast)
3. Mast dump
4. Mast raise (a relief valve limits the pressure in the mast lowering direction)
5. Valve for front right jack
6. Valve for front left jack
7. Valve for rear right jack
8. Valve for rear left jack

.062
3x
80 psi

100
psi

P T

95
12 Hydraulic Circuit Description

12.4.2 Controls in Main Console and Other Functions Powered By Auxiliary Pump

When the auxiliary pump selector valve directs oil to the main control console, the following control valves
are supplied with hydraulic oil and can be activated -reference schematic in Fig. 12.1 Functions Powered
By Auxiliary Pump.

Item 16 Slow feed directional valve

Item 28 Pulldown pressure cartridge
Item 17 Feed rate valve
Item 18A Chuck open/close
Item 24A Head opener
Item 20 Hi/lo water pump
Item 18B Main winch brake release
Item 24B Rod kicker
Item 19 Foot clamp open/close
Item 47 Thread compensation (adjustable setting)
Item 23A Main winch motor displacement (speed/torque) control (not shown)
Item 23B Rotation motor displacement (rpm/torque) control (not shown)
Item 15 Mud mixer (placed in series with air/oil cooler fan motors

12.4.3 Other functions powered by auxiliary pump

Item 63A/B Fans motors on air/oil cooler

Item 81 Pilot controllers for main valve
Item 96 Wireline hoist brake release
Item 50 Optional Spin-Out tool

96
12 Hydraulic Circuit Description

3000 3000
Max PSI

Fig 12.1 Functions Powered By Auxiliary Pump

97
12 Hydraulic Circuit Description

12.5 Secondary Pump Circuit

The standard CS4002 secondary pump is a load sensing pump producing 87 lpm (23 gpm) at 2,100
rpm and has a compensator setting of 206 bar (3,000 psi).The secondary pump item 2 powers the
mud/water pump only.

The standard water/mud is a FMCW1122 BCD powered by a 2 speed motor (Hi/Lo motor) item 8.
The hydraulic motor is switched between Hi and Lo by a control valve item 20 which is powered by
the auxiliary pump. Lo speed setting is used for drilling (high pressure, lower flow) and Hi speed
setting is used for hole flushing (max flow). The water/mud pump relief valve must be set at 69 bar
(1,000 psi) to prevent water pump overpressure.

Note: This section describes the standard CS4002 secondary pump, standard mud/ water pump
(FMCW1122BCD) and control. See Addendum sheet in Section 18 if customer has
specified a different mud/water pump requiring a different secondary hydraulic pump
and/or control components. Also see drill hydraulic schematic in Parts Manual.

1000
psi

2000
Max PSI

98
12 Hydraulic Circuit Description

12.6 Return Oil Circuit and Hydraulic Tank

Oil which has been circulated by the hydraulic pumps through the various valves and actuators is
returned to the hydraulic oil tank.
On its way back it passes through a thermostatic valve item 60 which directs the oil to the cooler item 62
when it reaches a temperature of 54C (130F). This allows the hydraulic oil to reach operating
temperature even in cold weather. A spring loaded bypass item 61 limits the pressure drop across the
cooler to a maximum of 4.5 bar (65 psi).
The hydraulic oil then passes through the return filter item 32 (see section 12.2.3 for detailed description)
mounted in the top of the hydraulic tank
The system includes a hand operated pump item 37 for filling the hydraulic tank. This pump is
permanently connected to the system through a check valve item 56. Hydraulic oil introduced by the fill
pump travels through the main return filter before reaching the hydraulic tank. This prevents ingress of
contamination when adding hydraulic oil to the system.

The hydraulic tank size is 500 litres (132 gallons) of oil. It is equipped with a combination sight glass and
thermometer (item 77) and a combined temperature and level switch item 78 mounted in the lid. The tank
bottom is sloped to bring any water to a drain port. A permanent magnet to trap iron particles is located in
the tank and is cleaned at the time the tank is drained and cleaned.

The hydraulic tank is pressurized for high altitude operation by an engine mounted compressor. The
compressor charges an air tank to 6.2 bar (90 psi) which can be used for air powered tools. Air from the
tank passes through a pressure reducing valve set at 0.55 bar (8 psi). The low pressure air then passes
through the charge air filter item 79 into the hydraulic tank. Breathers, items 74A and 74B, filter air drawn
into the tank when it cools and also protect the tank from overpressure with built-in 0.69 bar (10 psi) relief
valves.

99
12 Hydraulic Circuit Description

TEMP
130 F

65 psi 1725 MAX

RPM
6 GPM
10 10
6000 125 psi
10 10
Max PSI psi psi

60 psi
25 25
10
3 psi 3 psi 10 8 psi
25 psi

30 TEMP
psi
Max
SETTING
176 F

12.7 Hydraulic Oil Cooler

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

100
13 Electrical Circuit Description

13 Electrical Circuit Description

13.1 Electrical Fault Panel

The electrical fault panel serves the following functions:
A monitoring system for the hydraulic tank oil temperature and oil level.
A delayed automatic shutdown of the diesel when in a fault condition.
12 volt power source for the mast lights, console lights, and console accessories.

13.1.1 Normal Operation Sequence

When battery power is available the console lights and mast lights will function by means of the
corresponding light switches mounted on the operator console. (Note: The engine does not
need to be running for these lights to work.)
To crank and start the engine the following is required:
-all E-Stop buttons (3 on the drill plus an additional one if drill is equipped with optional rod rack
and helpers platform) must be in the normal (out) position.
-the friction lock rotation control lever must be in the neutral position since it is equipped with a
neutral switch.
When the ignition key switch is activated under normal conditions the Fault Panel indicating lights
will be off and the audible alarm will be silent.

13.1.2 Fault Condition Sequence

Should a hydraulic oil temperature or hydraulic oil level fault occur while the diesel is operating
the corresponding indicating light on the fault panel will be illuminated and the audible alarm will
sound to alert the operator to the fault condition.
If the diesel continues to run for more than 30 seconds (interval is adjustable) in a fault condition
the Fault Panel will shut the diesel down automatically. The purpose of the delay is to give the
operator time to pull back the drill string, secure the hole and if possible, idle the diesel.
When the Fault Panel automatically shuts down the diesel, the fault horn will continue to sound
and the corresponding fault indicating light will remain illuminated until the fault is recognized by
one of two actions:
The ignition key is turned off
The fault reset button is depressed
If the ignition key is turned off in a fault condition, the fault horn will be silent but the fault
indicating light will remain illuminated until the fault reset button is depressed. The purpose of the
indicator light is show which fault has occurred.
Once the fault has been corrected, depress and release the fault reset button on the fault panel.
If no fault is present, the fault indicating light will remain off, and the diesel will be ready to start
and run normally.
If the fault has not been corrected the corresponding fault light will once again be illuminated and
shut the diesel after 30 seconds.
If the fault reset button is depressed and released without correcting an indicated fault condition,
the corresponding fault light will again be illuminated. In this event the ignition key could start and
run the diesel, but only until the 30 second time delay expires and the engine is once again
automatically shutdown.
Any time the ignition key is in the on position and a fault condition exists, the audible alarm will
sound.

101
13 Electrical Circuit Description

13.2 Safety Systems Description

The CS4002 is equipped with several safety systems which use the electrical circuit. These safety
systems are for the protection of personnel and must be checked at the beginning of each shift.

13.2.1 Emergency Stops (E-Stops)

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

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

E-stops are located on the main control console, at the secondary control console, and the right side
of the drill opposite the secondary control console (closest location for helper when running rods out)

For drills equipped with the optional rod rack/helpers platform, there is a plug-in E-stop connection
accessible from the helpers platform. The helper can then locate the portable E-stop at a suitable
location on the platform. A jumper is used when the helpers E-stop is not plugged into the receptacle.

13.2.2 Rotation Pilot Controller Neutral Switch

The rotation pilot controller is equipped with a neutral switch which prevents the starting circuit from
closing and starting the engine, unless the rotation control lever is in the neutral position. This
prevents unexpected chuck rotation if the engine is started with the rotation lever (held in position by
friction) still in an operating position.

