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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.
1
1 Introduction
2
2 Safety Instructions
2 Safety Instructions
2.1 Organizational Measures
Dear operator,
2.1.1 The CS4002 core drill shall be operated
Before putting your new equipment into use, we only by personnel who have been fully
would like to direct your attention to the safety trained on the rig. Particular emphasis
aspects. Drilling can be hazardous to you and to shall be put on the Safety Instructions
the environment. Good order, training and well and proper maintenance of the drill.
maintained equipment are the key factors for
safe operation. This manual is no replacement 2.1.2 Keep this instruction book available on
for thorough training, but will, as a training aid the rig at all times.
and a reference book, help you to maintain a
safe working environment and keep the rig in 2.1.3 Always use personal protective
good operating condition. equipment as required by circumstances
or demanded by regulations. Always
Yours faithfully, use safety harnesses when climbing to
Atlas Copco Exploration Products the (optional) helpers platform, working
on the helpers platform, or when
climbing the service ladder.
Intended Use
2.1.4 If, during operation of the unit, any
The CS4002 diamond core drill is intended for abnormal action in the safety or
Surface exploration and investigation drilling operational systems is observed, the
within the published depth ratings of the drill. unit should be stopped and the problem
investigated and rectified.
Any use going beyond this shall be considered
"not intended use". The manufacturer is then not 2.1.5 Warning signs must be kept legible at all
liable for damage incurred as a result. times. Damaged signs should be
Unintentional use shall be at the owner's risk. replaced immediately.
Proper use also includes observing the safety
instructions and procedures in the operation, 2.1.6 Hydraulic and electrical systems are of a
maintenance, and service manuals as described complex nature, and can cause injury or
by the manufacturer. damage if not handled with care. Repair
and service shall be carried out by
The CS4002 should be operated, serviced and personnel with documented experience
repaired by personnel properly trained for their for these systems.
task. These personnel must have sound
knowledge about hazards in their respective 2.1.7 Welding repairs should only be carried
profession. out by a qualified welder in order to
meet the high standards that apply to
General safety regulations must be observed. Atlas Copco products. Special attention
Personnel should be aware of dangers resulting must be given to components which
from abuse of drugs and alcohols as well as could cause injury or serious damage.
effects of medicines legally prescribed, or
mixture of any of them. 2.1.8 After repairs, make sure that the rig has
been inspected and approved by the
No unauthorized alterations should be made to proper authorities before being brought
the drill. The manufacturer is not liable for any back to normal operation.
damage caused by unauthorized alterations.
3
2 Safety Instructions
2.1.9 Never make alterations or modifications 2.1.15 Fall arrest and restraint equipment must
to components of the unit, or alter be used whenever the vertical drop
pressure settings, particularly to the exceeds 3 m (10 ft) or as specified by
safety systems, which might result in local safety regulations. When climbing
hazardous consequences. The ladders (e.g. service ladder to the crown
manufacturers approval should be block), it is recommended to use a
requested for any modification done to guided type of fall arrest system in
the unit. which a rope grab is attached to a body
2.1.10 Mechanical aids should be used harness (See Figure 2.1). Fall restraints
whenever it is necessary to lift more and a guided type of fall arrest system
than 25 kg (50 lbs) are available, Atlas Copco part
3760009042. Follow instructions
2.1.11 Do not operate the drill when the wind supplied with the fall arrest and fall
speed exceeds 20 m/sec (45 mph). Use restraint equipment. Do not alter or
guy wires when required (see section misuse this equipment.
9.8) to prevent upset of the machine.
A body harness as shown in Figure 2.1
2.1.12 Always practice good housekeeping. is available from Atlas Copco as part
Keep the drill deck clear and the 3760008964. It should be used to climb
working area tidy. Prevent slippery the service ladder to the crown block.
conditions underfoot on the deck, the
driller platform, the helpers platform (if
so equipped) and the area surrounding
the drill.
