sandvik-de710pilotoperationmanual revision2 cd

DE710 Operator’s Manual

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Contents

INTRODUCTION 1 Using This Manual 1 Operation of the Drill Rig 1 Modifi cations 1 Machine Design 1 Seeking Assistance 1 Terms & Conditions of Sale 2 Contact Information 7

GENERAL DESCRIPTION 8

DETAILED SPECIFICATIONS 9

FAMILIARISATION TOUR 11 Left Hand Side Mast 11 Left Hand Side Tray 12 Rear of Rig 13 Right Hand Side 14

SAFETY INSTRUCTIONS 15 Safety Risk Protocol 15 Basic Safety Advice 16 Personal Danger & Out of Service Tags 17 Personal Danger Tags 17 Out of Service Tags 17 Safe General Work Practice 18 General Hazard Information 18 Perform All Maintenance Unless Specifi ed as Follows 19 Major Repairs to the Rig 20 Climbing Up Onto the Mast 20 Compressed Air 20 Fluid Penetration 20 Crushing or Cutting Prevention 20 Burn Prevention 21 Fire Extinguishers 21 Toxic & Irritating Substances 22

Electrical Shock 22 Fire or Explosion Prevention 22 Lines, Tubes & Hoses 23

SAFETY WARNING SIGNS & LABELSON THE MACHINE 24 Personal Protective Equipment 24 Warning Signs on the Control Cabinet 25 Warning Signs Rig Emergency Stop 26 Warning Signs on the Mast 27 Warning Sign Rod Spin Guard 28 Caution Sign on Rig Cab 28

MANUAL HANDLING 29 Size Up the Load 29 Correct Foot Positions 29 Proper Hold 29 Use Body Weight 29 When Moving the Load 29 To Lower the Load 29

SAFE DRILLING PRACTICE WARNINGS 30

WATER PUMP SAFETY INSTRUCTIONS 32

PRE-OPERATION INSPECTION 33 Rig Operation 33 Drill Control Cabinet Check List 33 Drill Tray Components Check List 33 Mast Structure & Components Check List 34 Preparations before Engine Start Up 34 Track Drive to Drill Operation 34

Copyright © Sandvik Mining & ConstructionDE710 OPERATORS MANUAL 2009

GENERAL INFORMATION 35 Familiarisation 35

RIG SET UP PROCEDURE 36 Initial Preparations 36

MAST ASSEMBLY GENERALINFORMATION 38 Mast Platform General Information 39 Mast and Platform Stay Rods General Information 40 Level the Drill 42 Mast Raise/Lower, Mast Dump Stay Rods General Information 45 Mast Raise/Lower 45 Mast Stay Rods 45 Mast Dump 45 Platform Support Beam and Basket Set Up Procedure 46 Platform Support Beam Stay Rod and Tension Stay Rod Set Up Procedure 48 Mast Raising Dumping and Lowering 50 Mast Stay Rods Final Set Up 54 Platform Stay Rod Set Up 54 Tension Stay Rod Set Up 54 Final Set Up of the Mast 55 Mast Ladder Set Up (Track Drive Rigs) 56 Mast Lowering 57

MAIN WINCH 59 Specifi cations 59 Control Lever Location 59 Familiarisation 59 Operation 62

MAIN WINCH FLOAT SYSTEM 63 Winch Float Off 63 Winch Float On 63

WIRE LINE WINCH 64 Specifi cations 64 Familiarisation 64 Operation 65

ROTATION - GENERAL 67 Specifi cations 67 Control Lever Location 68 Familiarisation 68 Rotation Head Visual Identifi cation 70 View of the Chuck Assembly on the Rotation Head 71 View of the Left-Hand Side of the Rotation Head Assembly 72 View of the Right-Hand Side of the Rotation Head Assembly 72 Rotation Head Spindle and Chuck Assembly Rod Guide Bushes and Chuck Rod Jaw Assemblies 73

ROD CLAMP VISUALIDENTIFICATION & NOTES 74 View of the Rod Clamp Assembly in the “OPEN” Position 74 View of the Rod Clamp Assembly in the “CLOSE” Position 74 Upper Rod Breaker Visual Identifi cation 74

TRIPPING RODS INTO THE HOLE 75 First Method Between the Head and the Rod Clamp Rotation Forward 75 Second Method Above the Rotation Head Rotation Reverse 79

TRIPPING RODS OUT OF THE HOLE 82 Initial Procedure 82 Ongoing Procedure 82 Removal of the Core Barrel 82 Adding Rods 83


ROTATION FOR DIAMOND DRILLING 84 Drilling 84 The Manual Mode of Operation for the Rotation Head 85

ROTATION HEAD FLOAT 86 Float “Break-Make” Familiarisation 86 Rotation Head Float Set Up Procedure (Make and Break) 86 Float Make Set Up 86 Float Break Set Up 87

ROD SPIN GUARD 88 Diamond Drilling High-Speed 500-1500 rpm 89

ROTATION MAKE CONTROL 90

ROTATION HEAD TRAVERSE 91 Specifi cations 91 Familiarisation 91 Traverse by Means of “Head Traverse” Lever 93 Traverse by Means of “Micro Feed” Lever 93 Hold Back, Pull Down, Micro Feed 93 Set Up of Hold Back and Pull Down Method 1 93 To Adjust the Pull Down and Micro-Feed 94 Set Up of Hold Back and Pull Down Method 2 94 To Adjust Pull Down 94 To Adjust Holdback and Micro-Feed 94 Head Traverse Cylinder and Drill String Forces 95 Example 1 - Starting NQ from the surface, 5000lbs. Pull Down 95 Example 2 - 300 metres (985 ft) NQ hole, 5000lbs. Pull Down 96 Example 3 - 1000 metres (3280 ft) NQ hole, 5000lbs. Pull Down 97

Example 4 - 320 metres (1060 ft), 10000lbs. Pull Down 98 Starting to Drill 99 At the Start of the Traverse Cylinder Stroke 99 Main Winch Float System 99 “Winch Float Off” 99 “Winch Float On” 99 Drilling 99

WATER PUMP CONTROLS ATTHE CONTROL CABINET 101 Familiarisation 101

WATER PUMP FOR DIAMONDDRILLING W1122BCD 102 Specifi cations 102 Operation 102 Mud Mixer 103 Mud Mixer Hydraulic System Specifi cations 103

ROD CLAMP 104 Specifi cations 104 Operation 104 Rod Clamp Visual Identifi cation & Notes 105 View of the Rod Clamp Assembly in the “OPEN” Position 105 View of the Rod Clamp Assembly in the “CLOSE” Position 105

BREAKOUT TOOL 106 Specifi cations 106 Operation 106

HEAD RACK OPERATION 107 “OUT” 107 “IN” 107

SLIDE ROLLER OPERATION 109 “IN” 109 “OUT” 109


MISCELLANEOUS INSTRUCTIONS 110 Fuel System 110 Electrics 110 Batteries 111 Battery Care 111 Battery Acid Material Safety Data Sheet 112 Identifi cation 112 Physical Description Properties 112 Other Properties 112 First Aid 112 Swallowed 112 Eye 112 Skin 112 Inhaled 113 Battery Acid Spills 113 Spills & Disposal Minor Spills 113 Major Spills 113 Disposal 113 Vehicle Jump Starting 114 Battery Charging 115 Battery Charging Guide 115

FIRE EXTINGUISHERS 116 Location 116 Orientation 116 Classifi cation 116

OPTIONS THAT CAN BE FITTEDTO DE710 RIG 118

SAFE-T-SPIN 119 Familiarisation 119 Safe-T-Spin Specifi cations 119 Safe-T-Spin Controls at the Control Cabinet 120 Safe-T-Spin Pilot Control Valve Assembly 120 Safe-T-Spin Make Up Torque Pressure Control 120 Safe-T-Spin Make Up Torque Pressure Gauge 120 Vertical Support 121 Vertical Support - Figure 1 121 Safe-T-Spin Module Bulkhead 121

Installation 122 Swing the Safe-T-Spin Away From Mast 125 Swing the Safe-T-Spin Towards the Mast 125 Remove the Safe-T-Spin from the Mast 126 Operational Checks 126 Make Up Torque Pressure Setting 127 Break Out Torque Adjustment 128 Operation 128 Make Up of Drill String 132 Making Up of the Drill String - General Notes 135 Trouble Shooting of Safe-T-Spin 136

TRACK DETAILEDSPECIFICATION 137 Maximum Operating Conditions and Dimensions 137 Appropriate O/A Dimensions 137 Hydraulics for Track Drive 138 Track Drive Familiarisation 139 Engine Controls and Monitoring Gauges 139 Familiarisation 139 Track Drive Controls from the Drill Control Cabinet 141 Track Drive Control Cabin 142 Track Drive Controls in the Track Drive Cabin 143 Track Operation 145 Before Starting the Engine 145 Mounting and Dismounting 145 Starting the Engine and Driving the Drill Rig 145 Engine Starting 146 Before Driving the Tracks 146 After Starting the Engine 147 Instructions for Driving the Rig from the Track Drive Cabin 148 Driving 148 Changing Direction from Forward to Reverse 148


Directional and Steering Controls 148 Left/Right Travel Lever 148 Steering 149 Turn on the Spot to the Left 149 Pivot Left Turn 149 Turn on the Spot to the Right 149 Pivot Right Turn 149 Driving On Inclines / Gradients / Rough Terrain 150 Instructions for Driving from the Drill Control Cabinet 151

MAINTENANCE 152 John Deere JD6068TF250 Service Schedule 152 Recommended Oils 153 Service Log Book 153 Recommended Service Schedule 153 Recommended Parts - John Deere JD6068TF250 154 Cummins 6BTA 5.9 Engine Service Schedule 155 Engine Lubricating Oil 156 Recommended Spare Parts 156 Recommended Parts - Cummins 6BTA 5.9C & QSB 6.7 157 Visual Maintenance Guide 158 View of Typical John Deere Engine from the Left-Hand Side of the Rig 158 View of Typical Cummins Engine from the Left-Hand Side of the Rig 159 View of Typical John Deere Engine from the Right-Hand Side of the Rig 160 View of the Typical Cummins Engine from the Right-Hand Side of the Rig 161

HYDRAULIC SYSTEM / OIL TANKSERVICE SCHEDULE 162 Hydraulic Oil Tank Visual Maintenance Guide 163 Return Line Filter Visual Maintenance Guide 164

Optional High Pressure Filter Visual Maintenance Guide 165 Hydraulic Oil Selection Chart 165 Recommended Spare Parts 165

P ROTATION HEAD SERVICESCHEDULE 166 Recommended Oils and Greases and Parts 166 Recommended Lubricating Oil 166 Bearing Grease 166 Spare Parts 166 P Rotation Head Visual Guide Part “A” 167 P Rotation Head Visual Guide Part “B” 167 P Rotation Head Visual Guide Part “C” 168

MAIN WINCH SERVICESCHEDULE 169 Recommended Oil 169 Recommended Greases 169 Main Winch Visual Maintenance Guide 170

WIRE LINE WINCH SERVICESCHEDULE 171

ROD CLAMP SERVICE SCHEDULE& VISUAL MAINTENANCE GUIDE 172

WATER PUMP SERVICESCHEDULE 173 Water Pump Recommended Oils and Greases 173 Recommended Lube 173 Recommended Greases 173

MAST SERVICE SCHEDULE 173


MAINTENANCE & INSPECTIONOF STEEL WIRE ROPES 174 Lubrication 174 Cleaning Ropes 175 Inspection of Wire Ropes 175 Criteria for Discarding a Rope 176 Broken Wires 176 Reduction in Diameter 176 Corrosion 176 Rope Deformation 177 Waviness 177 Birdcage 177 Loop Formations 177 Loose Wires 177 Nodes 177 Thinning of the Rope 177 Kinks 177 Flat Areas 177 Misplaced Outer Wires 178 Recommended Service Schedule and Oils for Wire Ropes 178 Steel Wire Ropes Lube Oils 178 Maximum Service Life of Wire Ropes 178 Service Life of Wire Ropes 178

TROUBLESHOOTING GUIDE 179 Scope Of Trouble Shooting Guide 179 References, Abbreviation Key and Other Notes 179 3 Stage Hydraulic Pump 180 Set Up Procedures For Controls Of The Main Pump, Second Pump and The Third Pump - Pumps 6A 6B and 6C 181 First Pump (Item 6A) 181 Main Control Pressure Relief Valve Setting 182 Pressure Regulator Setting 183 Maximum Flow Setting 183 Pump 6A Pressure and Flow Test 184 Pressure Regulator Test 185

Second Pump(Item 6B) Features Of Pump 6B 186 Flow Regulator Adjustment Procedure 186 Pressure Relief Valve Item 4 Adjustment Procedure 186 Pressure Regulator Adjustment Procedure 187 Third Pump Item 6C Features Of Pump 6C 188 Rotation Head Motor 189 Set Up Procedure For Controls 189 Rotation Chuck Operation 190 Rotation Head Operational Checks 190 Maximum Rotation Head Speed Setting 190 Motor Control End Regulator Setting 191 Rotation Reverse Speed Interlock Valve Check Procedure 191 Rod Spin Guard 191 Main Winch Motor 192 Set Up Procedure For Controls 192 Main Winch Counter Balance Valve Setting 193 Brake Release Pressure Reducing Valve 194 Test Proceedure 194 Main Winch Operational Checks 194 Miscellaneous Hints 195 Rotation, Main Winch And Wire Line Winch 195 Rotation 195 Unusually Slow Rotation Whilst Diamond Drilling, Very High Torque Reading (Main Pump Pressure Very High) 195 Main winch 196 Wire line winch 196 Diesel engine 196 Water Pump 196


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WI864-033 Revision 2 1 (196)Copyright © Sandvik Mining & ConstructionDE710 OPERATOR’S MANUAL 2009

INTRODUCTION

1. INTRODUCTION

1.1 Using This ManualThis manual will assist you to properly operate your Sandvik DE710 Drill Rig. The information contained within this manual covers technical data and procedures recommended by the manufacturer.

1.2 Operation of the Drill RigThe manufacturer recommends, in the interest of safety and proper operating procedures that all personnel engaged in operating or working around this rig is appropriately trained.

1.3 ModificationsNo structural or performance modifications, additions, changes and non-recommended operating or maintenance procedures can be carried out to the drill rig without the prior approval of the manufacturer.

1.4 Machine DesignThe drill has been designed to handle diamond core drilling up to the rated capacities as detailed in this manual. Operation of the drill beyond or outside the intended design purpose cannot be carried out without the prior approval of the manufacturer.

1.5 Seeking AssistanceIn the event that the given instructions in this manual; • Are difficult to understand • Are easily misinterpreted • Produce unexpected outcomes when followed • Do not cover eventualities or situations unanticipated at the time of writing Please refer to “GENERAL CONTACT INFORMATION” for the nearest Sandvik office to you.

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Copyright © Sandvik Mining & ConstructionDE710 OPERATOR’S MANUAL 2009

2 (196) WI864-033 Revision 2

1.6 Terms and Conditions of Sale - Equipment

The following Terms and Conditions are to be considered an integral part of the Agreement.

1. GENERAL:These Terms and Conditions of Sale shall govern the sale to Buyer by Sandvik Mining & Construction AB (“Seller”) and all of its global subsidiaries, agents and distributors of Sandvik Exploration Equipment (“Equipment”). At Buyer’s request, Seller may arrange packaging, transportation, insurance, equipment rental (e.g. cranes), which shall not be warranted as part of the Services. Seller’s acceptance of Buyer’s order is limited to Buyer’s acceptance of these Terms and Conditions and is expressly made conditional on Buyer’s assent to any additional or different terms and conditions contained herein. No modifications of, or additions to, these Terms and Conditions will be valid or enforceable against Seller unless specifically agreed to in writing by an authorized representative of Seller. Seller considers any provisions in conflict with these Terms and Conditions contained in any prior or subsequent order or communication from Buyer to be material and hereby objects to any such provisions. Buyer’s acceptance of any Equipment, Parts or Services covered by these Terms and Conditions or Buyer’s failure to specifically object to these Terms and Conditions prior to commencement of performance of order or provision of Services shall constitute acceptance of these Terms and Conditions (“Acceptance”).

2. ENTIRE AGREEMENT:These Terms and Conditions, together with the Price (defined in Section 4 hereof) and payment terms, description of Equipment, Parts, or Services, Buyer’s name and address and any other information or terms and conditions specifically stated in Seller’s offer, quotation, proposal or sales order acknowledgment constitute the entire agreement (the “Agreement”) between Seller and Buyer with reference to the subject matter hereof. Any purchase order issued by Buyer shall be deemed to (i) be for the record-keeping convenience of Buyer and (ii) confirm these Terms and Conditions and not add to, delete from, or change these Terms and Conditions.

3. LIMITED SCOPE OF SERVICES, TECHNICAL INFORMATION:Services Generally. Except to the extent expressly stated otherwise in this Agreement, the scope of the Services provided under this Agreement is limited to Seller’s stated scope and the provision of technical information about Seller’s Equipment and Parts, or performance of technical repair services by Seller. Seller shall have no authority to control or direct the manner in which technical information is used by Buyer or third parties and shall not be responsible or liable for the quality of any work performed using such technical information.

Seller shall not be or be deemed to be a principal with regard to Buyer or any of Buyer’s employees, agents, suppliers or subcontractors for Services performed in proximity to or in conjunction with Buyer’s employees, agents, suppliers or subcontractors.

Notwithstanding Section 3 hereof, Buyer shall have 30 calendar days from issuance of Seller’s offer, quotation or proposal within which to accept or reject Seller’s offer,

The warranties as set forth in Section 7 Warranties are applicable to Equipment supplied by the Seller

4. PRICE:Unless the express terms of Seller’s offer, quotation or proposal provide otherwise, the price quoted by Seller for the sale of Equipment, Parts and/or Services (“Price”) is firm for acceptance by Buyer for thirty (30) days from its original date, and is subject to re-quotation after such date. After Acceptance, any change in the scope of work, specification, start date, schedule, completion date, commissioning date or any other term of this Agreement shall be subject to a Change Order, and the Price will be adjusted to include any change in Seller’s list price for Parts, plus all new and increased costs of Seller for any Equipment and/or Services, including but not limited to: demobilization, remobilization, standby time, per diem, increased component and material prices, increased labor rates, storage charges, and insurance costs, plus 20% of such aggregate increase to cover overhead and other indirect costs. Payment due for any Change Order shall be made by Buyer over the remaining payment schedule of the Agreement.

Notwithstanding anything herein to the contrary, Prices quoted by Seller are exclusive of all costs related thereto, which may include, but shall not be limited to, crane rental, freight, packaging and special handling, insurance, all import/export duties and taxes including federal, state and local use, sales, property, or similar taxes, and Buyer shall pay actual costs and all such taxes in full, or shall reimburse Seller for any such costs and taxes paid by Seller (except taxes levied on Seller’s income). Buyer shall remit with signed Agreement any sales or use tax exemption certificates that apply.

5. PAYMENT TERMS:General. Unless expressly stated otherwise in this Agreement, the payment terms are seven (7) days from the date of Seller’s invoice.

Equipment. The payment terms for the sale of Equipment are net seven (7) days from date of Seller’s invoice, and the payment schedule for purchase of Equipment shall be as follows: • 30% of the contract value as a non-refundable deposit at time of order placement. Shipment and delivery commitments will start upon receipt of the deposit or upon the date the Agreement is signed, whichever is later, (“Start Date”).

• 30% of the contract value at the commencement of manufacture of the Equipment.

• 40% of the contract value prior to shipment of the Equipment.

Any modification in the payment schedule may result in a Price adjustment.

Other Payment Terms. If freight is arranged by Seller, Buyer will be responsible for actual freight charges, and all freight will be invoiced separately and is due in full five

TERMS & CONDITIONS OF SALE

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(5) days from invoice date.

Buyer agrees to pay a finance charge of 1.5% per month (18% per year) or the legal rate in Buyer’s state, whichever is less, on all invoices not paid in full when due.

For export shipments, and, at Seller’s option, for domestic shipments, all payment in accordance with the above payment schedule, shall be guaranteed by a confirmed and irrevocable letter of credit, or other security, acceptable to Seller.

Faxed invoices shall be allowed and receipt shall occur on the date the invoice is faxed. Hard copy of the invoice will be mailed to Buyer for confirmation purposes only. Payments are to be made by electronic transfer pursuant to the following instructions:

Electronic Funds Transfer Instructions:Bank:Branch:Bank Number :For Credit to: Account #: Reference: invoice #

EXCUSABLE EVENTS; CIRCUMSTANCES BEYOND SELLER’S CONTROL:Seller shall be entitled to an equitable adjustment in the Price (including, but not limited to, standby charge at the applicable rate(s) per hour for every employee and supervisor, and rental fees and costs for all rental equipment affected by the delays), and Buyer and Seller shall be entitled to an equitable adjustment in the time for performance hereunder upon the occurrence of an “Excusable Event”. As used herein, Excusable Event shall mean and refer, without limitation, to: (a) delays resulting from acts or omissions of Buyer, its contractors, subcontractors, or other persons for whom Buyer may be liable; (b) acts of God, fires, explosions, casualties, floods, earthquakes, tornadoes, severe weather, natural disasters, epidemics, civil disturbances, war, terrorism, riots, sabotage, accidents, restraints or injunctions issued by a court or other governmental entity or other government acts or restrictions, strikes, labor disputes or other work stoppages, power outages, public health emergencies, non-¬delivery of acceptable materials, or unusual delays in the supply of materials by suppliers; (c) transportation delays; (d) the discovery of any hazardous or toxic material, waste or substance at Buyer’s site; (e) the discovery of any concealed or unknown physical condition at Buyer’s site or the assembly site; (f) the occurrence of an amendment, modification, or enactment after the date of this Agreement of any law, statute, ordinance, code, order, rule or regulation of any government authority; or (g) the occurrence of any other events or matters which are beyond the control of Seller, irrespective of whether such contingency is specified herein or is presently occurring or anticipated.

6. PACKING; SHIPMENT:Unless expressly stated otherwise in this Agreement, all shipments are FCA Seller’s plant, warehouse, or other Seller designated shipping point (INCOTERMS 2000), and title and all risk of loss with respect to any goods shipped shall pass to Buyer when such goods are delivered to the

carrier at such point, subject to a purchase money security interest by Seller in all Equipment and Parts until payment in full is received by Seller. Buyer will be charged for export packing or other special packing required. No credit or deduction will be allowed if no packing is required. All delivery dates are estimates and do not constitute a guarantee of delivery on such dates. Unless special shipping instructions are received from Buyer at least thirty days prior to anticipated shipment, Seller shall use its own judgment as to carrier and means of shipment.

7. WARRANTIES:Buyer acknowledges that the Price is predicated on the limited warranties and limited warranty remedies in this Agreement, that the Price would be substantially higher if Seller’s liability were not so limited, and that Buyer accepts these limitations in exchange for such lower Price.

Equipment. Subject to the exceptions and limitations provided herein and in Seller’s offer, quotation or proposal, Seller warrants all Equipment to conform in all material respects to the description of the Equipment included in this Agreement, and against failure due to defects in materials and workmanship, for the earlier to occur of 2,000 machine hours or 12 months of use commencing on the Start-Up Date, but in no event longer than 18 months from the date of FCA shipment of the major components of the Equipment (the “New Equipment Warranty Period”). “Start-Up Date” shall be defined as the first date upon which Seller determines the Equipment is ready for use by Buyer and Seller turns over the Equipment to Buyer for use. This warranty excludes any wear and consumable parts, and any warranty of the useful life of such parts, except for such wear and consumable parts which are defective in materials and workmanship during the applicable Warranty Period set forth above.

Parts not manufactured by Seller but incorporated into Equipment are not warranted by Seller, but may be warranted separately by their respective manufacturers. Seller shall assign to Buyer whatever rights Seller obtains under any such warranties. Seller shall have no liability for the performance of such warranties, if any, other than to process warranty claims with such manufacturers on behalf of Buyer.

Other Equipment and accessories manufactured by another OEM may be warranted separately by that OEM, and Seller shall assign to Buyer whatever rights Seller obtains under any such warranties and process warranty claims with the respective OEM on behalf of Buyer.

Warranty Limitations. All warranties, whether from Seller or from another OEM, and any obligations of Seller shall automatically terminate with respect to Equipment which are operated in excess of rated capacities, erected or operated not in accordance with Seller’s or OEM recommendations, or are otherwise misused; are altered or repaired in any manner not authorized by Seller or by the OEM; are damaged; are not maintained in accordance with Seller’s or the manufacturer’s recommended practices and instructions, or in the case of Equipment, contain parts not supplied by Seller. In the event Buyer sells or otherwise transfers any Equipment or any Parts to a third party, all warranties shall immediately


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terminate. Any attempt by Buyer to transfer the warranties provided by Seller to any third party shall be void.THE FOREGOING WARRANTIES ARE THE SOLE AND EXCLUSIVE WARRANTIES GIVEN BY SELLER. AND SUBJECT TO PROVISIONS OF LOCAL REGULATORY ACTS, SELLER MAKES NO OTHER WARRANTIES OF ANY KIND WHATSOEVER, EXPRESS, IMPLIED, ORAL, WRITTEN OR OTHERWISE, INCLUDING WITHOUT LIMITATION WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE OR WARRANTIES ARISING BY CUSTOM, TRADE USAGE, PROMISE, EXAMPLE OR DESCRIPTION, ALL OF WHICH WARRANTIES ARE EXPRESSLY DISCLAIMED BY SELLER AND WAIVED BY BUYER.

8. WARRANTY REMEDIES:Equipment, If, at any time prior to the end of the applicable Warranty Period, there is a failure or breach of Seller’s applicable Warranty(ies) with respect to Equipment and Buyer notifies Seller in writing within thirty (30) days of discovery of such breach during the applicable Warranty Period, and the Equipment or Part is made available for inspection by Seller or, at the request of Seller, delivered freight prepaid to Seller, then Seller shall, at Seller’s sole option, either:

(i) repair such nonconformance or defect, or; (ii) furnish without charge, FCA Seller’s factory or warehouse, a replacement for any such nonconforming or defective Part.

Repairs or replacement Parts provided under the applicable Warranty are warranted only for the remainder of the original applicable Warranty Period. Seller, at its option, may issue a credit toward future Parts purchases from Seller in satisfaction of Seller’s obligations to repair or replace as set forth herein. The amount of any credit to be issued shall be the Price of the Part at the time of its failure, or Seller’s determination of the cost of labor, at Seller’s standard rates, and materials necessary to do the repair. Seller shall not be liable for the cost, including labor costs, of dismantling and installing replacement Parts or for any other expense connected therewith or for any special, exemplary, incidental or consequential damages. Ownership of any replaced Part shall revert to Seller.

THE FOREGOING REMEDIES SHALL CONSTITUTE BUYER’S SOLE AND EXCLUSIVE REMEDIES FOR BREACH OF WARRANTY AND ALL OTHER REMEDIES ARE HEREBY EXPRESSLY EXCLUDED.

9. CONFIDENTIALITY:All proposals, drawings, specifications, software, and technical data furnished to Buyer by Seller: (1) shall be retained in confidence (2) shall remain the exclusive property of Seller, (3) shall not be disclosed by Buyer to third parties or used in any manner not authorized by Seller, and (4) shall be returned to Seller upon request. All drawings, specifications, designs, plans, computer programs and other documents prepared by or on behalf of Seller (except for the assembly drawings supplied to Buyer) in connection with any Equipment, Parts and Services hereunder (the “Design Materials”), and all intellectual property rights in and to the Design Materials, are and shall remain Seller’s property. The Design Materials are for use solely with respect to any

Equipment or Parts which are the subject of this Agreement, and shall not, without Seller’s prior written consent, be used by Buyer, or its agents or contractors, on any other project, for completion of any Equipment, Parts or Services hereunder by others, or for any other services or work. The Design Materials are confidential, and Buyer agrees to keep the Design Materials confidential upon receipt of the same directly or indirectly from Seller or from any of Seller’s contractors, subcontractors, vendors or consultants, to use the Design Materials only as specifically authorized by Seller, and to return such Design Materials to Seller upon request. The obligation to keep the Design Materials confidential and to return them upon request shall survive the cancellation or termination of this Agreement or completion and delivery of any Equipment, Parts and/or Services.

10. RELEASE; INDEMNIFICATION:Release. Seller and Buyer release each other from liability for damage to and of each other’s material, machinery, equipment or other property. However, this section shall not relieve Seller of its warranty obligations hereunder.

Indemnity. Seller shall indemnify and hold harmless Buyer, its officers, directors, and employees from and against any claim (including costs, reasonable litigation expenses and attorney’s fees and other expenses) for personal injury to or death of any person or for damage to property of third parties, to the extent directly caused by the negligent acts or omissions of the Seller, its agents or employees arising out of the sale or installation of any Equipment or Parts hereunder.

Buyer shall indemnify and hold harmless the Seller, its officers, directors, employees and agents from and against any claim (including costs, reasonable litigation expenses and attorney’s fees and other expenses) for personal injury to or death of any person or for damage to property of third parties, to the extent caused directly by negligent acts or omissions of Buyer, its agents or employees arising out of or relating to the sale, installation, use or provision of any Equipment or Parts hereunder.

11. INSURANCE:Seller maintains for itself the following insurance (i) General Liability, (ii) Workers’ Compensation, statutory limits; (iii) Automobile. Seller shall not name Buyer as an additional insured on any of its policies of insurance nor waive any rights of subrogation.

12. WAIVER:No right or remedy of Seller shall be deemed to have been waived or renounced, in whole or in part, unless such waiver or renunciation is supported by consideration and is expressed in writing signed by Seller.

13. SELLER’S REMEDIES:Seller shall have all rights and remedies specified herein. All such rights and remedies are cumulative. In the event Buyer fails or refuses to make payment as required under this Agreement, Seller shall have the option of suspending its performance under this Agreement after notice to Buyer, and bring an action to recover the Price and related costs. No delay or failure by Seller to exercise any right or remedy shall impair in any manner


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whatsoever any of such rights or remedies or be con-strued to be a waiver of any breach or acquiescence therein, and any single or partial exercise of any such right or remedy shall not preclude other or further exercise thereof or the exercise of any other right or remedy. Buyer shall pay all costs and expenses paid or incurred by Seller in enforcing its rights hereunder including, without limitation, reasonable attorneys’ fees and court costs.

14. PERMITS AND LICENSES:Buyer shall secure and pay for any and all permits, licenses and governmental fees, inspections and ap-provals necessary for the installation, erection, and use of the Equipment or Parts. Seller will secure and pay for permits required for Seller to perform Services. Buyer shall promptly reimburse Seller in the event Seller must secure or pay for any license, fee, inspection or approval to perform Services.

15. COMPLIANCE WITH REGULATIONS:Seller shall provide Equipment in accordance with Seller’s good faith interpretation of applicable national codes and regulations in effect on the date of the Agreement. However, due to possible interpretations of such codes and regulations, Seller makes no representation and does not warrant or guarantee that Equipment does comply with all laws, codes, regulations and standards applicable to the use or operation of the Equipment within Buyer’s operation, or will eliminate hazards to Buyers’ personnel. Seller shall not be liable for injuries resulting from the removal or defeat of or additions or modifications to instructions, notices or warnings, guards or safety devices furnished or recommended by Seller. Any other national safety standards will be followed only when specified by Buyer and agreed to by Seller in this Agreement. In the event field modifications of Equipment or Parts are officially mandated within three (3) months after Start-Up Date, Seller will at Buyer’s request make such field modifications at Buyer’s expense but not to exceed Seller’s cost thereof. Buyer shall comply with all applicable laws and regulations in respect of its performance under this Agreement.

16. PATENTS:Seller shall indemnify, defend and hold harmless Buyer from any and all claims, actions, damages, costs, expenses and reasonable attorneys’ fees arising out of a claim of infringement of any patent alleged to have occurred as a result of the use of the Equipment, provided, however, that Seller shall have no obligation to defend, indemnify or hold harmless Buyer from any claim or threatened claim unless (i) Buyer promptly notifies Seller in writing of the claim or threatened claim; (ii) Seller has sole control of the response to the claim or threatened claim and of the defense of any action and of any negotiation or agreement relating to the settlement thereof; (iii) Buyer cooperates fully in the defense of the claim as requested by Seller at Seller’s expense; and (iv) the claim or threatened claim does not relate to (1) any modification of Equipment anyone other than Seller, (2) the use of Equipment with any equipment or parts not provided by Seller, or (3) any feature of the Equipment that was constructed or configured according to specifications provided by Buyer. At any time Seller is concerned about the possibility of any infringement or a claim therefore being asserted relating to the Equipment, or upon a finding by any court of competent jurisdiction of

infringement relating to the Equipment, Seller may, at its sole option and expense, either (i) procure for Buyer the right to continued use of the Equipment; (ii) modify the Equipment to avoid the claim of infringement; or (iii) substitute a suitable non-infringing replacement therefore. In no event shall Seller be liable to Buyer for any lost profits, consequential, exemplary, or incidental damages arising out of any claim or threatened claim of infringement or arising out of the modification of, or the substitution of different equipment the Equipment to avoid any claim or threatened claim of infringement. Notwithstanding the foregoing, Buyer shall indemnify, defend and hold Seller harmless from any and all claims, actions, damages, costs, expenses and reasonable attorney’s fees arising out of a claim that any Equipment, or part thereof, manufactured or rendered by Seller according to Buyer’s specifications, constitutes an infringement of any patent, copyright or trademark or infringes any other rights of any person.

The foregoing patent indemnity from Seller shall not extend to any equipment, software, parts, components or accessories not designed or manufactured by Seller. To the extent permitted, Seller will assign to Buyer whatever indemnity rights Seller is authorized to assign from an OEM to Buyer. with respect to that manufacturer’s equipment, software, parts, components and accessories.

17. LIMITATION OF LIABILITY:Buyer acknowledges that the Price is predicated on the enforceability of the following limitation of liability, that the Price would be substantially higher if Seller could not limit its liability as herein provided and that Buyer accepts this limitation of liability in exchange for such lower Price.

In no event shall Seller be liable to Buyer for any charges whatsoever, under any legal theory, in an aggregate amount in excess of the 7% of the contract price of the Equipment.