13.2.3 Crown Block limit Switch

The crown block is equipped with a limit switch to prevent the hoist plug/water swivel from being
pulled into the crown block. Tripping the limit switch cuts power to a normally open solenoid valve
which will then connect the pilot line (to the main valve winch raise valve section) to tank. This stops
the winch raising.

The operator can then lower the winch. This will reset the limit switch, the normally open solenoid
valve will close and the main winch can be operated again in both directions.

13.2.4 Audible Alarm When Operating Secondary Control Console

The audible alarm (beeping sound) will sound when operating any of the controls used for drill set-up
in the secondary control panel. A pressure switch senses when the tank side pressure of the control
valve increases above 5.5 bar (80 psi).

The audible alarm will make helper(s) aware that the jacks, mast or control console are being moved.

A test button on the main control console is used to test the audible alarm.

102
14 Trouble Shooting

14 Trouble-Shooting

Potential problems and solutions

The following guide is designed to help you identify and solve
hydraulic problems. The explanations may not provide all the
answers and but may be helpful.

Safety first
Remember to observe Safety Instructions listed in Section 2 in this
manual. Always use safe work practices.

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

103
14 Trouble Shooting

14.1 Trouble-Shooting - General

Type of fault Possible cause Remedy

1. Noisy pump caused by A. Oil is too viscous A. Change to proper viscosity

cavitation
B. Filter plugged B. Clean or replace

C. Suction line plugged C. Clean line

D. Suction line ball valve closed D. Fully open valve, pumps

or not fully open probably damaged, inspect.

E. Tank not sufficiently E. Check tank pressure, adjust

pressurized for high altitude pressure reducing valve from air
tank to specification

2. Noisy pump caused by A. Oil supply low A. Fill hydraulic tank, check low
aeration level switch mounted in tank

B. Air leaking into suction line B. Tighten fittings

C. Foaming oil C. Drain hydraulic tank and fill

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

3. Hydraulic system overheating A. Oil supply low A. Fill hydraulic tank

B. Oil in system too light B. Drain hydraulic tank and refill

with proper viscosity oil

C. Fan speed too low C. Check RPM 1750 both fans

D. Cooler fins dirty or plugged D. Clean fins

E. Excessive internal leakage in E. Connect a flow meter to the

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

F. Aeration of oil F. Tighten suction fittings

104
14 Trouble Shooting

Type of fault Possible cause Remedy

4. System not producing A. Excessive internal leakage A. Check amount of flow is

necessary pressure according to specification

B. Compensator spool stuck B. Disassemble, inspect, clean,

open or replace compensator

C. Compensator spring weak C. Check spring in compensator

or broken

D. No flow to compensator D. Check load sense line for

signal port damage, size, and length

E. Load sense line E. Connect and bleed of the

disconnected or filled with system
air

5. System does not produce A. Excessive internal leakage A. Check amount of flow
proper flow according to specification

B. Compensator spool stuck B. Disassemble, inspect, clean,

open or replace compensator

C. Compensator spring broken C. Check spring in compensator

D. Pump cavitation D. Check proper oil viscosity,

suction line, tank pressure

E. No load sense signal to E. Check load sense line and

compensator ports at valve

F. Load sense line F. Connect and bleed the system

disconnected or filled with
air

G. Low pilot pressure G. Test pressure.

105
14 Trouble Shooting

14.2 Trouble-Shooting Auxiliary Pump Circuit

Type of fault Possible cause Remedy

1. Little, erratic, or no feed A. Hydraulic plumbing is not A. Check schematic in Parts Manual and correct
pressure according to schematic plumbing if necessary.

B. Pressure gauge defective (false B. Check the face and needle in pressure gauge
reading) for damage, replace if necessary

C. Feed rate valve is not operating C. Check needle valve and internal bypass
properly check valve

D. Return line from manifold is D. Check oil flow back to tank

blocked

E. Slow feed directional valve is not E. Check for worn or damaged parts (slow feed
operating properly valve spool is detent)

F. Pressure reducing valve for F. Check for worn or damaged parts

pulldown pressure is worn or
damaged

G. Thru shaft from main pump is G. If main pump is ok check where auxiliary and
broken or damaged secondary are piggybacked at thru shaft.

H. Pump or compensator is bad or H. Check auxiliary pump for excessive case

out of adjustment drain flow (more than 11 lpm or 3 gpm),
pressure setting, and compensator for dirt and
worn or broken parts.
1. Position control levers in neutral.
2. Start engine.
3. Loosen jam nut on compensator adjustment
screw (inside screw).
4. While observing pressure on gauge turn
adjustment screw cw to increase and ccw to
decrease auxiliary pressure. Retighten jam
nut.

I. Contamination in control valve or I. Disassemble, clean, and inspect for broken

auxiliary pump manifold ports. parts

J. External problem such as main J. Disconnect main winch rope and check
winch brake or drillhead carriage condition of carriage rollers and replaceable
parts are affecting the feed ways. Troubleshoot brake release system if
process. necessary.

K. Feed cylinder or feed cylinder K. Check O-rings in block at rod end of cylinder.
seal kit is defective or worn Also check if oil is bypassing at piston seals.
Check internal condition of feed cylinder.