Figure 2.1
4
2 Safety Instructions
2.2.4 The drill is equipped with a fire 2.2.10 Never leave the rig unattended with the
extinguisher when shipped from the engine running. Carry the ignition key
factory. Always ensure that the fire with you.
extinguisher is kept on the drill and is in
good working order (see section 2.10) 2.2.11 Use extreme caution while handling
starter batteries. Wear gloves and
2.2.5 Operators and helpers should wear protective glasses when servicing
helmets with ear protectors, safety batteries. The batteries contain strong
glasses, safety shoes, gloves and acid which can seriously burn eyes, skin
suitable clothing. Loose fitting clothing and damage cloth, insulation and metal.
and jewellery can become caught in the First aid in case of acid in the eyes:
moving parts of the machinery, causing wash with plenty of clean water and
serious injury or even death. Use seek medical help. Disconnect the
suitable respirators in dusty conditions ground cable from the battery before
carrying out service in the electrical
system.
5
2 Safety Instructions
6
2 Safety Instructions
2.3.5 For truck mounted drills, ensure that 2.3.13 Take extreme precautions on rough
trucks operators manual is supplied roads. Do not exceed posted speed
and is kept in the truck. limits and match speeds to the road
conditions.
2.3.6 Always check your surroundings before
moving the drill so you become aware of 2.3.14 Before lowering the mast onto the front
any hazards. support frame, ensure the mast is
located in its proper dumped position
2.3.7 While moving the rig, no unauthorized (matching alignment arrows on mast
person should be allowed near the rig. and saddle)
Ask a supervisor for assistance when
moving the rig into dangerous positions 2.3.15 Ensure that the rig meets allowed
such as close to the edge of a quarry overall height limits
bench. Make sure the visibility is good.
Don't drive the rig into a dust cloud. 2.3.16 Always check the clearance of overhead
structures. When sufficient clearance is
2.3.8 When the drill is mounted on tracks and in doubt, stop and check the clearance.
is moved with the operator at the A common road accident with drills is a
console position, always use a spotter in collision with an overhead structure.
communication with the operator to
ensure that the drill is being safely 2.3.17 On trips, the driver should periodically
moved since visibility from the console check for any leaks (hydraulic oil,
position is very limited. engine radiator, fuel tank and lines). It is
recommended that a spill kit and
2.3.9 Even with the mast down, the drill absorbent be carried on the rig.
when mounted on a truck or tracks has
a high center of gravity. To prevent 2.3.18 For long distance shipping, or in
sideways tipping, never move the rig on sensitive environmental areas, it is
a side slope greater then 1 in 5. recommended to drain the hydraulic
reservoir and fuel tank.
7
2 Safety Instructions
2.4.4 When lowering the jacks, never use 2.4.12 The rod rack should be set to the correct
your finger to check the pin hole angle and position along the mast,
alignment (several people have lost a before the mast is raised. This will
portion of their finger doing this!). Use a ensure that the platform is horizontal
visual check only, using a second and at the correct height when the mast
person if required. Always secure the is raised to the drilling angle.
jacks with the locking pins provided.
2.4.13 The two backstay legs (one behind the
2.4.5 When raising the mast, ensure that no mast, the other behind the rod rack)
hoses, winch rope or cables are must be installed before operation of the
snagged. Snagging of hoses could drill. The cable restraint system is used
damage them and lead to leaks, and only on drills without the optional rod
snagging of winch rope or cables could rack/helpers platform
damage them as well. Always secure
the mast with the safety pins in the 2.4.14 The rod fallout guard (part 3760007966)
backstay leg(s). in front of the rod rack must always be
installed. This is a safety device to
2.4.6 It is important that the bottom of the ensure the rods cannot fall out of the rod
mast be supported and that the support rack in windy conditions.
is robust enough to take the full force
exerted on the rod when pulling with the 2.4.15 A safety chain or bar should be installed
main winch and/or the drillhead. If the around the first row. This will prevent the
support moves while pulling on a stuck rods being blown out of the rack if there
rod, the front of the drill could move up, are only a few steeply stacked rods in
depending on the angle of drilling. the rack.
2.4.7 Always secure the mast slide with the 2.4.16 Ensure personnel safety equipment is
securing pins provided available and in good order for securing
8
2 Safety Instructions
the helper when climbing the platform upward travel when winching the drill
access ladder and securing the helper rod.
when working on the platform.
2.5.5 Always keep a minimum of 3 wraps on
2.4.17 Ensure that the emergency E-stop for the main winch drum and the main
use on the helpers platform is plugged winch rope in a singe layer. Ensure that
in and is operational. the rope end is well anchored on the
drum flange.