Notwithstanding anything to the contrary contained in this Agreement, Seller and Buyer waive all claims against each other (and against each other’s parent company, affiliates, contractors, subcontractors, consultants, employees, agents and vendors) for any consequential, incidental, indirect, special, exemplary or punitive damages (including, but not limited to, loss of actual or anticipated profits, revenues or product; loss by reason of shutdown or non-operation; increased expense of manufacturing, operation, borrowing or financing; loss of use, productivity or shop space; or increased cost of capital), and regardless of whether any such claim arises out of breach of contract or warranty, tort, product liability, indemnity, contribution, strict liability or any other legal theory. All limitations in this Agreement on Seller’s liability, shall apply notwithstanding the fact that Seller’s warranties fail of their essential purpose or are held to be invalid or unenforceable.

Notwithstanding anything herein to the contrary, the rights and remedies specifically set forth in this Agreement are the sole and exclusive rights and remedies available to the parties, and neither party shall be entitled to avail itself of any other rights or remedies.

18. GOVERNING LAW:This transaction shall be deemed to have been made and


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entered into and shall be construed and enforced in accordance with the laws of the State (and then Country if no State) where the agreement is agreed and signed. Subject to the provisions of these Terms and Conditions of Sale, particularly Section 18 hereof, any suit commenced to enforce any right hereunder shall be instituted and maintained exclusively in any court of competent jurisdiction in Brisbane,Australia and the parties submit to, consent to, and waive any objection to the jurisdiction of those courts.

19. DISPUTE RESOLUTION:All disputes that arise out of or in connection with this Agreement : (i) outside of the United States, shall be finally settled under the Rules of Arbitration of the International Chamber of Commerce. (ii) within the United States shall be finally settled under the rules of the American Arbitration Association.

by a sole arbitrator appointed in accordance with the above rules, provided, however, that if the dispute involves a claim or counterclaim in aggregate amounts in excess of USD $500,000 (exclusive of interest and costs) three arbitrators shall be appointed in accordance with said rules.

Every person nominated or recommended to serve as an arbitrator hereunder shall be a neutral and impartial lawyer who has had training and experience as an arbitrator and who is or has been a partner in a law firm for at least 10 years as a practicing attorney specializing in the discipline that is the subject of the controversy, claim or dispute, with experience in the resolution of large commercial disputes.

Consistent with the expedited nature of arbitration, each party will, upon the written request of the other party or parties, provide the other with copies of documents relevant to the issues raised by any claim or counterclaim. Other discovery may be ordered by the arbitrator(s) to the extent the arbitrator(s) deems additional discovery relevant and appropriate, and any dispute regarding discovery, including disputes as to the need therefore or the relevance or scope thereof, shall be determined by the arbitrator(s), which determination shall be conclusive. The parties explicitly agree that exclusion of evidence by the arbitrator(s) on the grounds of irrelevancy or redundancy shall not be grounds for failure to confirm and enforce the award.

All expenses and fees of the arbitrator(s) and expenses for hearing facilities and other expenses of the arbitration shall be borne by the losing party unless the arbitrator in the award assesses such expenses other than to the losing party. Each party shall bear its own counsel fees and the expenses of its witnesses.

Any provisional remedy shall be available from the arbitrator(s) pending arbitration of the dispute. Any party may make an application to the arbitrator(s) seeking injunctive or other interim relief, and the arbitrator(s) may take whatever injunctive or other interim measures they deem necessary in respect of the subject matter of the dispute until such time as the arbitration award is ren-dered or the controversy is otherwise resolved. Such


interim measures may be taken in the form of an interim award, and the arbitrator may require security for the costs of any such measures.

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1.7 General Contact Information Sandvik Mining & Construction

Region 1 USC USA & CanadaTab Siegrist PLM Exploration Drills +1 404 5722261

Region 2 LAM Latin America Patricio Apablaza PLM Exploration Drills +56 2 6760275

Region 3 WAS West AsiaKausik Sen PLM Exploration Drills +91 2027104811

Region 4 EUR Nth/Central EuropeBob Taskovic PLM Exploration Drills +38111 222 7703

Region 5 CIS RussiaDmitry Lykov PLM Exploration Drills +7 495 9807556

Region 6 EAS East AsiaHaodong Xu PLM Exploration Drills +86 1065 3099706

Region 7 APC Australia PacificNeil Emery PLM Exploration Drills +61 7 36377446

Region 8 AFR AfricaJacques Erasmus PLM Exploration Drills +27 113147461

Please visit our website: www.miningandconstruction.sandvik.com

CONTACT INFORMATION

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2. GENERAL DESCRIPTIONThe Sandvik DE710 is a powerful and compact mid range diamond core drilling rig.

The Sandvik DE710 is the most versatile drill in its class, and is field proven in 4 continents.

Due to the compact size of the DE710 rig it can be configured to suit the following transport applications; • 4x4 truck mounted • Track carrier mounted (powered from the rig hydraulic system) • Skid or jack up style • Trailer mounted

The Sandvik DE710 can be packed for shipment in a standard 20ft shipping container.

The 8.925 metre long drill mast has a capacity to angle drill between the vertical position and 450. It lowers to a supported position for transportation. The design allows for the pulling of core tubes and running of rods and casings in 6 metre lengths. The mast has a mast dump system, to allow the mast height to be as low as possible to the ground level, for ease of operation by the driller and the offsider.

The hydraulic system for the rig is divided into five separate open loop circuits, which are powered by a John Deere JD6068TF250 or Cummins engine with a peak power rating of 134 kW (180 HP) at 2200 rpm.

GENERAL DESCRIPTION

DE710


3. DETAILED SPECIFICATIONSIn keeping with Sandvik standard drill rig rating practise, mechanical and hydraulic inefficiencies have been applied, all ratings are actual not theoretical.

Model • Sandvik DE710 Drill Rig.

Type • All hydraulic chuck drive core drill, specially designed for diamond core drilling up to the rated specifications.

Drill Mast • 6 metre rod pull capacity. • Capable of angles from vertical to 45°. • 1067mm mast dump. • Standard hydraulic mast raise cylinders

Drill Rod Rack • Racks rated full rig depth capacity in 6m stands. • Racks full rig capacity at all rated drilling angles. • Operator’s platform supplied.

Diesel Engine • John Deere JD6068TF250 or Cummins 6BTA 5.9C or QSB 6.7 Engine • 134 kW (180 HP) at 2,200 rpm.

Rotation P Head • P chuck drive • Side racking rotation head, moves to the left hand side of the mast, to allow operation of the main and wire line winches • Variable speed control of the rotation head speed, controlled from the control cabinet • Hollow spindle will accept up to P size drill rods. • Maximum inside diameter of spindle = 117mm • Air to oil lube oil cooler fitted in front of engine radiator. • Lube oil filter fitted on rig base. • High-low manual gear change. • 385 -1,500 rpm (step-less speed control - high gear) • 100 - 833 rpm in low gear • Chuck jaws = 5 per set double angle design • Out put torque at 100% efficiency: • Maximum torque low gear = 3,660 Nm to 194 rpm • Maximum torque high gear = 691Nm to 1,026 rpm • Boost Kit required for operation above 3000 mt

DETAILED SPECIFICAITONS

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Head Traverse • Hydraulic cylinder direct coupled to the Rotation Head carriage. • 3.54 m (11ft 3 inches) traverse • Maximum speed of 30 m/min up or down • Pull down 53.2 Kn (12,000 lbf) • Pull out 91.2 Kn (20,500 lbf)

Main Winch • Maximum pull 76.6 kN (17,200 lbs). • Maximum speed 55m/min. • Variable speed control of the main winch rope speed, controlled from the control cabinet • Failsafe park brake (spring applied and hydraulic pressure to release) is built into the main hoist gear box assembly.

Water Pump • FMC (Bean) W1122BCD • 37 GPM (140LPM) at pressures up to 1000 PSI (7000 kPa). • The water pump flow rate is controlled and is infinitely variable from the control cabinet.

Rod Breakout • Using rotation head in low gear at slow speed • 3,660 Nm. PQ head

Rod Clamp • Hydraulically operated, self energising rod clamp. • Easy to remove jaws. • Rod clamp jaw sets supplied for sizes B+, N+, H+ and P+ (44.5mm to 177.8mm) diamond drill rods.

Wire Line Winch • Capacity of 1,000 metres of 6 mm wire rope. • Variable speed control of the wire line winch rope speed, controlled from the control cabinet • Maximum pull 7.8 kN bare drum. • Maximum speed 270 m/minute full drum

Hydraulic Circuit • Highest quality axial piston pumps and motors in three independent open circuits, plus a pilot circuit. • Full flow 10 micron Beta rated return oil filtration. • Larger than average hose and control valves sizes to achieve highest possible circuit efficiency. • Air over Oil hydraulic oil cooler.

Rod Spin Guard • Cages off the rotating rods from the operator • Hydraulically interlocked with rotation • Reduces the rotation speed to 100 rpm when cage is opened.

Breakout Tool (Optional) • Capable of making up and breaking out drill rod joints with a maximum torque of 7500 Nm.

Depth CapacitiesRod Size B N HDepth Metres 1300 1000 680

DETAILED SPECIFICAIIONS

DE710


4. FAMILIARISATION TOUR

This section has been included to assist the operator to identify and locate the various components, which make up the Sandvik DE710 Drill Rig. An explanation of the operation of the components is listed in this section.

The familiarisation tour of the drill rig is Ground Level Based. All components can be located by walking around the rig at ground level.

4.1 Left Hand Side Mast

Refer to figure 1 for item number locations. 1. Rotation head 2. Mast structure 3. Rod clamp assembly 4. Breakout tool assembly 5. Mast Stay

FAMILIARISATION TOUR

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4.2 Left Hand Side Tray

Refer to figure 1 for item number locations 1. Jack leg assembly. The rig has four jack legs one at each corner of the tray. 2. Tray structure 3. Emergency stop switch and battery isolation switch 4. Hand pump to fill hydraulic oil tank 5. Hydraulic oil tank 6. Rig Battery 7. Control Cabinet Assembly 8. Fold Down Drillers Platform 9. Fuel/Water Separator 10. Rod Spin Guard 11. Fire Extinguisher 12. Jack Leg Controls 13. Mast Stay


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4.3 Rear of Rig

Refer to figure 1 for item number locations 1. Control cabinet 2. Fold down drillers platform 3. Track Trammig Controls 4. Jack Legs 5. Mast 6. Breakout Tool


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4.4 Right Hand Side

Refer to figure 1 for item number locations

1. Main Winch 2. Wire Line Winch 3. Cooler Radiator 4. Mast Stay 5. Mast Rack Support 6. Mud Pump 7. Main Winch Sheaves 8. Wire Line Winch Sheaves 9. Track Final Drive 10. Rotation Head 11. Control Panel 12. Rod Slide


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5. SAFETY INSTRUCTIONS

5.1 Safety Risk ProtocolSafety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or other persons. In the interest of safety to all personnel, who will operate and work with this drill rig. The following protocol will be used through out this section of the operator’s manual to indicate any potential safety risks.

• The purpose of the safety symbol and the signal word is to attract your attention to possible dangers. • The safety symbol, signal word and the explanations with them deserve your careful attention and understanding. • The safety symbol and the signal word do not by themselves eliminate any danger. • The instructions or warnings they give are not substitutes for proper accident prevention measures. • If for any reason you do not fully understand the wording in this section of the operator’s manual, you should contact your supervisor or contact Sandvik as soon as possible.

Sandvik cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are therefore not all inclusive.

If a tool, procedure, work method or operating technique not specifically recommended by Sandvik is used, you must satisfy yourself that it is safe for you and others.

You should also ensure that the product will not be damaged or made unsafe by the operation, lubrication and maintenance or repair procedures you choose. • The information, specifications, and illustrations in this publication are on the basis of information available at the time it was written. The specifications, torque settings, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service given to the product. Obtain the complete and most current information before starting any job. If in doubt, contact Sandvik.

SAFETY INSTRUCTIONS

DANGERThe signal word DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

WARNINGThe signal word WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

Hazards identified by the signal word WARNING present a lesser degree of risk of injury or death than those identified by the signal word DANGER.

CAUTIONThe signal word CAUTION, indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.

CAUTION may also be used to alert against unsafe practices associated with events that could lead to personal injury.

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5.2 Basic Safety Advice • Most accidents involving product operation, maintenance and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. All personnel involved with the operation and maintenance of this rig must be alert to any potential hazards. All personnel should have the necessary training, skills and tools to perform these functions properly. • Safety is up to you. Remember to ask if you do not know. • This manual is your mandatory reference. You must be fully aware of its contents and follow the instructions. Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and understood all the information contained in this manual. • Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death. • Make sure you are fully aware of any emergency procedures. • Make sure that all machinery is secure before operating. • Make sure the machine is set up properly and the drilling equipment is aligned correctly. • Ensure that cables and hoses are clear and secure. • Remember that working machines operate under high stress and loads. • Ensure that your hand tools and equipment are laid out correctly and are properly maintained. • Be sure to carry out the pre operational inspections and above all, report any defects or suspected defects. • Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or other persons. • The hazards are identified by words such as: “DANGER” “WARNING” “CAUTION” • Each of these words means: ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! • The message that appears under the warning, explaining the hazard, can be either written or pictorially presented. • Sandvik cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are therefore not all inclusive. If a tool, procedure, work method or operating technique not specifically recommended by UDR is used; you must satisfy yourself that it is safe for you and others. You should also ensure that the product will not be damaged or made unsafe by the operation, lubrication and maintenance or repair procedures you choose. • The information, specifications, and illustrations in this publication are based on the information available at the time it was written. The specifications, torque settings, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service given to the product. Obtain the complete and most current information before starting any job. If in doubt, contact Sandvik.

SAFETY INSTRUCTIONS

DE710


5.3 Personal Danger and Out of Service TagsThe following information is a general overview of the use of Personal Danger Tags and Out of Service Tags.The use of tags within the workplace serves as a warning that plant and equipment to which a tag is attached cannot be operated. There are two types of tags that are generally used: Personal Danger Tags and Out of Service tags. It is vitally important that correct procedures are followed when these tags are in use in order to prevent injury or damage to plant and equipment.

5.3.1 Personal Danger TagsPersonal Danger Tags are used to control risks arising from situations where equipment is under going maintenance, is under repair or is being constructed or tested. The purpose of which is to ensure equipment is not operated in order to prevent injury to those working on or operating the equipment and to also prevent damage to the equipment. There are many different types of personal danger tags an example is shown in the photograph. • Never operate any switch, control or valve which has a Personal Danger Tag attached. • Only those employees authorized to carry out repairs may attach a Personal Danger Tag. • All persons working on a piece of equipment must attach and remove their own Personal Danger Tag. They must also ensure that all relevant details are completed on the tag, including name, contact telephone number, date, and the reason for attaching tag. • Only the person whose name appears on the tag may remove it. • If you think that the tag is no longer in effect, contact the name of the person whose name appears on the tag, or if not available your supervisor. • Only when it has been cleared for safe operation may the tag be removed.

5.3.2 Out of Service Tags Out of Service Tags are placed on plant and equipment that is out of service for repair, alteration, commission-ing or decommissioning. There are many different types of out of service tags an example is shown in the photograph. • Never operate any equipment, switch or valve that has Out of Service Tag attached. • If you find a piece of equipment that is faulty, you must isolate the equipment, attach an Out of Service Tag to the point of isolation (e.g. plug, switch, control, etc.) and contact your supervisor to repair or decommission the equipment. • Those persons attaching a tag must include their name, contact telephone number, date and the reason for attaching the tag. • Only the person authorized to carry out the repairs or your supervisor may remove the Out or Service Tag when it has been determined that the equipment is safe to operate.

Please refer to the following items for more specific information on the use of Personal Danger Tags and Out Of Service tags. • The standard operating procedures for this rig as outlined by company that owns and operates this rig. • The standard operating procedures for the mining or exploration company that the rig is working for. • Local / state or federal laws governing the use of Personal Danger and Out Of Service Tags.

SAFETY INSTRUCTIONS

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5.4 Safe General Work PracticeWarning Signs and Labels • There are several specific safety signs on your machine. Please take the time to familiarize yourself with these safety signs. • Make sure that you can read all safety signs. Clean or replace these if you cannot read the words or see the pictures. When cleaning the labels use a cloth, water and soap. Do not use solvent, gasoline, etc. • You must replace a label if it is damaged, missing or cannot be read. If a label is on a part that is replaced, make sure a new label is installed on the replaced part.

5.5 General Hazard Information • Ensure that you and your assistants have the appropriate Personal Protection Equipment before starting work and that the equipment is utilised while working. • Wear a hard hat, protective glasses and other protective equipment as required by job conditions. • Do not wear loose clothing or jewellery that can catch on controls or other parts of the machine. • Make certain any protective guards and covers are fitted on the machine and securely bolted to the machine. • Keep the machine and the area around the machine, especially the deck, walkways and steps, clean and tidy and free of foreign material, such as debris, oil, tools etc. • Securely store all loose items such as lunch boxes, fuel and oil drums, drilling consumables, tools and other items, which are not part of the machine. • Prolonged exposure to load noises can cause impairment or loss of hearing. Wear a suitable hearing protective device such as earmuffs or ear plugs to protect against objectionable or uncomfortably loud noises. • Never put maintenance fluids into glass containers. • Use all cleaning solutions with care. • Report all needed repairs. • Do not allow unauthorised personnel on the machine. • Know the appropriate work-site hand signals and who gives them. Accept signals from one person only.

SAFETY INSTRUCTIONS

DE710


5.6 Perform All Maintenance Unless Otherwise Specified As Follows:

• Park the machine on level ground with the mast “LOWERED”. • Move all control levers to the neutral or “OFF” position. • To stop the engine, turn the Engine Start Switch “OFF” and remove the key. • Turn the Battery Disconnect Switch “OFF” and remove the key. • Attach an “PERSONAL DANGER TAG” an a “OUT OF SERVICE” or similar warning tag to the start switch at the drilling control panel and to the battery disconnect switch before servicing or re pairing the machine. • Wear an approved safety harness when any climbing over 2 metres in height is required.

SAFETY INSTRUCTIONS

CAUTION• Maintenance to the rig refers to general greasing of components and the changing of lubricating • oils as required.

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5.7 Major Repairs to the Rig

Always replace drill rig parts with factory parts or factory-approved equivalents.

5.7.1 Climbing Up onto the MastWhenever working above ground level it is good practice and the manufacturer’s recommendation that an appropriate safety harness and/or fall retarder is worn, on any component of the drill mast during normal drilling operation or for maintenance. • Wear an approved safety harness where any climbing over 2 metres in height is required.

5.7.2 Compressed Air • Compressed air can cause personal injury or death. When using it for cleaning, wear a protective face shield, protective clothing, gloves and protective shoes. The maximum air pressure must be below 205 kPa (30 psi) for cleaning purposes. • All flexible hoses used to convey compressed air, must be securely attached and have a suitable restraint device fitted to each hose end. This device must be securely fasten to the rig tray, rotation head, rotation head hose arm (if fitted) and mast assembly as required

5.7.3 Fluid Penetration • Escaping compressed air and fluids under pressure, even via a pinhole leak, can penetrate body tissue, cause serious injury, and possible death. • Avoid the hazard, by relieving the pressure before disconnecting hydraulic or compressed air lines. Tighten all connections before applying pressure. • Always use a board or cardboard when checking for a leak to protect you. • If an accident occurs, see a doctor familiar with this type of injury immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result.

5.7.4 Crushing or Cutting Prevention • Support equipment and implements properly when working beneath them. Do not depend on hydraulic cylinders to hold them up. An implement may fall if a control is moved, or if a hydraulic line breaks. • Never attempt adjustments while the rig is drilling or the engine is running unless otherwise specified. • Stay clear of all rotating and moving parts. • Keep objects away from moving fan blades. They will throw or cut any object or tool that falls or is pushed into them. • Do not use a kinked or frayed wire rope cable. Wear gloves when handling a wire rope cable. • Chips or other debris can fly off objects when struck. Make sure no one can be injured by flying debris before striking any object.

SAFETY INSTRUCTIONS

CAUTION• Refer to the points raised in PERFORM ALL MAINTENANCE SECTION. • Sandvik cannot anticipate every possible circumstance that might involve a major repair hazard. • If a tool, procedure, work method, repair or operating technique is used, you must satisfy • yourself that it is safe for you and others. • You should also ensure that the product will not be damaged or made unsafe by the operation, • lubrication and maintenance or repair procedures you choose.

DE710


5.7.5 Burn Prevention • Explosive release of fluids and steam from pressurized cooling system can cause serious burns. • Check the coolant level only after the engine has been stopped and the filler cap is cool enough to remove with your bare hand. • Slowly loosen the radiator cap to the first stop to relieve pressure before removing completely. • Cooling system additive contains alkali that can cause personal injury. Avoid contact with the skin, eyes and mouth. • Hot oil and components can cause personal injury. Do not allow hot oil or components to contact the skin. • Relieve all pressure in air, oil, fuel or cooling systems before any lines, fittings or related items are disconnected or removed. Allow any item that must be disconnected or removed to cool until the item can be handled with your bare hand or wear protective heat resistant gloves. • The exhaust system of the rig engine can get very hot. Avoid contact with any body part.

5.7.6 Fire Extinguishers • One fire extinguisher is fitted to the machine. Know its location and how to use it and have it serviced as recommended by the manufacturer.

SAFETY INSTRUCTIONS

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5.7.7 Toxic and Irritating Substances • If the machine is operated indoors, discharge engine exhaust fumes outdoors. • Fuels, oils, coolants, lubricants and battery electrolyte used in this rig and compressor (if fitted) are typical of the industry. Care should be taken to avoid accidental ingestion and skin contact. In the event of ingestion seek medical treatment promptly. Do not induce vomiting if fuel is ingested. Wash with soap and water in the event of skin contact. • Wear an acid resistant apron and a face shield or goggles when servicing the battery. If electrolyte is spilled on skin or clothing immediately flush with large quantities of water. • Have a Material Safety Data Sheet (MSDS) on site for all oils, fuel, lubrication oils, coolants and chemicals, drilling muds and fluids etc. Follow any guidelines outlined on the MSDS for any particular item.

5.7.8 Electrical Shock • Keep the rig, mast, towing vehicle or equipment carrier, compressor (if fitted), hoses, tools and all personnel at least ten (10) feet /3 metres from power lines and buried cables. • Keep all parts of the body and any hand held tools or other conductive objects away from exposed live parts of the electrical system. • Maintain dry footing, stand on insulating surfaces and do not contact any other portion of the rig or the compressor (if fitted) when making adjustments or repairs to exposed live parts of the electrical system. • Attempt repairs only in clean, dry well lighted and ventilated areas.

5.7.9 Fire or Explosion Prevention • Refuel from a fuel tank designed for this intended purpose. • All fuels most lubricants and some coolant mixtures are flammable. • Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire. • Do not smoke while refuelling or in a refuelling area. • Do not smoke in areas where batteries are charged, or where flammable materials are stored. • Do not smoke when checking battery electrolyte levels • Disconnect the grounded (negative) battery connection prior to attempting any repairs or cleaning of the rig. • When using jumper cables always connect positive (+) cable to positive (+) terminal of battery connected to starter solenoid and negative (-) cable from an external source to starter negative (-) terminal. (If not equipped with starter negative (-) terminal, connect to the engine block.) • Turn off a battery charger before making or breaking any connections to the battery. • Keep electrical wiring, including the battery terminals and other terminals in good condition. Replace any wiring that has cracked, cut, abraded or otherwise degraded insulation or terminals that are worn, discoloured, or corroded. Keep all terminals clean and tight. • Keep grounded conductive objects such as tools away from exposed live electrical parts such as terminals to avoid arcing, which might serve as a source of ignition. • Do not use starting aids such as ether on engines equipped with inlet manifold heaters. Such use could result in an explosion and personal injury. • Keep all fuels and lubricants stored in properly marked containers and away from all unauthorised personal. • Clean up spills of fuel, oil and coolant immediately after the spill occurs. • Store all oily rags and other flammable material in a protective container, in a safe place.

SAFETY INSTRUCTIONS

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• Do not permit flammable materials such as fuel, oil and other debris to accumulate on the machine. • Do not park or operate the machine under any trees or allow the mufflers or the exhaust outlets from any engines of the rig to contact the foliage of any trees etc. • Do not expose the machine to flames, burning brush, etc. • Shields, which protect hot exhaust components from oil or fuel spray in the event of a line, tube or seal failure, must be installed correctly. • Replace damaged fuel tanks, fuel lines immediately, rather than attempting to weld or otherwise repair them. • Do not store or attempt to operate this rig or the compressor (if fitted) with any known fuel leaks. • Do not use flammable solvents for cleaning purposes. • For rigs and equipment fitted with an acoustic sound deadening enclosure. • Do not permit liquids, of any kind or oil film, to accumulate on the bottom covers or on or under or around acoustic material, or on any external or internal surfaces. • Wipe down using an aqueous industrial cleaner or steam clean as required. If necessary, remove acoustic material, clean all surfaces, and then replace acoustic material. • Any acoustic material with a protective covering that has been torn or punctured should be re placed immediately to prevent accumulation of liquids or oil film within the material. • Shut off the engine and allow the equipment to cool before adding fuel, hammer oil, coolant, lubricants, air line antifreeze compound or battery electrolyte, or before replacing ether starting aid cylinders.

5.7.10 Lines, Tubes and Hoses • Do not bend or strike high-pressure lines. • Do not install bent or damaged lines, tubes or hoses. • Do not weld or flame cut on pipes or tubes that contain flammable fluids. Clean them thoroughly with non-flammable solvent before welding or flame cutting on them. • Repair any loose or damaged fuel and oil lines, tubes and hoses. • Leaks can cause fires. Contact Sandvik for repair or replacement. • Check lines, tubes and hoses carefully. Do not use your bare hand to check for leaks. Use a board or cardboard to check for leaks. See “FLUID PENETRATION” above for more details. Tighten all connections at the recommended torque. Replace if any of the following conditions are found: • End Fittings damaged or leaking. • Outer covering of flexible hoses, chafed or cut and wire reinforcing exposed. • Outer covering ballooning locally. • Evidence of kinking or crushing of the flexible part of hose. • Armour shields embedded in the outer cover. • End fittings displaced. • Make sure that all clamps, guards, and heat shields are installed correctly to prevent vibration, rubbing against other parts, and excessive heat during operation.

SAFETY INSTRUCTIONS

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6. SAFETY WARNING SIGNS AND LABELS ON THE MACHINEAll of the safety warning signs and labels on the machine will be presented in this section.

There are several specific safety signs and labels on your machine. Please take the time to familiarise yourself with these safety signs and labels. Make sure that you can read all safety signs and labels. Clean or replace any sign or label if you cannot read the words or see the pictures. When cleaning the labels use a cloth, water and soap. Do not use solvent, gasoline, etc. You must replace a sign or label if it is damaged, missing or cannot be read. If a sign or label is on a part of the machine that is replaced, make sure a new label is installed on the replaced part. The following information outlines the warning signs on the Sandvik DE710 drill rig, the reason for the sign and a location of the sign.

6.1 Personal Protective Equipment (PPE) Refer to figure 1.

The four signs indicate the minimum requirements for Personal Protective Equipment (PPE) that must be worn by all personnel on the drill site. Several other types of PPE may be required due to onsite conditions. Locations of SignsGenerally located on the left hand side near the left hand rear jack leg of the of the drill rig.

SAFETY WARNING SIGNS & LABELS

DE710


6.2 Warning Signs on the Control Cabinet

Refers to Winch Float Operation and Working Near or Under Power Lines.

Refers to Track Tramming Operations.


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6.3 Warning Signs Rig Emergency Stop

Refers to working under suspended objects

Refers to Mast Dump Operation


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6.4 Warning Signs on the Mast

Refers to Foot Clamp

Refers to climbing the mast

Refers to stepping onto hydraulic suction manifold


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6.5 Warning Sign Rod Spin Guard

6.6 Caution Sign on Rig Cab

Refers to Nip Points and Operation

Refers to “Driver Only” Permission


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7. MANUAL HANDLING • Where possible any lifting of equipment around the drill site should be carried out using a suitable mobile crane. However, if manual lifting is required the basic factors outlined below will assist to lift the load safely. • Remember the leg and thigh muscles are stronger than those of the back and abdomen.

7.1 Size Up the Load • You must know the weight and size (length, width and height) of the load to be lifted and moved. • If the load will obscure your vision when lifted, seek assistance from another person to lift and move the load. • If the load is above 50 lbs. (23 kilograms) in weight, seek assistance from another person to lift and move the load. • The length and width and height of the load should be less than 16inches (406mm) to allow your arms to be as straight as possible when lifting and carrying the load. If the load is greater in width than 16 inches (406mm), seek assistance from another person to lift and move the load. • You must know where the load is to be lifted and moved too. Ensure that the path to and from the load is clear of all obstacles and that the footing is level and of a solid and non slip construction. If the load is to be lifted to a height greater than your waist, it may be necessary to arrange for a platform for the load to be lifted to and then the load to be lifted again to the final position. • The weight of the load should be evenly distributed. • The load should be of a solid nature eg; a wooden box. If the object to be lifted is flexible, it may be necessary to securely fasten the item into a solid box.

7.2 Correct Foot Positions • Place one foot behind the load (rear foot) and the other beside the load (advanced foot), pointing in the direction in which the load is to be moved. • This action will bring the body over the load and both the load and the body are within the area of the feet. So that when the lift takes place, there is no fear of over balancing, and therefore no excessive strain on the back muscles. • Maintain a Straight Back • In order to lower the body to reach the load and maintain a straight back the legs must be relaxed the advanced leg to be approximately 90 degrees with the foot flat on the ground. • This will bring you within a firm grip of the load with the arms straight. • Do not confuse a straight back with a vertical back, which can not always be achieved.

7.3 Proper Hold • Grip the load with a full finger and palm grip. Do not use your finger tips to grip the load. Keep the head erect with the chin in. • This will assist in stabilising the straight back. Keep the arms close into the body and inside the legs.

7.4 Use Body Weight • Start the lift by the thrust of your legs, remember to maintain the factors already mentioned. • Move forward towards the load, and by keeping the arms straight the load will remain close to the body. The body is now moving upward and forward. The legs having initiated the move will now continue to straighten and lift the body and load. The forward movement of the body and the load will combine to make the lift so much easier.

7.5 When Moving The Load • Use your feet to change direction. • Do not twist your back to change direction or to lower the load. • By keeping the arms relaxed straight against the body, the movement of the legs in walking forward will help to propel the load.

7.6 To Lower the Load • To lower the load is the reverse of the factors outlined above.

MANUAL HANDLING

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30 (196) WI864-033 Revision 2

8. SAFE DRILLING PRACTICE WARNINGS • The following warnings attempt to highlight some of the more dangerous aspects of operating this machine. By no means do they relieve the operator of the need to be completely familiar with all sections of this manual at all times. • Before attempting to operate this machine it is mandatory that you read the operators manual carefully and completely. Familiarise yourself with all controls, gauges, levers and accessories and know what \ each item is designed to perform, its use, control and safety requirements and to follow instructions as outlined in this manual paying particular attention to all warning and caution notices. • Prior to operating this machine you must be qualified by experience and training in the practices of drilling related to the various drilling techniques that this machine can perform • You must be trained by your employer in safe working practices and methods to a standard whereby you are able to instruct others who are under your responsibility and are required to work on and operate this machine. • You must also read and understand all aspects of the safe working procedures and warnings related to optional equipment and accessories used with this machine. • Contact the manufacturer if you are in doubt as to the safe working condition of any component or its function or the maintenance procedures of this machine or before continuing to work with a suspected faulty component or machine. • Do not operate this machine or carry out any maintenance or other tasks without proper authorization from your employer. • Do not operate a faulty machine especially if it is in need of adjustment or repair. • Whenever working above ground level it is good practice and the manufacturer’s recommendation that an appropriate safety harness and/or fall retarder is worn, on any component of the drill mast during normal drilling operation or for maintenance requirements. • Never use the main winch, wire line winch or head traverse to transport people from one locality on the machine to another locality. • Do not exceed the rated capacities as listed on the specification sheet of any component, in particular: • main winch pull • wire line winch pull • traverse pull out • traverse pull down • engine rpm maximum specified • water pump maximum pressure and flow specified • rotation head maximum rpm • Do not exceed the rated capacity of any equipment fitted as an optional extra on this rig. • Beware of excessive head rod vibration and rod buckling due to excessive pull down. • Be aware of over head power lines and any other obstacles, before raising the mast. LOOK UP AND LIVE. • When raising or lowering the mast, ensure that no personnel are standing on the drill deck. • The mast stay must always be fitted into the correct location and secured to eliminate whipping or movement of the drill mast. • Never move the rig from site to site with the mast up. • Never leave a weight suspended from the wire line winch with the engine shut off. • Always pull on the rod string with main winch rope before opening the rod clamps. Slow down and stop the winch and suspended rod string before engaging the rod clamps. • Never stop the engine whilst rods are still suspended from the main winch. Engage the rod clamps, or attach the rod string to the rotation head. • Never stand under any suspended loads. • Wire ropes absorb moisture and corrode internally without any detectable sign on the surface. Even if the surface condition of the rope appears perfect, the main winch rope must be replaced every two years (single shift) or12 months (double shift) or more frequently if drilling water contains corrosive elements. • Ensure fire extinguishers are reachable and fully operational at all times. • Always disconnect the electrical safety switch (refer to electrical circuit) before welding on the machine, or when leaving the machine unattended. When welding, always apply the earth lead as close as possible to the item being welded. • Always service the machine with the recommended oils and greases or their equivalents. Refer to chapter 5 - Basic Maintenance.

SAFE DRILLING PRACTICE WARNINGS

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• Do not at any time allow hands or feet to rest on the following • Rod Clamp • The mast structure, as the rotation head is travelling up or down. • Rotation Head • Whenever a rod spanner or other loose tool is used to restrain the rotation torque, be aware that a carelessly placed tool can slip and kill. • When connecting or disconnecting a rod joint using the rotation head, always use the rotation control lever. For more details on this subject refer to chapter four - “Rotation”. • Observe the following safety note and warning regarding the use of the pilot control levers for the main drill functions.