106
14
14.2 Trouble-Shooting Auxiliary Pump Circuit (contd)
Type of fault
2. Hydraulic chuck opens
partially, not at all, or leaking
hydraulic oil (not grease) at
chuck body.
3. Chuck jaws not holding drill
rod or slipping.
Possible cause
A. Relief valve for chuck (located
below the control valve lever)
is stuck, contains
contamination, damaged, or
pressure setting is not correct.
B. Control valve spool is damaged
or broken.
C. Auxiliary pump or compensator
problem.
D. Damage to internal sliding
parts of chuck.
E. Seal kit, piston, or cylinder, is
worn or damaged.
A. Incorrect chuck jaw size, worn
jaws, or damaged.
B. Hydraulic pressure entering
chuck cylinder when chuck
control valve is in the closed
position.
C. Internal parts of cylinder or
chuck are not moving
properly.
D. Excessive contamination inside
chuck and jaws.
Trouble Shooting
Remedy
A. Remove relief valve and inspect for
damage and dirt. Make sure relief
valve was not over tightened into
housing. Set pressure at 90 bar
(1,300 psi)
B. Check for worn or damaged parts in
control valve.
C. Check auxiliary pump for excessive
case drain flow (more than 11 lpm or 3
gpm), pressure setting, and
compensator for contamination and
worn or broken parts.
D. Disassemble chuck, clean all parts,
and inspect for galling, wear, or broken
parts. Use caution when removing 7/16
in bolts at top plate. Remove evenly
due to spring pressure below.
E. Remove piston from cylinder and
install new seal kit. Inspect piston and
cylinder for wear or damage. Make
sure relief setting is not too high if
cylinder is bulged.
A. Inspect jaws and check for right part #.
Check the correct size of rod bushings
(upper and lower) are being used if
damage to carbide is occurring.
B. Install 206 bar (3,000 psi) gauge at
chuck and determine if pressure is
entering chuck cylinder. If only a small
amount is entering when chuck control
valve is in closed position, check the
valve for wear or damage.
C. Disassemble chuck, clean, and inspect
for damaged parts.
D. Clean carbide inserts and sliding areas
of jaws.
107
14
14.2 Trouble-Shooting Auxiliary Pump Circuit (contd)
Type of fault
4. Mud mixer not rotating,
rotating slow, or erratic.
5. Hydraulic jacks, mast raise,
etc. will not operate at all or
erratic.
108
Possible cause
A. Quick disconnects not
connected properly or pilot
inside is broken
B. Mud mixer control valve
(flow divider) is worn or
damaged.
C. Drain port (port B) from
control valve not connected
to tank or is line plugged.
D. Hydraulic motor at mixer
assembly is defective.
E. Relief valve at flow divider
inlet is set too low or is
leaking
F. Auxiliary pump or
compensator is bad or out
of adjustment.
A. Selection valve in main
console position
B. Hydraulic cylinder leaking
internally or damaged.
C. Control valve is worn or
damaged.
D. Auxiliary pump or
compensator is bad or out
of adjustment.
E. Selection valve not working
properly
Trouble Shooting
Remedy
A. Check quick disconnects for
damage/broken parts or does not
go together freely.
B. Check the spool and housing of
control valve for wear or damage
C. Connect tank line or clean line
D. Troubleshoot hydraulic motor for
damage or internal leakage.
E. Check relief valve setting of 138
bar (2,000 psi). Reset if necessary.
F. Troubleshoot pump for proper
settings, excessive internal wear,
and compensator problem.
A. Move valve to secondary console
position
B. Troubleshoot the cylinder.
C. Inspect control valve spool and
housing for wear or damage.
D. Check auxiliary pump for
excessive case drain flow (more
than 11 lpm or 3 gpm), pressure
setting, and compensator for
contamination and worn or broken
parts.
E. Check selector valve
14
14.2 Trouble-Shooting Auxiliary Pump Circuit (contd)
Type of fault
6. Rotation speed (high to low)
is erratic or not changing
rpm when turning rotary
control valve in or out.
Possible cause
A. Main pump or compensator
problem.
B. No pressure from rotary
control valve
C. Swivel angle adjustment
screws are not properly set
(located on both sides of
hydraulic motor).
D. Rotary valve cartridge is
worn, damaged, or
contamination inside.
E. Hydraulic control valve at
hydraulic motor is worn,
damaged, not adjusted
properly, or contains
contamination
F. Internal wear or damage to
displacement parts inside
hydraulic motor.
G. Erratic rpm can be caused
by problems beyond the
hydraulic system such as
problems in the drilling
process, transmission, or
the drillhead.
Trouble Shooting
Remedy
A. Check the other functions on main
valve for correct operation. If they
are working properly continue
troubleshooting B thru J. If some
problem persists, troubleshoot the
main valve or main pump circuit.
B. Check the auxiliary pump and
compensator
C. See set-up procedure, section 15,
for setting min and max
displacement or simply try turning
the adjustment screw slightly and
observe if rpm changes. Check
the set-up procedure for correct
rpm setting procedure and using a
hand photo-tachometer, set the
engine speed and head rotation to
specification. The engine speed is
set at 2100 rpm and the head high
speed is 1300 rpm. It is not
recommended to overspeed
either.
D. Remove the rotary control valve
cartridge from housing and check
for wear, damage, or
contamination.
E. Carefully disassemble valve and
check for wear, broken parts, or
contamination. Use caution when
disassembling as some parts may
be spring loaded.
F. Troubleshoot the hydraulic motor
according to Rexroth
troubleshooting guide manual.
G. Disconnect the drillhead from drill
string and observe if rotation
improves.
109
14
14.3 Trouble-Shooting Main Pump Circuit
Type of fault Possible cause
1. Rotation section A. Main pump or
in main valve compensator problem
bank producing
slow rpm, no
revolutions, or
lack of pressure.
B. Problem in primary or
secondary shuttles
C. Relief valve in main
valve is stuck or
damaged
D. Main valve spool in
rotation section is worn or
damaged
E. Incorrect pilot
pressures for shifting
main valve spool
F. Flow compensator
spool in rotation section
blocked or stuck
G. No load sense signal
from main valve to pump
110
Trouble Shooting
Remedy
A. Troubleshoot main pump and compensator. Check
for proper suction, contamination, compensator
pressure setting, standby pressure setting, and
excessive case drain leakage -more than 20 lpm (6
gpm) is excessive for this pump. Check
compensator spools for wear, damage, and
contamination. Compensator setting is 324 bar
(4,700 psi). For the Rexroth 4M22 main valve, the
standby pressure is 26.2 bar (380 psi).
If compensator and standby pressure settings are
correct and problem persists, do a flow/pressure
check on the main pump with a flow meter.
See Rexroth manual located in Parts Manual for
more information.
B. Check/remove, clean, and inspect the shuttle in the
rotation section. If ok, check the shuttles in
remaining valve sections as they may affect this
function.
C. Remove and inspect main relief valve for
contamination, wear, damage, and proper pressure
setting. Pressure setting for the main relief is 362
bar (5,260 psi).
D. Check main valve spool and housing for wear,
contamination, or damage.
E. Check pilot pressures produced by pilot control
valve. For the Rexroth 4M22 main valve, the pilot
pressures should be in range of 6 to 25 bar (87 to
363 psi)
F. Carefully remove compensator spool and check for
wear, damage, or contamination.
G. Check the load sense line from valve to main pump
for obstruction in hose
14 Trouble Shooting

14.3 Trouble-Shooting Main Pump Circuit (contd)

Type of fault Possible cause Remedy

2. Rotation section in H. Problem in hydraulic H. Try turning the min and max displacement
main valve bank motor on drillhead. adjusting screws slightly and observe if rpm
producing slow changes. Check the drill setup procedure,
rpm, no section 15, for correct min and max rpm
revolutions, or lack settings and reset if required. Drillhead high
of pressure speed is 1300 rpm and it is not recommended
(contd). to overspeed

I. Load sense relief valve I. Lock chuck on rod held in foot clamp and check
settings in main valve max pump pressure - should be at 240 bar
not to specification (3,500 psi)

J. Problem in transmission J. Disconnect hydraulic motor from transmission

or drillhead housing. and see if problem still exists.

3. Fast feed section A. Similar problems as in A. Perform same checks as for rotation section
in main valve bank rotation section: main
does not move pump, main valve, pilot
feed cylinder, too pressure or load sense
slow, or erratic. line

B. Load sense relief valve B. Check the load sense limiting valve by running
settings in main valve the cylinder into end position and read system
not to specification pressure gauge - should be 165 bar (2,400 psi)
in both directions

C. Problem in feed cylinder. C. Troubleshoot the feed cylinder checking for

worn seal kit or damage to cylinder.

D. Problem in the drillhead D. Do inspection of rollers, and ways

carriage rollers or the
replaceable ways

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14 Trouble Shooting

14.3 Trouble-Shooting Main Pump Circuit (contd)

Type of fault Possible cause Remedy

4. Main winch section A. Similar problems as in A. Perform same checks as for rotation section
in main valve bank rotation section: main
producing slow pump, main valve, pilot
winch, no winching, pressure or load sense line
erratic, or winch not
holding load. B. Load sense relief valve B. Check the load sense relief valve by disconnecting
settings in main valve not and capping lines to main winch motor. Activate
to specification winch control - system pressure gauge should be
324 bar (4,700 psi) in both directions

C. No pressure from manual C. Check brake release valve.

brake release valve when
valve is in brake release
position

D. Problem in Braden winch D. Troubleshoot Braden winch according to installation,

maintenance, and service manual located in Part
Manual

E. Problem in structural or E. Check structural area where winch is mounted.

mounting parts of Braden Make sure mounting platform is strong and
winch mounting surface is even

5. Wireline section in A. Similar problems as in A. Perform same checks as for rotation section
main valve bank rotation section: main
producing slow, pump, main valve, pilot
erratic, or no rotation pressure or load sense line
of the wireline winch
drum. B. Load sense relief valve B. Check the load sense relief valve by disconnecting
settings in main valve not and capping lines to wireline winch motor. Activate
to specification winch control - system pressure gauge should be
207 bar (3,000 psi) in both directions

C. Brake does not release C. Check automatic brake release valve, shuttle valve
and pressure line from auxiliary pump circuit

H. Problem in hydraulic motor H. Troubleshoot hydraulic motor and counterbalance

mounted to winch drum. valve mounted on the winch

I. Damage to structural or I. Check assembly and mounting area of winch to

mounting parts on winch. main frame and condition of sheave wheels and
crown block.

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14 Trouble Shooting

14.4 Trouble-Shooting Secondary Pump Circuit

Type of fault Possible cause Remedy

6. The mud/water A. Wrong rotation direction A. The motor on the mud/water pump is designed
pump will not of pump. to turn in one direction only (ccw when viewed
turn or stalls at from the shaft end of the motor). If the
low pressure. direction is reversed, hydraulic pump and
motor damage will occur.