2.4.18 Ensure that no loose tools are kept on
the platform; that could fall from the 2.5.6 Monitor the condition of the main winch
platform. rope. At the first sign of wear or broken
strands, the main winch rope must be
replaced.
2.5.3 Use the wireline winch only for the 2.5.15 The audible alarm will sound on low
purpose intended, never for general hydraulic oil level or high hydraulic oil
service. The wireline winch moves too temperature (a light on the electrical
fast for any general service winching. panel will show whether low level or
high temperature caused the alarm).
2.5.4 The main winch block limit switch, The engine will shut down in about 30
located at the crown block, is meant for seconds after start of the alarm (time
emergency use only to prevent the period is adjustable). This gives the
winching plug from being pulled into the driller time to stop drilling, pull the rods
crown block. Do not use it for stopping back and secure the drill hole.
9
2 Safety Instructions
2.5.16 Ground conditions can deteriorate after Drills Equipped with Optional Rod
heavy rainfall. Inspect jack and mast Rack/Helpers Platform
support areas daily.
2.5.25 Check that the emergency E-stop on the
2.5.17 Never operate the drill when the wind helpers platform is in good working
speeds exceed 20 m/sec (45 mph) See order at the beginning of each shift.
section 9.8.3 regarding guy wire
requirements 2.5.26 Ensure that there are no loose tools on
the helpers platform that could fall and
2.5.18 Do not operate the drill in lightning cause injury or damage.
storms. This could result in
electrocution. 2.5.27 Ensure that safety equipment is used for
climbing to, and working on, the helpers
2.5.19 Snow/ice/freezing rain can make the platform. Each time before using the
work area hazardous. Take necessary safety equipment, check that it is in
precautions prior to working. Provide good working order.
wind protection for personnel when
operating in cold and windy conditions. 2.5.28 Only one man equipped with small tools
Working in cold conditions can make it is allowed on the helpers platform at
difficult to work safely. any one time
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 2.6 Tear-Down of Drill
preventer), if required.
2.6.1 Always put mast into transport position,
2.5.21 The operator should periodically check fully retract jacks, and retract the
for hydraulic oil, fuel and radiator console before moving the rig.
leakage. Any leaks found must be
rectified. It is recommended that a spill 2.6.2 Before lowering the mast onto the front
kit and absorbent be available at the drill support frame, ensure the mast is
site. located in its proper dumped position
(matching alignment arrows on mast
2.5.22 It is important to practice good and saddle)
housekeeping and prevent slippery
underfoot conditions in the working 2.6.3 Be careful to avoid snagging or
areas. damaging any hose, winch rope or cable
when moving the mast to the travel
2.5.23 Oily rags, bare conductors, spilled or position.
leaking fuel or oil present a fire hazard
and must be prevented 2.6.4 Always ensure that securing pins are in
place (jacks, backstay legs, mast slide,
2.5.24 The foot clamp can crush feet or hands. and guards)
Keep feet and hands away from the foot
clamp. 2.6.5 Always secure any loose items so they
cannot fall off the deck.
10
2 Safety Instructions
2.7.2 Any maintenance should be done using 2.7.12 Welding near computer controlled
acceptable lockout procedures to engines can cause ECU damage.
ensure personal safety. Disconnect batteries and ECU
harness prior to welding.
2.7.3 Make sure the engine is stopped and
hydraulic, air, and water circuits are 2.7.13 Use only certified welders for any
properly depressurized before being welding repairs.
worked on.
2.7.14 Avoid hot areas of the rig such as the
2.7.4 Make sure all components that can engine exhaust system when
move when hydraulic lines/components maintaining/servicing the rig. Allow
are disconnected (e.g. drillhead, mast, cool-down time prior to removing
etc.) are in the lowest position or heat shields and guards
supported by temporary means such as
blocks or chains before working on the 2.7.15 A qualified person should inspect
drill. high stress locations on a yearly
basis.
2.7.5 When replacing components, always
purge air from the components prior to 2.7.16 Never use oversize fuses or
use to prevent uncontrolled movement. breakers. These present a fire
hazard.