• During normal drilling operations, it is necessary to work close to moving components such as rotating drill rods, winch ropes, sheaves, rod clamps, hydraulic cylinders, drive shafts, fan blades, belts, pulleys, rotating drive head, pivoting frames, jacking legs and various other components. When this is necessary, use good safe working practices paying attention that no part of the body or clothing (avoid loose clothing and tuck in long hair) be caught on or near any moving item, pinch point, heat source, or projection which could cause injury or damage. The operator must ensure a safe working environment for themselves and others assisting. • Certain component testing requires the motor to be running throughout their duration. In this case use due care and carefully follow the testing procedures as outlined in this manual. • Always replace parts with factory parts or factory approved equivalents. • Do not modify the drill in any way without the prior written approval of the manufacturer. • Always use the same grade bolts, hoses and cables as supplied or recommended by the manufacturer. • Before opening or disconnecting any hydraulic line or disconnecting any load bearing component, support all loads by blocks, chains or other appropriate means, reduce the systems pressure to zero and stop the motor. • Make sure all guards are in place and in good operating condition before starting the machine. • Observe and follow all maintenance, service and operating instructions. • Obey all safety rules. • All warning signs, operating instructions and decals attached to the machine must be clearly readable and left unobstructed at all times. If any of these become damaged they must be replaced immediately. • Always visually inspect the drill whilst it is working so as to become aware of early warning signs such as oil drips or excessive movement. • Always thoroughly inspect the machine if it has been left unattended for some time to ensure that no sabotage has occurred or that hydraulic lines have been left closed or blocked after carrying out servicing or maintenance procedures. • Always vent any pressure from the drill rods before breaking the joints. • Always correctly set the hold back, pull down and micro feed controls.

SAFE DRILLING PRACTICE WARNINGS

WARNING• Never engage two or more main drilling functions at the same time, with the exception of and • only with care:• • Rotation + Traverse • If a wrong combination of two or more pilot units is operated at the same time, a very dangerous • control malfunction can occur, resulting in an unexpected and sudden surge in speed of one or • the other function.

CAUTION• Neither the MAIN WINCH and WIRE LINE WINCH nor ROTATION or any combination of two or • more control units should ever be used simultaneously other than as stated in the warning note • below.

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32 (196) WI864-033 Revision 2

9. WATER PUMP SAFETY INSTRUCTIONSMany accidents occur every year through careless use of mechanical equipment. You can avoid hazards associated with high-pressure equipment by always following the safety precautions listed below.

• SHUT DOWN OR DISENGAGE the pump and all accessory equipment before attempting any type of service. Failure to do this could cause injury from moving pump parts or components under high pressure.

• BLEED OFF ALL PRESSURE to the pump and piping before attempting any maintenance to the pump. Failure to do so may spray water or chemicals at high pressure onto service personnel.

• NEVER OPERATE THE PUMP WITHOUT A PRESSURE RELIEF VALVE, burst disc, or other type of properly sized overpressure safety device installed.

• ALWAYS USE A PRESSURE GAUGE when operating the pump. The pressure must never exceed the maximum pressure rating of the pump or damage may occur. This damage can cause leakage or structural damage resulting in injury to personnel.

• ENSURE THAT NO VALVES ARE PLACED BETWEEN THE PUMP AND PRESSURE RELIEF VALVE. If the pump is started with a closed or restricted valve in-line before the pressure relief valve, the pump may build up pressure in excess of its rated limits and burst causing injury to personnel.

• USE SHIELDS OR COVERS AROUND PUMPS when pumping hot water, chemicals, or other hazardous liquids. This precaution can prevent the exposure of service personnel to these fluids should leakage occur.

• ALWAYS USE GUARDS on all belt drives and couplings. Guards can prevent personnel from becoming entangled and injured in rotating parts.

• USE EXTREME CAUTION WITH SOLVENTS used to clean or degrease equipment. Most solvents are highly flammable. Observe all safety instructions on packaging.

• NEVER MODIFY THE PUMP TO PERFORM BEYOND ITS RATED SPECIFICATIONS.

WATER PUMP SAFETY INSTRUCTIONS

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10. PRE-OPERATION INSPECTION

The pre-operation inspection is a series of checks, which must be carried out before the rig is moved from site to site and before operation of the rig is commenced. Each check will ensure the machine is prepared for normal operation.

The pre-operation inspection is concerned with the whole rig including climbing on board to inspect the mast assembly. The inspection involves checking for:

• Loose, broken or missing parts • Dirt and trash build up • Fluid leaks and levels • Control lever setting • Instrument operation • Correct adjustments • Vision blind spots • Potential hazards • Cleanliness

Start the pre-operation inspection from the drill control cabinet.Refer the familiarisation sections for both the rig and track drive for component location.

10.1 Rig Operation10.1.1 Drill Control Cabinet Check List • Check all control levers are in “Neutral” position or in the “Off” position. • Check all gauges and control levers are in good working order. • Check all hoses and valves for any oil leaks. • Check the fold-down operator platforms (if fitted to the rig) is correctly positioned and secured for operation of the rig. • Check the operator’s platform is free of any grease or mud to ensure the operator will not slip.

10.1.2 Drill Tray Components Check List • Check the jack leg feet are resting against suitable foundation, bed log etc. • Check the oil level in the hydraulic oil tank is at the correct level. • Check the ball valve between the hydraulic oil tank and pump group is open. • Check the engine air filter hood is not clogged. • Check the engine exhaust muffler outlet is not plugged with any foreign matter. • Check the diesel engine fuel, lubricating oil and water coolant and batteries are to the correct operational levels and that all service schedules are up to date. • Check the rig engine radiator is not blocked up with trash. • Check the suction hose and auxiliary hose from the water pump have been correctly connected. • Check the drill deck (tray) for any loose items and secure as required. • Check all hoses and valves for any oil leaks.

PRE-OPERATION INSPECTION

WARNING• Failure to carry out this basic pre-operation checklist could lead to death or personnel injury.• Do not attempt to operate this rig until all repairs that may be required have been completed.• Do not attempt to operate this rig until you have been trained in every function of the rig and fully • understand the operator’s manual.

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34 (196) WI864-033 Revision 2

10.1.3 Mast Structure and Components Check List • Check the main and wire line winch ropes have been correctly reeved over the sheaves at the top of the mast. • Check the operational condition of the main and wire line winch ropes replace as required. • Check the main winch rope clamps are all fitted and securely fasten. • Check all hoses leading to the mast structure and all components are in good working order. • Check the mast is set up for the correct drilling angle. • Check the mast stay rods have been fitted and that all pins used in the assembly of the stay rods have been secured with lynch pins. • Check the platform stay rods have been fitted and that all pins used in the assembly of the stay rods have been secured with lynch pins. • Check the tension stay rod has been fitted and that all pins used in the assembly of the stay rods have been secured with lynch pins. • Check that all components for the mast basket assembly, including the basket support beam have been correctly fitted, and that all bolts are securely tightened. • Check the access ladder to the mast basket assembly is clean and in good working order. • Check any emergency access from the mast basket assembly (if fitted) is clear of any trash debris etc and is in good working order. • Check the mast assembly for any loose items, secure as required. • Check all hoses and valves for any oil leaks. • Check the mast base is firmly resting against a suitable foundation (sleepers). • Check the rotation head lube oil level and that the rotation head and chuck is in good working order. • Check the rotation head lube oil cooling system is in good working order.

10.1.4 Preparations before Engine Start UpThe following procedure will be necessary after shifting position or when starting a new hole. • Ensure that the correct pre-operation inspection has been fully completed and that the maintenance schedule is up to date. • A shut-off ball valve is located between the suction hoses of the pumps and the hydraulic oil tank. Ensure the ball valve is fully “OPEN” provide your own safety lock. • Ensure all control levers are in neutral or in the “OFF” position. • Check the drill deck and mast for loose items. Pay particular attention around the engine fan belt and alternator. Secure all loose items. • Check that no items will catch, or become caught when raising the mast.

10.2 Track Drive to Drill Operation

If this rig is a track drive, climb into the track drive control cabin and locate the drill–track selector valve, item 1 figure 1. Operate the “Drill –Track” selector valve lever into “DRILL” position.

PRE-OPERATION INSPECTION

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11. GENERAL INFORMATION

11.1 FamiliarisationPlease refer to figure 1 for item number locations. 1. Volt Meter This gauge indicates the voltage of the electrical system for the rig. 2. Engine Coolant Temperature Gauge This gauge indicates diesel engine coolant operating temperature. 3. Engine Oil Pressure Gauge This gauge indicates diesel engine lubricating oil pressure. 4. Emergency Stop Switch This switch when activated by pushing on the red button will shut down the engine during an emergency situation. The button must be reset before recommencing drilling operations. To reset the button turn the knob clockwise. 5. Filter Pressure Gauge This gauge indicates the pressure in the hydraulic oil return manifold directly before the oil flows through the main return filter element to the hydraulic tank. It indicates when the filter element needs replacing. 6. Diesel Engine Rpm Tachometer & Hour Meter This gauge indicates diesel engine speed in revolutions per minute. The hour meter gauge indicates the actual operating hours of the rig engine. 7. Engine Start Switch The engine start switch key has three operations which are: • When turned fully clockwise, cranks the diesel engine over, • When the engine starts the key is released, the key will spring return to the “ON” position which supplies power to the electrical system of the engine. • To stop the engine the key is turned counter clockwise to the “OFF” position. • When the engine is not running the key must be in the “OFF” position. 8. Bypass Switch Whenever the engine is started this button must be pushed in and held in until the engine oil pressure builds up to operating pressure. 9. Fuse Holder The fuse holder has been positioned at the control cabinet for ease of trouble shooting of the engine electrical system. 10. Light Switch This switch has two operations which are; • When the switch is pushed “IN” the light in the control cabinet and the lights fitted to the track drive cabinet will not illuminate. • When the switch is pulled “OUT” the light in the control cabinet and the lights fitted to the track drive cabinet will illuminate. 11. Engine Throttle This knob controls the diesel engine speed (rpm). To increase the engine speed pull the handle down. To decrease the engine speed push the handle up.

GENERAL INFORMATION

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36 (196) WI864-033 Revision 2

12. RIG SET UP PROCEDUREThe following information will outline a basic procedure to set the rig up for drilling.

12.1 Initial Preparations 1. Check the drill site is reasonable level. 2. Check the drill site ground conditions will support the weight of the drill rig and the maximum pull out of traverse system of the rig. A typical DE710 drill rig mounted on a crawler base weighs 8,500 Kg (18,700 Lbs.). Maximum pull out of a typical 200DLS is 9301 Kg (20,500 lbs.). The combined weight of the rig and maximum pullout of the traverse system is 8,500 Kg (18,700 lbs.) + 9301 Kg (20,500 lbs.) = 17,801 Kg (39,200lbs.).

3. Position the rig over the proposed drill hole. 4. Remove the jack leg feet from there transport location. 5. Fit and pin the jack leg feet to the inner jack legs 6. Place suitable high quality load bearing hardwood sleepers or bed logs of sufficient strength, size and length to transfer the combined weight of the rig and maximum pullout to the ground. 7. Operate the jack leg control levers one at a time and lower each jack leg onto the sleepers or bed logs. 8. Operate the jack leg control levers one at a time or in combination and level the drill rig tray. Check the drill tray is level with a sprit level and carry out any fine adjustments as required to level the drill rig tray. 9. Climb up onto the mast and check for any loose or broken equipment. Especially the following items

• The bolts and nuts that secure the upper and lower mast sections together. • The bolts and nuts that secure the upper rod slide to the upper and lower mast sections. • The pins the secure the mast stay rods to the lower mast section have lynch pins fitted to them. Also check the adjust pins (middle pin) of the mast stay rods have lynch pins fitted to them. • The bolts and nuts that secure the components of the slide roller to the lower mast section and to the rod slide.

RIG SET UP PROCEDURE

WARNING• Use high quality, load bearing, hardwood sleepers or bed logs of sufficient strength, size and • length to transfer the combined weight of the rig and maximum pullout to the ground.

WARNING• Jack the rig up in a steady manner. Excessive jacking of one corner of the rig could damage • equipment fitted to the rig.

WARNING• Wear an approved safety harness and fall arrestor when ever climbing up to or down from the • mast.

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10. Climb up onto the mast and grease the main winch sheaves at the top of the mast. 11. If required remove the guards from the main rope sheaves at the top of the mast and reeve the main winch rope over sheaves. Replace the guards over the sheaves. 12. If required remove the guards from the wire rope sheaves at the top of the mast and reeve the wire line winch rope over sheaves. Replace the guards over the sheaves.

RIG SET UP PROCEDURE

WARNING• This part of the set up procedure requires the operation of the main and wire line winch control • lever.• There is limited direct line of sight from the control cabinet to the top of the mast when the mast • is lowered. • An observer must be positioned to relay messages to the driller at the control cabinet and the • person near the sheaves at the top of the mast. • Check the main and wire line winch ropes have been positioned over the equipment on the drill • tray so that the ropes will not catch on or become caught by any equipment as the mast is raised. • Check the main and wire line winch ropes have sufficient length to allow the mast to be raised. • It may be necessary to operate the controls of the main and wire line winch during the mast raise • operation to allow the ropes to have sufficient length to stop the rope ends contacting the • sheaves.

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38 (196) WI864-033 Revision 2

13. MAST ASSEMBLY GENERAL INFORMATIONRefer to figure 1 for item number locations.

The mast structure is made up of two sections: 1. Upper mast. 2. Lower mast.

The upper mast section item 1 contains the following: • Main winch and wire line winch rope sheaves. • Support for the upper rod slide.

The lower mast section item 2 contains the following: The rotation head. • The traverse cylinder. • The rod clamp. • Attachment points for the platform support beam. • Attachment point for the mast dump cylinder barrel. • Attachment points for the mast stay rods.

The upper mast section is bolted to the lower section.

MAST ASSEMBLY GENERAL INFORMATION

WARNING• Only structural grade bolts nuts and washers are to be used to connect the mast sections • together.• Refer to the parts book for the correct grade and size of bolts to use to bolt the upper and lower • mast sections together.

DE710


13.1 Mast Platform General InformationPlease refer to figure 1 for item number locations. 1. Basket 2. Structural bolt, nut and washers securing the sector plate item 5 to the basket item 1. 3. Structural bolt, nut and washers securing the sector plate item 5 and the basket item 1 through the +/-10 degree hole of platform support beam sector item 6. 4. Structural bolt, nut and washers securing the sector plate item 5 and the basket item 1 through the pivot hole of the platform support beam sector plates item 6. The basket item 1 and sector plate item 5 pivot around the bolt and nut item 4. 5. Sector plate bolted to basket item 1. 6. Platform support beam sector plate. 7. Platform support beam

The lower mast section is manufactured with the platform support beam attachment position.

The platform and basket assembly is designed to allow the stacking of drill rod and casing in six-meter lengths against the pipe rest, which is part of the platform support beam.

The sector plates (figure 2) are bolted to each side of the basket. The basket and the sector plates are then bolted to the sector plates on the platform support beam.

The holes in the platform sector plates have holes drilled in them that allow the basket to be set up at ten degree (10°) increments. The sector plates (figure 2) that are bolted to the basket have six holes drilled in each of them. Three of the holes are drilled in line and the other holes are drilled in a radius from the bolt hole item 3.

Each hole has a particular operation in regards to the set up of the basket assembly as outlined below. Please refer to figure 2 for item number location. • Bolt hole item 1 will allow a bolt and nut to secure the sector plate to the basket. • Bolt hole item 2, if used will set the basket at +/- 10 degree increments e.g. 90-80-70-60-50 degrees. • Bolt hole item 3 is the pivot point for the basket and sector plate on the platform support beam sector plates. • Bolt hole item 4 allows a + / - 5 degrees increment of the basket, depending on which hole is selected in the support beam sector plate. • Bolt holes items 5 and item 6 allow a + /- 2.5 degree increment of the basket, depending on which hole is selected in the platform support beam sector plate.


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40 (196) WI864-033 Revision 2

13.2 Mast and Platform Stay Rods General InformationRefer to figure 1 for item number locations. 1. Platform support beam and basket 2. Platform stay rod 3. Platform tension stay rod 4. Mast stay rods

The mast assembly is supported by two mast stay rods item 4.

The platform support beam item 1 and the attached basket are supported by one platform stay rod item 2 and one tension stay rod item 3.

The platform stay rod is pinned to the platform stay rod support beam item 5.

The tension stay rod is pinned to the tension stay rod support beam item 6.

The mast support stay rods are pinned to the mast and to the tray.

Each of the stay rods is fitted with a threaded stay rod adjuster at the end of the stay rod. Figure 2 item 1 shows an example of the threaded stay rod adjuster on the platform stay rod.

The threaded adjuster is pinned to the stay rod support beams or to the tray. This threaded adjuster permits the stay rods to be adjusted to the correct length after the mast has been set to the drilling angle and the mast base has been dumped to ground level.


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Each of the stay rods has an adjust pin figure 1 item 1, that is fitted to the stay rods after the rig is finally set up. The adjust pin locks the inner and outer stay rod leg in place.

The mast stay rods are stored for transport on the mast refer to item 1 figure 2. The mast stay rods are raised with the mast.

The platform stay rods item 1 figure 3 and the tension stay rod item 2 figure 3 are pinned to the platform support beam before the mast is raised.

The platform and tensioned stay rods are raised with the mast.


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42 (196) WI864-033 Revision 2

13.3 Level the Drill The rig is equipped with a jack leg at each corner of the drill tray.

Each leg is independently operated from the jack leg control valve that is located near the hydraulic oil tank on the left hand side of the drill rig.

Each leg has a self-closing pilot open check valve assembly fitted to guard against hose rupture and to ensure the leg will stay at the required height when the rig is level.

The jack leg levers can be operated in combination with each other in the following sequence. • Both left hand front and rear • Both right hand front and rear. • Both left and right rear • Both left and right front

Refer to figure 1 for item number location: 1. Left front jack leg control. 2. Right front jack leg control. 3. Left rear jack leg control. 4. Right rear jack leg control.

The jack legs have feet that must be fitted to each jack leg. Refer to figure 2. The feet are pinned to the inner jack leg.

Place suitable hardwood sleepers or bed logs under the jack leg feet.


WARNING• Use high quality, load bearing, hardwood sleepers or bed logs of sufficient strength, size and • length to transfer the combined weight of the rig and maximum pullout to the ground.

DE710


Platform Stay Rod Support Beam Stabiliser LegThis rig has a platform stay rod support beam fitted to the tray.

The support beam has a stabiliser leg that must be fitted to it during set up. This leg transfers the loads from the support beam to the ground.

The following information will assist you to set up the stabiliser leg.

Refer to figure 1 for item number location. 1. Platform support beam item 1 in the transport position. 2. Pin item 2 securing the platform support beam to the tray support item 3 for the platform support beam.

Refer to figure 2 for item number location. 1. The platform support beam item 1 has been pulled out of the tray support by removing the lock pin item 2. When the platform support beam has been fully extended out of the tray support, the lock pin item 2 must be refitted and secured in place with a lynch pin. 2. The platform support beam stabiliser leg is made up of items 3, 4 5, and 6. 3. Item 4 is the outer leg. 4. Item 5 is the inner leg fitted with an adjustable foot. 5. Item 4 is a pin fitted with a lynch pin to secure the outer leg to the platform support beam. 6. Item 6 is a pin fitted with a lynch pin to secure the inner leg to outer leg. 7. To fit the stabiliser leg assembly to the plat form support beam, the inner leg must be completely retracted inside and pinned to the outer leg. 8. The stabiliser leg assembly can then be fitted to the platform support beam and pinned in place by the pin item4. Item 4 must be secured by a lynch pin. 9. Item 6 pin can then be removed and the inner leg allowed to slide down until the holes in the outer leg and the inner leg line up. Item 6 can be refitted and secured in place by a lynch pin. 10.The adjustable foot can then be adjusted until it rest firmly against the ground or on a suitable sleeper or bed log.


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44 (196) WI864-033 Revision 2


WARNING• Refer to following warning tag regarding the stay rod support beam stabiliser leg

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13.4 Mast Raise/Lower, Mast Dump, Stay Rods General Information13.4.1 Mast Raise / LowerThe mast is raised or lowered by the operation of two cylinders connected to the mast dump frame and the tray of the drill rig.

A control lever in figure 1 (item 1) at the control cabinet face controls the operation of the mast raise cylinders. The mast raise cylinders have holding valves fitted to lock the mast in position during set up of the mast and operation of the rig.

13.4.2 Mast Stay Rods (Figure 2)Four stay rods support the mast and the platform basket assembly during drilling operations. • The platform stay rod is connected to the platform support beam on the mast and to the platform support beam on the tray. The platform stay rod is raised with the mast. • The tension stay rod is connected to the platform support beam on the mast and to the tension stay rod support beam on the tray. The tension stay rod is raised with the mast. • The mast stay rods are connected to the locating lugs on the lower mast section and to the tray support at the front of the rig, when the mast is at the correct angle and dumped onto the ground. • The mast stay rods also connect to another set of locating lugs on the mast for transport.

13.4.3 Mast DumpThe mast is raised or lowered through the mast dump frame slides by the operation of a cylinder connected from the mast dump frame to the lower section of the mast. The mast dump cylinder is controlled by the operation of a lever in figure 3 (item 1) at the control cabinet face. The mast dump cylinder has a holding valve fitted locking the mast in position during set up of the mast and operation of the rig.Ensure the mast base has suitable sleepers or bed logs under it to support the mast and the maximum pull out loads.


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46 (196) WI864-033 Revision 2

13.5 Platform Support Beam and Basket Set Up ProcedureRefer to figure 1 for item number locations: 1. Basket 2. Platform support beam 3. Sector plates

Park a vehicle with a flat tray on the back of it near the right hand front side of the rig.

Place the platform support beam on the tray of the vehicle.

Have two assistants stand on the tray on the vehicle. Have two assistants stand on the tray of the drill rig.

Pick up the platform support beam and slide the platform support beam under the fixed upper rod slide. Line the bolt holes of the platform support beam up to the bolt holes in the plates on the lower mast.

Attach the beam to the mast attachment points with the eight structural grade bolts, nuts and washers. Ensure that a washer is used under both the head of the bolts and nuts. Tighten all bolts and nuts.

Bolt the sector plates to the basket.

Align the pivot bolt holes of the basket and sector plates to the pivot bolts on the sector plates on the plat-form support beam.


WARNING• The plat form support beam will have to held in position until the bolts and nuts that secure the • beam to the left hand side of the mast have been fitted.

WARNING• Only structural grade bolts, nuts and washers must be used to connect the platform support • beam to the mast.

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A structural grade washer must be fitted under the head of the bolt and nut. Leave the nuts loose for the moment.

Pivot the basket around until the basket is at the correct position to have the basket floor level when the mast is set up for drilling. Fit structural grade bolts, nuts and washers to the holes in the sector plates. A structural grade washer must be fitted under the head of the bolt and nut.

Check the basket is at the correct angle, then tighten all of the bolts and nuts to secure the basket to the platform support beam.


WARNING• Only structural grade bolts, nuts and washers must be used to connect the basket to the platform • support beam.

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48 (196) WI864-033 Revision 2

13.6 Platform Support Beam Stay rod and Tension Stay Rod Set Up ProcedureRemove the platform stay rod and tension stay rod from the transport location.

Refer to the parts manual and check that all components of the platform stay rod are available.Refer to the parts manual and Check that all components of the tension stay rod are available.

Remove the adjust pin (middle pin) of the platform stay rod. Check the inner leg of the platform stay rod will easily slide in and out of the outer leg of the platform stay rod.

Remove the adjust pin (middle pin) of the tension stay rod. Check the inner leg of the tension stay rod will easily slide in and out of the outer leg of the tension stay rod.

Slide the inner leg of the platform stay rod completely in. Move the inner leg in or out until the holes in the inner and outer leg line up. Fit the adjust pin (middle pin), secure the adjust pin with a lynch pin.

Slide the inner leg of the tension stay rod completely in. Move the inner leg in or out until the holes in the in-ner and outer leg line up. Fit the adjust pin (middle pin), secure the adjust pin with a lynch pin.

Have two assistants lift up, and position the platform stay rod so that the outer leg is facing towards the basket.

Have two assistants lift up and position the tension stay rod so that the outer leg is facing towards the basket.

Have two assistants lift up and position the platform stay rod near the mast platform support beam. Have the assistant in the basket align the platform stay rod pin holes with plate on the platform support beam. Fit the pin to secure the platform stay rod outer leg to the platform support beam. Secure the pin with a lynch pin. Lower the platform stay rod onto the ground.

Have two assistants lift up and position the tension stay rod near the mast platform support beam. Have the assistant in the basket align the tension stay rod pin holes with plate on the platform support beam. Fit the pin to secure the platform stay rod outer leg to the platform support beam. Secure the pin with a lynch pin. Lower the tension stay rod onto the ground.

Have the assistant climb down from the basket.


WARNING• Check the inner legs of the platform and tension stay rods , they must slide easily inside the • outer leg. There must not be any mechanical binding of the inner leg to the outer leg. • If necessary strip the stay rod assembly apart, clean the inner and outer legs and reassemble the • stay rod.

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Refer to figure 1 for item number locations.The tension stay rod item 1 and platform stay rod item 2 should now be securely pinned to the platform sup-port beam item 3.

Figure 2 indicates the rig set up to this point.


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13.7 Mast Raising Dumping and Lowering

Mast Raise • Check the mast for any loose items. Secure these items before attempting to raise the mast. • To raise or lower the mast, run the diesel at 750 to 800 rpm. • Avoid start-stop movements during the mast raise / lower operation. • Check the following items have been correctly attached to the mast: • Platform support beam and basket. • Main and wire line winch ropes reeved through the sheaves at the top of the mast.

• The platform stay rod is attached to the platform support beam. • The tension stay rod is attached to the platform support beam. • Operate the mast raise /lower control lever and begin to raise the mast.


WARNING• Be aware of overhead powerlines, before raising the mast!• LOOK UP AND LIVE!• NEAR IS FAR TOO CLOSE

WARNING• Check the main and wire line winch ropes have sufficient length to allow the mast to be raised. • It may be necessary to operate the controls of the main and wire line winch during the mast raise • operation to allow the ropes to have sufficient length to stop the rope ends contacting the • sheaves.

CAUTION• Have an assistant guide the platform stay rod during the mast raise operation.• Have an assistant guide the tension stay rod during the mast raise operation.

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• Raise the mast until it is vertical. • Remove the pin securing the plat form stay rod support beam in the tray support. • Fully extend the platform stay rod support beam out of the tray support. • Move the beam in or out until the pin holes of the beam and tray support line up. • Fit the pin back into the tray support and platform stay rod support beam. Secure the pin with a lynch pin. • Remove the pin securing the tension stay rod support beam form support beam in the tray. • Fully extend the tension stay rod support beam out of the tray support. • Move the beam in or out until the pin holes of the beam and tray support line up. • Fit the pin back into the tray support and tension stay rod support beam. Secure the pin with a lynch pin. • Fit the platform stay rod support beam stabiliser leg. • Have an assistant remove the bottom pins from the mast stay rods. Refer to figure 1 item 1 for the location of the bottom pins of the mast stay rods. • Operate the mast raise /lower control lever and begin to slowly lower the mast. As the mast lowers the mast stay rods will pivot around the top pins


CAUTION• Have an assistant guide the platform stay rod during the mast lowering operation.• Have an assistant guide the tension stay rod during the mast lowering operation.• Have two assistants guide the mast stay rods during the mast lowering operation.

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• As the mast is lowered the mast stay rods will eventually hang over the tray support for platform stay rod support beam. See figure 1. When this occurs stop operation of the mast lower control lever. • Have an assistant grasp one of the mast stay rods inner leg. • Have another assistant remove the adjust pin (middle pin) from the mast stay rod. • Manoeuvre the stay rod assembly threaded adjuster onto the lug provided on the tray support. • Pin the inner leg to the support beam. Secure the pin with a lynch pin. • Repeat the last four instructions to the other mast stay rod.

• Have an assistant grasp the platform stay rod inner leg. • Have another assistant remove the adjust pin (middle pin) from the platform stay rod. • Manoeuvre the platform stay rod assembly threaded adjuster onto the lug provided on the platform stay rod support beam support. • Pin the inner leg to the support beam. Secure the pin with a lynch pin.

• Operate the mast raise/lower control lever and begin to raise the mast. As the mast is raised the mast and platform stay rod outer leg will move up the inner leg. • As the mast nears the required drilling angle, reduce the raising speed by easing off on the control lever to bring the mast to a gentle stop. • Check the mast angle with a spirit level.


CAUTION• Do not fit the adjust pin back into the mast stay rod assemblies, until the mast angle has been • achieved.

CAUTION• Do not fit the adjust pin back into the mast stay rod assemblies, until the mast angle has been • • achieved.

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Mast Dump • Operate the mast dump control lever “DOWN” and dump the mast base onto sleepers or bed logs.

• Ensure the mast base has suitable sleepers or bed logs under it to support the mast.


CAUTION• During the mast raising or lowering procedure, ensure no cables, hoses, ropes or stay rods will • catch on any other part of the drill rig.• During any kind of mast raise or lowering operation no personnel should be allowed on the drill • deck, except for final fitting or removal of the stay rods and or stay rod pins after which the drill • deck must be cleared again.

CAUTION• As the mast is lowered through the mast dump frame slides, the outer leg of the mast and • platform stay rods should slide down over the inner leg. Check there is no mechanical binding of • the outer legs to the inner legs. • Guide the tension stay rod so it does not spear into the ground during the mast dumping • operation.

CAUTION• The mast dump cylinder must never be fully retracted at any time during set up or operation of • the rig.• If necessary, pack under the mast base with suitable sleepers or bed logs to ensure the mast • dump cylinder is never fully retracted.

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13.8 Mast Stay Rods Final Set Up • Check the mast angle is correct. • Adjust the inner stay rod - see figure 1 - on the threaded adjuster until the holes line up with the holes in outer stay rod. • Lock the outer stay rod to the inner rod with the lock pin, secure the pin with a lynch pin provided. • Repeat the last two instructions for the other mast stay rod.

13.8.1 Platform Stay Rod Set Up • Get a small ladder for an assistant to stand on. • Place the ladder in a suitable position so that any body standing on the ladder can easily reach the adjust pin holes on the platform stay rod. • Get an assistant to climb up and stand on the ladder. • Adjust the inner stay rod on the threaded adjuster until the holes line up with holes in the outer stay rod. • Lock the outer stay rod to the inner rod with the adjust pin, secure the pin with a lynch pin provided.

13.8.2 Tension Stay Rod Set Up • Get a small ladder for an assistant to stand on. • Place the ladder in a suitable position so that any body standing on the ladder can easily reach the adjust pin holes on the tension stay rod. • Remove the adjust pin from the tension stay rod. • Slide the inner leg out of the inner leg until the tension stay rod threaded adjuster can be pinned to the tension stay rod support beam. • Secure the pin with a lynch pin. • Adjust the inner stay rod leg until a hole in the outer leg lines up with a hole in the inner leg. • Lock the outer leg to the inner leg with the adjust pin and secure the adjust pin with the lynch pin provided.


WARNING• Regardless of drilling angles, the stay rods must always be fitted with the top pin, the bottom pin • and the adjust pin secured with the lynch pins provided.• Never attempt to operate the mast raise / lower control with the stay rods locked in position; • otherwise damage to equipment will result.

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13.8.3 Final Set Up of the Mast • Refer to figure 1 for item number locations. • The mast is now set up as follows; • The mast has been raised to the required angle and dumped onto suitable sleepers or bed logs. • The mast stay rods item 1 have been fitted and pinned in place. • The platform stay rod item 2 has been fitted and pinned in place. • The tension stay rod item 3 has been fitted and pinned in place. • The platform stay rod beam stabiliser item 4 leg has been fitted pinned in position and the foot adjust to rest against a solid support.


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13.8.4 Mast Ladder Set Up (Track drive Rigs)

Refer to figure 1 for item number locations.The mast ladder on track drive rigs has a section item 1 near the joint between the upper and lower masts, that can be pivoted up to allow the ladder to clear the top of the track drive control cabinet.

This section is pinned at an angle to allow for the clear-ance. A pin item 2 at each end of the pivoting section, secure the pivoting section in place. • Have an assistant climb the mast. • Remove the pins and pivot the section so that it lines up with the rest of the mast ladder. Refit the pins and secure them with the lynch pins supplied.

• Figure 2 shows the pivoting section item 1 in line with the rest of the mast ladder.


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13.9 Mast Lowering • On track drive rigs carry out the following; • Climb the mast and remove the pin securing the pivoting section of the ladder. (Use harness) • Pivot this section towards the mast. • Secure the pivoting section in place by fitting the pins. Secure the pins with the lynch pins provided. • Have an assistant climb up and stand on the hydraulic oil cooler • Remove the adjust pins (middle pins) from the mast stay rods. • Get a small ladder for an assistant to stand on. • Place the ladder in a suitable position so that any body standing on the ladder can easily reach the adjust pin holes on the platform stay rod. • Get an assistant to climb up and stand on the ladder. • Remove the adjust pin (middle pin) from the plat form stay rod. • Remove the bottom pin from the tension stay rod. • Operate the mast dump control lever “UP”. • As the mast moves up guide the tension stay rod. • Operate the mast raise / lower control lever “DOWN”. • Slowly lower the mast until the top hole (item 1 figure 1) in the mast stay rod outer legs almost lines up with the bottom hole in the inner legs The stay rods will almost be completely retracted (closed up).

• Adjust the inner leg of the stay rods until the adjust pins (middle pins) can be fitted. Secure the adjust pins with lynch pins. • Place the ladder in a suitable position so that any body standing on the ladder can easily reach the adjust pin holes on the platform stay rod. • Get an assistant to climb up and stand on the ladder. • Adjust the inner stay rod on the threaded adjuster until the holes line up with holes in the outer stay rod. • Lock the outer stay rod to the inner rod with the adjust pin, secure the pin with a lynch pin provided. • Have an assistant grasp one of the mast stay rods outer legs. • Have another assistant remove the bottom pin from the mast stay rod and the mast stay rod support on the tray. • Repeat for the other mast stay rod • Have an assistant grasp the platform stay rod outer leg. • Have another assistant remove the bottom pin from the platform stay rod and the platform stay rod support beam. • Operate the mast raise / lower control lever “UP”.


CAUTION• As the mast is lowered, the outer leg of the mast and platform stay rods should slide down over • the inner leg. Check there is no mechanical binding of the outer legs to the inner legs. • Guide the tension stay rod so it does not spear into the ground during the mast lowering • operation.

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• Raise the mast until it is vertical. • Adjust the threaded adjusters of the mast stay rods until the mast stay rods can be pinned to the lugs on the mast for transport. • Operate the mast raise / lower control lever “DOWN”.