B. Check pump 2 speed B. Check Hi/Lo speed control is set in Lo speed

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

C. Problem with 2 speed C. Check for proper hose plumbing. Troubleshoot

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

D. Secondary pump D. Check the secondary pump pressure should

problem be 207 bar (3,000 psi)

E. Pump suction or relief E. Troubleshoot the pump for suction problem,

valve problem water/mud pump relief valve stuck or damaged

F. Problem beyond F. Inspect hydraulic motor adapter and mud pump

hydraulic motor for damage.

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14 Trouble Shooting

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15 Hydraulic Set-up Procedure

15 Hydraulic Set-Up Procedure

The Hydraulic Set-Up procedure is added to the manual to provide the mechanic
with detailed procedures to set the hydraulic adjustments on the machine. This
will be useful when adding new components such as variable hydraulic motors,
hydraulic pumps, cartridges etc. which generally will not have been preset
pressures, volume stops etc. at the factory or vendor. This will prevent damage to
components due to over-speeding, over-pressure etc. Also the procedure will be
useful when making hydraulic adjustments after a general overhaul.

General Commissioning Notes:

-if some settings appear to be difficult to do, there may be air in the applicable hydraulic lines and
bleeding of the lines may be required to remove the air.
-Pressure and flow adj. (adj.) screws in valves typically increase pressure/flow when the adjustment is
turned clockwise and reduce pressure/flow when the adjustment is counter clockwise. For some valves,
the adjustment direction is reversed and is noted in the procedure.

Acronyms:
adj. = adjustment
min. = minimum
max. = maximum

1. PREPARATIONS FOR COMMISSIONING

OPERATIONS RESULTS COMMENTS

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

-Prime all pumps and motors

-Prime rotation head lubrication system

-Lock ball valves open

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

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15 Hydraulic Set-up Procedure

2. HYDRAULIC PUMP ADJUSTMENTS PRIOR TO STARTING ENGINE

OPERATIONS RESULTS COMMENTS

Main Pump (1st pump after engine)

-Loosen high pressure compensator lock nut (inside adj. screw)
-Turn adj. screw counter clockwise until the spring pressure is
released, then turn clockwise until a slight spring pressure is felt
against it.
-Loosen stand-by compensator lock nut (outside adj. screw) and turn
adj. screw counter clockwise to release spring pressure.

Auxiliary Pump
-Loosen high pressure compensator lock nut (inside adj. screw)
-Turn adj. screw counter clockwise until the spring pressure is
released, then turn clockwise until a slight spring pressure is felt
against it.
-Loosen stand by compensator lock nut (outside adj. screw) and turn
adj. screw clockwise it bottoms out. Tighten lock nut. (Auxiliary
pump only)

Secondary ( Powers Mud/Water Pump)

-Loosen high pressure compensator lock nut (inside adj. screw)
-Turn adj. screw counter clockwise until the spring pressure is
released, then turn clockwise until a slight spring pressure is felt
against it.
-Loosen stand-by compensator lock nut (outside adj. screw) and turn
adj. screw counter clockwise to release spring pressure.

3. CUMMINS ENGINE STARTUP AND HYDRAULIC OIL TANK PRESSURE

SETTING
OPERATIONS RESULTS COMMENTS

-Start engine. See Section II of Drill Manual Diesel Power Unit

for instruction for the model of engine used. AFTER ENGINE IS
WARMED UP, increase engine R.P.M. to 2100 R.P.M.

-Back out pressure reducing valve on air tank.

-Set unloader valve on engine mounted air compressor (screw

clockwise to reduce pressure) to 60 PSI (pressure gauge on tank)

-Set pressure reducing valve feeding hydraulic tank to 8 PSI (gauge

mounted on valve) and push in plastic locking cap.

-Shut engine off. Monitor tank pressure and check that pressure
stays constant. If pressure leaks off, find source of air leak and
correct.

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15 Hydraulic Set-up Procedure

4. AUXILIARY PUMP HIGH PRESSURE COMPENSATOR SETTING

OPERATIONS RESULTS COMMENTS
-Prior to setting auxiliary pump, back out adj. screw on pressure
reducing valve feeding valve manifold with 4 x D03 valves. Also
back out adj. screw on flow control valve controlling flow to cooler
fan motors

-Pump pressure is indicated on auxiliary system gauge in control

console

-Adjust compensator (inside adj. screw) to 2500 PSI. Tighten lock

nut.

5. PRESSURE REDUCING RELIEVING VALVE FEEDING 4 X D03 MANIFOLD

(HEAD OPENER, PILOT PRESSURE,MAIN WINCH BRAKE RELEASE, TRAY
LIFTER AND FOOT CLAMP)
OPERATIONS RESULTS COMMENTS
-Connect 3000 PSI gauge to test fitting in pressure reducing valve
feeding Hi/Lo water pump speed control and valve manifold with
4 x D03 valves.

-Loosen lock nut and adjust PRV to 1450 PSI.

-Tighten lock nut and remove gauge

Main Control valves can now be operated

6. COOLING FAN RPM

OPERATIONS RESULTS COMMENTS
-Adjust flow control valve for cooling fan flow so speed of upper
fan increases to 1725 rpm. Lock flow control valve

-Measure and record rpm of lower cooling fan

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15 Hydraulic Set-up Procedure

7. MAIN PUMP AND MAIN VALVE PRESSURE RELIEF SET UP

OPERATIONS RESULTS COMMENTS
7.1 Main pump stand by pressure
-Start and run engine at low idle.
-Connect 1000 PSI test gauge to test fitting in main pump
-Adjust this pressure to 380 PSI and tighten lock nut

7.2 Main valve pressure relief (2 persons required for rest of

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

7.3 Main pump high pressure compensator

-Close needle valve on flow meter and hold control lever for main
hoist in raise position.
-Lower high pressure compensator setting (inside adj. screw) to
4700 PSI and tighten lock nut.
- Put lever in neutral and open needle valve.

7.4 Check main pump flow

-Increase engine speed to 2100 rpm, open flow meter needle valve
and put main hoist control in raise position. Pump flow should be
about 72 gpm.
-Start turning the flow meter needle valve in until the high pressure
compensator starts to de-stroke the pump (approximately
4,300.S.I.). Pump flow should be about 67 G.P.M.
-Open needle valve, return main hoist control to neutral. Idle the
engine for a few minutes to cool down then shut off.
- Disconnect test equipment & re-connect main hoist hoses.

8. CHUCK PRESSURE
OPERATIONS RESULTS COMMENTS

-Back out adj. screw of pressure reducing relieving valve located

under chuck control valve and connect 2000 psi gauge to test fitting
located there.

-Place chuck control lever in open position. Adjust pressure

reducing relieving valve to 1300 PSI.

-Tighten lock nut, place control lever in neutral, remove gauge -

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15 Hydraulic Set-up Procedure

9. HEAD OPENER PRESSURE

OPERATIONS RESULTS COMMENTS

-Tee a 3000 PSI gauge into port of pressure reducing relieving valve
set in section 5.

- Move drill head to side and back again while observing the
pressure required to slide the drillhead. Record the maximum
pressure to move drillhead.

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

-Back out mud mixer relief valve adj. screw.

-Connect 3000 PSI pressure gauge into hydraulic pressure line to

mud mixer (line dead headed)

-Open mud mixer line fully and set relief valve to 2000 PSI. Lock
adjusting screw.

-Disconnect pressure gauge and connect flow meter into hydraulic

pressure hose line to mud mixer.

-Connect hydraulic lines to mud mixer and place mud mixer in a

barrel of water.

-Open mud mixer valve fully and record flow - should be about
6 GPM.

-Check that flow shuts fully off.

-Rotation of mud mixer should be counter clockwise (viewed from

hose end) If not correct swap hoses at the mud mixer motor.

-Disconnect pressure line to mud mixer and open mud mixer control
valve. Check fan speed remains constant. Flow from fan motors
should flow over relief valve.