2.7.6 Be very careful when tracing leaks in the
pressurized systems. Hydraulic oils, 2.7.17 Periodically check that all danger and
water or air under pressure could warning labels, as specified in the
penetrate under the skin and cause parts manual, are present and
complicated injuries or infection. If this legible. Any missing decals must be
happens, see a doctor at once. replaced.
2.7.7 Do not use pressure settings different 2.7.18 Never climb the mast using the
from factory settings without consulting service ladder while the rig is
with the factory. Mechanical failures or running.
other dangerous situations resulting in
death or injuries could occur with 2.7.19 Procedures in section 15 must be
settings that are different from factory used for setting min and max
settings. displacements on replacement
11
2 Safety Instructions
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
Fig. 2.13
Fig. 2.15
13
2 Safety Instructions
14
3 Environmental Instructions
Chemicals
3 Environmental Instructions Dispose of chemicals such as drilling additives,
other additives, glycol etc. according to the
Dear operator, manufacturers instructions and local
regulations. Avoid the use of cleaning agents
Atlas Copco Exploration Products recognizes containing chlorinated solvents. There are
the importance of environmental issues. As part environmentally better alternatives now available
of our commitment to a better environment, we on the market. Follow national regulations
want to inform you, the customer, of how you regarding handling and disposal of wastes.
can minimize the effect on the environment
when using an Atlas Copco product. These Metals (steel, aluminium, etc.)
simple but important instructions will help to These products are recyclable and should be
preserve the environment. taken care of according to national regulations
and recycled where local programs exist.
Oil
Leaks of hydraulic and lubrication oils pose an
environmental threat. Changing lubricating and Plastics and rubber
hydraulic oils, hydraulic hoses and hydraulic These products are often labelled according to
filter elements also pose a potential threat to the different classes. In those cases they are
environment. recyclable and should be disposed of according
Collect all oil spills and waste (e.g. oil filter to national regulations and recycled where local
elements) contaminated with oil. Dispose of programs exist.
according to national regulations.
Use biologically decomposable hydraulic oils Electrical components (cables, electronics,
and lubricating oils for Atlas Copco products etc)
wherever possible. Contact your nearest Atlas Used components should be disposed of
Copco office for more information. according to national regulations and recycled
where local programs exist.
Engine
Engine emissions are toxic and pose an Spill Kit and Absorbent
environmental threat. Always provide for fresh Always carry a spill kit and suitable absorbent
air when an engine is running. Well-maintained for hydraulic oil and anti freeze.
air filters help keep emissions at a low level.
Daily Inspection
Fuel (Petrol/Gas, Diesel): Fuel spillage poses Inspect fuel tank, hydraulic tank, radiator and
an environmental threat. Collect all wastes and cooler for leaks daily.
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.
15
3 Environmental Instructions
16
4 Hoisting the Drill
17
4 Hoisting the Drill
18
5 Specifications
5 Specifications
5.1 General
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
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:
Options
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
2438
22
5 Specifications
4.09 m
(13' 5")
11.04 m
(36' 2")
23
5 Specifications
14327
1010
400
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
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
29
6 Design Features
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
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
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).
32
6 Design Features
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
34
7 Controls
7 Controls
7.1 Main Control Panel (Pilot Operated)
35
7 Controls
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.
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.
38
7 Controls
27. Audible Alarm (not shown) - Provides 31. Pulldown Pressure Gauge Shows
audible warning for low oil level & high oil pressure on the pulldown side of the feed
temperature, main winch rope cylinder. A calibrated decal ring is
management (see section 6.6), operation translates the pressure to feed cylinder
of secondary console controls (hyd jack pulldown force (in pounds).
movements, mast raising etc.).
29. Spindle Tachometer Provides the chuck 33. Circuit Breaker Provides protection of
rpm. main electrical control panel.
39
7 Controls
40
7 Controls
1 9 8 7 6 5 4 3 2
41
7 Controls
42
8 Diesel Engine Start-Up
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)
43
8 Diesel Engine Start-Up
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.
8.2.2 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.
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
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.
47
9 Drill Set-up
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.
48
9 Drill Set-Up
49
9 Drill Set-Up
50
9 Drill Set-Up
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
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 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.
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
52
9 Drill Set-Up
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.
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
55
9 Drill Set-Up
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.
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.