• Lower the mast until the mast is resting on the mast support on the tray • Have an assistant climb up onto the mast and stand in the basket. • Have two assistants lift up and support the platform stay rod. • Have the assistant in the basket remove the platform stay rod pin. • Have the two assistants lower the platform stay rod onto the ground. • Have two assistants support the tension stay. • Have the assistant in the basket remove the tension stay rod pin. • Have the two assistants lower the tension stay rod onto the ground. • Park a vehicle with a flat tray on the back of it near the right hand front side of the rig. • Have two assistants stand on the tray and remove the basket from the sector plates on the platform support beam. • Lower the basket onto the tray of the vehicle. • Remove the basket from the tray and put into the transport position. • Have the two assistants stand on the tray and support the platform support beam that is bolted to the mast. • Have an assistant climb up onto the tray and remove the bolts the secure the platform support beam to the mast. • Have the two assistants remove the platform support beam from the mast and lower the platform support beam onto the tray of the vehicle.


CAUTION• Have an assistant guide the platform stay rod during the mast raising operation.• Have an assistant guide the tension stay rod during the mast raising operation.• Have two assistants guide the mast stay rods during the mast raising operation.

CAUTION• Have an assistant guide the platform stay rod during the mast lowering operation.• Have an assistant guide the tension stay rod during the mast lowering operation.

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14. MAIN WINCH14.1 Specifications • Maximum pull of 76.6 kN (17,200lbf) • Maximum speed of 55m/minute. • A park brake is built into the main winch gearbox that is spring engaged and hydraulic pressure disengaged. • Hydraulic pilot operated control of the main winch control valve permits infinitely variable speed control of the winch rope from minimum to maximum.

14.2 Control Lever LocationThe following information will assist the operator to locate the control functions that could be used during the main winch and rod handling operations.

14.3 FamiliarisationPlease refer to figure 1 for item number locations:

1. MAIN WINCH “UP-DOWN” This pilot control lever controls the direction of operation and the speed of the main winch rope by controlling the flow of oil from the main pump via the main control valve to the main winch motor. The main winch motor has an automated control that will allow the winch to pull at maximum speed dependant on the pilot control lever position, the diesel rpm and the weight of drill rod being raised or lowered. 2. ROTATION HEAD “FORWARD-REVERSE” This pilot control lever controls the direction of operation and the speed of the rotation head, by controlling the flow of oil from the main pump via the main control valve to the rotation head motor. The rotation head speed (rpm), can be varied by the position of the lever, the setting of the rotation speed control and the diesel rpm. The lever can be locked in any of four positions for rotation forward by moving the lever to the right. The four positions allow the selection of minimum to maximum oil flow from the main pump via the main control valve. The lever when moved to the left will spring return to the neutral or centre position.

3. HEAD TRAVERSE “UP-DOWN” This pilot control lever controls the direction of operation and the speed of the rapid traverse system for the rotation head, by controlling the flow of oil from the main pump via the main control valve to the traverse cylinder. The head traverse speed can be varied by the position of the lever, and the diesel rpm.

MAIN WINCH

CAUTION• The rotation head should not be run in “REVERSE” for long periods of time. The rotation head • lube system does not operate in the reverse direction and damage could occur to the rotation • head without correct lubrication.

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4. MAIN PRESSURE GAUGE This gauge indicates the actual main pump pressure during the operation any of the four main functions of traverse, wire line winch, rotation and main winch. 5. DRILL MAKE “OFF-ON” This lever connects the rotation torque control to the hydraulic system when the lever is in the “ON” position. 6. ENGINE THROTTLE This knob controls the diesel engine rpm. 7. FLOAT “OFF - FLOAT” This lever engages the head float system. This lever is used in combination with the Rotation control lever to make up rod joints when adding drill rod to the drill string. 8. CHUCK “HOLD-RELEASE” This lever controls the operation of the chuck assembly, which is attached to the rotation head. It has two operational positions; “HOLD” In this position the chuck assembly of the rotation head will be engaged and will clamp (hold) the drill rod. In this position the winch float system will be automatically ‘Engaged’ provided the winch float control has been activated to the ‘On’ position. “RELEASE” In this position the chuck will be released and will not grip the drill rod. In this position the winch float system will be automatically ‘Disengaged’. Note The hold position is spring applied. If the rig looses power the chuck will self energise regard less of lever position. 9. ROD CLAMP “CLOSE -OPEN” This lever controls the operation of the rod clamp assembly at the base of the mast. It has two operational positions. “CLOSE” In this position the rod clamp jaw assemblies will be engaged and will clamp (hold) the drill rod. “OPEN” In this position the rod clamp will be released and the jaw assembly will not grip the drill rod. 10. UPPER BREAKER This lever powers the upper breaker fitted to the rotation head of this rig. Push the lever up to operate the jaws of the upper breaker against the drill rod. 11. WINCH FLOAT “OFF-ON” The main winch of this rig is fitted with a winch float system. This system allows the winch rope that is connected to the water swivel to travel down the mast during drilling. The winch float system can be engaged / disengaged at the control panel by the use of the winch float lever. The winch float system has two positions, which are described below “WINCH FLOAT OFF” • In this position the winch rope will not travel down the mast with the water swivel. The brake of the winch is applied and the winch rope will support the weight of the drill string. • This allows the driller to stop feeding the rotation head and drill string down the mast. • Rotation of the drill rods can stop and the chuck can be released and the rotation head can be traversed “UP” the mast. • When the head has been traversed up the mast, the chuck can be engaged and rotation and feeding can recommence. • This process allows the driller to use drill rods and core barrel assemblies that are longer than the head traverse stroke of the rig. “WINCH FLOAT ON” • In this position the winch rope will travel down the mast with the water swivel. The brake of the winch is released and the winch rope will not support the weight of the drill string.

MAIN WINCH

WARNING• The Main Winch float lever must be in the “OFF” position when using the Main Winch to trip rods • into or out of the hole.

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12. POWER FLOAT “MAKE/BRAKE” CONTROLS This control adjusts the hydraulic pressures in the traverse cylinder to allow the head to float down. 13. SLIDE ROLLER “IN- OUT” CONTROLS This control operates the hydraulic system for the slide roller. The slide roller has two operating positions, which are; “IN” When the slide roller is “IN” the drill rod will run against the rod slide. “OUT” When the slide roller is “OUT” the drill rod will roll against the roller instead of running against the rod slide. This position allows the offsider to get there hands behind the drill rod to make rod handling easier. 14. HEAD RACK “OUT-IN” CONTROL This control operates two hydraulic cylinders on the head carriage assembly. The cylinders will move the rotation head into two positions, which are; “OUT” The rotation head will be pulled to the left hand side of the mast. This action will allow a clear line of access to the drill rod clamped in the rod clamp. This will allow drilling personnel to directly connect the main winch rope hoisting plug to the drill string or to allow the wire line rope overshot to be fed into the drill rod clamped into the rod clamp. “IN” The rotation head will be pushed in so that the centre line of the rotation head chuck assembly will be in line with the drill rod clamped into the rod clamp.

MAIN WINCH

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14.4 Operation 1. Once the engine throttle is set, the main winch operation becomes a one-lever function, the further the main winch lever is moved the faster the winch hoists or lowers.

2. For most hoisting operations it is best to run the engine at 2200 rpm, control the speed of the main winch operation with the main winch pilot control lever, then before stopping, slow the winch down by easing off the main winch lever, rather than letting it snap home.

3. The main winch lowering function is slowed down and stopped hydraulically by a holding valve connected to the winch motor. Once stopped, the fail safe spring applied park brake in the main winch engages, preventing the hoist from creeping.

MAIN WINCH

WARNING• Never operate any combination of two or more pilot controls, i.e. the MAIN WINCH, WIRELINE • WINCH, ROTATION or TRAVERSE, simultaneously other than as stated in the warning note below.• Never engage two or more main drilling functions at the same time.• With the exception of and only with care: • • Rotation + Traverse• If a wrong combination of two or more pilot units is operated at the same time, a very dangerous • control malfunction can occur, resulting in an unexpected and sudden surge in speed of one or • the other function.

WARNING• Never stop the engine whilst rods are still freely suspended from the main winch! Engage the rod • clamp or the rotation head chuck.• The maximum main winch capacity is 64.9 kN. = 14600 lbs. use the main winch hoist plug as • supplied in the standard accessories, for all main winch hoisting - lowering operations.• Check the pin fitted to the main winch rope metalling socket is securely fastened to the metalling • socket. • Do not allow the main winch rope to cross over itself on the winch drum.• The diesel engine rpm must be above 1400 for all main winch operations• After every lowering operation where a slack rope condition could have occurred, check the • drum for tangled rope before putting weight on the rope.

CAUTION• When pulling rods out of the rod clamp, first take up the weight of the drill rod string with the • main winch rope, then open the clamp. • When lowering rods, slow the winch down by easing off the lever and bring it to a stop before • closing the clamps.

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15. MAIN WINCH FLOAT SYSTEMPlease refer to figure 1 for location of the winch float control.

The main winch of this rig is fitted with a winch float system. This system allows the winch rope that is connected to the water swivel to travel down the mast during drilling.

The winch float system can be engaged / disengaged at the control panel by the use of the winch float lever item 1.

The winch float system has two positions, which are described below:

15.1 Winch Float Off • In this position the winch rope will not travel down the mast with the water swivel. The park brake of the winch is applied and the winch rope will support the weight of the drill string. • This allows the driller to stop feeding the rotation head and drill string down the mast. • Rotation of the drill rods can stop and the chuck can be released and the rotation head can be traversed “UP” the mast. • When the head has been traversed up the mast, the chuck can be engaged and rotation and feeding can recommence. • This process allows the driller to use drill rods and core barrel assemblies that are longer than the head traverse stroke of the rig.

15.2 Winch Float On • In this position the winch rope will travel down the mast with the water swivel. The brake of the winch is released and the winch rope will not support the weight of the drill string.

MAIN WINCH FLOAT SYSTEM

WARNING• The main winch float lever must be in the off position when using the main winch to trip rods into • or out of the hole.

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16. WIRE LINE WINCH16.1 Specifications • The wire line winch drum contains 1,000 mtrs of 6 mm wire rope. • Maximum rope speed of 270 m/per minute (full drum). • Maximum pull of 7.8 kN (bare drum). • Hydraulic pilot operated control of the wire line winch control valve permits infinitely variable speed control of the winch rope from minimum to maximum.

16.2 FamiliarisationPlease refer to figure 1 for item number locations 1. WIRE LINE WINCH “UP-DOWN” This pilot control lever controls the direction of operation and the speed of the wire line winch rope by controlling the flow of oil from the main pump via the main control valve to the wire line winch motor. The wire line rope speed can also be varied by the diesel rpm. 2. MAIN PRESSURE GAUGE This gauge indicates the actual main pump pressure during the operation any of the four main functions of traverse, wire line winch, rotation and main winch. 3. ENGINE THROTTLE This knob controls the diesel engine rpm. 4. HEAD RACK “OUT-IN” CONTROL This control operates two hydraulic cylinders on the head carriage assembly. The cylinders will move the rotation head into two positions, which are; “OUT” The rotation head will be pulled to the left hand side of the mast. This action will allow a clear line of access to the drill rod clamped in the rod clamp. This will allow drilling personnel to guide the wire line rope overshot into or out of the drill rod clamped into the rod clamp. “IN” The rotation head will be pushed in so that the centre line of the rotation head chuck assembly will be in line with the drill rod clamped into the rod clamp.

WIRE LINE WINCH

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16.3 Operation

1. Check the drill rod joint is approximately 150 -200 mm above the rod clamp jaws. 2. Operate the rod clamp control lever to the “CLOSE” position and clamp the drill rod in the rod clamp. 3. Slowly operate the rotation lever into “REVERSE” and at the same time slowly operate the head traverse lever “UP” to break the drill rod joint. 4. When the rod joint has screwed apart continue to slowly operate the head traverse lever until the pin end of the drill rod held in the chuck is 50 to 100mm above the box end of the thread held in the rod clamp. 5. Operate the head rack lever into the “OUT” position and completely rack the head out.

6. Once the engine throttle is set, the wire line winch operation becomes a one-lever function, the further the wire line winch lever is moved, the faster the winch lifts or lowers.

7. After every lowering operation where a slack rope condition could have occurred, check the drum for tangled rope before putting weight on the rope. 8. The wire line winch lowering function is slowed down and stopped by means of a double holding valve, which is connected to the ports of the wire line winch motor. There is no failsafe park brake fitted.

WIRE LINE WINCH

WARNING• As the head moves to the left hand side of the mast check that no hoses especially the water • swivel hose catch on any part of the mast.• The head can be safely racked out to the left hand side of the mast with a three metre head rod. • Do not attempt to rack to the side with a 6 metre head rod. The head rod could catch on the rod • slide. This action could damage equipment and bend the head rod.

WARNING• Never operate any combination of two or more pilot controls, i.e. the MAIN WINCH, WIRE LINE • WINCH, ROTATION or TRAVERSE, simultaneously other than as stated in the warning note below.• Never engage two or more main drilling functions at the same time.• With the exception of and only with care: • • Rotation + Traverse• If a wrong combination of two or more pilot units is operated at the same time, a very dangerous • control malfunction can occur, resulting in an unexpected and sudden surge in speed of one or • the other function.

WARNING• The wire line winch is designed for wire line winch operations only, such as pulling the inner tube • and surveying the hole.• Never use it for any other hoisting purposes. • Never leave a weight suspended from the wire line winch with the engine stopped. The winch will • creep down if a weight is left suspended from the winch rope.

CAUTION• This following procedure is basic and does not cover all the requirements that the drilling • conditions that you encounter.• This procedure will have to be modified to suit your drilling conditions.• Follow the procedure as outlined in your companies “Standard Operating Procedures SOP”

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9. Use the wire line winch with diesel rpm between 800-1000 rpm. This combined with the control lever movement will give a very large range of rope speed. 10. Slowly operate the wire line winch pilot lever “UP” to lift the overshot out of the storage area. 11. Slowly operate the wire line winch pilot lever “DOWN” and have an assistant guide the overshot into the drill rod clamped in the drill string. 12. When the overshot is completely engaged in the drill rod slowly increase the speed of the wire line rope.

13. When the overshot has latched onto the inner tube stop operation of the wire line winch pilot lever. 14. Check the wire line winch drum for any loose rope. Correct this problem as required. 15. Slowly engage the wire line winch pilot lever “UP” and begin to raise the overshot and the inner tube. 16. Do not use excessive speed when raising the wire line winch rope. 17. When the overshot is just coming out of the drill rod clamped in the rod clamp, decrease the speed of the wire line winch rope to minimum. 18. When the overshot and inner tube are out of the drill rod, have an assistant grasp the inner tube and guide the end of the inner tube to the core recovery area. 19. Slowly operate the wire line winch pilot lever “DOWN” and lower the inner tube down. 20. Release the overshot from the inner tube. 21. Attach the overshot to another inner tube. 22. Slowly operate the wire line winch pilot lever “UP” and raise the inner tube up until it is above the drill rod clamped in the rod clamp. 23. Slowly operate the wire line winch pilot lever “DOWN” and have an assistant guide the inner tube and overshot into the drill rod clamped in the rod clamp. 24. When the over shot is just about to enter the drill rod stop operation of the wire line winch lever. 25. Release the locking latches of the over shot and allow the inner tube to drop into the drill rod. 26. Operate the head rack lever into the “IN” position and completely rack the head in. 27. Check the head is completely racked in and the drill rod held in the chuck is inline with the drill rod clamped in the rod clamp. 28. Carry on with any operations necessary to begin drilling.

WIRE LINE WINCH

WARNING• Do not use any mechanical device to lock the wire line winch lever into the engaged position • either up or down.• Severe damage could occur to equipment if the wire line can not be stopped due to some • mechanical device locking the wire line winch lever in place.

WARNING• Do not use excessive speed while lowering the wire line winch rope into the drill rod.• The winch drum could turn faster than the rope can lower into the drill rod. The wire line rope on • the drum could unravel and loop over itself and cause damage to the wire line winch.• The rope should be under tension as it is lowered allowing the over shot to pull the rope into the • drill rod.

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17. ROTATION – GENERAL17.1 Specifications • P chuck drive. High -low manual gear change. 100-1500 rpm step-less speed control. • 487-1,026 rpm in low gear. • 708 -1,500 rpm in high gear. • Chuck jaw set to suit B, N, H and HWT sized diamond drill rod. • Chuck and spindle bushings to suit B, N, H and HWT sized diamond drill rod. • Out put torque at 100% efficiency: • 3,660 Nm at low speed in low gear for maximum break out • 2,024 Nm at low speed in high gear for maximum break out • 691 Nm at 1,026rpm • 562 Nm at 1500 rpm. • Pilot adjustable speed control. • Hollow spindle will accept up to HWT size drill rods. • Air to oil lube oil cooler fitted in front of engine radiator. • Lube oil filter fitted on the left hand side of the rig tray. The P Rotation Head gear box has two in built gear ratios. These are, 5.4:1 and 3:1 and they are selected by the gear lever on the rotation head.

A variable displacement hydraulic motor drives the rotation head gearbox. The displacement of this motor is pilot pressure regulated and is controlled by the driller at the control panel. In effect, there is a very wide range of speed and torque settings, which can be used and is variable by fingertip control at any time. These variables are: • Engine rpm. • Main Hydraulic Pump Flow (via the main control valve). • Gear Selected (High or Low gear). • Hydraulic Motor Displacement (Speed). • Torque Limiter (Make Pressure).

Once the diesel throttle is set and the gear ratio selected, the rotation speed is controlled by the main rota-tion lever position and the rotation speed control adjustment.

The rotation Make Up torque can be controlled by the by the Rotation Make Pressure knob at the control panel when the Drill Make lever is in the “ON” position.

The P rotation head and chuck assembly will allow B, N, H and HWT drill rod to pass through the rotation head spindle and chuck. Provided the chuck is in the “RELEASE” (open) position and the rod jaw assemblies are correctly fitted.

The P rotation head will allow B, N and H drill rod reaming shells, bits and locking couplings to pass through the rotation head spindle and chuck provided the rod jaw assembly and any rod guide bushes are removed.

ROTATION - GENERAL

WARNING• The rotation head must have a rod fitted to the chuck prior to rotating the head and the chuck • control lever must be in the “HOLD” position.• The chuck can be damaged if the rotation head is turned with the chuck in the release position.

CAUTION• When gears do not engage when shifting, use a hand held pipe wrench on the drill rod to line up • the gear teeth. Do not operate the hydraulic motor for this purpose. Ensure that detent in the gear • box housing is fully engaged in the gear selector shaft.

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17.2 Control Lever LocationThe following information will assist the operator to locate the control functions that could be used during the rotation operations.

Please refer to figure 1 for item number locations. 17.3 Familiarisation 1. ROTATION HEAD “FORWARD-REVERSE” This pilot control lever controls the direction of operation and the speed of the rotation head, by controlling the flow of oil from the main pump via the main control valve to the rotation head motor. The rotation head speed (rpm), can be varied by the position of the lever, the setting of the rotation speed control and the diesel rpm. The lever can be locked in any of four positions for rotation forward by moving the lever to the right. The four positions allow the selection of minimum to maximum oil flow from the main pump via the main control valve. The lever when moved to the left will spring return to the neutral or centre position. Note The rotation head should not be run in “REVERSE” for long periods of time. The rotation head lube system does not operate in reverse direction and damage could occur to the rotation head without correct lubrication. 2. HEAD TRAVERSE “UP-DOWN” This pilot control lever controls the direction of operation and the speed of the head traverse system for the rotation head, by controlling the flow of oil from the main pump via the main control valve to the traverse cylinder. The head traverse speed can be varied by the position of the lever, and the diesel rpm. 3. MAIN PRESSURE GAUGE This gauge indicates the actual main pump pressure during the operation any of the four main functions of traverse, wire line winch, rotation and main winch. 4. ENGINE THROTTLE This lever controls the diesel engine speed (rpm). Pull the lever down to increase engine speed. Push the lever up to decrease engine speed. 5. DRILL MAKE “OFF-ON” This lever connects the rotation torque control to the hydraulic system when the lever is in the “ON” (down)position. 6. ROTATION SPEED “INCREASE” This adjustable pressure relief control valve controls the pilot pressure to the rotation head motor. The pilot pressure determines the displacement of the motor. The displacement combined with the pump flow set the speed of the motor. 7. ROTATION TORQUE “INCREASE” This adjustable pressure control valve controls the maximum make up torque of the rotation head. This valve is activated when the drill make “OFF-ON” valve is operated. 8. MICRO FEED “UP-DOWN” This lever controls the direction of hydraulic oil flow to the traverse cylinder via the micro feed circuit. This circuit has the following valves in it, pull down pressure control, micro feed speed control and the hold back-pressure control valve

ROTATION - GENERAL

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9. CHUCK “HOLD-RELEASE” This lever controls the operation of the chuck assembly, which is attached to the rotation head. It has two operational positions “HOLD” In this position the chuck assembly of the rotation head will be engaged and will clamp (hold) the drill rod. In this position the winch float system will be automatically ‘Engaged’ provided the winch float control has been activated to the ‘On’ position. “RELEASE” In this position the chuck will be released and will not grip the drill rod. In this position the winch float system will be automatically ‘Disengaged’. Note The hold position is spring applied. If the rig looses power the chuck will self energise regardless of lever position. 10. ROD CLAMP “OPEN -CLOSE” This lever controls the operation of the rod clamp assembly at the base of the mast. It has two operational positions. “CLOSE” In this position the rod clamp jaw assemblies will be engaged and will clamp (hold) the drill rod. “OPEN” In this position the rod clamp will be released and the jaw assembly will not grip the drill rod. 11. WATER PUMP “ON-OFF” This lever controls the hydraulic oil flow to the water pump motor. It is used to start and stop the water pump. 12. WINCH FLOAT “OFF-ON” The main winch of this rig is fitted with a winch float system. This system allows the winch rope that is connected to the water swivel to travel down the mast during drilling. The winch float system can be engaged / disengaged at the control panel by the use of the winch float lever. The winch float system has two positions, which are described below “WINCH FLOAT OFF” In this position the winch rope will not travel down the mast with the water swivel. The brake of the winch is applied and the winch rope will support the weight of the drill string. This allows the driller to stop feeding the rotation head and drill string down the mast. The rotation of the drill rods can stop and chuck can be released and the rotation head can be traversed “UP” the mast. When the head has been traversed up the mast, the chuck can be engaged and rotation and feeding can recommence. This process allows the driller to use drill rods and core barrels assembly that are longer than the head traverse stroke of the rig. “WINCH FLOAT ON” In this position the winch rope will travel down the mast with the water swivel. The brake of the winch is released and the winch rope will not support the weight of the drill string.

ROTATION - GENERAL


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13. ROTATION HEAD RPM TACHOMETER This gauge indicates rotation head revolutions per minute. This is useful to know when carrying out diamond drilling to ascertain the correct feed rate. 14. DIESEL ENGINE RPM TACHOMETER This gauge indicates diesel engine speed in revs per minute. 15. HEAD RACK “OUT-IN” CONTROL This control operates two hydraulic cylinders on the head carriage assembly. The cylinders will move the rotation head into two positions, which are; “OUT” The rotation head will be pulled to the left hand side of the mast. This action will allow a clear line of access to the drill rod clamped in the rod clamp. This will allow drilling personnel to guide the wire line rope overshot into or out of the drill rod clamped into the rod clamp or to connect /disconnect the main winch rope hoist plug to the drill rod clamped into the rod clamp. “IN” The rotation head will be pushed in so that the centre line of the rotation head chuck assembly will be in line with the drill rod clamped into the rod clamp.

17.4 Rotation Head Visual IdentificationView of the Rotation Head, Upper Breaker, and Rod Clamp Assemblies.

Refer to figure 1 for item number locations. 1. Rotation head motor. 2. Rotation head gear box. (Behind Guard) 3. Spindle rod guide bush and retainer. 4. Gear selector (high /low gear). 5. Chuck assembly. 6. Rod clamp assembly. (Guard removed for photo) 7. Upper rod breaker assembly. 8. Fixed rod slide.

ROTATION - GENERAL

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17.5 View of the Chuck Assembly on the Rotation Head

Refer to figure 1 for item number locations

1. Chuck assembly 2. Chuck operation indicator bolts When the bolt heads are flush with the top cap holder, the chuck rod jaws are clamped around the drill rod. When the bolt heads are inside the top cap holder, the chuck jaws are released from the drill rod. 3. Rod jaw set. The rod jaw set is held in the chuck bowl by the top cap holder. 4. Top cap holder.

ROTATION - GENERAL

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17.6.1 View of the left-hand side of the rotation head assembly.

Refer to figure 1 for item number location.

1. Gear box breather. 2. Tachometer sender (behind guard). 3. Drill head guard. 4. Gear selector lock pin 5. Gear selector. 6. Chuck bowl grease nipple.

17.6.2 View of the right-hand side of the rotation head assembly.

Refer to figure 2 for item number locations.

1. Top seal slinger cover grease nipple. 2. Grease nipple for top seal. 3. Lube oil fill port. 4. Lube oil level plug. 5. Grease nipple for chuck cylinder thrust bearings (behind guard). 6. Grease nipple to grease the chuck bowl housing.

ROTATION - GENERAL

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17.6.3 Rotation Head Spindle and Chuck Assembly Rod Guide Bushes and Chuck Rod Jaw Assemblies

Refer to the photos on the previous pages to locate the respective items. Use the following table to determine the correct part.

ROD/ CASING SIZEPQ CHUCK JAW ASSEMBLYSANDVIK P/NO

PQ CHUCK ROD GUIDE BUSHSANDVIK P/NO

PQ SPINDLE ROD GUIDE BUSHSANDVIK P/NO

BW/BWL/BQ ROD. AW CASING

5 x PD27210BX + PD27210BM PD27210BS PD27210D

NWL/NQ ROD 5 x PD27210BW + PD27210BL PD27210BR PD27210C

HW/HWL/HQ ROD 5 x PD27210BV + PD27210BK PD27210BQ PD27210B

HWT ROD 5 x PD27210BU + PD27210BJ PD27210BP NOT AVAILABLE

ROTATION - GENERAL


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18. ROD CLAMP VISUAL IDENTIFICATION AND NOTES The rod clamp fitted to this rig allows the passing of B, N, H and P drill rod, reaming shell, drill bit and locking coupling, provided the correct rod jaw assembly has been fitted.

18.1 View of the Rod Clamp Assembly in the “OPEN” Position.

Refer to figure 1 for item number location. 1. Rod clamp assembly 2. Chuck assembly 3. Jaw holder pin. The jaw holder pin pins the jaw holder to the jaw lever. 4. Jaw holder with rod jaw bolted to the jaw holder. 5. Jaw lever.Note Rod clamp stop block. The stop block limits the opening height of the rod jaw. The block is normally fitted when any rod handling operations occur. (Not shown.)

18.2 View of the Rod Clamp Assembly in the “Close” Position.

Figure 2 shows a rod clamp assembly.

This photograph shows the rod clamp assembly in the “CLOSE” position with rod jaws, item 1, gripping the drill rod, item 2.The rod jaws are bolted to the jaw holders and the jaw holders are pinned to the jaw levers item 3.

Note: Figure 1 & 2 shown with Rod Clamp Guard removed.

18.3 Upper Rod Breaker Visual Identification

Please refer to figure 3 for part location.The upper rod breaker assembly is made up of the upper breaker, the carriage and the column.The upper breaker is connected to the carriage. The carriage slides inside the column. The column is bolted to the rotation head. The upper breaker spring returns to the open position and requires hydraulic pressure to clamp drill rod. The upper breaker is operated from the control cabinet. The upper breaker is operated to clamp drill rod during operations to make up, or break out drill rod joints. The upper breaker can float up to break out a drill rod joint or float down to make up a drill rod joint.Rod jaws for B, N, H and P sized drill rod can be fitted to the upper breaker.

ROD CLAMP VISUAL IDENTIFICATION & NOTES

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19. TRIPPING RODS INTO THE HOLETwo methods will be described. • The first method will use the power float operation and the rotation head in forward rotation to make up the rod joint between the rotation head and the rod clamp assembly. • The second method will use the rotation head in reverse rotation to make up the rod joint above the head. This method requires the use of an upper rod breaker which is fitted above the PQ rotation head spindle.

19.1 First Method Between The Head And The Rod Clamp Rotation Forward • Initial procedure B, N, H and HWT drill rods or equivalent. • Refer to the pictures on the previous pages to view the components of the clamp, rotation head and chuck assemblies.

1. Remove the rod spin guard assembly. 2. Operate the clamp lever to the “RELEASE” position. 3. Remove the rod jaw assemblies from the rod clamp jaws levers. 4. Traverse the rotation head to a suitable position up the mast so that the rotation head when racked outwards will not interfere with any other part of the rig. 5. Operate the winch float lever to the “OFF” position. 6. Remove the main winch rope from the water swivel. Remove the water swivel. Attach the main winch rope to the hoist plug. 7. Operate the main winch lever “DOWN” and lower the hoist plug. 8. Connect the hoist plug to the box end of the drill rod connected to the locking coupling of the core barrel assembly.

NoteThe core barrel assembly must be connected to a drill rod so that the core barrel assembly can be lowered through the rod clamp assembly.The assumption is that a 3-meter barrel is being used to drill with.If a 6- metre barrel is used connect the hoist plug directly to the locking coupling.

TRIPPING RODS INTO THE HOLE

WARNING• The second method could result in the rod joints in the hole undoing, if the rod joint is made up • incorrectly.

WARNING• Tripping rods into the hole requires a person working in conjunction with the rig operator from • the mast platform basket or rig deck to load hoisted drill rods.

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10. Operate the main winch lever “UP” and raise the drill rod and core barrel assembly until it is above the rod clamp assembly. 11. Operate the main winch lever “DOWN” and “SLOWLY” lower the core barrel assembly until it is completely through the rod clamp assembly. 12. Fit the correct size rod jaw assembly to the rod clamp jaw levers. 13. Operate the clamp lever to the “HOLD” and “RELEASE” position, several times to check the operation of the rod jaw assembly. 14. Operate the clamp lever to the “RELEASE” position. 15. Operate the main winch lever “DOWN” and “SLOWLY” lower the core barrel assembly and drill rod until the hoist plug is between150-200 mm above the rod clamp jaw assembly. 16. Operate the clamp lever to the “HOLD” position. 17. Operate the main winch lever “DOWN” to take the weight off the rope. Remove the hoist plug from the drill rod box end or locking coupling. 18. Rack the Rotation Head to the central position. 19. Operate the traverse lever “DOWN” and traverse the rotation head “SLOWLY” down the mast until the chuck is 50–100 mm above the drill rod clamped in the rod clamp assembly. 20. A hoist plug extension may have to be fitted to the hoist plug. This extension will allow the drill rod to be lowered through the rotation head spindle. 21. Operate the main winch lever “DOWN” and lower the hoist plug if the drill rods are stacked in a rod rack at ground level. Operate the main winch lever “UP” and raise the hoist plug if the drill rods are stacked against the pipe rest of the platform support beam. 22. Connect the hoist plug to the drill rod in the rod rack. 23. Operate the main winch lever “UP” and raise the drill rod until it is above the rotation head. 24. Operate the chuck lever to the “RELEASE” position. Hold the lever in the release position. 25. Operate the main winch lever and “SLOWLY” lower the drill rod through the rotation head.

26. Connect the drill rod to the rod clamped in the rod clamp. Engage the thread by hand a couple of turns.

MAST ANGLE

PLATFORM SUPPORT BEAM LOCATION FIRST ROW OF RODS POSITION

90 Lower mast 20 degrees slope with fi rst row approximately 700 mm from the front of the mast base.

80 Lower mast Parallel to mast.70 Lower mast Parallel to mast.60 Lower mast Beside the right-hand rear jack leg.50 Lower mast Beside the right-hand rear jack leg.

45 Lower mastBeside the right-hand rear jack leg. With the bottom of the drill rod approximately 500 mm behind the jack leg towards the mast base.


WARNING• Care must be taken that no rig functions are activated until all personnel are free and clear of the • rod string.

CAUTION• Take care with the drill rod thread as the rod is lowered through the rotation head spindle bush • • and the rod jaw assembly in the chuck.

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27. Operate the chuck lever to the “HOLD” position. 28. Operate the main winch lever “DOWN” and take the weight off the winch rope. 29. Operate the drill / make lever to the “ON” position. Leave the drill / make lever in this position for the rest of the tripping in procedure. Note Refer to the Drill / Make section of this manual for further information. 30. Operate the float lever to the “MAKE” position and at the same time slowly operate the rotation lever into the “FORWARD” position until the rod joint is made up and the main pressure gauge reads the predetermined make torque pressure. Release the rotation lever. Note Refer to the Float section of this manual for further information. 31. Operate the float lever to the “OFF” position. 32. Operate the chuck lever to the “RELEASE” position. Hold the lever in the release position. 33. Operate the main winch lever “UP” and take the weight of the drill string. 34. Operate the rod clamp lever to the “RELEASE” position. When the clamp is released (opened), return the lever to the neutral position as the clamp will stay in the released position. 35. Operate the main winch lever “DOWN” and lower the drill string through the rotation head and the clamp, until the hoist plug is not lower than 200 mm from the top of the rotation head upper breaker. 36. Operate the rod clamp lever to the “HOLD” position. 37. Operate the main winch lever “DOWN” to take the weight off the rope. Remove the hoist plug from the drill rod. 38. Operate the chuck lever to the “HOLD” position.

On Going Procedure 39. Operate the main winch lever “DOWN” and lower the hoist plug if the drill rods are stacked in a rod rack at ground level. Operate the main winch lever “UP” and raise the hoist plug if the drill rods are stacked against the pipe rest of the platform support beam.

40. Connect the hoist plug to the drill rod in the rod rack. 41. Operate the main winch lever “UP” and raise the drill rod until it is above the rotation head. 42. Operate the main winch lever “DOWN” and “SLOWLY” lower the drill rod until the drill rod pin thread can be inserted into the drill rod box thread of the rod clamped in the rod clamp. Engage the thread by hand a couple of turns.

43. Operate the chuck lever to the “RELEASE” position. Hold the lever in the release position. 44. Operate the traverse lever slowly “UP” and raise the rotation head until the rod joint is below the chuck assembly. 45. Operate the main winch lever “DOWN” and take the weight off the winch rope. 46. Operate the chuck lever to the “HOLD” position.