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15 Hydraulic Set-up Procedure

11. WIRELINE HOIST SETTINGS

OPERATIONS RESULTS COMMENTS
11.1 Preparation
-Disconnect hoses from manifold mounted on wireline winch motor
and cap.
-Back out adj. screw on pressure reducing valve to wireline brake
release (port 3A)
-Fully back out adj. screw on 3-way directional valve (port 5A), turn
in turn, and tighten lock nut
-Screw in volume stops on wireline winch main valve section to
limit max flow on ports A & B
-Back out W/L winch load sense relief valve setting on ports A & B

11.2 Wireline Load Sense Pressure

-Place wireline winch lever in the raise position.
-Adjust wireline load sense relief valve (raise side) to 3000 PSI
using the main pump pressure gauge
-Repeat for wireline load sense relief in lowering position

11.3 Wireline Brake Release Valve Setting

-Hold wireline winch lever in raise position
-Using test port and 1000 psi gauge, set pressure reducing valve
(port 3A) to wireline brake release to 300 PSI

11.4 Wireline Counterbalance Valve setting

-Turn adj. screw fully counter clockwise (screw will remain
stationary or may move in and C/B valve relief will be a max.
setting). Then turn adj. screw turn counter clockwise and tighten
locknut. (Setting will be approx. 3900 PSI).

11.5 Wireline flow

-Connect flow meter into hoses
-Operate wireline winch control and adjust main valve section
volume stops to give 30 gpm in both directions (screw volume stops
out to increase flow)
-Lock volume stops, remove flow meter and reconnect hoses
-Operate wireline hoist and check drum rpm for correct rotation.
Should be about 180 rpm.

11.6 Wireline Brake Holding

-Disconnect wireline winch brake line and cap
-Gently move wireline control in lower position. If wireline drum
turns (parking brake slips), record pressure on main pump pressure
gauge.
-Reconnect brake line

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15 Hydraulic Set-up Procedure

12. FEED CYLINDER COUNTERBALANCE (C/B) VALVE

OPERATIONS RESULTS COMMENTS

-Run fast travel down until cylinder bottoms out. Select "Make"
setting at drill/make control (position 21 in Fig. 7.1). Hold fast
travel lever in down position while adjusting "Make" pressure
until main pump load sense pressure gauge reads 570 psi. (The
"Make" pressure setting controls main pump load sense pressure
so this is effective for all main pump functions).

-Close feed rate valve and screw out (counter clockwise) the C/B
adj. screw to increase C/B relief valve setting (valve located in
port 2A on feed block)

-Raise drillhead to mid stroke with fast travel up.

-Put fast travel in down direction. Load sense pressure gauge

should read 570 psi and drillhead should not move.

- Screw in C/B valve screw (reduces C/B relief valve setting)

until drillhead just starts to move (C/B valve relief has opened at
3120 PSI which is 30% above 2400 PSI max pullback pressure.
The pilot pressure signal from the fast travel down is calculated
from formula:
Pilot pressure= C/B set pressure/(pilot ratio + 0.51) when
load induced pressure is zero
With pilot ratio of 5, pilot pressure is about 570 psi

-Reset drill/make control to drill position

13. FAST TRAVEL LOAD SENSE PRESSURES

OPERATIONS RESULTS COMMENTS
-Back out fast travel load sense relief valves far enough to enable
drillhead to move up and down

-Run fast travel up and down to clear any air from feed cylinder (if
required, increase load sense pressure to move feed cylinder)

-Screw in fast travel volume stop screw for down direction in main
valve to position that gives approximately same speed in down
direction as the up direction (about 3.5 ft in 3 seconds)

-Run fast travel up until cylinder bottoms out

-While holding fast travel lever in up position, adjust fast travel load
sense relief valve for travel up to 2400 PSI using the main pump
pressure gauge.

-Repeat for fast travel down and set load sense for travel down at
2400 psi.

-check fast travel speed in down direction is same as for up

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15 Hydraulic Set-up Procedure

direction, should be approx 3.5 ft in 3 seconds. If necessary adjust

down direction volume stop screw in main valve.

-Record speed in up and down direction.

14. PROGRAMMING OF DRILLHEAD DIGITAL RPM DISPLAY AND WATER

PUMP FLOW RATE DISPLAY
OPERATIONS RESULTS COMMENTS
Reference Red Lion Bulletin CUB5-D, Drawing No. LP0584
Found in OEM Parts Manual

14.1 Setting 4002 Drillhead Digital RPM Display

-Per section 6.2 Module 2 -Rate Setup Parameters, enter
DSP=60 for rate scaling display value
INP =6 for Rate Scaling Input Value

14.2 Setting Mud Pump Flow Rate Based On Mud Pump RPM
-Per section 6.2 Module 2 -Rate Setup Parameters, enter
DSP=60 for rate scaling display value (converts pulses per seconds
into pulses per minute)
INP =102 for Rate Scaling Input Value for display in GPM
(1 GPM=6x630/37 with 6 pulses per pump revolution)
INP= 27 for Rate Scaling Input Value for display in LPM
(1 LPM = 6x630/140 with 6 pulses per pump revolution)

15. ROTATION PRESSURE LOAD SENSE PRESSURE

OPERATIONS RESULTS COMMENTS

-Disconnect rotation hose (reverse rotation direction).

-While holding rotation lever in reverse direction, adjust rotation

load sense relief valve to 3500 PSI using the main pump pressure
gauge.

-Disconnect rotation hose in forward direction and repeat procedure

to set load sense relief for forward direction to 3500 PSI

-Reconnect both rotation hoses

16. ROTATION MOTOR - DISPLACEMENT ADJUSTMENT

OPERATIONS RESULTS COMMENTS
Procedure to set the 160 cc rotation motor at 145 cc max
displacement and 105 cc min displacement

-Spray paint bottom spindle adapter with flat black paint, install
reflective tape for R.P.M. photo tachometer.

-Remove the min displacement adj. screw from the 160 cc Rexroth
rotation motor and check that length is 110 mm long. If it isnt,

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15 Hydraulic Set-up Procedure

replace screw with part # 3760008988 (110 mm). Re-install with

in. of threads showing above the lock nut and tighten the lock nut.
(initial adj. only)

-Remove the max displacement adj. screw from the 160 cc Rexroth
rotation motor and check that length is 80 mm long. If it isnt,
replace screw with part # 3760009055 (80 mm). Re-install with
in. of threads showing above the lock nut and tighten the lock nut.
(initial adj. only)

-Make sure head lubrication system (oil pump, filter, hoses, etc.) is
primed and full of 90-weight oil and chuck bearings are greased.

DO NOT ROTATE CHUCK IN OPEN POSITION

DO NOT ROTATE IN CLOSED POSITION WITHOUT
JAWS AND LIFTING BAIL INSTALLED

-Set engine R.P.M. at 1700.

-Place transmission in 3rd gear.
-Turn rotation speed control clockwise to high speed (minimum
motor displacement).
-Place rotation control lever in forward position.

-Check lubrication oil flow by loosening fittings where the oil enters
the rotation head - DO NOT ROTATE HEAD WITHOUT
LUBRICATION OIL FLOW.

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

-Verify that transmission in 3rd gear (shift lever position out and up )

-Place rotation control lever in the fully forward position and set
engine speed at 2100 RPM.

-Screw out rotation speed control (motor at max displacement).

-Check rotation speed on reflective tape with photo tachometer.

RPMs should be 480 rpm

-Loosen max. displacement adj. screw on motor and slowly screw

in until spindle rpm reaches 535 rpm. Tighten lock nut and reinstall
plastic cap.

-Screw in rotation speed control (motor at min. displacement).

-Check rotation speed on reflective tape with photo tachometer.

RPMs should be 660 rpm

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15 Hydraulic Set-up Procedure

-Loosen min. displacement adj. screw on motor and slowly screw

out until spindle rpm reaches 745 rpm. Tighten lock nut and reinstall
plastic cap.

-Put transmission in high gear, Check rotation speed control.

Rotation speed should change from 940 to 1300 rpm as rotation
speed adjustment is turned from fully out to fully in.

-Check the digital display on the console with the photo tachometer.