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:
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.
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.
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.
.
57
9 Drill Set-Up
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.
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
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
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).
61
10 Drilling
62
10 Drilling
3 2
63
10 Drilling
64
10 Drilling
65
10 Drilling
66
10 Drilling
67
10 Drilling
68
10 Drilling
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)
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.
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.
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
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
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
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.
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.
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.
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
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)
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.
11-5
11.4 Service Point Detailed Instructions
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
11-6
11.4 Service Point Detailed Instructions
11-7
11.4 Service Point Detailed Instructions
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
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)
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
11-9
11.4 Service Point Detailed Instructions
Oil Filter
Remove plug to check
chain tension Check
vertical level
here, behind
adjuster
plate.
Oil Pump Strainer
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
11-11
11.4 Service Point Detailed Instructions
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
11-12
11.4 Service Point Detailed Instructions
Lift cylinder
clevis pins
(4 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.
11-14
11.5 Periodic Inspections
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
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:
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
11-18
12 Hydraulic Circuit Description
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
89
12 Hydraulic Circuit Description
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.
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
90
12 Hydraulic Circuit Description
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.
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
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.
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
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
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.
96
12 Hydraulic Circuit Description
3000 3000
Max PSI
97
12 Hydraulic Circuit Description
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
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
60 psi
25 25
10
3 psi 3 psi 10 8 psi
25 psi
30 TEMP
psi
Max
SETTING
176 F
100
13 Electrical Circuit Description
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.
Should a hydraulic oil temperature or hydraulic oil level fault occur while the diesel is operating
the corresponding indicating light on the fault panel will be illuminated and the audible alarm will
sound to alert the operator to the fault condition.
If the diesel continues to run for more than 30 seconds (interval is adjustable) in a fault condition
the Fault Panel will shut the diesel down automatically. The purpose of the delay is to give the
operator time to pull back the drill string, secure the hole and if possible, idle the diesel.
When the Fault Panel automatically shuts down the diesel, the fault horn will continue to sound
and the corresponding fault indicating light will remain illuminated until the fault is recognized by
one of two actions:
The ignition key is turned off
The fault reset button is depressed
If the ignition key is turned off in a fault condition, the fault horn will be silent but the fault
indicating light will remain illuminated until the fault reset button is depressed. The purpose of the
indicator light is show which fault has occurred.
Once the fault has been corrected, depress and release the fault reset button on the fault panel.
If no fault is present, the fault indicating light will remain off, and the diesel will be ready to start
and run normally.
If the fault has not been corrected the corresponding fault light will once again be illuminated and
shut the diesel after 30 seconds.
If the fault reset button is depressed and released without correcting an indicated fault condition,
the corresponding fault light will again be illuminated. In this event the ignition key could start and
run the diesel, but only until the 30 second time delay expires and the engine is once again
automatically shutdown.
Any time the ignition key is in the on position and a fault condition exists, the audible alarm will
sound.
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13 Electrical Circuit Description
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.
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.
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.
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
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
2. Noisy pump caused by A. Oil supply low A. Fill hydraulic tank, check low
aeration level switch mounted in tank
104
14 Trouble Shooting
5. System does not produce A. Excessive internal leakage A. Check amount of flow
proper flow according to specification
105
14 Trouble Shooting
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
E. Slow feed directional valve is not E. Check for worn or damaged parts (slow feed
operating properly valve spool is detent)
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.
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 Trouble Shooting
2. Hydraulic chuck opens A. Relief valve for chuck (located A. Remove relief valve and inspect for
partially, not at all, or leaking below the control valve lever) damage and dirt. Make sure relief
hydraulic oil (not grease) at is stuck, contains valve was not over tightened into
chuck body. contamination, damaged, or housing. Set pressure at 90 bar
pressure setting is not correct. (1,300 psi)
3. Chuck jaws not holding drill A. Incorrect chuck jaw size, worn A. Inspect jaws and check for right part #.
rod or slipping. jaws, or damaged. Check the correct size of rod bushings
(upper and lower) are being used if
damage to carbide is occurring.
107
14 Trouble Shooting
4. Mud mixer not rotating, A. Quick disconnects not A. Check quick disconnects for
rotating slow, or erratic. connected properly or pilot damage/broken parts or does not
inside is broken go together freely.