WARNING• Tripping rods into the hole requires a person work in conjunction with the rig operator from the • mast platform basket or rig deck to load hoisted drill rods.


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47. Operate the drill / make lever to the “ON” position. Leave the drill / make lever in this position for the rest of the tripping in procedure. Note Refer to the Drill / Make section of this manual for further information. 48. Operate the float lever to the “MAKE” position and at the same time slowly operate the rotation lever into the “FORWARD” position until the rod joint is made up and the main pressure gauge reads the pre determined make torque pressure. Release the levers. Note Refer to the Float section of this manual for further information. 49. Operate the float lever to the “OFF” position. 50. Operate the chuck lever to the “RELEASE” position. Hold the lever in the release position. 51. Operate the traverse lever “DOWN” and traverse the head down until the chuck is 50–100 mm above the drill rod joint, which is clamped in the rod clamp assembly. 52. Operate the main winch “UP” and take the weight of the drill string. 53. Operate the rod clamp lever to the “RELEASE” position. When the clamp is released (opened), return the lever to the neutral position as the clamp will stay in the released position. 54. Operate the main winch lever “DOWN” and lower the drill string through the rotation head and the Lower rod clamp assembly, until the hoist plug is not lower than 200 mm from the top of the rotation head upper breaker. 55. Operate the Lower rod clamp lever to the “HOLD” position. 56. Operate the main winch lever “DOWN” to take the weight off the rope. Remove the hoist plug from the drill rod. 57. Repeat steps 37 to 56 inclusive for the rest of the tripping in procedure.


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19.2 Second Method Above The Rotation Head Rotation Reverse • Initial procedure B, N and H drill rods or equivalent. • Refer to the pictures on the previous pages to view the components of the rod clamp, rotation head, chuck and upper breaker assemblies.

1. Remove the rod spin guard assembly. 2. Operate the rod clamp lever to the “RELEASE” position. When the clamp is released (opened), return the lever to the neutral position as the clamp will stay in the released position. 3. Remove the rod jaw assemblies from the rod clamp jaw levers. 4. Traverse the rotation head to a suitable position up the mast so that the rotation head when racked outwards will not interfere with any other part of the rig.

5. Operate the winch float lever to the “OFF” position. 6. Remove the main winch rope from the water swivel. Remove the water swivel. Attach the main winch rope to the hoist plug. 7. Operate the main winch lever “DOWN” and lower the hoist plug. 8. Connect the hoist plug to the box end of the drill rod connected to the locking coupling of the core barrel assembly.NoteThe core barrel assembly must be connected to a drill rod so that the core barrel assembly can be lowered through the rod clamp assembly.The assumption is that a 3-meter barrel is being used to drill with.If a 6- metre barrel is used connect the hoist plug directly to the locking coupling.

9. Operate the main winch lever “UP” and raise the drill rod and core barrel assembly until it is above the rod clamp assembly.

10. Operate the main winch lever “DOWN” and “SLOWLY” lower the core barrel assembly until it is completely through the rod clamp assembly. 11. Fit the correct size rod jaw assembly to the rod clamp jaw levers. 12. Operate the clamp lever to the “HOLD” and “RELEASE” position, several times to check the operation of the rod jaw assembly. 13. Operate the clamp lever to the “RELEASE” position. 14. Operate the main winch lever “DOWN” and “SLOWLY” lower the core barrel assembly and drill rod until the hoist plug is between 150-200 mm above the rod clamp jaw assembly. 15. Operate the clamp lever to the “HOLD” position. 16. Operate the main winch lever “DOWN” to take the weight off the rope. Remove the hoist plug from the drill rod box end or locking coupling. 17. Rack the Rotation Head to the central position.



WARNING• Tripping rods into the hole requires a person to work in conjunction with the rig operator from • the mast platform basket or rig deck to load hoisted drill rods.

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19. Operate the traverse lever “DOWN” and traverse the rotation head “SLOWLY” down the mast until the chuck is 50–100 mm above the drill rod clamped in the rod clamp assembly. 20. A hoist plug extension may have to be fitted to the hoist plug. This extension will allow the drill rod to be lowered through the rotation head spindle. 21. Operate the main winch lever “DOWN” and lower the hoist plug if the drill rods are stacked in a rod rack at ground level. Operate the main winch lever “UP” and raise the hoist plug if the drill rods are stacked against the pipe rest of the platform support beam. 22. Connect the hoist plug to the drill rod in the rod rack. 23. Operate the main winch lever “UP” and raise the drill rod until it is above the rotation head. 24. Operate the chuck lever to the “RELEASE” position. Hold the lever in the release position. 25. Operate the main winch lever and “SLOWLY” lower the drill rod through the rotation head.

26. Connect the drill rod to the rod or locking coupling of the core barrel assembly clamped in the rod clamp. Engage the thread by hand with a hand held pipe wrench. Remove the pipe wrench.

27. Operate the chuck lever to the “HOLD” position. 28. Operate the main winch lever “DOWN” to take the weight off the rope. 29. Operate the drill / make lever to the “ON” position. Leave the drill / make lever in this position for the rest of the tripping in procedure. Note Refer to the Drill / Make section of this manual for further information. 30. Operate the float lever to the “FLOAT” position and at the same time slowly operate the rotation lever into the “FORWARD” position until the rod joint is made up and the main pressure gauge reads the pre-set make torque pressure. Release the rotation lever. Note Refer to the Float section of this manual for further information. 31. Operate the float lever to the “OFF” position. 32. Operate the chuck lever to the “RELEASE” position. Hold the lever in the release position. 33. Operate the traverse lever “DOWN” and traverse the head to the lowest position on the mast. 34. Operate the main winch lever “UP” to just take the drill rod and core barrel weight. 35. Operate the clamp lever to the “RELEASE” position. When the clamp is released (opened), return the lever to the neutral position as the clamp will stay in the released position. Note The rod clamp will need to stay in the released position for the rest of the tripping in procedure. 36. Operate the main winch lever “DOWN” and lower the rod string until the rod joint is at least 50 mm above the top of the rotation head spindle and below the upper breaker jaws. 37. Operate the chuck lever to the “HOLD” position. 38. Operate the main winch lever “DOWN” to take the weight from the rod string. Remove the hoist plug from the rod string. 39. Operate the main winch lever “DOWN” and lower the hoist plug if the drill rods are stacked in a rod rack at ground level. Operate the main winch lever “UP” and raise the hoist plug if the drill rods are stacked against the pipe rest of the platform support beam. 40. Connect the hoist plug to the drill rod in the rod rack.\ 41. Operate the main winch lever “UP” and raise the drill rod until it is above the rotation head.



CAUTION• Take care with the drill rod thread as the rod is lowered through the rotation head spindle bush • and the rod jaw assembly in the chuck.

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42. Operate the main winch lever “DOWN” and “SLOWLY” lower the drill rod until the drill rod pin thread can be inserted into the drill rod box thread of the rod clamped in the chuck. Engage the thread by hand with a hand held pipe wrench. Remove the pipe wrench.

43. Operate the main winch lever “DOWN” and take the weight off the winch rope. 44. Operate the drill / make lever to the “ON” position. Leave the drill / make lever in this position for the rest of the tripping in procedure. Note - Refer to the Drill / Make section of this manual for further information. 45. Operate the upper breaker control lever to the “CLAMP” position. 46. Slowly operate the rotation head lever into “REVERSE” until the rod joint is made up, and the main pump pressure gauge reads the preset make up torque pressure reading. Release the rotation lever. 47. Operate the upper breaker lever to the neutral position. Please note the lever will spring return to the neutral position. The upper breaker will automatically spring return to the open position. 48. Operate the main winch lever “UP” to just take the drill string. 49. Operate the chuck lever to the “RELEASE” position. Hold the lever in the release position. 50. Operate the main winch lever “DOWN” and lower the rod string until the rod joint is at least 50 mm above the top of the rotation head spindle and below the upper breaker jaws. 51. Operate the chuck lever to the “HOLD” position. 52. Operate the main winch lever “DOWN” and take the weight off the winch rope. 53. Remove the hoist plug from the drill rod clamped in the chuck. 54. Operate the main winch lever “DOWN” and lower the hoist plug if the drill rods are stacked in a rod rack at ground level. Operate the main winch lever “UP” and raise the hoist plug if the drill rods are stacked against the pipe rest of the platform support beam. 55. Connect the hoist plug to the drill rod in the rod rack. 56. Repeat steps 41 to 55 for the rest of the tripping cycle.



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20. TRIPPING RODS OUT OF THE HOLE20.1 Initial ProcedureRefer to the pictures on the previous pages to view the components of the clamp, rotation head and chuck assemblies. The upper rod breaker mounted to the Rotation head will be used. 1. Remove the rod spin guard assembly. 2. Traverse the rotation head and the drill string “DOWN” to the lowest position on the mast. 3. Operate the clamp lever to the “RELEASE” position. When the clamp is released (opened), return the lever to the neutral position as the clamp will stay in the released position. Note The rod clamp will need to stay in the released position for the rest of the tripping out procedure. Check that the drill bit does not contact the bottom of the hole. 4. Remove the main winch rope from the water swivel. Remove the water swivel. Attach the main winch rope to the hoist plug. Attach the hoist plug to the drill string held in the rotation head chuck. 5. Operate the winch float lever to the “OFF” position. Check the drill / make lever is in the “DRILL” position. 6. Decrease fully the rotation head speed control. The rotation head motor must be on maximum dis placement. When the motor is on maximum displacement the motor can produce maximum torque to break out a rod joint.

20.2 Ongoing Procedure 7. Operate the main winch lever “UP” and take the weight of the drill string. 8. Operate the chuck lever to the “RELEASE” position. Hold the lever in the release position. 9. Operate the main winch lever “UP” and raise the drill string until the rod joint is at least 50 mm above the rotation head spindle and below the upper breaker jaws. 10. Operate the chuck lever to the “HOLD” position. 11. Operate the main winch lever “DOWN” to take the weight off the winch rope. 12. Operate the Upper Rod Breaker to “CLAMP” closed position. 13. Slowly operate the rotation head lever “FORWARD” until the rod joint is broken. Release the lever. 14. Operate the Upper Rod Breaker to “RELEASE” open position. 15. Operate the main winch lever “UP” and take the weight of the separated drill string. 16. Operate the main winch lever “DOWN” and lower the separated drill string into the rod rack. 17. Remove the hoist plug from the drill rod. 18. Operate the main winch lever “UP” if the rod rack is at ground level or “DOWN” if the rods are being stacked against the pipe rest of the platform support beam. 19. Attach the hoist plug to the drill string held in the rotation head. 20. Repeat steps 6 to 19 inclusive for the rest of tripping out procedure until the core barrel assembly is near the surface.

20.3 Removal of the Core BarrelWhen the last rod with the core barrel attached to it, is raised to the surface, the following procedure can be used. 1. Operate the clamp lever to the “HOLD” position. 2. Operate the chuck lever to the “RELEASE” position. Hold the lever in the release position. 3. Operate the traverse lever “UP” and traverse the rotation head above the end of the drill rod clamped in the rod clamp. 4. Rack the Rotation Head out to the side of the mast. 5. Attach the main winch rope hoist plug to the drill rod. 6. Operate the winch lever “UP” and take the weight of the drill rod and the core barrel assembly. 7. Operate the clamp lever to the “RELEASE” position. 8. Operate the main winch lever “UP” and slowly raise the core barrel assembly above the rod clamp assembly. 9. Operate the main winch lever “DOWN” and lower the drill rod and core barrel onto the rod rack.

TRIPPING RODS OUT OF THE HOLE

WARNING• Removal of the Core Barrel out of the hole requires a person work in conjunction with the rig • operator to aid in guiding the Core barrel into the rod rack.

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20.4 Adding Rods The following procedure outlines a method that can be used to add drill rods during the drilling program. • Open the Rod Spin guard. • Run the diesel engine between 1200-1400 rpm. • Operate the winch float lever to the “OFF” position • Decrease the rotation speed control fully counter clockwise. • Remove the water swivel from the drill string. • Fit the main winch rope to the hoist plug. • Operate the clamp lever to the “HOLD” position. • Operate the chuck lever to the “RELEASE” position. • Operate the main winch and fit a drill rod through the rotation head spindle and into the rod clamped in the rod clamp. Start the thread by hand. • Operate the traverse lever “UP” and move the rotation head chuck assembly above the rod joint. • Operate the chuck lever to the “HOLD” position. • Operate the drill make lever to the “ON” position. Note Please refer to the drill make section of this manual for further information. When adding a drill rod, “making” the joint, with the rotation head ensure the main pressure does not exceed 200 bar. It is then possible to break the same joint with the rotation head in low gear in reverse at the same system pres sure. • Operate the float lever to the “FLOAT” position and at the same time operate the Rotation lever into the Forward Position “SLOWLY” until the rod joint is made up and the Main Pressure gauge reads the predetermined make up pressure. Release the levers. • Operate the rotation float lever to the “OFF” position. • Fit the water swivel to the drill string. • Fit the main winch rope to the water swivel. Take up the slack of the main winch rope. • Move the chuck lever to the “RELEASE” position • Operate the traverse lever “UP” slowly and move the rotation head up to a point between 90 and 100 mm from the top of its travel. • Operate the chuck lever to the “HOLD” position. • Operate the traverse lever “UP” slowly to just take the weight of the drill string. • Operate the main winch control lever “UP” and take up the slack of the main winch rope. • Operate the clamp lever to the “RELEASE” position. • Operate the drill make lever to the “DRILL” position.

TRIPPING RODS OUT OF THE HOLE

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21. ROTATION FOR DIAMOND DRILLING High Gear 0 - 1500 rpm.Low Gear 0 – 833 rpm. • Push the high-low gear selection lever into high gear (3:1 ratio).

21.1 Drilling • The rotation head lube oil system has a sight glass fitted near the lube oil tank on the rotation head. During operation of the rotation head in forward rotation the driller should on a regular basis check that lube oil is passing through the sight glass. • When ready to drill, run the diesel engine up to maximum speed (2200 rpm). • Operate the water pump “ON-OFF” lever to the “ON” position to start the water pump and fill and flush the hole. Note Refer to the water pump section of this manual for further information. Close and lock the rod spin guard. • Engage the rotation lever and slowly move it to the full forward speed position and lock it in place by moving the lever to the right.

• Slowly increase the rotation speed by turning the Rotation Speed control “CLOCKWISE”, until the required rotation rpm is achieved. The rotation rpm will be indicated on the rotation head tachometer. • Move the Winch Float lever to the “ON” position. Note Refer to the main winch float section of this manual for further information. • Lower the bit on bottom and start drilling. After setting the hold back - pull down - micro feed speed (penetration) and the water pump flow controls. Note Refer to the hold back, pull down and micro feed section of this manual for further information

ROTATION FOR DIAMOND DRILLING

WARNING• The rotation head must have a rod fitted to the chuck prior to rotating the head and the chuck • • control lever must be in the “HOLD” position.• The chuck can be damaged if the rotation head is turned with the chuck in the release position.


CAUTION• When gears do not engage when shifting, use a hand held pipe wrench on the drill rod to line up • • the gear teeth. Do not operate the hydraulic motor for this purpose. Ensure that detent in the gear • box housing is fully engaged in the gear selector shaft.

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21.2 The Manual Mode of Operation for the Rotation HeadThe Manual Mode will show a bind-up (Torque Increase) in the hole, which will show up on the main pressure gauge.

• The diesel is at maximum speed. • The rotation lever is moved forward fully. • The rotation speed control is adjusted to the required rotation speed.

With the main rotation lever in full forward position and the MAIN PRESSURE gauge reading below 240 bar the rotation speed will be at the required speed as set by the rotation speed control. As the hole now gets deeper and more torque is required the ROTATION TORQUE can be increased by slightly decreasing the rotation speed control until the MAIN PRESSURE GAUGE settles around 235-240 bar. Any time there is a bind-up down the hole the MAIN PRESSURE will jump to 250 bar or higher and the rotation speed will noticeably decrease.The maximum stalling torque when diamond drilling in high gear (3.1:1 Ratio) is approximately 985 Nm (726 ft lbs.) at 250 bar (3625 PSI).

NoteFor any kind of diamond drilling, always work the diesel at maximum speed. If the rotation speed needs to be reduced, decrease the rotation speed control. Gently ease the main rotation lever off to slow down and stop the rotation as stopping too briskly can undo the rod joints.

ROTATION FOR DIAMOND DRILLING

WARNING• The rod spin guard must be in place, when the rotation head is working.• The only time the guard can be removed is to add - subtract drill rods to the rod • No maintenance or servicing of rotation head or rod clamp assembly can be performed while • rotation of a drill rod is occurring.

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22. ROTATION HEAD FLOAT 22.1 Float “Break - Make” FamiliarisationThis lever engages the head float system. This lever is used in combination with the Rotation control lever to make up rod joints.The float system balances the weight of the rotation head and any drill rod held in the chuck. As the weight of the head and rod is balanced, the drill rod thread only needs to apply enough force to screw the rod joint together.

22.2 Rotation Head Float Set Up Procedure (Make and Break)Please refer to figure 1 for item number locations.

1. Float “BREAK” position, 2. Float “MAKE” position, 3. Float “BREAK” speed control (clockwise to increase), 4. Float “MAKE” speed control (clockwise to increase).

22.3 Float Make Set Up • Operate the traverse lever and bring the rotation head to the bottom of the mast. • Operate the chuck lever to the “RELEASE” position. • Using the main winch lever, hoist a 6-metre length of the drill pipe that you will be drilling with and lower it through the rotation head spindle. • Operate the chuck lever to the “HOLD” position. Operate the main winch to take the weight off the winch rope. Remove the hoist plug. • Operate the traverse lever “UP” and slowly traverse the rotation head and attached drill rod up the mast approximately 500 mm • Adjust the pressure setting of item 4 to the minimum setting by turning the adjustment knob counter clockwise. • With the diesel at 1400 to 1500 rpm, operate the float lever item 1 to the “MAKE” position (lever down, position 2). • Adjust the “MAKE” power float speed control valve item 4 until the rotation head just moves down the mast. • The “MAKE” float system should be set so that the drill rod threads do not have to pull the rotation head down to make up the joint. • Adjust the make control valve item 4 as required.

ROTATION HEAD FLOAT

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22.4 Float Break Set UpNoteThe float break operation will not be required when the upper rod breaker is fitted to the rotation head. • Operate the traverse lever and bring the rotation head to the bottom of the mast. • Operate the check lever to the “RELEASE” position. • Using the main winch lever, hoist a 6 metre length of the drill pipe that you will be drilling with and lower it through the rotation head spindle. • Operate the chuck lever to the “HOLD” position. Operate the main winch to take the weight off the winch rope. • Operated the traverse lever up until there is a distance between the rod clamp and the bottom of the chuck of at least 500 mm. • With the diesel at 1400 to 1500 rpm, operate the float lever to the “BREAK” position (lever up, position 1). • Adjust the “BREAK” power float speed control, item 3, until the rotation head will just move up the mast. • The float system should be set so that when you push up on the rotation head with minimal force, the head will move up. Note The float control will have to be adjusted to suit the particular drilling conditions that you are working with eg; 1.5 or 3 metre rods, rod size and mast angle.

ROTATION HEAD FLOAT

WARNING• Failure to correctly set-up the float controls may lead to threads being damaged.

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23. ROD SPIN GUARDRefer to figure 1 for item number locations. 1. Rod spin guard shown in the “Closed” position. 2. Rod spin guard handle. The handle is spring loaded. The handle must be lifted up to open the rod spin guard. 3. Rod spin guard interlock valve plunger. 4. Rod spin guard interlock valve at the side of the mast is engaged when the guard is closed.

This rig is fitted with a rod spin guard that, when used correctly, stops access to the drill string by drilling personnel working around or near the mast base. The guard is also fitted with a rod spin guard interlock system, the operation of which is described below.

ROD SPIN GUARD

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23.1 Diamond Drilling High -Speed 500 - 1500 rpm.With the rotation pilot lever engaged in the forward position, and the rod spin guard in the “CLOSED” position. The following will happen; • The handle will lock the rod spin guard in place • The rod spin guard will push against the rod guard interlock valve plunger. This will allow high-speed operation of the rotation head.

• With the rod spin guard in the “OPEN” position - figure 1, only slow rotation of the rotation head is possible. This allows for making up and breaking out of the drill string.

ROD SPIN GUARD

WARNING• The rod spin guard must be in place, when the rotation head is operating.• The only time the guard can be removed is to add - subtract drill rods to the rod string.• No maintenance or servicing of rotation head or rod clamp assembly can be performed while • rotation of a drill rod is occurring.

CAUTION• If the handle is not locked in place the rod spin guard could vibrate into the “OPEN” position • enough to allow the interlock valve to open. • This will cause a sudden reduction in rod string rpm, which could loosen the rod joints in the • hole.

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24. ROTATION MAKE CONTROLWith this system, the forward rotation torque can be reduced from the maximum setting by adjusting the “ROTATION MAKE” control knob that is fitted to the control panel.

NoteThere must be a rod in the rotation head and rod clamp to set the drill / make control.

• Fit a drill rod to the rotation head. • Shift the rotation head into HIGH gear. Check with the rotation lever that the rotation head has a minimum 60 rpm. • Operate the drill make lever in figure 1 (item 2) to the “ON” position (lever down). • Undo the lock nut of the Rotation Make Torque valve in figure 1 (item 3) and reduce to minimum setting (counter clockwise rotation). • Operate the clamp lever to the “HOLD” position. • With the diesel engine between 1400-1500 rpm, engage the rotation lever - figure 1 (item 1) - into forward and stall the rotation head. • Check the pressure setting on the main pressure gauge in figure 1 (item 4). • Adjust the rotation make torque control clockwise in small increments. After each adjustment of the drill make torque control engage the rotation lever fully forward and check the pressure setting. • Lock the lock nut of the rotation make torque control when the correct pressure has been set. • Check the setting by engaging and disengaging the rotation lever into the forward position

• Use the table below as a guide to the maximum torque settings than can be achieved from the rotation head.

Note 1. 1 Foot pound (Ft lbs.) equals 1.356 Newton Metre (Nm) (1 bar equals 14.5 psi). 2. The above torque figures are maximum at given pressures. 3. Rotation Motor is at maximum displacement.

• Shift to low gear if required.

FORWARD ROTATION TORQUE AT 100 % EFF.WITH THE MOTOR AT MAXIMUM DISPLACEMENT

MAIN PRESSUREBAR

HIGH GEAR3 :1 RATIO

Nm

LOW GEAR5.4:1 RATIO

Nm100 510 918150 765 1377200 1020 1836230 1173 2111

ROTATION MAKE CONTROL

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25. ROTATION HEAD TRAVERSE25.1 Specifications • Hydraulic cylinder direct coupled to the Rotation Head carriage. • Head traverse of 3,450 mm • Maximum speed up or down of 30 m/min at 2200 rpm. • PULL DOWN 53.2 Kn (12,000 lbf) • PULL OUT 91.2 Kn (20,5 00 lbf)

25.2 FamiliarisationPlease refer to figure 1 for item number location. 1. HEAD TRAVERSE “UP-DOWN” This pilot control lever controls the direction of operation and the speed of the rapid traverse system for the rotation head, by controlling the flow of oil from the main pump via the main control valve to the traverse cylinder. The head traverse speed can be varied by the position of the lever, and the diesel rpm. 2. PULL DOWN PRESSURE GAUGE This gauge indicates the actual hydraulic oil pressure used during drilling. The conversion ring converts hydraulic pressure in the rod end of the traverse cylinder to pounds (lbs.) of bit weight. 3. MAIN PRESSURE GAUGE This gauge indicates the actual main pump pressure required too operate the head traverse. 4. ENGINE THROTTLE This lever controls the diesel engine rpm 5. HOLDBACK “DECREASE-INCREASE” This adjustable pressure control valve controls the hydraulic oil pressure required in the piston end of the traverse cylinder when using the micro feed system. The pressure is used to balance the weight of the drill rods and core barrel in the hole. 6. MICRO FEED CONTROL “INCREASE-DECREASE” This adjustable valve controls pull down feed oil flow to the traverse cylinder. This oil flow produces the penetration rate of the drill bit into the ground. 7. PULL DOWN “DECREASE- INCREASE” This adjustable valve controls the pressure of the hydraulic oil used in the micro feed system and due to this pressure acting against the annulus surface area of the traverse cylinder produces the bit weight required to drill with. The pull down pressure (bit weight) can be read on the pull down pressure gauge.

ROTATION HEAD TRAVERSE

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8. MICRO FEED “UP-DOWN” This lever controls the direction of hydraulic oil flow to the traverse cylinder via the micro feed circuit. This circuit has the following valves in it, pull down pressure control, micro feed speed control and the hold back-pressure control valve. 9. WINCH FLOAT “OFF-ON” The main winch of this rig is fitted with a winch float system. This system allows the winch rope that is connected to the water swivel to travel down the mast during drilling. The winch float system can be engaged / disengaged at the control panel by the use of the winch float lever. The winch float system has two positions, which are described below “WINCH FLOAT OFF” In this position the winch rope will not travel down the mast with the water swivel. The brake of the winch is applied and the winch rope will support the weight of the drill string. This allows the driller to stop feeding the rotation head and drill string down the mast. The rotation of the drill rods can stop and chuck can be released and the rotation head can be traversed “UP” the mast. When the head has been traversed up the mast, the chuck can be engaged and rotation and feeding can recommence. This process allows the driller to use drill rods and core barrels assembly that are longer than the head traverse stroke of the rig. “WINCH FLOAT ON” In this position the winch rope will travel down the mast with the water swivel. The brake of the winch is released and the winch rope will not support the weight of the drill string.

10. DIESEL ENGINE RPM TACHOMETER This gauge indicates diesel engine speed in revs per minute.



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25.3 Traverse By Means Of “Head Traverse” Lever • Maximum speed is 30 m (100 ft) per minute up. Diesel engine at 2200 rpm. • Hydraulic pilot operated control of the head traverse control valve permits infinitely variable speed control of the rotation head from minimum to maximum as the head is traversed up or down the mast.

25.4 Traverse By Means Of “Micro Feed” Lever • The micro feed lever is used to obtain a down-feed, at a controlled rate via the micro feed speed control. The micro feed lever is also used to obtain and up-feed, at maximum micro feed speed depending on diesel engine rpm, to lift the rod string off the bottom of the hole or in case of an emergency situation. • The micro feed will not function correctly if: • The micro feed speed control valve is closed. • The HOLD BACK is over balanced. • The PULL DOWN is set incorrectly. • There are restrictions in the drill hole. • Operate the winch float lever into the “on” position. This will allow the main winch rope, which is connected to the water swivel to float down with the rotation head.

25.5 Hold Back, Pull Down, Micro Feed

HOLD BACK is applied to counteract the weight of rotation head, rods and in hole tools. PULL DOWN is then applied to achieve a desired maximum bit weight.

25.6 Set Up Of Hold Back and Pull Down Method 125.6.1 To Adjust Holdback • Run diesel at 1200 to 1500 rpm. • Decrease PULL DOWN control to zero. • Increase fully the micro feed speed control. • Rotate the rods slowly with the flushing medium circulating i.e. Water Mud etc. • Engage the micro feed lever “DOWN”. • Adjust the HOLD BACK so that the rotation head just stops creeping down - but do not unreasonably over adjust the HOLD BACK. Note As the drill hole progresses, readjust the HOLD BACK every 12-18 metres to compensate for the weight of rods added.



CAUTION• Do not attempt to operate these functions unless you have fully understood the workings of the • system and the resulting forces on the drill string as illustrated by the four worked examples on • the following pages.

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25.6.2 To Adjust the Pull Down and Micro-Feed • Hold the rods using the rod clamp. • Engage the micro feed lever into down position • Increase the micro feed speed control • Increase the PULL DOWN pressure by adjusting PULL DOWN control, until the required maximum bit weight is obtained on the PULL DOWN gauge. • When drilling, control the rate of penetration by adjusting the micro feed speed control.

25.7 Set Up Of Hold Back and Pull Down Method 225.7.1 To Adjust Pull Down Traverse the head to the bottom of the mast: • Engage the micro-feed lever into down position. • Increase (fully open) the micro-feed speed control. • Increase the pull down pressure by adjusting the pull down control until the required maximum weight on the bit is obtained on the pull down gauge.

25.7.2 To Adjust Holdback and Micro Feed • Traverse the head to the top of the mast and fit the next drill rod. • Run diesel at 1200 to 1500 rpm. • Decrease (fully close) the micro-feed speed control. • Rotate the rods slowly with the flushing medium operating. • Engage the micro-feed lever “DOWN”. • Adjust the holdback so that the rotation head just stops creeping down but not more. Over adjusting the holdback is not necessary. • When drilling, control the rate of penetration by adjusting the micro-feed speed control.

Example 700 m (2300 ft) NQ or equivalent size:Allow a maximum PULL DOWN of 15500 lbs, see also the worked example No 4 on the following pages.

Hole Depth Maximum Allowable Pull Down InPounds

In Metres In Feet BQ or Equiv. NQ or Equiv. HQ or Equiv. 0 - 100 0 – 330 2500 5300 12700

100 - 200 330 – 660 3600 6800 14900 200 - 300 660 – 980 4800 8200 17100 300 - 400 980 – 1310 5900 9700 19300 400 - 500 1310 – 1640 7100 11100 21500 500 - 600 1640 – 1970 8200 12600 23700 600 - 700 1970 – 2300 9400 14000 25900 700 - 800 2300 – 2620 10500 15500 800 - 900 2620 – 2950 11700 16900 900 -1000 2950 – 3280 12800 18400


CAUTION• If more PULL DOWN is required, for example to “strip” an impregnated diamond drill bit, do so • with the rods turning and the bit “on-bottom” but do not exceed the maximum allowable PULL • DOWN for your present hole depth and rod size as shown in the following table.

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25.8 Head Traverse Cylinder and Drill String Forces25.8.1 Example 1 - Starting NQ from the surface, 5000 lbs. Pull Down


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25.8.2 Example 2 - 300 metres (985 ft) NQ hole, 5000 lbs Pull Down


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25.9 Starting To Drill25.9.1 At The Start of the Traverse Cylinder Stroke • Correctly set the HOLD BACK and PULL DOWN as per the instructions. • Decrease the micro feed speed control fully. • With the bit off bottom, start the rotation and circulate the flushing medium (water, mud) • Operate the winch float lever to the “ON” position.

25.9.2 Main Winch Float SystemThe main winch of this rig is fitted with a winch float system. This system allows the winch rope that is connected to the water swivel to travel down the mast during drilling. The winch float system can be engaged / disengaged at the control panel by the use of the winch float lever. The winch float system control lever has two positions, which are described below:

25.9.3 “Winch Float Off” • In this position the winch rope will not travel down the mast with the water swivel. The brake of the winch is applied and the winch rope will support the weight of the drill string. • This allows the driller to stop feeding the rotation head and drill string down the mast. • The rotation of the drill rods can stop and chuck can be released and the rotation head can be traversed “UP” the mast. • When the head has been traversed up the mast, the chuck can be engaged and rotation and feeding can recommence. • This process allows the driller to use drill rods and core barrels assembly that are longer than the head traverse stroke of the rig.

25.9.4 “Winch Float On” • In this position the winch rope will travel down the mast with the water swivel. The brake of the winch is released and the winch rope will not support the weight of the drill string.

25.9.5 Drilling • Engage the micro feed direction lever “DOWN”. • Increase the micro feed speed control to obtain the required penetration rate. • Override the micro feed with the head traverse lever and gently bring the bit on bottom.

As drilling commences the following can be observed: • In free cutting formations the penetration rate will be as preset. • The PULL DOWN pressure (bit weight) would most likely be less than preset. • If the drill bit strikes a band of hard rock the PULL DOWN pressure (bit weight) can increase to the maximum preset value as the penetration rate slows down and in extreme cases could come to a stop. • This system will constantly tell via the PULL DOWN gauge, the hardness of formation being drilled through.• While drilling, the pull down pressure gauge will register variations as a result of:

DESCRIPTION PULL DOWN PRESSURE

- HARDNESS OF FORMATION HARDER "UP" SOFTER “DOWN”

- BLUNT BIT "UP"- PLUGGED BIT OR BLOCK-OFF IN CORE BARREL "UP"

- VIBRATION IN HOLE "UP"- EXCESSIVE TORQUE REQUIRED TO DRILL "UP"

- CAVING OR FRACTURED INFORMATION IN FORMATION "UP"IN CAVITY “DOWN”


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Towards the End of the Traverse Cylinder Stroke • Operate the winch float lever to the “OFF” position and allow the micro feed to take the slack if any out of the main winch rope.

• Operate the micro feed lever to the neutral position. • Slowly move the rotation lever to the neutral position, to stop the rod string rotating. • Operate the water pump “ON-OFF” control to the “OFF” position. • Operate the chuck control lever to the “RELEASE” position. • Operate the traverse lever and traverse the rotation head to the top of the mast. • Operate the chuck control lever to the “HOLD” position. • Operate the water pump “ON-OFF” control to the “ON” position. • Operate the rotation lever to start rotation of the rod string. • Engage the winch float control lever to the “ON” position. • Engage the micro feed lever to the “DOWN” position to recommence drilling.


WARNING• The rod spin guard must be in place when rotation head is working. The only time the guard can • be “opened” is to add-subtract drill rods to the rod string.• No maintenance or servicing of rotation head or rod clamp assembly can be performed while • rotation of a drill rod is occurring.

CAUTION• Never decrease the HOLD BACK to increase bit weight or penetration!• Use the PULL DOWN pressure control to increase bit weight.• Use the micro feed speed control to increase penetration rate as required.• Adjust the HOLD BACK every 12-18 metres to compensate for added rods.

CAUTION• Do not put excessive tension on the main winch rope, as this could break the core when the • chuck is released.

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26. WATER PUMP CONTROLS AT THE CONTROL CABINET26.1 FamiliarisationPlease refer to figure 1 for item number locations.