17. MAIN WINCH LOAD SENSE PRESSURES

OPERATIONS RESULTS COMMENTS

-Fully screw in load sense reliefs for both A and B ports. (Max
pressure limited to 4700 psi main pump compensator).

18. MAIN WINCH MOTOR MIN. & MAX. DISPLACEMENT ADJUSTMENT

OPERATIONS RESULTS COMMENTS

Procedure to set the 160 cc winch motor at 135 cc max

displacement and 75 cc min displacement

-Install reflective tape for R.P.M. photo tachometer on drum.

-Remove the min displacement adj. screw from the 160 cc Rexroth
rotation motor and check that length is 100 mm long. If it isnt,
replace screw with part # 3760008987 (100 mm). Re-install with
in. of threads showing above the lock nut and tighten the lock nut.
(initial adj. only)

-Remove the max displacement adj. screw from the 160 cc Rexroth
rotation motor and check that length is 90 mm long. If it isnt,
replace screw with part # 3760008986 (90 mm). Re-install with 7/8
in. of threads showing above the lock nut and tighten the lock nut.
(initial adj. only)

-Screw out winch speed control (motor at max displacement).

-Hold winch rotation control lever in the fully raise position and set
engine speed at 2100 RPM.

-Check spindle rpm on reflective tape with photo tachometer.

Should be about 25 rpm

-Loosen max. displacement adj. screw on motor and slowly screw

in until spindle rpm reaches 28 rpm. Tighten lock nut and re-install
plastic cap.

-Screw in winch speed control (motor at min. displacement).

-Check drum rpm with photo tachometer. Should be approx 43
rpm.

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15 Hydraulic Set-up Procedure

-Loosen min. displacement adj. screw on motor and slowly screw

out until drum rpm reaches 55 rpm. Tighten lock nut and reinstall
plastic cap.

-Check winch speed control. Drum rpm should change from 28 to

55 rpm as winch speed adjustment is turned from fully out to fully
in. Record rpm range.

19. MAIN HOIST COUNTERBALANCE VALVE (TYPE SUN CAIG)

OPERATIONS RESULTS COMMENTS

19.1 Cartridge Setting

-Ensure C/B valve adj. screw is fully turned out counter clockwise
(gives max set pressure setting of 6,000 psi)

19.2 C/B Cartridge Opening Check

When main hoist is connected to water swivel, the manual hoist
brake release control releases the brake and pilots open the
counterbalance valve. Check correct function of brake release as
follows:
-Rotate main hoist slowly in raise direction and note pressure on
main pump pressure gauge should be about 150 to 500 PSI
depending on rpm.
-Rotate main hoist slowly down (brake not released) and note
pressure on main pump pressure gauge - should be about 1500 PSI
-Engage main hoist brake release and rotate hoist slowly down.
Note pressure on main pump pressure gauge - should be about 150
to 500 PSI. This indicates that counterbalance valve is being piloted
open by the hoist brake release valve.

20. MAST PULLDOWN RELIEF VALVE AND COUNTERBALANCE VALVES ON

MAST RAISE AND MAST DUMP CYLINDERS
OPERATIONS RESULTS COMMENTS

-Remove hose from pulldown side of mast raise cylinders and

attach 3000 PSI gauge. Check that max pressure (controlled by
adjustable relief valve on pulldown side of mast raise valve section)
is 2,500 PSI. Adjust if necessary. Remove gauge and re-connect
hose

-If the counterbalance valves on mast raise and mast dump cylinders
need to be set or reset, the adj. screws on the valves should be
turned fully ccw (screw will remain stationary or may move in and
C/B valve relief will be a max. setting). Then turn adj. screw turn
cw and tighten locknut.

-Record mast raise pressure with top section folded out, mast
dumped back and rotation head at bottom of stroke.

-Record mast raise pressure with top section folded out, mast

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15 Hydraulic Set-up Procedure

dumped forward and rotation head at top of stroke.

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

21.1 Hydraulic Pump Standby Pressure:

-Connect hoses to FMC mud pump (pressure, return, case drain) and
install reflective tape on rotation indicator wheel.

-Plumb mud pump into a barrel of water. (2 suction hose 1

discharge hose).

DO NOT TURN F.M.C. PUMP WITHOUT WATER IN

CYLINDERS; IT WILL DAMAGE THE PISTON CUPS.

-Run engine at 2100 rpm R.P.M and fully open mud pump control
valve.

-Set two-speed motor at high speed (pull out speed control knob)

-Adjust secondary pump stand-by pressure (outside adj. screw) until

FMC W1122BCD input speed is 650 rpm (gives 38 gpm water
flow) using photo tach.

-Turn stand-by pressure adjustment cw to increase flow/speed and

ccw to decrease flow/speed.

CHECK MUD PUMP CRANK TURNS IN DIRECTION

SPECIFIED BY FMC.

-Check the console digital mud pump flow meter should read 34
gpm at 630 mud pump input rpm

21.2 Mud Pump Relief Valve (water side) Setting And

Secondary Pump High Pressure Compensator Setting
-Connect 5000 psi gauge into secondary pump outlet line
-Reduce secondary pump high pressure compensator setting (inside
adjusting screw)
-Screw in mud pump relief valve adjustment screw
-Install throttle valve on mud pump outlet line and open throttle
valve.
-Set pump speed selector to low speed (push in speed control knob)
-Run engine at 1200 rpm and operate mud pump control fully open.
-Increase pump high pressure compensator setting (inside adjusting
screw) and adjust water side throttle valve until water pressure
reaches 1100 psi.
-Turn water side relief valve adjusting screw ccw until water comes
out of relief valve.
-Lock relief valve setting and record pump compensator pressure.
-Reduce pump high pressure compensator setting until water
pressure reaches 1000 psi.
-Lock pump compensator adjustment screw and record compensator

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15 Hydraulic Set-up Procedure

pressure.
-Check and record max pump rpm and water pressure obtained in
high speed mode
-Check and record max pump rpm and water pressure obtained in
low speed mode
-Turn off water flow and remove test equipment

22. OPERATION CHECK ALL FUNCTIONS

OPERATIONS RESULTS COMMENTS
Thermostatic valve setting of 130 F when testing drill at low
power, reservoir temperature should increase to 130 F and then level
off
All functions controlled in console operate in direct indicated in
console decals (as applicable)
Slow feed down

Drillhead power float

Main hoist brake and release

Wireline hoist and brake

Make pressure operation

Hydraulic jacks

Mast dump

Mast raise & lower, stiff leg pinning (no rod rack)

Water pressure release valve at console

Lighting system

Water Pump Hi/Lo Speed Control

Limit switch on main hoist for minimum 3 wraps

Limit switch on main hoist for rope crossing/second layer

Hydraulic tank pressure not leaking off through relief valves

Special equipment 1: folding mast operation

Special equipment 2: UDR spin out tool. Check flow from pressure
compensated flow control valve with flow meter and record.

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15 Hydraulic Set-up Procedure

23. OPERATION CHECK OF SAFETY DEVICES

OPERATIONS RESULTS COMMENTS
All E stop operations: console, auxiliary valve position, rod stacking
area, plug-in E stop on helpers platform outlet (if drill equipped
with helpers platform option)

Crown block limit switch

Neutral switch on rotation pilot controller

Audible alarm (beeper) on console control panel

Audible alarm (beeper) when operate secondary panel controls

Perimeter guard on main winch and wireline winch

Drillhead guard

If Equipped With Helpers Platform

-Fall arrestor for climbing platform access ladder

-Intermediate tie off when transitioning from ladder to body harness

on platform (tie off point marked)
-Operation of body harness for helper on platform (tie off point
marked)
-Operation of fall arrestor for climbing service ladder to crown

-Portable E-stop and plug-in accessible from helpers platform

Commissioning & Testing Signoff

Mechanics name (print & sign):
Date:

128
16 Spin-Out Tool Option

16 Spin-Out Tool Option

16.1 Safe-T-Spin Wireline Rod Make/Break Tool

Safe-T-Spin is a trademark of UDR. The attached information is a copy of UDR

documentation.
16.1.1 Introduction

Safe-T-Spin Specifications

CAPACITY: BO, NO, HO Wireline Drill Rods and HW Casing

MAX TORQUE - Break out: 3,000 Nm
MAX TORQUE - Make Up: 2,100 Nm
CONTROLS: All Hydraulic
RECOMMENDED OIL FLOW: 100 lpm
MAX SUPPLY PRESSURE: 180 bar
WEIGHT: Safe-T-Spin 91 kg
Mounting Arm 25 kg

General Information

This manual describes the complete modifications for fitting a Safe-T-Spin to UDR1000 drill rigs from
1000-44 onwards, for rigs prior to 1000-44 details will be furnished on request from UDR. Fitting of the
Safe-T-Spin on UDR1000 drill rigs will directly influence the available headroom required in the mast to
safely trip rods. As a result and depending on the model and configuration of the drill rig, some update
modifications are mandatory, while another update modification is strongly recommended. A brief
description of each update modification is given below. The requirement for each rig is shown in the table
in Section 1.7.