5. Hydraulic jacks, mast raise, A. Selection valve in main A. Move valve to secondary console
etc. will not operate at all or console position position
erratic.
B. Hydraulic cylinder leaking B. Troubleshoot the cylinder.
internally or damaged.
108
14 Trouble Shooting
6. Rotation speed (high to low) A. Main pump or compensator A. Check the other functions on main
is erratic or not changing problem. valve for correct operation. If they
rpm when turning rotary are working properly continue
control valve in or out. troubleshooting B thru J. If some
problem persists, troubleshoot the
main valve or main pump circuit.
109
14 Trouble Shooting
1. Rotation section A. Main pump or A. Troubleshoot main pump and compensator. Check
in main valve compensator problem for proper suction, contamination, compensator
bank producing pressure setting, standby pressure setting, and
slow rpm, no excessive case drain leakage -more than 20 lpm (6
revolutions, or gpm) is excessive for this pump. Check
lack of pressure. 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).
F. Flow compensator G. Check the load sense line from valve to main pump
spool in rotation section for obstruction in hose
blocked or stuck
110
14 Trouble Shooting
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)
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
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14 Trouble Shooting
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
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
112
14 Trouble Shooting
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.
113
14 Trouble Shooting
114
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.
Acronyms:
adj. = adjustment
min. = minimum
max. = maximum
-Fill all fluid levels (radiator, engine, main hoist, hydraulic tank,
drill head and mud pump)
-Back out flow control valve for cooling fan flow , and main valve
load sense relief valves
115
15 Hydraulic Set-up Procedure
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)
-Shut engine off. Monitor tank pressure and check that pressure
stays constant. If pressure leaks off, find source of air leak and
correct.
116
15 Hydraulic Set-up Procedure
117
15 Hydraulic Set-up Procedure
8. CHUCK PRESSURE
OPERATIONS RESULTS COMMENTS
118
15 Hydraulic Set-up Procedure
-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
-Open mud mixer line fully and set relief valve to 2000 PSI. Lock
adjusting screw.
-Open mud mixer valve fully and record flow - should be about
6 GPM.
-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.
119
15 Hydraulic Set-up Procedure
120
15 Hydraulic Set-up Procedure
-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)
-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)
-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.
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15 Hydraulic Set-up Procedure
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)
-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
-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.
-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.
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15 Hydraulic Set-up Procedure
-Check the digital display on the console with the photo tachometer.
-Fully screw in load sense reliefs for both A and B ports. (Max
pressure limited to 4700 psi main pump compensator).
-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)
-Hold winch rotation control lever in the fully raise position and set
engine speed at 2100 RPM.
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15 Hydraulic Set-up Procedure
-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
21. SECONDARY HYDRAULIC PUMP SETUP FOR FMC W1122BCD MUD PUMP,
WATER PUMP RELIEF VALVE SETTING AND WATER PUMP TEST
OPERATIONS RESULTS COMMENTS
-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)
-Check the console digital mud pump flow meter should read 34
gpm at 630 mud pump input rpm
126
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
Hydraulic jacks
Mast dump
Mast raise & lower, stiff leg pinning (no rod rack)
Lighting system
Special equipment 2: UDR spin out tool. Check flow from pressure
compensated flow control valve with flow meter and record.
127
15 Hydraulic Set-up Procedure
Drillhead guard
128
16 Spin-Out Tool Option
Safe-T-Spin Specifications
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.
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
The following procedures can be used to fit the safe-t-spin to the mast for a 650 rig.
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 Spin-Out Tool Option
A. Reeve the main winch rope through the snatch block with the mast in the drilling 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 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 Spin-Out Tool Option
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.
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 Spin-Out Tool Option
A. To remove the safe-t-spin from the mast is a reversal of the procedure of sections 16.2.1.1.
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.
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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16 Spin-Out Tool Option
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.
BREAK: There is no torque setting adjustment for breaking the rod joint.
16.2.3 OPERATION
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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16 Spin-Out Tool Option
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.
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.
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.
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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16 Spin-Out Tool Option
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.
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16 Spin-Out Tool Option
Note: Bushes must be replaced in the jaws once they are heated!
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16 Spin-Out Tool Option
138
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
140