1. WATER PUMP “OFF-ON” This valve when in the “ON” position operates a pilot controlled valve to allow hydraulic oil flow from hydraulic pump number 2 to the water pump fine and coarse controls. When in the “OFF” position the pilot controlled valve allows the oil flow from hydraulic pump number 2 to vent to the hydraulic oil tank at low pressure. 2. WATER PRESSURE GAUGE This gauge indicates the actual working pressure of the water or mud used during drilling. 3. WATER PUMP FINE CONTROL This adjustable needle valve controls the hydraulic oil flow to the water pump motor. Because of this control the speed of the water pump can be adjusted to control the amount of water supplied to the drill string and to the drill bit. It is used for normal drilling operations. The water flow can be increased by turning the valve knob in a clockwise direction. 4. WATER PUMP COARSE CONTROL This ball valve is used to send maximum hydraulic oil flow from hydraulic pump number 2 to the water pump motor. The valve allows maximum oil flow to the water pump allowing it to operate at maximum speed, dependant on diesel rpm, and supply maximum water flow to the drill string. This control is normally engaged to pump the core barrel down the drill string. 5. ENGINE THROTTLE This lever controls the diesel engine speed. 6. DRAIN VALVE “OPEN-CLOSED” This valve vents the drill string of water pressure when drilling has stopped and the water pump has been turned “OFF”. 7. WATER VALVE “OFF-ON” This valve turns the water pump flow “OFF-ON” to the drill string.

WATER PUMP CONTROLS AT CONTROL CABINET

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27. WATER PUMP FOR DIAMOND DRILLING W1122BCDRefer to figure 1 for item number locations.

1. FMC W1122 water pump assembly. 2. Water pump drive motor. 3. Water pressure relief valve. 4. Water pump inlet. 5. Water pump assembly base frame. 6. Mud mixer flow control. 7. Auxiliary water valve.

27.1 Specifications • FMC (Bean) W1122 BCD. • 37 GPM (140 LPM) at pressures up to 1000 PSI (7000 kPa). • The water pump flow rate is controlled and is infinitely variable from the control cabinet. • Water pressure relief valve fitted to pump outlet.

27.2 Operation • Ensure the water pump suction hose is a minimum 2” inside diameter, air tight, as short as possible and the suction head is kept to a minimum. • The drain valve must be in the “CLOSED” position. • The water valve must be in the “OPEN” position. • Engage the water pump “ON-OFF” lever to the “ON” position. • Adjust the water pump flow by using the water pump fine control valve to obtain the desired water flow. • Once the desired water flow is set, simply work the water pump “ON-OFF” valve to start and stop the water pump. • The water pump coarse control is used in conjunction with the water pump “ON-OFF” ball valve when maximum water flow is needed e.g. to pump a tube down the hole or to flush a hole. With the water pump coarse control “ON” simply work the water pump “ON-OFF” ball valve to start and stop the water pump. • The water pressure relief valve can be set as desired at any time. If the relief valve responds due to a core blockage or any other reason, the relief valve exhaust water will discharge underneath the control cabinet as an additional warning to the high water pressure gauge reading.

WATER PUMP FOR DIAMOND DRILLING W1122BCD

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27.3 Mud MixerPlease refer to figure 1 for item number locations.

1. Mud mixer flow control valve. 2. Mud mixer valve control lever and locking knob.

The mud mixer flow control valve is located on the base frame of the water pump assembly at the front right hand side of the rig.The speed of the mud mixer can be controlled from minimum to maximum by a lever on the flow control item 2 figure 1.

The operation of the mud mixer can be started and stopped via the lever on the flow control valve.

A mud mixer or any other suitable hydraulic powered equipment can be connected to the hydraulic system of the rig via two connections.

Two connections have been provided: • Hydraulic oil pressure and flow to the mud mixer motor, from the mud mixer flow control. • Hydraulic tank return from the mud mixer motor.

27.3.1 Mud Mixer Hydraulic System SpecificationsThe maximum hydraulic oil flow from the flow control with the diesel engine at 2200 rpm = 55 lpm (14.5 US gpm).

The maximum pressure relief valve setting for the mud mixer system is 138 bar (2000 psi).

WATER PUMP FOR DIAMOND DRILLING W1122BCD

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28. ROD CLAMP

28.1 Specifications • Hydraulically operated, self energising rod clamp. • Easy to remove jaws. • The rod jaws are bolted to the jaw holders the jaw holders are pinned to the jaw levers on the rod clamp base. • Rod clamp jaw sets supplied for sizes B+, N+, H+ and P+ (44.5 mm to 177.8 mm) diamond drill rods.

28.2 Operation • To operate, simply place the control lever (item 1) figure 1 into the required position. • Close position, the drill rod is clamped by the rod jaws • Open position, the drill rod is not clamped by the rod jaws.

ROD CLAMP

WARNING• When pulling rods, always take up rope slack with the main winch before opening the rod • clamps.• Do not rest hands - feet - legs on rod clamp assembly.• Do not remove the rod clamp guard unless for maintenance or repairs.• Check the distance between the rod clamp jaw assemblies in the “OPEN” position and the chuck • before operating the rotation head.

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28.3 Rod Clamp Visual Identification and Notes The rod clamp fitted to this rig allows the passing of B, N, H and P drill rod, reaming shell, drill bit and locking coupling, provided the correct rod jaw assembly has been fitted.

28.3.1 View of the rod clamp assembly in the “OPEN” Position.Refer to figure 1 (right) for item number location. 1. Rod clamp assembly. 2. Chuck assembly . 3. Jaw holder pin. The jaw holder pin pins the jaw holder to the jaw lever. 4. Jaw holder with rod jaw bolted to the jaw holder.

Refer to figure 2 for the following: 5. Rod clamp stop block. The stop block limits the opening height of the rod jaw. The block is normally fitted when any rod handling operations occur. 6. Jaw lever. 7. Guard.

28.3.2 View of the Rod Clamp Assembly in the “Close” Position.

This photograph - figure 3 - shows a rod clamp assembly. This photograph shows the rod clamp assembly in the “CLOSE” position with rod jaws item 1 gripping the drill rod item 2.The rod jaws are bolted to the jaw holders and the jaw holders are pinned to the jaw levers item 3.Item 4 shows the Guard Brackets.

Note - Figure 1 & 3 shown with Rod Clamp Guard removed.

ROD CLAMP

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29. BREAKOUT TOOLThe break out tool fitted to this rig (item 1) in figure 2 is operated from the control cabinet by the breakout tool control lever (item 1) in figure 1. The breakout tool is used to break out or make up diamond drill rod and casing.

29.1 SpecificationsThe maximum torque of the breakout pipe wrench in both directions is set to 7500 Nm, (5500 ft-lbs).

Comparative torque values: (Nm) • Rotation Head Maximum: 3660 • HQ Joint recommended: 2100 • CH 101 Joint recommended: 3390

29.2 OperationTo operate the breakout tool, carry out the following: • Fit the breakout tool to the required position in the pivot assembly. Check the breakout tool cylinder is securely pinned to the pivot assembly. Check the breakout tool pipe wrench is securely pinned to the breakout tool cylinder rod clevis. • Operated the breakout control lever at the control panel, refer to item 1 in figure 1. To make a rod joint the breakout tool cylinder rod must retract. To break a rod joint the breakout tool cylinder rod must extend. • To change over from “making” to “breaking” a joint simply rotate the cylinder rod to which the breakout pipe wrench is attached around 180 degrees.

BREAKOUT TOOL

WARNING• Do not rest your hands or feet on the breakout tool pipe hook and wrench assembly when • making or breaking rod joints.• Check the pipe wrench is securely pinned to the breakout tool cylinder rod clevis.• Check the breakout tool cylinder is securely pinned to the breakout tool pivot assembly on the • left-hand side of the mast.• Check the pipe wrench jaws have been correctly adjusted to the drill rod and check the pipe • wrench jaws are square to the drill rod. An incorrectly set up pipe wrench could slip and cause • serious injury.

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30. HEAD RACK OPERATIONThe head rack control lever item 1 figure 1 is operated to move the rotation head to the left hand side of the mast to allow access to the drill string for operations when the main winch or wire line winch will be operated.

The rotation head can be moved into two positions.

30.1 “OUT” With the control lever in this position the rotation head will move to the left-hand side of the mast (figure 2) to allow access to the drill string for operations when the main winch or wire line winch will be operated.

30.2 “IN”With the control lever in this position the rotation head will move into the drill position (figure 3) where the centre line of the chuck of the rotation head will be in line with the drill string centre line. The head rack lever item figure 1 in shown in the “IN” position

HEAD RACK OPERATION

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With care “SIDE RACK” is possible with the rotation head in any position along the mast.

Rotate the head rack control lever item 1 figure 1 clockwise into the “OUT” position (lever horizontal) to operate the head rack hydraulic cylinders to move the rotation head into the “OUT” position at the left hand side of the mast.

Rotate the head rack control lever item 1 figure 1 counter clockwise into the “IN” position (lever vertical) to operate the head rack hydraulic cylinders to move the rotation head into the “IN” position where the centre line of the chuck of the rotation head will be inline with the drill string centre line.

HEAD RACK OPERATION

WARNING• Do not rest hands on the head rack frame during operation of the head rack control lever.

DE710


31. SLIDE ROLLER OPERATIONThe slide roller control lever is operated to move the slide roller assembly item 1 figure 1, so that it is in front of the rod slide fitted to the upper mast.

The slide roller will allow the offsider in the basket to get there hands around the drill rod for rod handling operations.

The slide roller control lever item 1 figure 2 can be moved into two positions.

31.1 “IN”With the control lever in this position the slide roller will move into the position behind the rod slide.

31.2 “OUT” With the control lever in this position the slide roller will move into the position in front of the rod slide. Refer to figure 3, you will see the slide roller item 1 in front of the rod slide.

SLIDE ROLLER OPERATION

WARNING• Do not rest your hands on the slide roller during operation of the slide roller control lever.• The slide roller control lever should be in the “IN” position when the drill rods are being rotated • for drilling operations.

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32. MISCELLANEOUS INSTRUCTIONSLong life of components and high operating efficiency can only be achieved if the hydraulic oil and gearbox lube oils are adequately filtered and kept at optimum operating temperatures. Lube oil pressures are equally important. A collapse of lube oil pressure in such vital components as the engine or rotation head can cause expensive breakdowns.

The rotation head lube oil system has a sight glass fitted near the lube oil tank on the rotation head. During operation of the rotation head in forward rotation the driller should on a regular basis check that lube oil is passing through the sight glass.

A thermostatic valve is fitted to the hydraulic system. This valve will keep the minimum operating temperature of the hydraulic oil at approximately 60°C (140°F).

32.1 Fuel System • In order to provide adequate cooling to diesel fuel injectors, the minimum fuel left in the fuel tanks before re-fuelling must not be less than 10% of the total fuel capacity. • If the system capacity is say, 500 litres, a minimum of 50 litres should be left in the tank.

32.2 Electrics • The belt driven 65 AMP engine alternator powers the electrical circuit. • A battery disconnect switch is provided for the battery. The switch is located on the left hand side of the rig.

MISCELLANEOUS INSTRUCTIONS

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32.3 Batteries

32.4 Battery Care

Carry out the following to care for batteries; • Ensure all switches are “OFF” before working on, or near batteries. • Check the battery is securely fastened to the rig tray. • Fill batteries in a well ventilated area. • Avoid breathing in fumes when electrolyte is added to batteries. • Do not smoke cigarettes when observing the battery electrolyte levels. • Do not use a naked flame when observing the battery electrolyte levels. • Always wear protective glasses and rubber gloves and rubber aprons when working with batteries. • Do not wear any metallic jewellery (rings, bracelets, chains, watch straps) when carrying out servicing or installation of batteries. • To avoid shorting, metallic objects should not be placed on top of the battery. • Check electrical connections. Make sure battery terminals and cable connections are clean and tight. The application of a thin layer of petroleum jelly can help reduce corrosion. • Avoid spilling or dripping electrolyte. Refer to the first aid section. • Batteries are heavy; use correct lifting procedures are use when moving batteries. • Keep the battery clean and dry. • Dirt on battery’s surface leads to discharge and corrosion. Avoid spilling oil or grease onto the top of the battery. To remove dirt or moisture, wash with a solution of bicarbonate of soda and water. Rinse afterwards with clean water. Ensure vent plugs are in place at all times.


CAUTION• Sulphuric acid in battery electrolyte is poisonous. It is strong enough to burn skin, eat holes in • clothing, and cause blindness if splashed into eyes. • Batteries give off flammable fumes, which can explode. Keep sparks and flames away from • batteries. Use a flashlight to check battery electrolyte levels.

CAUTION• Never check battery charge by placing a metal object across the posts. Use a voltmeter or • hydrometer.• Always remove the grounded NEGATIVE (-) battery clamp or terminal first and replace it last.

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32.5 Battery Acid Material Safety Data Sheet

32.5.1 IdentificationProduct Name: BATTERIES, WET, FILLED WITH ACID, ELECTRIC STORAGEOther Names: Lead Acid Battery, Wet. UN No: 2794Hazchem No: 2W Dangerous Goods Class: 8Packing Group: III Poisons Schedule: S6Flashpoint: n/a Flammability Limits: n/aSolubility in Water: (Battery Fluid) 100 % Manufacturers Product Code: BatteryUse: Starting, lighting ignition for car, truck, boat, standby power

32.5.2 Physical Description PropertiesAppearance: (Battery) Rectangular Plastic Box (Battery Fluid) Clear, Colourless, Mobile LiquidBoiling/Melting Point: No Information availableVapor Pressure: No Information availableSpecific Gravity: (Battery Fluid) 1.20 to 1.28 @ 25 Degrees Celsius

32.5.3 Other PropertiesIngredients Chemical Entity: Cas No: Proportion:Battery Fluid (Diluted Sulphuric Acid) 7664-93-9 30 to 60 %Lead Dioxide 1309-60-0 10 to 30 %Lead 7439-92-1 30 to 60 %

32.6 First Aid32.6.1 SwallowedAcid contents: • Rinse mouth with plenty of water. • If poisoning occurs, contact doctor or Poison Information Centre. • If swallowed, DO NOT induce vomiting. Give a glass of water.

32.6.2 EyeAcid contents:If this product comes in contact with the eyes; • Immediately hold the eyes open and wash continuously for at least 15 minutes with fresh running water. • Ensure irrigation under eyelids by occasionally lifting upper and lower lids. • Transport to hospital or doctor without delay. Removal of contact lenses after an eye injury should only be undertaken by skilled personnel.32.6.3 SkinAcid contents:If this product comes in contact with the skin: • Immediately flush body and clothes with large amounts of water, using safety shower if available. • Quickly remove all contaminated clothing, including footwear. • Wash affected areas with water (and soap if available) for at least 15 minutes. • Transport to hospital or doctor.


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32.6.4 InhaledAcid contents: • If fumes or combustion products are inhaled, remove to fresh air. • Lay patient down. Keep warm and rested. • If available, administer medical oxygen by trained personnel. • If breathing is shallow or has stopped, ensure clear airway and apply resuscitation. • Transport to hospital or doctor without delay.

32.7 Battery Acid Spills

32.7.1 Spills And Disposal Minor SpillsIf contents exposed: • Clean up all spills immediately • Avoid breathing vapours and contact with skin and eyes • Control personal contact by using protective equipment • Neutralize contain and absorb spill with sand, earth, inert material or vermiculite. • Wipe up. Place in suitable labelled container for waste disposal. • Use soda ash or slaked lime to neutralize.

32.7.2 Major Spills • Do not touch the spill material. Clear the area of personnel and move upwind. • Alert Fire Brigade and tell them the location and nature of hazard. • May be violently or explosively reactive. Wear full body protection with breathing apparatus. Prevent, by any means available, spillage from entering drains or water course. Consider evacuation. • Stop leak if safe to do so. • Contain spill with sand, earth or vermiculite. • Collect recoverable product into labelled containers for recycling. • Neutralizes/decontaminate residue. • Collect solid residue and seal in labelled drums for disposal. • Wash area and prevent run off into drains. • After clean up operations, decontaminate and launder all protective clothing and equipment before storing and re-using. • If contamination of drains or waterways occurs, advise emergency services. • DO NOT USE WATER OR NEUTRALISING AGENTS INDISCRIMINATELY ON LARGE SPILLS. • Use soda ash or slaked lime to neutralize.

32.8 DisposalAcid contents: • Recycle wherever possible • Consult State Land Waste Management Authority for disposal • DO NOT discharge into sewer or waterways. • Use soda ash or slaked lime to neutralize.


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32.9 Vehicle Jump Starting

Vehicle Jump Starting, procedure is as follows and should be followed carefully: Check batteries are the same voltage.

• Turn off all electronic loads, check vehicles are not touching and are in park or neutral. • Check that vehicles have the same terminal earthed. If not, refer to manufacturers instructions. • Always use heavy-duty jumper cables capable of carrying the current and voltage of the batteries. • Inspect both batteries before connecting booster cables. • Do not jump start a damaged battery. • Refer to the vehicle owners’ manual for other specific information • Refer to the picture on the following page. Carry out following steps in sequence: 1. On negative grounded system, Connect positive (+) booster cable to positive (+) terminal of dis charged battery. 2. Then Connect the other end of the positive (+) cable to the positive (+) terminal of the assisting battery 3. Connect one end of the negative (-) cable to the negative (-) terminal of assisting battery. 4. Make the final connection of the negative (-) cable to the engine block or car frame of the stalled vehicle, away from battery. 5. Make sure cables are away from fan blades and other moving vehicle parts. 6. Start the engine of the assisting vehicle. 7. Attempt to start the engine of the vehicle with the discharged battery. 8. If the vehicle with the discharged battery does not start, stop the starting process and allow at least 3-5 minutes before attempting to start the vehicle with the discharged battery again. 9. After starting, remove cables in reverse order, starting with the one connected to the engine block or car frame.


WARNING• Exploding Battery:• Batteries generate explosive gasses during vehicle operation and when being charged. Flames, • sparks, burning cigarettes or other ignition sources must be kept away at all times. • Always wear eye protection when working near batteries:• When charging batteries, work in a well ventilated area - never in a closed room. Always turn the • battery charger or ignition off before disconnecting a battery.

DE710


32.10 Battery Charging

Always turn the charger off before attaching, rocking, or removing the terminal clamps. Keep open flames and sparks away from the battery. Keep vent caps in place. Charge in well ventilated area. Follow the battery charger manufacturer’s instructions. Always follow any instruction supplied with the battery or printed on the battery. Specific charging rates or times are difficult to detail due to a number of other features such as: • The electrical capacity of the battery. • Temperature of the electrolyte. • Battery state of charge at the start of the charging period. • Battery age and condition.

32.10.1 Battery Charging Guide

Rated Battery Capacity(Reserve Minutes) Slow Charge Fast Charge80 Mins or Less 15 hrs. @ 3 Amps 2.5 hrs. @ 20 Amps 1.5 hrs @ 30 AmpsAbove 80 to 125 Mins 21 hrs. @ 4 Amps 3.75 hrs. @ 20 Amps 1.5 hrs @ 50 AmpsAbove 125 to 170 Mins 22 hrs. @ 5 Amps 5 hrs. @ 20 Amps 2 hrs @ 50 AmpsAbove 170 to 250 Mins 23 hrs. @ 6 Amps 7.5 hrs. @ 20 Amps 3 hrs @ 50 AmpsAbove 250 Mins 24 hrs. @ 10 Amps 6 hrs. @ 40 Amps 4 hrs @ 60 Amps

12-Volt batteries recommended charging rate and time from a Fully Discharged Condition (ie. Flat, Discharged). Fast Recharging is not Recommended. Check the batteries specifications for the Reserve minutes.


WARNING• Exploding Battery:• Batteries generate explosive gasses during vehicle operation and when being charged. Flames, • sparks, burning cigarettes or other ignition sources must be kept away at all times. • Always wear eye protection when working near batteries:• When charging batteries, work in a well ventilated area - never in a closed room. Always turn the • battery charger or ignition off before disconnecting a battery.

CAUTION• Use extreme care when handling Batteries. If battery fluid (dilute sulphuric acid) is spilled or • • splashed onto clothing or the body, wash with water and neutralise with a solution of baking • soda and water. Electrolyte splashed into eyes is extremely dangerous. If this occurs, gently • open eyes and wash with cool clean water for 5 minutes. Call a doctor.

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33. FIRE EXTINGUISHERS33.1 LocationExtinguishers are mounted with special brackets to the front face of the front legs of the rig. Extinguishers are normally shipped loose by Sandvik with the accessories and have to be clamped to the brackets by the client.

Should for any reason the brackets be also shipped loose, they have to be welded or bolted to the rig struc-ture at a suitable place.

33.2 Orientation The extinguishers should be supported so that the identification label is visible from the direction of approach.

33.3 ClassificationThe extinguishers supplied contain DRY CHEMICAL POWDER and are rated A, B, E.

The Dry Chemical Powder extinguisher is suitable for the following types of fires:

CLASS A: Wood, cloth, paper, etc., (ordinary combustible materials). CLASS B: Grease, oil, petrol etc. (flammable liquids). CLASS E: Fires started by electrical equipment.

These extinguishers can also be used for fires involving flammable gases such as hydrogen, acetylene, LPG etc. (CLASS C FIRES)

This means, the extinguishers are suitable for all conventional fires.

The only exceptions are fires of combustible metals, such as magnesium, titanium, zirconium and sodium. These metals are not used in this drill rig.

FIRE EXTINGUISHERS

CAUTIONFire Extinguishers • Once an extinguisher with dry chemical powder has been operated, even if only a small amount • of powder was used up, the valve has to be cleaned and the unit recharged. • Powder particles settling in the valve seat will prevent the valve from sealing properly and the • propellant (compressed nitrogen) will slowly leak out.• Then the gauge will be on EMPTY and the extinguisher is useless.

DE710


The following (typical) sign is located as near as possible to the location of the fire extinguishers fitted to the drill rig tray.

FIRE EXTINGUISHERS

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34. OPTIONS THAT CAN BE FITTED TO A DE710 RIG

OPTIONS THAT CAN BE FITTED TO DE710 RIG

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35. SAFE-T-SPIN 35.1 Familiarisation The Safe-T-Spin tool (item 1) in figure 1 has been designed with the safety of drilling crews in mind.

At Sandvik we have recognised that one of the areas where operators are prone to accidents is during the tripping of rods, both into and out of the hole on dia-mond coring programs.

Fatigue, along with using “Stillson” type pipe wrenches to make and break rods can increase the chances of an accident.

The Safe-T-Spin has been designed as a compact tool capable of making up (including pre-torquing the rods) and breaking out of drill rod threads during rod tripping operations.

It is self-centring and fully floating, and is powered from the existing hydraulic circuit. Extensive testing has been carried out, with the test unit completing in excess of 60,000 cycles at varying angles from 45° to vertical.

35.2 Safe-T-Spin Specifications

• Capacity: B, N, H Wire line Drill Rods and HW Casing • Max Torque – Break Out: 3,000 Nm • Max Torque – Make Up: 2,100 Nm • Controls: All Hydraulic • Recommended Oil Flow: 100 lpm • Max Supply Pressure: 180 bar • Weight: Safe-T-Spin 91 kg Mounting Arm 25 kg

SAFE-T-SPIN

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35.3 Safe–T–Spin Controls at the Control Cabinet Please refer to figure 1 for item number locations.

35.3.1 SAFE-T-SPIN PILOT CONTROL VALVE ASSEMBLY - ITEM 1

This lever controls the direction and speed of the safe-t-spin unit.

Pull the lever away from the control cabinet face to the “MAKE” position to make up the rod joint.

Push the lever towards the control cabinet face to the “BREAK” position to break out the rod joint.

Partial operation of the lever in either direction will operate the safe-t-spin slowly. Continued engagement of the lever will increase the speed of operation of the safe-t-spin.

35.3.2 SAFE-T-SPIN MAKE UP TORQUE PRESSURE CONTROL - ITEM 2

This control is used to preset the make up torque of the SAFE-T-SPIN wire line rod pre-torque make break tool. The make torque control is needed so that correct make up torque is applied to the particular drill rod being used in the drilling program.

35.3.3 SAFE-T-SPIN MAKE UP TORQUE PRESSURE GAUGE - ITEM 3

This gauge is used to indicate the pressure that is set by the SAFE-T-SPIN make up torque control. The SAFE-T-SPIN that is fitted to this rig is powered by the oil flow from the second hydraulic oil pump.

SAFE-T-SPIN

DE710


35.4 Vertical SupportPlease refer to figure 1 for item number locations.

The safe-t-spin module (item 1) is supported by a support structure (item 2).

The support structure has a spring in it (item 3). This spring balances the weight of the safe-t-spin module so that the drill rod thread only has the weight of drill rod supported by the main winch resting on it.

The spring also allows the module to float up to break out a rod joint or down to make up a rod joint.

The support structure is slid into a mast support (item 4) and is pinned into a bracket (item 5).

35.5 Safe-T-Spin Module BulkheadA bulkhead - figure 2 - has been provided (typically) near the right-hand rear jack leg of the tray of the rig to connect the safe-t-spin module to the hydraulic system for the safe-t-spin.

SAFE-T-SPIN

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35.6 InstallationThe following procedures can be used to fit the safe-t-spin to the mast for a DE710 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.

1. Reeve the main winch rope through the snatch block with the mast in the transport position.

2. Refer to figure 1 Locate the following items, item 1 lifting socket, item 2 lifting base, item 3 pin and item 4 clip.

3. Refer to figure 2 Attach the lifting base, lifting socket and then pin to the safe-t-spin assembly. Secure the pin with the clip. Fit the locking pins of the lifting base to the holes provided in the safe-t-spin housing.

SAFE-T-SPIN

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4. Refer to figure 1 Connect the main winch rope, using a suitable Dee shackle and a chain or rope sling item 1, to the lifting socket.

5. Using a combination of rod boom movements and operation of the main winch lift the safe-t-spin above the rod clamp assembly and onto the mast, until the cam followers of the support and the roller brackets touch the mast.

Note - DE810 model shown.

6. 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.

7. Refer to figure 2 Secure the safe-t-spin assembly to the vertical support by two lynch pins, one in each vertical support pin. Item 1 is indicating the lynch pin in top vertical support pin.

8. Remove the main winch rope and the lifting base and socket from the Safe-T-Spin assembly.

SAFE-T-SPIN

WARNING• Check the safe-t-spin as it is lifted into the mast and lowered down the mast. • Check the position on the locking hook in case it also catches the lower traverse guards.

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9. Refer to figure 1 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.

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


11. Refer to figure 2 The safe-t-spin is held against the mast by a hook at the top left hand side of the safe-t-spin assembly. Turn the tab to place the hook into the mast and hold the safe-t-spin against the mast.

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

SAFE-T-SPIN

WARNINGSafe – T – Spin Installation • The safe-t-spin must be swung into the mast until the mast is in the final set up position. • The safe-t-spin will foul with the rod bin during mast set up if it is swung out of the mast during • set up.

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35.7 Swing the Safe-T-Spin Away From Mast For mast angles between 90 and 45 degrees, release the hook assembly, take hold of the handles provided on the safe-t-spin module and the support arm and swing the safe-t-spin away from the mast.

For mast angles between 60 and 45 degrees, two men are required to swing the safe-t-spin away from the mast. One man must fit the swing arm to the front of the safe-t-spin module and the second must grip the handle of the support bracket. Refer to the warning above regarding your grip and footing conditions.

35.7.1 Swing the Safe-T-Spin Towards the Mast. • For mast angles between 90 and 60 degrees, take hold of the handles provided on the safe-t-module and the support arm and swing the safe-t-spin towards the mast. • Carefully swing the safe-t-spin away from the mast.

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

Carefully swing the safe-t-spin towards the mast and secure the safe-t-spin with the hook on the left-hand side of the safe-t-spin support arm.

SAFE-T-SPIN

WARNINGSwing Safe–T–Spin Away from the Mast • Check 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.

WARNINGSwing Safe–T–Spin Towards the Mast • Check 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.

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35.8 Remove the Safe-T-Spin from the MastTo remove the safe-t-spin from the mast is a reversal of the previous procedures.

35.9 Operational Checks

1. Refer to figures 1 and 2. 2. Operate the rod clamp to the closed position. 3. Fit the rod clamp travel stop pin to the rod clamp base. 4. Checks that the safe-t-spin support arm is secured to the vertical support with lynch pins. 5. 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. 6. Check that the rod 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. 7. 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 mast. 8. Check the conditions of the inserts in the jaws of the Safe-T- Spinner for wear. 9. Check for any foreign matter that may stop the jaws from rotating. 10. Check the hoses for the safe-t-spin motor have been correctly connected. 11. Check the safe-t-spin operation is as per the name tags on the control cabinet 12. Check the safe-t-spin attachment bolts are tight. 13. Check the safe-t-spin pivot bushes are in good working order. 14. Check the vertical support float springs and linear bearings are in good working order. 15. Check the spinner (safe-t-spin) torque control is at the minimum setting before operating. Adjust this setting when using the Safe-T-Spin.

SAFE-T-SPIN

WARNINGRod Clamp Travel Stop Pin • The rod clamp travel stop pin must be used with the safe-t-spin.• The rod clamp jaws will contact the safe-t-spin housing, when the rod clamp is open, if the stop • pin is not fitted.

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35.10 Make Up Torque Pressure Setting To adjust the make up torque pressure settings, carry out the following procedure.

1. Completely “DECREASE” the spinner torque control to minimum setting. 2. The diesel engine should be 1600-1800 rpm and the hydraulic oil temperature should be at 60 degrees C. 3. Operate the safe-t-spin control lever completely into “MAKE” position and stall the safe-t-spin against a rod clamped in the rod clamp, the same size as the rod size you will drill with. 4. Refer to the table below as a guide, adjust the spinner torque control until the required pressure can be read on the spinner (safe-t-spin) make torque gauge.

Rod Size Make Up Torque ( Nm)Spinner (Safe-T-Spin) Make

Torque Pressure (1000kPa )

B+ 1250 88 (8800 kPa)

N+ 1650 116 (11600 kPa)

H+ 2100 147 (14700 kPa)

HW Casting 1250 88 (8800 kPa)

SAFE-T-SPIN

CAUTIONMake Up Torque • Slowly engage the Safe-T-Spin control lever to make the joint. • If the control lever is suddenly engaged, the rod joint could over tighten due to inertia of the • Safe-T-Spin jaws suddenly gripping the rod.

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35.10.1 Break Out Torque Adjustment There is no torque setting adjustment for breaking out the rod joint.

35.10.2 OperationBreak Up Of Drill StringThe Safe-T-Spin is now ready to break apart the drill string according to the following instructions:

• Support the drill string in the rod clamp with the box end of the rod beneath the safe-t-spin module. The box end of the drill rod must be located between 100 and 120 mm above the rod clamp jaws when the jaws are closed. • Refer to figure 1 and 2 • Fit the rod clamp travel stop pin to the rod clamp base. The stop pin is required to keep the rod clamp jaws and lever arms from hitting the safe-t-spin base. • Swing the safe-t-spin into place as described earlier. • Check the safe-t-spin is 535 mm above the mast base to the top of the safe-t-spin module.

Note Two coil springs in the vertical support allow the Safe-T-Spin module to float up as the rod joint is screwed apart in order to eliminate rod thread damage.

SAFE-T-SPIN

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1. Slowly operate the rapid traverse control lever “UP” and traverse the head to the top of the mast.

2. Operate the head rack control lever “OUT” and rack the head out completely.

3. Operate the Safe-T-Spin to ensure that the jaws are in the fully “OPEN” position.

4. Refer to figure 1. Insert the hoist plug extension through the safe-t-spin.

5. Screw the hoist plug extension pin into the drill string box end and tighten.

6. Take the weight of the rod string with the main winch rope.

7. Open the rod clamp.


8. Refer to figure 2. Hoist the drill string until the next rod joint to break is between the rod clamp item 1 and safe-t-spin item 2. Stop hoisting.

9. Close the rod clamp.

10. Lower the main winch rope slightly to relieve any tension on the main winch rope.

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11. Refer to figure 1. Slowly operate the rapid traverse lever “DOWN” until the plug rest is supporting the hoist plug.


12. Refer to figure 2. Break the rod joint apart by engaging “Make-Break” control lever to the “Break” position. Continue depressing this lever until rod joint is unscrewed. Release the control lever to neutral.

Note Engage the lever slowly to break the joint.

SAFE-T-SPIN

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13. Operate the Safe-T-Spin briefly into “MAKE” to ensure that the jaws are in the fully “OPEN” position.

14. Refer to figure 1. Hoist the drill string until the rod pin end clears the safety-t-spin housing.

15. Refer to figures 2, 3 and 4. Lower the rod string with the main winch and place the rod in the rod rack.

16. Refer to figure 5. Remove the hoist plug from the rod string.

17. Refer to figure 6. Raise the hoist plug and reconnect it back into the drill rod clamped in the rod clamp.

18. Repeat steps 1 to 16 for the remainder of the drill string.

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

Note Refer to the pre-torque control pressure setting section for the procedure to set the spinner.

1. Refer to figure 1 and 2. Fit the rod clamp travel stop pin to the rod clamp base. The stop pin is required to keep the rod clamp jaws and lever arms from hitting the Safe-T-Spin base. 2. Operate the Safe-T-Spin to ensure the jaws are in the “OPEN” position.

SAFE-T-SPIN

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3. Refer to figure 1. Attach the hoisting plug to core barrel locking coupling. 4. Open the rod clamps. 5. Refer to figures 2, 3, 4 and 5. Raise the core barrel over the safe-t-spin. 6. Refer to figures 6 and 7. Lower the core barrel assembly through the Safe-T-Spin. Continue to lower the core barrel until the rod joint of the hoist plug extension and the core barrel will be 100-120 mm above the rod clamp jaws when the jaws are closed.

Note - DE810 Model shown.

SAFE-T-SPIN

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8. Close the rod clamp. Take the weight off the winch rope by lowering the main winch slightly. 9. Remove the hoist plug extension from the core barrel rod by operating the control lever to “BREAK”. This will spin the hoist plug extension out of the box thread of the core barrel. 10. Attach the hoist plug to the next rod in the rod rack. 11. Raise the drill rod from the rod rack until it is over the safe-t-spin. 12. Operate the Safe-T-Spin to ensure the jaws are in the “OPEN” position. 13. Lubricate the drill rod pin end thread. 14. Lower the drill rod through the safe-t-spin. 15. Engage the drill rod pin end thread into the drill rod box thread supported in the rod clamp. 16. Take the weight off the winch rope by lowering the main winch slightly. 17. Engage the Safe-T-Spin into “BREAK” slightly, this will allow the pin end rod thread to line up and drop into the box thread. 18. Make up the rod joint by engaging the “Make-Break” control lever to “Make” function. Continue engaging this control lever until rotation stops and the Safe-T-Spin make torque gauge reads the correct setting. Note Engage the lever slowly to break the joint. 19. Take the weight of rod string with the main winch. 20. Open the rod clamp. 21. Lower the drill rods into the drill hole until the rod joint of the hoist plug extension and the drill rod will be 100-120 mm above the rod clamp jaws when the jaws are closed. 22. Close the rod clamp. 23. Take the weight off the winch rope by lowering the main winch slightly. 24. Remove the hoist plug extension from the drill rod box thread by operating the control lever to “break”. This will spin the hoist plug extension “out” of the box thread. 25. Attach the hoist plug to the next rod in the rod rack. 26. Repeat the steps from 10 to 25 for the remainder of the drill string.