UM 68 - Safe-T-Spin

This update modification contains all the components and information required to fit the support structure
to the mast, modify the control cabinet and modify the hydraulic circuit, including installing components.
Details are contained in Section 5.

UM65 Foot Clamp Modification

This update modification is MANDATORY. As the Safe-T-Spin is mounted as low as possible in the mast,
the travel of the foot clamp lever arms must be limited so they do not interfere with the travel of the Safe-
T-Spin. This update modification contains all the components and information required to fit the foot
clamp lever arm limiter. Details are contained in section 4.9.

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16 Spin-Out Tool Option

16.2 Safe-T-Spin Operators Manual

16.2.1 Installation for Operation

The following procedures can be used to fit the safe-t-spin to the mast for a 650 rig.

16.2.1.1 Mast Vertical

Where possible the safe-t-spin should be fitted to the mast with the mast vertical and prior to the mast
being set up for the final drill angle.

A. Reeve the main winch rope through the snatch block with the mast in the transport position.
B. Attach the Lifting Base, Lifting Socket and Lifting Connecting Pin to the safe-t-spin assembly. Pin the
lifting connecting pin with a grip clip. Fit the locking pins of the lifting base to the holes provided in the
safe-t-spin housing.
C. Connect the main winch rope, using a suitable D shackle, to the hole on the lifting socket for a 90-
degree mast. The lifting socket has five holes in it; each hole is hard stamped for a particular mast
angle.
D. Swing the vertical support out of the mast. Using a combination of rod boom movements and operation
of the main winch lift the safe-t-spin into the mast, until the cam followers of the support and the roller
brackets touch the mast.

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

E. Lower the safe-t-spin to a position where the vertical support bracket for either the left-hand or right-
hand mount can be swung into the mast. Align the pins of the vertical support and the bushed holes of
the support bracket, slowly lower the safe-t-spin onto the pins of the vertical support. Pin the safe-t-
spin assembly to the vertical support.
F. Remove the main winch rope and the lifting base and socket from the safe-t-spin assembly.
G. Adjust the height of the safe-t-spin until it is 535mm above the mast base to the top of the safe-t-spin.
If necessary adjust the height of the safe-t-spin by turning the shaft adjustment hexagon (24mm across
the flats) at top of the support structure.
H. Plug the hydraulic oil supply and drain hoses for the safe-t-spin into their respective quick release
couplings and secure the hook to lock the safe-t-spin into the mast. The engine of the rig may have to
be shut down to allow the quick release couplings to be assembled. The safe-t-spin is now ready for
operation.
I. The mast can be set up for the required drill angle if required to do so.

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

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16.2.1.2 Mast Set Up at any angle between 90 and 45 Degrees.

A. Reeve the main winch rope through the snatch block with the mast in the drilling position.

WARNING: ANY PERSONNEL REQUIRED TO CLIMB THE MAST, WHEN IT IS SET UP

FOR DRILLING MUST WEAR AN APPROVED SAFETY HARNESS.

B. Attach the Lifting Base, Lifting Socket and Lifting Connecting Pin to the safe-t-spin assembly. Pin the
lifting connecting pin with a grip clip. Fit the locking pins of the lifting base to the holes provided in the
safe-t-spin housing.
C. Connect the main winch rope, using a suitable D shackle, to the hole on the lifting socket for the
particular mast angle. The lifting socket has five holes in it; each hole is hard stamped for a particular
mast angle.

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

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

WARNING: CHECK THE SAFE-T-SPIN AS IT IS LIFTED INTO THE MAST AND LOWERED
DOWN THE MAST. THE SAFE-T-SPIN BRACKETS CAN FOUL WITH THE
GUARDS COVERING THE LOWER TRAVERSE SHEAVES. ALSO CHECK THE
POSITION ON THE LOCKING HOOK IN CASE IT ALSO CATCHES THE
LOWER TRAVERSE GUARDS.
FOR MAST ANGLES BETWEEN 60 AND 45 DEGREES TWO MEN MUST HOLD BACK THE
SAFE-T-SPIN UNTIL THE ROLLERS CONTACT THE MAST. THIS IS DUE TO
THE LENGTH OF THE FULLY EXTENDED ROD BOOM.

E. Lower the safe-t-spin to a position where the vertical support bracket for either the left-hand or right-
hand mount can be swung into the mast. Align the pins of the vertical support and the bushed holes of
the support bracket, slowly lower the safe-t-spin onto the pins of the vertical support. Pin the safe-t-
spin assembly to the vertical support.
F. Remove the main winch rope and the lifting base and socket from the safe-t-spin assembly.
G. Adjust the height of the safe-t-spin until it is 535mm above the mast base to the top of the safe-t-spin.
If necessary adjust the height of the safe-t-spin by turning the shaft adjustment hexagon (24mm across
the flats) at top of the support structure.
H. Plug the hydraulic oil supply and drain hoses for the safe-t-spin into their respective quick release
couplings and secure the hook to lock the safe-t-spin into the mast. The engine of the rig may have to
be shut down to allow the quick release couplings to be assembled. The safe-t-spin is now ready for
operation.

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

Right-hand mount.

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

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

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

16.2.1.4 Procedure to swing the Safe-T-Spin into the mast.

Right-hand mount.

A. Check that the safe-t-spin support arm is secured to the vertical support with lynch pins.
B. Check the safe-t-spin is 535 mm above the mast base to the top of the safe-t-spin; if necessary adjust
the height of the safe-t-spin by turning the shaft adjustment hexagon (24mm across the flats) at top of
the support structure.
C. Check that the foot clamp is closed and that the box end of the rod does not protrude more than 120
mm above the rod jaws, before swinging the safe-t-spin into the mast.

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

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

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

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

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16.2.1.5 Procedure to remove the Safe-T-Spin from the mast.

A. To remove the safe-t-spin from the mast is a reversal of the procedure of sections 16.2.1.1.

16.2.2 Operational Checks

A. Check the conditions of the inserts in the jaws of the Safe-T- Spinner for wear and check for any
foreign matter that may stop the jaws from rotating.
B. Check the hoses for the Safe-T-Spinner motor have been correctly connected and the operation is as
per the name tags on the control cabinet
C. Check the Safe-T-Spin attachment bolts are tight.
D. Check the Safe-T-Spin pivot bushes float spring and linear bearings are in good working order.
E. Check the Safe-T-Spin torque control is at the minimum setting before operating. Adjust this setting
when using the Safe-T-Spin.
F. Check the Safe-T-Spin is 535 mm above the mast base to the top of the spinner; if necessary adjust
the height of the spinner by turning the shaft adjustment hexagon nut (24mm across the flats) at top of
the support structure.
G. Check that the foot clamp stop pin has been fitted to the foot clamp base.

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

16.2.2.1 Pre Torque Control Pressure Setting

Make:
To set or adjust the hydraulic pressure to the Safe-T-Spin and to obtain an accurate pre-torque, when
making up the drill rods the following procedure is used:
A. Set the Safe-T-Spin torque control to the minimum setting.
B. Stall the Safe-T-Spin against a foot clamped in the foot clamp, the same size as the rod size you will
drill with. The diesel engine should be 1600- 1800 rpm and the hydraulic oil temperature should be at
60 degrees C. The Safe-T-Spin control lever should be fully engaged in the "make" position.