SAFE-T-SPIN

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35.10.4 Making Up the Drill String – General Notes Before making up the rod joints for the first time, examine the rods carefully for damage that may have occurred during transport to the drilling site.

Remove any accumulated dirt from both the box and pin threads and apply thread lubricant.

Make up the joint by hand. There will be a slight “stand-off” when the joint is hand tight. In order to make the shoulders butt; it is necessary to torque the joint to the recommended torque. 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 hoist 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.

SAFE-T-SPIN

CAUTIONMake Up The Drill String • 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.

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35.11 Trouble Shooting of Safe-T-SpinThe following tables may assist with any problems that may occur during operation of the Safe-T-Spin.

Problem Probable Causes Recommended SolutionsNo functions operate Hydraulic power supply not con-

nected→ Connect hoses to drill hydraulic supply.

Quick couplers damaged or dirty. → Clean or replace quick couplers.

Pilot pressure → Check the pilot pressure at the pressure test point located at pilot pressure relief valve near rear left hand jack leg.

Problem Probable Causes Recommended SolutionsSafe-T-Spin will not operate Hydraulic hoses not connected → Connect hoses.

Quick couplers damaged or dirty. → Clean or replace quick couplers.

Broken chain / sprockets → Inspect gearbox and replace chain / sprockets as required.

Hydraulic motor failure → Replace the hydraulic drive mo-tor.

Safe-T-Spin make up torque control set too low

→ Reset Safe-T-Spin make up torque as per instructions.

→ Replace the cartridge in the spinner torque control valve on the panel.

SAFE-T-SPIN

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36. TRACK DETAILED SPECIFICATION 36.1 Maximum Operating Conditions and DimensionsGross Vehicular Mass - 8,500 kg 18,734 lbsAverage ground pressure at G.V.M - 59.6 kPa 8.6 psi Includes 600 litres of diesel fuelMaximum parking angle - 10 degreesMaximum speed - 3.5 km/h Creep speed - 1.0 km/hMaximum grade ability - 25 degrees Sideways stability - 20 degrees

36.2 Approximate O/A DimensionsWidth: - 2150 mmLength: - 10530 mm (mast length)Length: - 3375 mm jack leg centresLength: - 4500 mm tray lengthHeight: - 2500 mm

TRACK DETAILED SPECIFICATION

WARNING• The park brakes of the track final drive are designed to hold the rig up to maximum 10-degree • angle. Do not park the rig on steeper angles. • Check the travel route before driving to anticipate any potential area that may require you to park • the rig on angles greater than 10 degrees. Change the route if necessary or modify the existing • route to remove any potential problems.

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36.3 Hydraulics For Track Drive

• John Deere or Cummins diesel engine, driving one open loop axial piston pumps of 170litres per minute at 2100 rpm. The flow is divided by the operation of the in-built flow control system of the left and right track spools. Each spool will deliver a maximum flow of 80 litres to each track drive motor. This allows one pump to supply both track drive motors.

• In the drill mode, pump number 6A powers the following items; • Rotation • Traverse • Wire Line Winch • Main Winch • In the track drive mode, pump number 6A powers the left and right hand track drive motors. • Selection of track drive or drill mode is achieved by the operation of a selector valve which is located in the track drive control cabin. • The track drive system is controlled by means of a dual pilot oil control valve, which controls the track drive sections of the main control valve. The track drive system can be operated from the track drive control cabin and from the rear of the rig while standing on the driller’s platform.

• Selection of track drive operation from cabin / rear positions is achieved by the operation of a selector valve which is located in the track drive control cabin. • The track drive motors are equipped with spring applied hydraulic pressure to release parking brakes and with in built dual counter balance valves to prevent the vehicle running away. • The diesel engine speed (rpm) is controllable from the drill control panel and the track drive cabin.


WARNING• Refer to the warning sign in the track drive control cabin regarding the maximum diesel engine • rpm.• Do not exceed 2100 rpm during any tramming operation.

WARNING• Operation of the track drive system from the driller’s platform is for set up operations over the • hole only.• Do not tram (travel) for long distances, while operating the track drive system from the rear • control as there is no seat or seat belt for the safety of the operator.

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36.4 Track Drive FamiliarisationThe track drive familiarisation tour will begin at drill control cabinet.

36.5 Engine Controls and Monitoring GaugesThe following information will assist the operator to locate the engine controls and monitoring gauges at the control cabinet. Please refer to figure 1 for any item number locations. 36.6 FamiliarisationPlease refer to figure 1 for item number locations. 1. Volt Meter This gauge indicates the voltage of the electrical system for the rig. 2. Engine Coolant Temperature Gauge This gauge indicates diesel engine coolant operating temperature. 3. Engine Oil Pressure Gauge This gauge indicates diesel engine lubricating oil pressure. 4. Emergency Stop Switch This switch when activated by pushing on the red button will shut down the engine during an emergency situation. The button must be reset before recommencing drilling operations. To reset the button turn the knob clockwise. 5. Filter Pressure Gauge This gauge indicates the pressure in the hydraulic oil return manifold directly before the oil flows through the main return filter element to the hydraulic tank. It indicates when the filter element needs replacing. 6. Diesel Engine Rpm Tachometer & Hour Meter This gauge indicates diesel engine speed in revolutions per minute. The hour meter gauge indicates the actual operating hours of the rig engine. 7. Engine Start Switch The engine start switch key has three operations which are; • When turned fully clockwise, cranks the diesel engine over, • When the engine starts the key is released, the key will spring return to the “ON” position which supplies power to the electrical system of the engine. • To stop the engine the key is turned counter clockwise to the “OFF” position. • When the engine is not running the key must be in the “OFF” position. 8. Bypass Switch Whenever the engine is started this button must be pushed in and held in until the engine oil pressure builds up to operating pressure.


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9. Fuse Holder The fuse holder has been positioned at the control cabinet for ease of trouble shooting of the engine electrical system. 10. Light Switch This switch has two operations which are; • When the switch is pushed “IN” the light in the control cabinet and the lights fitted to the track drive cabinet will not illuminate. • When the switch is pulled “OUT” the light in the control cabinet and the lights fitted to the track drive cabinet will illuminate. 11. Engine Throttle This knob controls the diesel engine rpm. The diesel rpm can be reduced to idle by pushing on the button in the centre of the knob. To increase engine rpm turn the knob clockwise to decrease engine rpm turn the knob counter clockwise.


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36.7 Track Drive Controls from the Drill Control CabinetRefer to figure 1 for item number locations.

1. Left track pilot control lever. The rig will travel forward when the lever is moved towards the jack leg. The rig will travel in reverse when the lever is moved away from the jack leg. 2. Right track pilot control lever. The rig will travel forward when the lever is moved towards the jack leg. The rig will travel in reverse when the lever is moved away from the jack leg.

Please dismount from the operator’s platform at the drill control cabinet and walk to the track drive cabin at the front of the rig.


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36.8 Track Drive Control CabinRefer to figure 1 to locate the items listed below.

1. Step in cabin 2. Lock pin for hand rail 3. Hand grips 4. Suspension seat and seat belt.


WARNING• The driver is the only person permitted inside the track drive cabin.• The hand rail must be closed and pinned in the closed position during any tramming operations.• The seat belt provided with the driver’s seat must be worn at all times during any tramming of the • rig.• Refer to all of the warning signs in the track drive control cabin prior to any tramming operations.• Do not exceed 2100 rpm during any tramming operation.

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36.9 Track Drive Controls in the Track Drive Cabin

Please climb into the track drive control cabin and locate the following controls, refer to figure 1 to assist in locating the items.

NO CONTROL WHAT IT DOES

1 Emergency Shut Down Button

This button is interconnected with the other emergency stop switches located at the drill control cabinet. The switch is used to stop the diesel engine in the case of an emergency situation.

2 Cabin / Rear Selector

This rig has been equipped with a two track drive operating positions. With the selector in the “CABIN” position, the track drive system is operated from the track drive control cabin. With the selector in the “REAR” position, the track drive system is operated from the drill control cabinet while standing on the operator’s platform.Please note the rear position is for setting the drill rig up over the hole only.

3 Left Track – Right Track Dual Lever Pilot Control Valve

This valve when the levers are moved as per the name tags, supplies the pilot oil pressure to operate the pump and directional control valve spool for the track drive hydraulic system.

4 Drill –Track Selector ValveThis selector valve is operated to direct the oil fl ow from the pilot system to either the track drive pilot control valves or to the pilot system of the rig.

5 Horn Switch This push button switch will activate a horn to alert bystanders to the presence of the drill rig.


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NO CONTROL WHAT IT DOES6 Lights Operates Driving / Work Lights

7 Engine Throttle

This lever controls the diesel engine rpm from minimum (850 rpm) to maximum (2100 rpm) and is held in any position by a friction brake.Please note this throttle control operates independently of the throttle control at the drill control cabinet.

8 Engine Oil Pressure Guage9 Engine Temperatures Guage

Track Drive MotorsPlease disembark from the track drive cabin so that you can continue your tour. Turn to the left and walk beside the left-hand track drive assembly.At the rear of the rig look under the rig tray, you will see the track drive motors and final drive can be observed. The track drive familiarisation tour is now completed.


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36.10 Track Operation

36.10.1 Before Starting the Engine • Check the track drive – drill selector valve is in the “TRACK DRIVE” position. • Check the cabin / rear selector is in the required position. • Check the maintenance schedule is up to date. • Make sure no one is working on, underneath or close to the machine before starting the engine or beginning to move the machine. • Make sure the area around the rig is free of all personnel. • Check that all components of the mast platform assembly have been removed from the mast. • The mast platform assembly must be securely stored on the drill rig tray or on another vehicle. • Check that the main and wire line winch ropes have been secured for transport. • Check that the mast is resting against the mast rest pads, which form part of the mast cradle. • Check the operator’s platform at the drill control cabinet has been secured for transport. • Check the engine oil level is on the full mark. • Check the hydraulic oil level is on the full mark on the sight glass on the hydraulic oil tank • Walk around the drill rig and inspect hoses and valves to the track motors. Faulty hoses or valves are a severe safety hazards when driving tracks, especially on gradients.

36.10.2 Mounting and Dismounting • Mount and dismount the machine only where a ladder and handholds is provided. • Inspect, and when necessary, clean and have repairs made to the ladder and handholds before mounting and dismounting. • Face the machine when mounting and dismounting. • Maintain a three-point contact (two feet and one hand or one foot and two hands contact) with the steps and handholds. • Never get on or off a moving machine. • Do not try to climb on or off the machine when carrying tools or supplies. Use a hand line to pull equipment up onto the platform. • Do not use any controls as a handhold when entering or leaving the track control cabin.

36.11 Starting the Engine and Driving the Drill RigWith all the pre start checks and inspections done, this rig can be driven from the track drive cabin.


WARNING• Only one person is allowed in the track drive cabin when driving this machine.

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36.12 Engine Starting • Start the engine from the operator’s platform at the drill control cabinet. • Never short across the starter terminals or across the batteries, as this could damage the electrical system. • Do not start the engine or move any of the controls if there is a warning tag “DO NOT OPERATE” or similar attached to the start switch or controls. • Move all hydraulic controls to the “NEUTRAL” or “OFF” positions before starting the engine. • Diesel engine exhaust contains the by-products of combustion, which may be harmful to your health. Always start and operate the engine in a well-ventilated area. If in an enclosed area, vent the exhaust to the outside.

1. Turn the “power on” (ignition) key 2. Press the engine start override button to start the engine. 3. Release the power on key after the engine starts.

4. Hold the engine start override button down, until the engine oil pressure builds up to the normal operating level. 5. Do not crank the engine for more than 30 seconds. Allow the starter motor to cool for 2 minutes before cranking again.

36.13 Before Driving the Tracks • Clear all personnel from the machine and the area. • Clear all obstacles from the path of the machine. Beware of hazards such as wires, ditches, etc. • Walk around the drill rig and inspect hoses and valves to the track motors. Faulty hoses or valves are a severe safety hazards when driving tracks, especially on gradients. • Become familiar with how to control the machine when descending steep declines. • Before descending steep declines set the diesel speed at maximum 1500 rpm. • On downhill travel do not let the mass of the rig drive the diesel higher than 2,500 rpm by easing lever back towards neutral. • 1,0 km/hr or 3 metres (10 feet) in 10 seconds is equivalent to very slow walking.


CAUTION• The “POWER ON” key must be kept in the “ON” position while the engine is running to maintain • electrical and hydraulic functions and prevent serious machine damage.

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36.14 After Starting the Engine • Keep engine speed low (850-900 rpm) until the engine oil pressure shows up on the gauge. If it does not show up within 10 seconds, stop the engine and investigate the cause before starting again. Failure to do so can cause engine damage. • Allow the engine and the hydraulic oil to warm up at low idle for at least five minutes. • And again, be sure no one is working on or near the machine to prevent injury. • Keep the machine under control at all times to prevent injury.

• Operate the controls only with the engine running to prevent uncontrolled movement. • Check for the proper operation of all controls and protective devices while moving slowly in an open area. • Watch the Mast clearances when moving the machine. • The operator must be satisfied that no one will be endangered before moving the machine. • Report any needed repairs noted during operation. • Stay a safe distance from the edge of cliffs, overhangs and slide areas. • If the machine begins to sideslip on a grade, immediately turn the machine downhill. • Be careful to avoid the conditions, which could lead to tipping when driving on hills, banks or slopes, and when crossing ditches, ridges or other obstructions. • Keep the machine under control and do not work it over its capacity. • Avoid changing the direction of travel on a slope, which could result in tipping or side slipping of the machine. • Never straddle a wire rope or similar device, nor allow others to do so. • Local or State Codes, and/or job site Operating Directives may require a specific minimum distance from obstacles. • The driver is the only person to sit in the track drive control cabin and operate the track drive controls. The seat belt must be worn and be correctly adjusted.


WARNING• Sandvik cannot anticipate every possible circumstance that might involve a potential hazard. • The warnings in this publication and on the product are therefore not all inclusive. If a tool, • procedure, work method or operating technique not specifically recommended by Sandvik is • used, you must satisfy yourself that it is safe for you and others. You should also ensure that • the product will not be damaged or made unsafe by the operation, lubrication and maintenance • or repair procedures you choose.

WARNING• The park brakes of the track final drive are designed to hold the rig up to maximum 10-degree • angle. Do not park the rig on steeper angles. • Check the travel route before driving to anticipate any potential area that may • require you to park the rig on angles greater than 10 degrees. Change the route • if necessary or modify the existing route to remove any potential problems.

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36.15 Instructions for Driving the Rig from the Track Drive Cabin

36.15.1 Driving • Slowly push both pilot control levers forward at the same time to travel forward. Any increase in lever movement will increase the travel speed at the set engine speed (rpm). • To make spot and pivot turns, refer to the Directional and Steering Controls section of this manual. • When making turns in soft material, travel in a forward direction occasionally to clear the tracks. • Reduce the engine speed when manoeuvring in tight quarters or when breaking over a rise. • Slowly move both travel levers to the centre position to stop the machine.

36.15.2 Changing Direction from Forward to Reverse 1. Slowly move both travel levers towards the centre position and the machine stops. 2. Then move both travel levers slowly rearward from the centre position. Any increase in lever movement will increase the travel speed at the set engine speed (rpm). 3. Slowly move both travel levers to the centre position to stop the machine.

36.16 Directional and Steering ControlsAny increase in lever movement will increase the travel speed at the set engine speed (rpm).

36.16.1 Left / Right Travel Lever:

Forward – Move the left travel lever forward to operate the left track in a forward direction.

Centre – Move the travel lever back to centre (NEUTRAL POSITION) to stop the track and apply the brakes.

Reverse – Move the left travel lever backward to operate the left track in a reverse direction.


WARNING• The hydraulic oil could overheat if the rig is traversed backwards and forwards or when • manoeuvring in tight quarters for long periods of time at high system pressure and at maximum • diesel rpm. • The driller operator must check the hydraulic oil temperature at regular intervals while tramming. • Maximum oil temperature must not exceed 80 ºC• Beware of the approach and departure angles of the rig.• The approach angle for the front of the rig is 18 degrees. • The departure angle for the rear of the rig is 18 degrees.• Under dry, stable soil conditions, this machine can climb or descend slopes of 25 degrees and • traverse (sideways) slopes of 20 degrees. • For less favourable ground, involving combinations of wet rock, soil or clay, these angles must • be reduced. • Unexpected loss of traction or landslide may occur, resulting in uncontrolled slippage down the slope, which is capable of causing personal injury or death. • It is the operator’s responsibility to ascertain the prevailing ground conditions.• Sandvik take no responsibility for any damage to either machine or property as a result, directly • or indirectly, of the operator failing to heed this warning.

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36.16.2 Steering • Move both travel levers the same distance in the same direction (either forward or reverse) for straight-line travel. When the travel levers are moved in the reverse direction, the machine will always travel towards the driven sprockets. • When the travel levers are moved in the forward direction, the machine will always travel towards the idlers.

36.16.3 Turn On The Spot To The Left: • Move the left lever backwards and the right lever forward at the same time, allowing a quick left turn (counter track rotation).

36.16.4 Pivot Left Turn: • Move the right travel lever forward allowing the machine to turn to the left, pivoting on the left track.

36.16.4 Turn On The Spot To The Right: • Move the right lever backwards and the left lever forward at the same time, allowing a quick right turn (counter track rotation).

36.16.5 Pivot Right Turn: • Move the left lever forward, allowing the machine to turn to the right, pivoting on the right.


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36.17 Driving On Inclines / Gradients/ Rough Terrain • Whenever travelling over rough terrain the diesel engine rpm should be reduced to a minimum level to maintain operation of the track drive system. This combined with minimum travel lever movement should provide control over the rig’s movement. • The hydraulic cooling system of the rig has been designed for drilling conditions only. The hydraulic oil could overheat when traversing up inclines for long periods of time, eg over 20 minutes at maximum travel speed, where high system pressure and maximum diesel rpm is used. • If the rig is required to travel up an incline for extended periods, the travel speed must be decreased by the operation of the travel control levers. • The hydraulic oil temperature must not exceed 80 Degrees Centigrade at any time when traversing up an incline. • Before descending steep declines set the diesel speed at max. 1500 rpm. • On downhill travel do not let the mass of the descending rig, drive the diesel engine higher than 2000 rpm. Ease the control levers towards NEUTRAL to slow down. • 1,0 km/hour or 3 metres (10 feet) in 10 seconds is equivalent to very slow walking.


WARNING• The park brakes of the track final drive are designed to hold the rig up to maximum 10-degree • • angle. Do not park the rig on steeper angles. • Check the travel route before driving to anticipate any potential area that may require you to park • the rig on angles greater than 10 degrees. Change the route if necessary or modify the existing • route to remove any potential problems. • Under dry, stable soil conditions, this machine can climb or descend slopes of 25-degrees and • traverse slopes of 20-degrees.• For less favourable ground, involving combinations of wet rock, soil or clay, these angles will be • reduced. • Unexpected loss of traction or landslide may occur, resulting in uncontrolled slippage down the • slope, which is capable of causing personal injury or death.• It is the operator’s responsibility to ascertain the prevailing ground conditions.• Sandvik take no responsibility for any damage to either machine or property as a result, directly ‘• or indirectly, of the operator failing to heed this warning.

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36.18 Instructions for Driving from the Drill Control CabinetFollow the instructions as outlined in the previous section for operation of the track drive system, but note the following items • The track drive selector control must be operated to the “REAR” position. • The diesel engine rpm should be reduced to a minimum level to maintain operation of the track drive system. • Locate and read the following sign near the rear track drive control levers. • The rear track drive position is for setting the rig up over the drill hole.


WARNING• The drill site should be level. If necessary have the drill site levelled before parking the rig on • site. • Do not tram from rear position. For set up over hole only.• The park brakes of the track final drive are designed to hold the rig up to maximum 10-degree • angle. Do not park the rig on steeper angles.

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37. MAINTENANCE37.1 John Deere JD6068TF250 Service Schedule

Notes 1. Replace or clean the primary air cleaner element when the restrictor indicator shows a vacuum of 625mm (25in.) H2O. 2. Check the condition of the secondary (safety) air filter element, reuse if in good condition. 3. During engine break-in, change the oil and filter for the first time before 100 hours of operation. 4. Replace crankshaft damper every 4500 hours or 60 months, whichever occurs first. 5. If John Deere COOL-GARD is used, the flushing interval may be extended to 3000 hours or 36 months. If annual testing is preformed and additives are replenished, the flushing may be extended to 5000 hours or 60 months, which ever occurs first.

Refer to the John Deere operation and maintenance manual for further information

KEY: Single Shift = 10 hrs per dayDouble Shift = 20 hrs per dayY = Yes for service

10HRS

250HRS

500 HRS

1200HRS

2000HRS

CONTROL PANELCheck engine water temperature (panel) YCheck engine oil pressure (panel) YCheck engine volt meter (panel) YENGINECheck engine oil level and radiator coolant level YCheck air cleaner dust valve & restrictor indicator YFill fuel tank YVisual walk around inspection YCheck fuel fi lter at engine and at the fuel tank YChange engine oil and replace fi lter (note 3) YService battery YClean crankcase vent tube YCheck air intake hoses, connections & system YReplace fuel fi lter elements at engine and fuel tank YCheck automatic belt tensioner YCheck engine electrical ground connection YPrimary air fi lter element (note 1) YSecondary (Safety) air fi lter element (note 2) YCheck cooling system YCoolant solution analysis- add SCAs as needed YPressure test cooling system YCheck engine speeds YCheck crankshaft vibration damper (note 4) YFlush cooling system (note 5) YCheck and adjust engine valve clearance YTest Thermostats Y

MAINTENANCE

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37.2 Recommended OilsDiesel Engine Break-In OilNew engines are filled at the factory with John Deere Engine BREAK-IN OIL. During the break-in period, add John Deere break-in oil as required. (part number TY22041).

The break in oil must be changed after 100 hours of operation.

Other oils may be used if they meet one or more of the following: • API Service Classification CD • API Service Classification CC • API Specification E1

The oil viscosity for the engine (Once Break-in is complete) should be based on the expected air temperature range during the period between oil changes.

Preferred Engine OilsThe following oil is preferred. • John Deere PLUS-50

The following oil is also recommended: • John Deere TORQ-GARD SUPREME

Other oils may be used if they meet one or more of the following: • John Deere UNI-GUARD • API service classification CG-4 • API service classification CF-4 • ACEA specification E3 • ACEA specification E2 • CCMC specification D5 • CCMC specification D4 • Multi-viscosity diesel engine oils are preferred.

If diesel fuel with sulphur content greater than 0.5% is used, reduce the service interval by 50%.

37.3 Service Log BookSandvik strongly recommends that Clients keep a Log Book in which all regular maintenance and all repair work is recorded. This will serve as a reminder and proof that scheduled maintenance is carried out as recommended. It will also keep track of repairs and their frequency.

Entries with short description of maintenance or repair work with date and signature should be sufficient.

37.4 Recommended Service Schedule • Single Shift = 10 hrs per day • Double shift = 20 hrs per day • For 10 hrs Check daily or at the end of the shift • For 50 hrs + 10 hrs service • For 250 hrs + 50 hrs service • For 1500 hrs + 250 hrs service • For 3000 hrs Perform all listed services

Oil Viscosity Air Temperature RangeSAE 0W – 30 -40°C / 30°C -40°F / 86°FSAE 5W – 30 -30°C / 30°C -22°F / 86°F

SAE 10W – 40 -20°C / 40°C -4°F / 104°FSAE 15W – 40 -15°C / 50°C 10°F / 122°F

MAINTENANCE

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37.5 Recommended Parts - John Deere JD6068TF250The following part numbers have been supplied by the supplier of the engine to Sandvik.PD Numbers are Sandvik Supplied.

Fan Belt BE00000387

Oil Filter Element PD22929QR

Fuel Filter Element PD22929PP

Outer Air Filter Element PD22929PE

Inner Air Filter Element (Safety) BE00000388

Top Radiator Hose R128455

Bottom Radiator Hose R128480

Thermostat PD22929PC

Thermostat Cover Joint PD22929PB

Water Bypass Tube Seal PD22929PA

Water Pump Assembly PD22929PX

Water Pump Joint PD22929PV

Rocker Cover Joint R123543

Injector PD22929NV

Starter Motor RE70960

Alternator AT220393

20 litre Coolant CP1606

Coolant Conditioner Bottle TY16004

Radiator Coolant John Deere Pre diluted

Antifreeze / Summer Coolant John Deere Cool-Gard

Refer to JOHN DEERE operation and maintenance manual POWER TECH 4.5L & 6.8L 4045 & 6068 series engines or your nearest JOHN DEERE engine distributor for more specific information.

MAINTENANCE

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37.6 CUMMINS 6BTA5.9 ENGINE SERVICE SCHEDULE

Note:Refer to the Cummins Engine Operation and Maintenance Manual for “B” Series Engine for detailed procedures to carry out the above service schedule.Replace the remote water /diesel fuel separator fuel element more frequently if using diesel fuel from 205 litre drums.

KEY SINGLE SHIFT 12 HRS PER DAYKEY DOUBLE SHIFT 24 HRS PER DAYKEY ‘Y’ TO CARRY OUT

12 HRS

250 HRS

500 HRS

1000 HRS

2000 HRS

Check for oil and coolant leaks, loose or damaged parts and any change in engine appearance.

Y

Check the lubricating oil level. YCheck the coolant level. YCheck the condition of the fan drive belt YCheck the fan for any broken or damaged blades. YDrain the fuel water separator on the engine. YPeriodically check the engine lube oil pressure and water temperature and voltmeter gauges at the control panel.

Y

Inspect the remote mounted water / diesel fuel separator fi lter

Y

Check the condition of the rig and truck’s batteries, including the battery terminals, leads and electrolyte levels.

Y

Change the engine lubricating oil. YChange the engine oil fi lter. YInspect the air intake system for cracked hoses, loose clamps, and damaged or broken pipes.

Y

Inspect the air fi lter elements for blockages and any dam-age.

Y

Check the anti-freeze and coolant additive concentration. YReplace the fuel fi lter elements. YClean the radiator cooler core assembly YReplace the remote water / diesel fuel separator fi lter ele-ment

Y

Adjust the valve lash clearance of the engine YInspect the following;Fan drive belt tension.Fan belt tensioner pulley bearing.Fan hub pulley bearing

Y

Carry out the following work on the cooling system.Drain the cooling systemFlush the cooling system.Refi ll the cooling system with anti-freeze / coolant

Y

Inspect the vibration damper for wear and tear. YInspect the alternator bearings for wear and tear. YInspect the starter motor for wear and tear YInspect the operation of the diesel emergency shut down system and the electrical wiring harness for wear and tear.

Y

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37.7 Engine Lubricating Oil The Cummins Engine Company, Inc. recommends the use of a high quality SAE15W-40 heavy duty engine lubricating (such as Cummins Premium Blue) which meets the American Petroleum Institute (API) performance classification CF4/SG.

Note:C /SG/SF engine lubricating oils can be used where CF4 is not available, but the lubricating oil change interval must be reduced to one half the interval given in the maintenance schedule.

A sulphated ash limit of 1.0 mass percent is suggested for optimum valve and piston deposit and lubricating oil consumption control. The sulphated ash content must not exceed 1.85 mass percent.

37.8 Recommended Spare Parts

Fan Belt: PD 23759QDOil Filter: PD 23759KYFuel Filter: FUEL WATER SEPARATOR ELEMENT: PD 22929Y FUEL FILTER ELEMENT: PD 23759QFAir Cleaner: PRIMARY ELEMENT: PD 23759B ELEMENT: PD 23759CEngine Coolant CUMMINS TEC-50. System capacity including engine/radiator 20 litres.

Refer to the CUMMINS ENGINE Operators Manual for specific information on oil, fuel and engine coolant requirements, or get advice from your local CUMMINS ENGINE Dealership.

MANUFACTURERWINTER

(-25°C to 20°C)(-15°F to 70°F)

SUMMER

(-10°C to 45°C)(-14°F to 115°F)

CUMMINS

CASTROL

AMPOL

ESSO

ESSO

SHELL

BP

CUMMINS PREMIUM BLUE

RX SUPER

LONG HAUL

ESSO LUBE XD-3 15W/40

EXXON HEAVY DUTY 15W/40

MYRINA L

VANELLUS LA

MAINTENANCE

DE710


37.9 Recommended Parts - Cummins 6BTA 5.9C & QSB 6.7The following part numbers have been supplied by the supplier of the engine to Sandvik.PD Numbers are Sandvik Supplied.

6 BTA 5.9 C QSB 6.7 Lts

Fan Belt PD 23759QD 3289941

Oil Filter Element PD 23759KY LF 3970

Fuel Filter Element PD 23759QF FF 5421

Fuel Water Separator PD 22929Y FF 19732

Outer Air Filter Element PD 23759B AF 25454

Inner Air Filter Element PD 23759C AF 25468

Thermostat 3972071 4929642

Water Filter 3802289 NC

Water Pump 3286278 3800984

Water Pump Joint 3906698 3906698

Rocker Cover Joint 3930906 4899226

Injection Pump 3916910 4988593

Fuel Pump (Drain) 4983584

Starter Motor 3964432 3971615

Alternator 4936877 4936877

Turbo Charger 3802289 4955156 HOLSET HX 35W

Refer to CUMMINS ENGINE operation and maintenance manual or your nearest CUMMINS ENGINE distributor for more specific information.

MAINTENANCE

DE710


158 (196) WI864-033 Revision 2

37.10 Visual Maintenance Guide37.10.1 View of typical John Deere engine from the left hand side of the rig.

Please refer to figure 1 for item number location 1. Engine radiator assembly. 2. Exhaust muffler. 3. Air filter assembly. 4. Engine oil fill cap in rocker cover (Under cover). 5. Engine lube oil dip stick. 6. Fuel / Water Separator. 7. Emergency Stop Switch. 8. Starter Motor.

MAINTENANCE

DE710


37.10.2 View of typical Cummins engine from the left hand side of the rig.

Please refer to figure 1 for item number location 1. Engine Radiator Assembly 2. Exhaust Muffler 3. Air Filter Assembly 4. Engine Oil Fill Point 5. Engine Oil Dip Stick 6. Fuel-Water Separator 7. Primary and Secondary Fuel Filters

MAINTENANCE

DE710


160 (196) WI864-033 Revision 2

37.10.3 View of typical John Deere engine from the right hand side of the rig.

Please refer to figure 1 for item number location 1. Engine fuel filter 2. Alternator 3. Auxillary Pump 4. Engine oil filter

MAINTENANCE

DE710


37.10.4 View of typical Cummins engine from the right hand side of the rig.

Please refer to figure 1 for item number location 1. Engine Oil Filter 2. Alternator 3. Starter Motor Assembly

MAINTENANCE

DE710


162 (196) WI864-033 Revision 2

38. HYDRAULIC SYSTEM / OIL TANK SERVICE SCHEDULE

Notes: 1. Please refer to the oil selection table for the maximum oil operating temperatures. The oil level should be visible in the sight glass at all times during operation of the rig. 2. The return filter element must be replaced if the filter pressure gauge reads 2 bar and the oil temperature is at 60°C. 3. The hydraulic oil should be tested for wear particles and water content every 1500 hrs and if necessary changed out as indicated by the test results. The hydraulic oil tank must be refilled by using the hand pump on the rig. This will ensure that the return line filter filters the oil entering the tank. 4. With every oil change, the hydraulic tank must be fully drained and thoroughly cleaned before refilling. 5. Filling directly into the tank bypassing the filters will void warranty of the hydraulic system.

Oil Level Indicator Glass

KEY: Single Shift = 10 hrs / day Double Shift = 20 hrs / dayY = Yes for service

10HRS

250 HRS

1500HRS

3000HRS

Check periodically while drilling the hydraulic oil level & temperature gauge at the reservoir (note 1) Y

Check periodically while drilling the fi lter pressure gauge at the panel.The pressure gauge reading must “NOT” exceed 2 bar (30psi.) At operating temperature of 60oc. (note 2)

Y

Visual Inspection for Oil Leaks YReplace the Return Line Filter Element YReplace the Tank Breather Element YDrain the tank and replace the oil (note 3) YClean the reservoir at oil change (note 4) YClean the Oil Cooler Core Y

HYDRAULIC SYSTEM / OIL TANK SERVICE SCHEDULE

DE710


38.1 Hydraulic Oil Tank Visual Maintenance Guide

Please refer to figure 1 for item number location. 1. Return line filter. 2. Drain manifold (behind return line filter). 3. Tank breather element. 4. Hydraulic oil level and temperature gauge. 5. Pump isolation ball valve. 6. Drain valves (at the bottom of the tank). 7. Suction Manifold.


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164 (196) WI864-033 Revision 2

38.2 Return Line Filter Visual Maintenance Guide

CleaningRemove the Filter cover and then the contamination basket together with the element. Remove any contamination, remove the element from the contamination basket and replace it with a new element. Replace item B ‘O’ Ring.

Note: The Filter Element Is Designed As A Throw-Away, Non-Cleanable Item.