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

ROD SIZE MAKE UP TORQUE SAFE-T-SPIN MAKE

( Nm) TORQUE PRESSURE ( BAR )
BO 1250 88
NO 1650 116
HO 2100 147
HW Casing 1250 88

CAUTION: SLOWLY ENGAGE THE SAFE-T-SPIN CONTROL LEVER TO MAKE THE

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

BREAK: There is no torque setting adjustment for breaking the rod joint.

16.2.3 OPERATION

16.2.3.1 Break Out of Drill String

The Safe-T-Spin is now ready to break apart the drill string according to the following instructions:
A. Support the drill string in the foot clamp with the box end of the rod beneath the rod driver assembly.
The box end of the drill rod must be located between 80 and 100 mm above the foot clamp jaws when
the jaws are closed.
B. Fit the foot clamp stop pin to the foot clamp base. The stop pin is required to keep the foot clamp jaws
and lever arms from hitting the Safe-T-Spin base
C. Swing the Safe-T-Spin into place as described earlier.
D. Check the Safe-T-Spin is 535 mm above the mast base to the top of the Safe-T-Spinner, if necessary
adjust the height of the spinner by turning the shaft adjustment hexagon nut (24mm across the flats) at
top of the support structure. The 535mm will allow the Safe-T-Spin to float up or down as required to
break the joint.

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

E. Operate the Safe-T-Spin to ensure that the jaws are in the fully "open" position.
F. Insert the winch plug extension through the Safe-T-Spin.
G. Screw the winch plug extension pin into the drill string box end and tighten.
H. Take the weight of the rod string with the main winch rope.
I. Open the foot clamp.
J. winch the drill string until the next rod joint to break is between the foot clamp and Safe-T-Spin and the
stop winch indicator light (if fitted) has illuminated. Stop winching.
K. Close the foot clamp.
L. Lower the main winch rope slightly to relieve any tension on the main winch rope.
M. Break the rod joint apart by engaging "Make-Break" control lever to the "Break" position. Continue
depressing this lever until rod joint is unscrewed. Release the control lever to neutral

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NOTE: ENGAGE THE LEVER SLOWLY TO BREAK THE JOINT.

N. Winch the drill string until the rod pin end clears the Safety-T-Spin housing. Lower the rod string with
the main winch and place the rod in the rod rack.
O. Remove the winch plug from the rod string. Raise the winch plug and reconnect it back into the drill
string clamped in the foot clamp.
P. Repeat steps E to O for the remainder of the drill string.

16.2.3.2 Make Up of Drill String

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

NOTE: REFER TO THE PRE-TORQUE CONTROL PRESSURE SETTING SECTION FOR

THE PROCEDURE TO SET THE SPINNER.

A. Fit the foot clamp stop pin to the foot clamp base. The stop pin is required to keep the foot clamp jaws
and lever arms from hitting the Safe-T-Spin base
B. Operate the Safe-T-Spin to ensure the jaws are in the "Open" position.
C. Attach the winching plug to core barrel locking coupling.
D. Open the foot clamps. Raise the core barrel assembly.
E. Lower the core barrel assembly through the Safe-T-Spin and the foot clamps.
F. Close the foot clamp. Take the weight off the winch rope by lowering the main winch slightly.
G. Remove the winch plug extension from the core barrel locking coupling by operating the control lever
to "break". This will spin the winch plug extension out of the box thread.
H. Attach the winch plug to the next rod in the rod rack.
I. Raise the drill rod from the rod rack
J. Connect the drill rod to the rod / core barrel supported in the foot clamp. Take the weight off the winch
rope by lowering the main winch slightly. Engage the Safe-T-Spin into the "break" slightly, this will
allow the rod thread to line up and drop into the box thread.
K. Make up the rod joint by engaging the "Make-Break" control lever to "Make" function. Continue
engaging this control lever until rotation stops and the Safe-T-Spin make torque gauge reads the
correct setting.

NOTE: ENGAGE THE LEVER SLOWLY TO MAKE THE JOINT.

L. Take the weight of rod string with the main winch.

M. Open the foot clamp.
N. Lower the drill rods into the drill hole.
O. Close the foot clamp. Take the weight off the winch rope by lowering the main winch slightly.
P. Remove the winch plug extension from the drill rod box thread by operating the control lever to "break".
This will spin the winch plug extension "out" of the box thread.
Q. Repeat the steps from "F" to "P" for the remainder of the drill string.

16.2.3.3 Making up the Drill String - General Notes

Before making up the rod joints for the first time, examine the rods carefully for damage that may have
occurred during transport to the drilling site. Remove any accumulated dirt from both the box and pin
threads and apply thread lubricant. Make up the joint. There will be a slight "stand-off" when the joint is

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hand tight. In order to make the shoulders butt; it is necessary to torque the joint to the recommended
torque.

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

Avoid stabbing the pin end of the rods when making them up, lower the pin end slowly into the box end
and engage the thread by hand. During tripping of the drill string, the threads of the winch plug should be
checked on a regular basis for wear and dirt accumulation and cleaned when necessary.

It is important that the rods be made up with a 20% greater torque than the torque at which the rods will
be operated.

16.2.4 Trouble Shooting Guide

PROBLEM PROBABLE CAUSES RECOMMENDED SOLUTIONS

No functions operate Hydraulic power supply not Connect hoses to drill hydraulic
connected supply.
Quick couplers damaged or Clean or replace quick couplers.
dirty. Check the pilot pressure at the
Pilot pressure to the "make - pressure test point at Valve No 9 at
break" pilot control is low Pump 10d on the hydraulic circuit for
the rig.

PROBLEM PROBABLE CAUSES RECOMMENDED SOLUTIONS

Safe-T-Spin will not Hydraulic hoses not
Operate connected
Quick couplers damaged or
dirty
Broken chain / sprockets
Hydraulic motor failure
Safe-T-Spin torque control
set too low
Connect hoses.
Clean or replace couplers.
Inspect gearbox and replace chain /
sprockets as required. Replace
hydraulic motor.
Reset Safe-T-Spin torque as per
instructions.
Replace the cartridge in the spinner
torque control valve on the panel.

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16.3 Safe-T-Spin Maintenance

16.3.1 Maintenance Schedule

Planned Maintenance Schedule

Weekly Wash-out and grease Spinner box.( 1 to 2 pumps )
Grease linear bearings on mounting arm. (1 pump)
Grease cam followers on mounting arm.(1 pump )
3 Monthly Lid off, Hose out thoroughly and Grease, including light grease of top bronze
bush and chain.
Annual Same as 3 monthly; shim to reduce chain slack, renew chain where
necessary. Fit minor overhaul kit. Orientate ring gear and cam at 45 deg to
allow even wear. Kit contents listed below.
Bi-Annual Carry out all servicing listed above; fit new upper and lower bronze thrust
rings. Part numbers listed below.
General Tungsten inserts in the jaws should be changed at drillers / rig fitter's
discretion.

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

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

Minor Overhaul Kit Contents.

Reference Section 4.1 Drawing SP8150-3 for exploded view,

Item No. Part No. Description. Quantity.

21 PD22873AG Stainless Balls 58
16 WU8151 Outrigger Bush 1
23 PD22923Z Bush Permalube 6
25 PD22923AE Thrust Washer 6
27 PM28605E8 Skt/Hd C/Sunk Capscrew 12

Major Overhaul Kit Contents.

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

Item No. Part No. Description. Quantity.

9 WU7449 Thrust Ring Top 1
36 WU9278 Thrust Ring Bottom 1

Additional Miscellaneous Parts

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

Item No Part No Description Quantity

1-2 PD22923AK Bush Permaglide 2

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17 Addendum Sheets

17 Addendum Sheets

This section contains addendum sheets with Operators Instruction Manual information
for those CS4002 drills that do not use the standard engines, water pumps, water pump
circuits etc. Also see the hydraulic schematic specific to the customers drill included in
the Parts Manual.

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17 Addendum Sheets

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