Description Sandvik Part No.Complete Filter Assembly PD22981 BA

1 Element PD22981 CP2 “O” Ring PD22981 BG3 “O” Ring PD22981 AC4 “O” Ring PD22981 BF5 M12 X 20 Schs 4 Required PD22879 AA6 Plug7 Contamination Basket


DE710


38.3 Hydraulic Oil Selection Chart

38.4 Recommended Spare Parts

Hydraulic Oil ChartAmbient

TemperatureRange

Hydraulic Oil Type

Tank TemperaturesShort Duration

Cold StartFor Best

Effi ciencyShort Duration

Maximum-15°C to +20°C(5°F to 68°F)

WinterOil Table

-15°C(5°F)

35-60°C(95-140°F)

65°C(149°F)

0°C to +45°C(32°F to 113°F)

SummerOil Table

0°C(32°F)

55-80°C(131-176°F)

85°C(185°F)

Winter Oil Summer OilShell Tellus Oil T 32 Tellus Oil T 68Mobil Dte 13 M Dte 16 M

Castrol Hyspin Awh 32 Hyspin Awh 68Caltex Rando Oil Hd Az-32 Rando Oil Hd Cz-68

BP Shf 32 (Bartran Hv 32) Shf 68 (Bartran Hv 68)

Part Description Part Number QtyReturn Filter Element PD22981CP 1

“ O ” Rings For Above PD22981BGPD22981ACPD22981BF

111

Hydraulic Oil Tank Breather PD22981ER 1Hydraulic Oil Tank Gasket WU8325 1Hydraulic Oil Tank Oil Temperature / Sight Glass PD22981BS 1


DE710


166 (196) WI864-033 Revision 2

39. P ROTATION HEAD SERVICE SCHEDULE

39.1 Recommend Oils and Greases and Parts

39.1.1 Recommended Lubricating Oil Industrial extreme pressure gear oil the rotation head lubricating oil must meet the following specifications: • ISO GRADE 220 (180 – 220 Centistokes at 40 degrees C) • Castrol Alpha SP220, Mobil gear 630, Shell Omala Ep220, Esso Spartan Ep220 • Minimum refill qty 10 litres

Note Does Not Include The Lube Oil Hoses To / From The Lube Oil Cooler Located On The Radiator Cooler Assembly.

39.1.2 Bearing Grease The bearing grease must meet the following specifications: • High quality grade lithium soap base containing Molybdenum Disulphide penetration meeting NGLI #2

39.1.3 Spare Parts • Oil Filter Complete Sandvik Part Number PD22985CB • Oil Filter Element Sandvik Part Number PD22985EX

KEY: Single Shift = 10 hrs / dayDouble Shift = 20 hrs / dayY = Yes for service

GreaseNipples

10HRS

250HRS

1500HRS

Inspect periodically while drilling the lube oil fl ow sight glass at the lube oil sump tank. Y

Grease air & water swivel. One to two shots with grease gun. Do not over-grease. 1 Y

Grease the top bearing cover grease nipple at the end of each traverse cylinder stroke e.g. every 3 metres. One shot of grease per grease nipple with grease gun.

1 Y

Grease the chuck cylinder thrust bearing via the grease nipple. One to two shots with grease gun. 1 Y

Grease the chuck bowl housing via the grease nipples. One to two shots with grease gun 2 Y

Grease the bottom bearing cover grease nipple at the end of each traverse cylinder stroke e.g. every 3 metres. One shot of grease per grease nipple with grease gun.

1 Y

Change the lubricating oil of the rotation head YClean the lube oil cooler fi ns, which is located at the radiator cooler assembly. Y

Replace the lube oil fi lter, which is located on the left side of the engine. Y

Clean the rotation head breather. YReplace the water swivel packing. Replace as requiredCheck the spindle endplay and chuck pre-load. YStrip the chuck assembly. Clean and inspect components and repair/replace as required. Y

Check and adjust the spindle end play and chuck preload Y

P ROTATION HEAD SERVICE SCHEDULE

DE710


39.2 P Rotation Head Visual Guide Part “A”

Please refer to figure 1 for item number location.

1. Rotation head motor. 2. Upper rod breaker 3. Grease nipple in top bearing cover. This grease nipple will allow the driller operator to grease area between the slinger and the top seal assembly of the output shaft of the rotation head. The grease will assist with keeping any water and drilling fluids away from the top seal assembly. 4. Hose bundle to rotation head 5. Rotation head gearbox. 6. Lube oil distribution manifold 7. Rotation head gearbox breather under cover. 8. Rotation head tachometer sender under cover. 9. Lock pin for gear selector. 10. High / low gear selector. 11. Lube oil tank air bleed nipple. 12. Lube oil sight glass. (Later models have guage attached) 13. Chuck assembly. 14. Lube oil tank drain nipple.

39.3 P Rotation Head Visual Guide Part “B”

Please refer to figure 2 for item number locations. 1. Gear selector lock pin. 2. High / low gear selector 3. Grease nipple in bottom bearing cover under rod slide. The grease from this nipple will extrude out of the gap between the bottom bearing cover and the chuck adaptor. 4. Lube oil tank air bleed nipple. 5. Lube oil tank. 6. Lube oil sight glass. (Later models have guage attached) 7. Lube oil tank drain nipple. 8. Grease nipple to grease the chuck bowl housing. 9. Grease nipple for chuck cylinder thrust bearings (at rear).


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168 (196) WI864-033 Revision 2

39.4 P Rotation Head Visual Guide Part “C”

Please refer to figure 1 for item number locations. The items in figure 1 are located on the right hand side of the rotation head gearbox. 1. Lube oil level plug 2. Gearbox lube oil drain cap.


DE710


40. MAIN WINCH SERVICE SCHEDULE

40.1 Recommended Oil • Qty. 1.9 litres • Indicative only, fill until the oil comes out of the level plug.

40.2 Recommended Greases • Castrol APX-Tor equivalent


10HRS

250HRS

1000HRS

Visually inspect the winch rope, winch drum, rope clamps and main winch rope sheaves. Y

Check the oil level planetary / brake gearbox. YGrease the main winch rope sheaves at the top of the mast. YCheck the main winch rope clamp bolts are tight. YGrease the main winch drum bearing.Two – three shots of grease with grease gun. Y

Drain and replace the lube oil in the gearbox. YCheck the main winch frame (side plates) bolts and bearing bolts for tight-ness. Y

Repack the winch bearing with grease. Y

AmbientTemperature

ISOIndex

AGMA LubricantNumber

-40°C to -20.5°C-40°F to -5°F VG100 3EP

-20.5°C to 4.4°C-5°F to 40°F VG100 3EP

4.4°C to 40°C40°F to 105°F VG150 / VG320 4EP / 5EP

40°C to 65°C105°F to 150°F VG320 6EP

MAIN WINCH SERVICE SCHEDULE

DE710


170 (196) WI864-033 Revision 2

40.3 Main Winch Visual Maintenance GuidePlease refer to figures 1, 2, 3, 4 for item numberlocations.

1. Guard over planetary gearbox and rope clamps 2. Planetary gearbox complete with park brake under guard 3. Main winch rope clamps under guard 4. Main winch frame 5. Main winch rope socket 6. Main winch drum outboard bearing. The bearing is fitted with a grease nipple to grease the bearing. 7. Main winch hydraulic motor 8. Left hand side mast raise cylinder 9. Planetary gearbox lube oil drain or fill hole depending on the position of the holes. 10. Planetary gearbox lube oil drain or fill hole depending on the position of the holes.

MAIN WINCH SERVICE SCHEDULE

DE710


41. WIRE LINE WINCH SERVICE SCHEDULE & VISUAL MAINTENANCE GUIDE

1. Hydraulic motor and counterbalance valve assembly. 2. Winch drum. 3. Winch drum bearing. 4. Access hole for wire line winch rope clamp.


10HRS

250HRS

1000HRS

Visually inspect the winch rope, winch drum, rope clamps and wire line winch rope sheaves. Y

Grease the wire line rope sheaves at the top of the mast. YClean and repack the wire line bearing with grease. Y

WIRE LINE WINCH SERVICE SCHEDULE & VISUAL MAINTENANCE GUIDE

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172 (196) WI864-033 Revision 2

42. ROD CLAMP SERVICE SCHEDULE & VISUAL MAINTENANCE GUIDE

1. Grease nipple for greasing jaw pivot shafts. 2. Jaw holder with rod jaw bolted to holder. 3. Rod clamp base. 4. Rotation Head.

NoteShown with Rod Clamp Guard removed.


GreaseNipples

10HRS

250HRS

1500HRS

Grease the rod clamp jaw shaft. 4 YClean the gripper pads of the rod jaws. YStrip the rod clamp assembly and inspect for wear and tear replace parts as required. Y

ROD CLAMP SERVICE SCHEDULE & VISUAL MAINTENANCE GUIDE

DE710


43. WATER PUMP SERVICE SCHEDULE

44. MAST SERVICE SCHEDULE

43.1 Water Pump Recommended Oils and Greases

43.1.1 Recommended Lube • Sae 30

43.1.2 Recommended Grease • Castrol APX-T or equivalent


10HRS

70HRS

1000HRS

2000HRS

Inspect the packing of the plungers for leakage. YInspect the plunger rod oil seals for leakage. YInspect the water pump assembly for the following:Any damage, loose or broken components. Y

For overnight shutdown when freezing temperatures are anticipated. Drain all water from the pump chambers and piping. Y

Inspect the lube oil level. The pump assembly must be level before the oil level is checked. Check the lube oil level via the tap in the rear cover.Lube oil should fl ow out of the tap, when the tap is open and the pump is not operating.Inspect the oil for any milky appearance. This indicates a water leak past the plunger rod seals.

Y

Check the operation of the water pressure relief valve. YDrain and refi ll the Lube Oil. YClean the magnetic plug in the pump gear case Y


10HRS

50HRS

Grease the mast pivot pins. 2 YGrease the mast raise cylinder pivot pins. 4 YGrease the main winch sheaves bearings 2 YGrease the rod spin guard interlock valve 1 Y

WATER PUMP SERVICE SCHEDULE

DE710


174 (196) WI864-033 Revision 2

45. MAINTENANCE AND INSPECTION OF STEEL WIRE ROPES

45.1 LubricationLubrication impregnated into the rope during manufacture is not sufficient to last the life of the rope. Additional lubrication should be added to rope during service.

For general purpose applications, a medium viscosity black oil is considered suitable. For corrosive conditions, a high penetration, water-repellent rust-inhibiting oil should be used.

See recommended oils and for frequency of application. Most commonly, oils are applied with a brush.

It is important that lubrication of steel wire rope is carried out regularly and not only after the first damage has been detected. Lubrication adds more than 50% to the life of your rope!

MAINTENANCE & INSPECTION OF STEEL WIRE ROPES

DE710


45.2 Cleaning Ropes

From time to time, steel wire rope should be cleaned externally. This applies particularly to ropes used under abrasive or corrosive conditions.

Cleaning should be carried out with a soft wire brush or with compressed air. It may be combined with lubrication.

45.3 Inspection of Wire RopesThe inspection should be a visual assessment of the condition of as much rope as possible, including the points of attachment to the equipment.

A thorough inspection should be carried out once a month. After broken wires or other damage have been detected the intervals should be reduced. If any faults in the rope have been detected which do not require the rope to be discarded, it has to be entered in the Rig Maintenance log book with location, description and date.

If during an inspection, ends of broken wires are detected which might cross over adjacent wires and destroy them when running over sheaves, these broken wire ends must be removed.

Under no circumstances should the broken wire ends be pinched off with a pair of nippers. The best method is to move the wire ends backwards and forwards until they break deep in the valley between two outer strands.

With thicker wires a tool should be moved backwards and forwards on the surface of the rope, thus bending the wires until they break.


DE710


176 (196) WI864-033 Revision 2

45.4 Criteria for Discarding a Rope

A wire rope must be removed if one or more of the following criteria apply:

45.4.1 Broken WiresThe rope has to be discarded when four or more broken wires are visible in any length of 10 times the rope diameter:Example: D = 13 mm; L = 130 mm.

45.4.2 Reduction in DiameterReduction in diameter can be caused by abrasion, corrosion or a local failure of the rope core. The rope has to be discarded if the outside diameter of the rope is reduced by 1mm or more.

45.4.3 CorrosionCorrosion may be external or internal, general or localised. A wire rope should be discarded when the surface of the wires is severely roughened or pitted, or if the wires are slack within the strands due to wastage.


DE710


45.5 Rope Deformation

45.5.1 WavinessWhen the rope is laid on a level surface under no load, the maximum height of the “wave” should not be greater than the nominal rope diameter + α, otherwise the rope should be removed from service.

45.5.2 Birdcage (Basket Deformation)Ropes with a birdcage must be discarded.

45.5.3 Loop FormationsWire or groups of wires may form a line of loops parallel to the axis of the rope. This deformation is often caused by shock-loading. Loop formations are a justification for discard.

45.5.4 Loose WiresWhere loose outer wires are found without any adjacent mechanical damage, the most likely cause will be corrosion and the rope should be removed from service.

45.5.5 NodesA node is a local increase in rope diameter with the core easily visible between several covering strands. A node is a justification for discard.

45.5.6 Thinning of the RopeThinning is a reduction in the diameter of the rope over a short length. The most likely cause is rope rotation which has allowed the rope to unlay, resulting in the overload and reduction in diameter.

45.5.7 KinksRopes with kinks must be discarded.

45.5.8 Flat AreasBending the rope over an edge causes flat areas. Such ropes must be discarded.


DE710


178 (196) WI864-033 Revision 2

45.6 Misplaced Outer Wires

Misplaced Outer Wires are wires forced out of position along the line of the rope to form small flattened loops. This can be caused by bad drum spooling or by the rope being drawn across a sharp edge. Lang’s lay ropes are often worst affected. Misplaced outer wires are a justification for discard.

When dealing with ropes, please bear in mind: • Ropes snapping under load may cause severe injuries. • Ropes snapping and dropping a drill string may cause great damage to drill rods and drill rig. • Handle a rope carefully and keep it lubricated and it’s useful life will increase dramatically.

45.7 Recommended Service Schedule and Oils for Wire Ropes

45.8 Steel Wire Ropes Lube Oils • MOBILE: MOBILARMA 798 • CASTROL: TRIBOL METAL LUBE 1-911SF • TALCOR: SWR Compound

45.9 Maximum Service Life of Wire RopesWire ropes absorb moisture and corrode internally without any detectable sign on the surface. Sandvik therefore recommends that the ropes, regardless how perfect their appearance might seem, be replaced and discarded in accordance with the following table: • PULL DOWN ROPE SINGLE EVERY 12 MONTHS - DOUBLE SHIFT EVERY 24 MONTHS - SINGLE SHIFT • MAIN-WINCH ROPE: EVERY TWELVE MONTHS

45.10 Service Life of Wire RopesThis following information is an extract from one of our normal wire rope suppliers Handling and Storage manual.

Maximum service life of wire ropes is determined from date of fitting the wire rope to the rig provided that the wire rope has been stored in accordance with the following:-

Wire ropes should be stored on timber off the floor or ground to prevent sweating and corrosion and under cover in dry conditions free from possible attack by corrosive agents such as mill dust, sulphur or acid fumes. If wire ropes are stored for any length of time in warm or hot conditions, they should be turned over periodically to maintain uniform lubrication of the wire rope. The wire rope should be relubricated if necessary.

KEY SINGLE SHIFT 12 HRS PER DAYKEY DOUBLE SHIFT 24 HRS PER DAYKEY ‘Y’ TO CARRY OUT

12

HRS

250

HRS

1500

HRS

Visually inspect all ropes and associated load bearing components before starting each shift. Y

Thoroughly inspect all ropes every YLubricate all ropes every YCheck rope clamp bolts are tight on the winch drums every YClean the ropes as required. YThoroughly inspect all associated load bearing components and their fasteners every Y


DE710


46. TROUBLESHOOTING GUIDE

46.1 SCOPE OF TROUBLE SHOOTING GUIDEThis guide covers basic adjustments for the following components; • Hydraulic pump for the Main Winch, Rotation Head, Traverse, Wireline Winch and Safe-T-Spin systems (Tracks and/or Safe-T-Spin where applicable) • Hydraulic pump for Water Pump system. • Hydraulic pump for the Pilot control and Slide Roller systems. • Rotation Head motor • Main Winch motor • Miscellaneous Hints

46.2 REFERENCES, ABBREVIATION KEY AND OTHER NOTES • Obtain copies of the following drawings for the particular rig and use them as a reference source; • Hydraulic Circuit, DE710-CTXX Drawing Number HYD14420 (Latest revision). • Hydraulic Circuit, Boost Pump Kit Drawing Number HYD 14415 (Latest revision). • Hydraulic Circuit, Safe-T-Spin Kit Drawing Number HYD 14405(Latest revision). • The item numbers on the hydraulic circuit drawing will be used as reference numbers through out this procedure. • Refer to other sections of the operator’s manual when necessary • Testing and procedures are to be carried out by suitably trained personnel. • The following abbreviations will appear throughout this procedure. A.P.R. = Acceptable Pressure Range in bar /psi. A.T.R. = Acceptable Temperature Range in ºC. A.M.R. = Acceptable Measurement Range in mm / inch. A.R.R. = Acceptable Revolution Range in rpm. • Use these letters for reference to what is an acceptable range to work in. • Generally, the hydraulic oil temp should be between 50ºC to 60ºC for most of the procedures. Please note the hydraulic oil flow to the cooler has a thermal valve fitted in the system, that will keep the oil temperature stable.

TROUBLESHOOTING GUIDE

DE710


180 (196) WI864-033 Revision 2

46.3 3 STAGE HYDRAULIC PUMPThis section will cover the first three pumps of the pump group, pumps 4 and 5 are gear pumps, normally driven from the camshaft of the engine.

1. Pump No.1 Main Winch, Rotation, Traverse, Wireline Winch, {Tracks, Safe-T-Spin Where Applicable}.

2. Pump No.2 Water Pump

3. Pump No.3 Pilot Controls, Slide Roller, {High Altitude Hydraulic Boost Pump Where Fitted} 4. Pump No.4 And 5 (Mounted On The Camshaft Drive Of The Cummins 6cta Engine) Micro Feed, Head Float, Rod Clamp, Breakout Tools, Set-Up Cylinders Mud Mixer and Auxilliary Functions


WARNING• Refer to general safety, read and thoroughly understand this section.

DE710


46.4 SET UP PROCEDURES FOR CONTROLS OF THE MAIN PUMP, SECOND PUMP AND THE THIRD PUMP - PUMPS 6A 6B AND 6C

46.4.1 FIRST PUMP (ITEM 6A)

FEATURES OF PUMP 6A

1. Maximum flow adjustment screw. Do not make any adjustments to this screw.

2. Case Drain.

3. Pressure port.

4. Pressure regulator adjustment screw. (Pressure cut off)

5. Flow regulator adjustment screw.

6. Suction port

7. Constant Power adjustment screw. NORMALLY THIS ADJUSTMENT IS NOT SUPPLIED. This adjustment is NOT used in the DE710 rig.

8. “M” port for pressure gauge connection.

9. “X” port of pump 6A.

10. Minimum flow adjustment screw.(under cap) Note Do not make any adjustments to this screw.


WARNING• Refer to general safety, read and thoroughly understand this section.

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182 (196) WI864-033 Revision 2

Flow regulator setting 1. Check if the pump controls have been preset by the supplier. 2. Refer to the photos on the previous page to locate pump 6A control positions. 3. Check the pilot levers for the main drill functions (main winch, wire line winch, rotation and traverse) are in the neutral position. 4. Tee a 40 bar / 580-psi pressure gauge and a pressure test point into the “M” port of pump 6A. 5. Start the engine and operate at 1200-1300 rpm. 6. Check the pressure reading on the pressure gauge. The pressure gauge should read 19.5-20 bar / 282-290 psi. If the gauge does not register the correct reading carry out the following instructions. 7. Remove the flow regulator cap nut. Loosen the flow regulator locknut. 8. Using an Allen key, adjust the flow regulator adjustment screw until the pressure gauge at the “M” port indicates 19.5 - 20 bar / 282 – 290 psi.

9. Tighten the flow regulator locknut and replace the cap nut. 10. Recheck the flow regulator pressure setting. 11. Remove the pressure gauge from the “M” port.

46.4.2 MAIN CONTROL PRESSURE RELIEF VALVE SETTING 1. Remove the hose from the “P” port of item 32 diverter valve and plug the hose and cap the fitting. 2. Remove the pressure regulator cap nut. 3. Loosen the pressure regulator locknut. 4. Using an Allen key, adjust the pressure regulator adjustment screw of pump 6A clockwise all the way in, then back out the screw by 1/2 turn tighten the locknut. 5. Reduce the pressure setting of the main control valve pressure relief cartridge by turning the adjustment screw out one full turn. 6. Remove the pressure hoses from the rotation head motor and plug the hoses, cap the fittings to stop any dirt ingress. 7. Start the engine and operate at 1800-1850 rpm. 8. Engage the rotation control lever into the forward position completely. 9. Set the pressure relief valve to 276 bar / 4000 psi. for pump 6A. Tighten the lock nut on the pressure relief cartridge adjustment screw. 10. Check the pressure setting via the main pump pressure gauge by disengaging and re engaging the rotation forward control lever.

Actual fl ow regulator setting A.P.R 19.5-20 BAR A.P.R. 282-290 PSI

Actual pressure regulator setting A.P.R 276-278 BAR A.P.R. 4000-4030 PSI

Actual diesel rpm A.R.R 1800-1850 RPM


DE710


46.4.3 PRESSURE REGULATOR SETTING 1. Remove the hose from the “P” port of item 32 diverter valve and plug the hose and cap the fitting. 2. Remove the pressure hoses from the rotation head motor and plug the hoses, cap the fittings to stop any dirt ingress. 3. Remove the pressure regulator cap nut. 4. Loosen the pressure regulator locknut. 5. Start the engine and operate at 1800-1850 rpm. 6. Engage the rotation control lever into the forward position completely. 7. Using an Allen key, slowly turn the pressure regulator adjustment screw (maximum system pressure) counter clockwise. • Turning the setting screw clockwise increases the pressure. • Turning the setting screw counter-clockwise reduces the pressure. • One turn of the adjustment screw corresponds to 50 bar /725psi pressure in the range 20 to 250 bar / 290 to 3625psi. • Observe the pressure reading at main pump pressure gauge. 8. Set the pressure regulator to 258 bar / 3750 psi for pump 6A. 9. Tighten the locknut and fit the cap nut. 10. Check the pressure setting via the main pump pressure gauge by disengaging and re engaging the rotation forward control lever.

NOTE • The pressure relief valve, of the main control valve item No. 24, may open and vent to tank, if the pressure regulator is set above 260 bar / 3770 psi. If this happens, refer to section 16.1.2 and reset the pressure relief valve opens at 276 bar / 4000 psi.

46.4.4 MAXIMUM FLOW SETTING 1. Remove the pressure hoses from the rotation head motor and connect a bi directional 300 lpm / 80 US gpm minimum 350 bar /5000 psi flow meter to the rotation head hoses. 2. Cap the fittings on the rotation head motor to stop any dirt ingress. 3. Check the flow meter pressure control is fully decreased. 4. Start the engine and operate at 2200-2210 rpm. 5. Engage the rotation control lever into the forward position completely. 6. Check the flow meter reading it should indicate 175-177 lpm. 7. If the flow meter is indicating a flow higher than 175-177 lpm, the maximum flow screw of the pump will have to be adjusted until the maximum flow reading is 175-177 lpm at 2200 rpm with the oil at an operating temperature of 45-60 degrees C.

Actual pressure regulator setting A.P.R 258-260 BAR A.P.R. 3750-3780 PSI


Actual pressure regulator setting A.F.R 175-177 LPMA.F.R. 46.2- 46.7 US GPM



DE710


184 (196) WI864-033 Revision 2

46.4.5 PUMP 6A PRESSURE AND FLOW TESTNote • The operating temperature of the hydraulic oil should be 45 to 60 degrees C. • The flow and pressure test will not provide the correct reading if the pressure regulator is not correctly set. 1. Remove the pressure hoses from the rotation head motor and connect a bi directional 300 lpm / 80 US gpm minimum 350 bar /5000 psi flow meter to the rotation head hoses. 2. Cap the fittings on the rotation head motor to stop any dirt ingress. 3. Start the engine and operate at 2200-2210 rpm. 4. Engage the rotation control lever into the forward position completely. 5. Note the flow meter reading. 6. Slowly adjust the pressure control of the flow meter until the pressure gauge on the flow meter indicates 250 bar / 3625 psi. 7. Note the diesel engine rpm and readjust the engine rpm until the engine is operating at 2200-2210 rpm. 8. Note the flow meter reading, is should read 168-170 lpm. 9. Fill in the table below.

FLOW TEST RESULTS NO PRESSURE

Actual fl ow meter reading A.F.R 175-177 LPM A.F.R. 46.2- 46.7 US GPM

Actual operating pressure A.P.R 10-15 BARA.P.R 145- 218 PSI

Actual oil temperature A.T.R 45 - 60°CActual diesel rpm A.R.R 2200-2210 RPM

FLOW TEST RESULTS NO PRESSURE

Actual fl ow meter reading A.F.R 168-170 LPM A.F.R. 44.3- 44.9 US GPM

Actual operating pressure A.P.R 250-252 BARA.P.R 3625-3654 PSI

Actual oil temperature A.T.R 45 - 60°C Actual diesel rpm A.R.R 2200-2210 RPM


DE710


46.4.6 PRESSURE REGULATOR TEST 1. Remove the pressure hoses from the rotation head motor and connect a bi directional 300 lpm / 80 US gpm minimum 350 bar /5000 psi flow meter to the rotation head hoses. 2. Cap the fittings on the rotation head motor to stop any dirt ingress. 3. Start the engine and operate at 2200-2210 rpm. 4. Engage the rotation control lever into the forward position completely. 5. Note the flow meter reading. 6. Slowly adjust the pressure control of the flow meter until the pressure gauge on the flow meter indicates 250 bar / 3625 psi. 7. Continue to slowly adjust the pressure control of the flow meter until the flow reading begins to drop off. This should happen at a pressure reading of 258 bar / 3750 psi at the main pump pressure gauge item 50 at the control cabinet of the rig. 8. Check the operation of the pressure regulator by carrying out the following; • When the pressure control has increased the pressure to 258 bar / 3750 psi, the flow from the pump should decrease, but the pressure should stay at 258 bar until the pump barrel goes against the minimum flow screw of the pump. Note • Adjust the pressure control of the flow meter until the pump flow has decreased to 100 lpm. • It is not necessary to adjust the flow below 100 lpm. • The main reason for the test is to ensure the pump will de-stroke when the pressure regulator setting of 258 bar/ 3750 psi is reached. • Reduce the pressure setting of the flow meter, when the pressure is below 258 bar / 3750 psi. the flow reading should increase to 168-170 lpm


DE710


186 (196) WI864-033 Revision 2

46.5 SECOND PUMP(ITEM 6B) FEATURES OF PUMP 6B 1. Pressure Regulator adjustment screw

2. Flow Regulator adjustment screw 3. Pressure Relief Valve adjustment

46.5.1 FLOW REGULATOR ADJUSTMENT PROCEDURE 1. Refer to the picture to locate the regulator adjustment screw. 2. Remove the hydraulic oil pressure hose from the water pump motor. Cap the fitting and plug the hose end with steel plugs. 3. Remove the flow regulator cap nut and loosen the lock nut. Note • When the cap nuts are loosened, a slight oil weep will occur. 4. Fit a 40 bar / 580 psi pressure gauge to the pressure test coupling item 14 connected to the pressure relief valve item 4, which is connected to the pump 6B pressure port. 5. At the control panel set the water pump hydraulic controls as follows: • Water Pump on-off: “OFF” • Water Pump fine control: “CLOSED” ( fully counter clockwise) • Water Pump coarse control: “CLOSED” (lever up) 6. Start the engine and set the diesel rpm to 1800 to1850 rpm. 7. Operate the water pump on-off control to the “ON” position. 8. Adjust the flow regulator adjustment screw until the pressure gauge reads 14-15 bar / 205-220 psi.

9. Tighten the flow regulator lock nut and replace the cap nut. 10. Check the setting by operating the water pump on-off control “OFF-ON” several times. Note • The flow regulator cannot be set correctly if pressure relief valve or the water pump on / off ball valve is faulty. 11. Operate the water pump on-off control to the “OFF” position. Stop the engine.

46.5.2 PRESSURE RELIEF VALVE ITEM 4 ADJUSTMENT PROCEDURE 1. Refer to the picture on page 21 for the location of the pump regulator setting screws. 2. Remove the pressure regulator cap nut. 3. Loosen the pressure regulator locknut. 4. Using an Allen key, adjust the pressure regulator adjustment screw of pump 6B clockwise all the way in, then back out the screw by 1/2 turn tighten the locknut. 5. Fit a 250 bar / 3625 psi pressure gauge to the pressure test coupling item 14 at pressure relief valve item 4, which is connected to the pump pressure port of pump 6B. 6. Remove the hydraulic oil pressure hose from the water pump motor. Cap the fitting and plug the hose end with steel plugs.

Actual fl ow meter reading A.P.R 14-15 BARA.P.R. 205-220 PSI

Actual operating pressure A.R.R 1800-1850 RPM


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7. Reduce the setting of the pressure relief valve item 4 by turning the adjustment screw out two full turns. 8. Start the engine and set the diesel rpm to 1800 to1850 rpm. 9. Operate the water pump on-off control to “ON”. 10. Adjust the pressure relief valve adjustment screw until the 200 bar /2900 psi is indicated on the pressure gauge. 11. Tighten the locknut of the adjustment screw of the pressure relief valve. 12. Check the setting by operating the water pump on-off control “OFF-ON” several times.

13. Operate the water pump on-off control to the “OFF” position. Stop the engine. 14. Refit the pressure hose onto the water pump motor if no further adjustment is required.

46.5.3 PRESSURE REGULATOR ADJUSTMENT PROCEDURE 1. Refer to the picture on page 21 for the location of the regulator setting screws. 2. Fit a 250 bar pressure gauge to the pressure test coupling item 4 at the pressure relief valve item 4, which is connected to the pump 6B pressure port. 3. Remove the pressure hose from the water pump motor. Cap the fitting on the motor and plug the hose end with steel plugs 4. At the control panel set the water pump hydraulic controls as follows: • Water Pump on-off: “OFF” • Water Pump fine control: “CLOSED” (fully counter clockwise) • Water Pump coarse control: “OPEN” (lever down) 5. Remove the pressure regulator cap nut and loosen the lock nut. Note • When the cap nuts are loosened, a slight oil weep will occur. 6. Start the engine and set the diesel rpm to 1800 to1850 rpm. 7. Using an Allen key set the pump pressure regulator adjustment screw (maximum system pressure) by turning the adjustment screw as follows. • Adjusting the pressure regulator setting screw clockwise increases the pressure. • Adjusting the pressure regulator setting screw counter-clockwise reduces the pressure. • One turn of the setting screw corresponds to 50-bar pressure in the range 20 to 250 bar. 8. Observe the pressure reading on the gauge connected to the test coupling. 9. Operate the water pump on-off control to the “ON” position. 10. Adjust the pressure setting to 180 bar. Tighten the lock nut and replace the cap nut.

Note • Do not exceed the pressure relief valve setting, note that pump pressure regulator setting is generally 15-20 bar lower than relief valve setting. • The pressure regulator cannot be set correctly if the pressure relief valve or the water pump on / off ball valve is faulty. 11. Check the setting by operating the water pump on-off control “OFF-ON” several times. 12. Operate the water pump on-off control to the “OFF” position. Stop the engine. 13. Refit the pressure hose onto the water pump motor if no further adjustment is required.

Actual fl ow meter reading A.P.R 198-200 BARA.P.R. 2871-2900 PSI


Actual fl ow meter reading A.P.R 178-180 BAR A.P.R. 2581-2610 PSI



DE710


188 (196) WI864-033 Revision 2

46.6 THIRD PUMP ITEM 6C FEATURES OF PUMP 6C

1. Pressure Regulator adjustment screw 2. Flow regulator adjustment screw. 3. Reduce the rotation the rotation speed control item 37 fully. The rotation speed control is located at the drill control cabinet. 4. Remove the flow regulator cap nut and loosen the locknut. Note • When the cap and lock nuts are loosened, a slight oil weep will occur. 5. Using an allen key, turn the flow regulator setting screw clockwise all the way in, tighten the locknut. Replace the cap nut, finger tight will do at this stage. 6. Remove the pressure regulator cap nut and loosen the locknut 7. Using an allen key, slowly turn the pressure regulator setting screw (maximum system pressure) clockwise. • Turning the setting screw clockwise increases the pressure. • Turning the setting screw counter-clockwise reduces the pressure. • One turn of the setting screw corresponds to 50 bar / 725 psi pressure in the range 20 to 250 bar / 290 to 3625 psi. • Observe the pressure reading at the 250 bar / 3625 psi pressure gauge. 8. Set the pressure regulator to 210 bar / 3050 psi for pump 6C. Note • The pressure relief valve item No.44, which is part of the pressure flow control manifold, may open and vent to tank, if the pressure regulator is set above 210 bar / 3050 psi. • If this happens set the pressure relief valve to open at 224 bar / 3250 psi by adjusting the pressure regulator. 8. Remove the flow regulator cap nut and loosen the locknut. 9. Using an allen key, turn the flow regulator setting screw counter-clockwise until the pressure gauge reads 100 bar / 1450 psi. 10. Adjust the flow regulator setting screw in until the gauge reads 210bar / 3050 psi. Continue turning the screw in a further ½ turn. 11. Tighten the locknut and replace the cap nut.

Actual pressure regulator setting BAR A.P.R 210-211PSI A.P.R. 3050-3065

Actual diesel rpm RPM A.R.R 1800-1820


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46.7 ROTATION HEAD MOTOR

FEATURES OF HYDRAULIC MOTOR

1. “X” Port on motor control block

2. Control regulator screw

3. Maximum speed screw

4. Optional case drain port. Not used on this application.

Note: • Case drain port for this motor is on the opposite side of motor. • Minimum speed screw is on the opposite side of the motor.

46.7.1 SET UP PROCEDURE FOR CONTROLS

Rotation Head Speed Control

1. The rotation head speed control item 37 is located at the drill control cabinet. 2. Fit a 60 bar / 870 psi pressure gauge to the pressure test coupling for the “X” port of the rotation head motor. The test coupling is located at the pressure flow control manifold at the rear of the hydraulic oil tank. 3. Slowly increase and decrease the pressure setting of rotation speed control and observe the pressure gauge reading. 4. The gauge reading should follow the change in movement of the rotation speed control. 5. Fully increase the rotation speed control and note the maximum reading. 6. If the pressure setting does not reach the pressure stated below in the table, inspect the following items. • Replace item 37 with another cartridge and recheck the operation. • Inspect the pressure setting of item 35 in the flow control block. To check the pressure setting of item 35 remove the hose from port “P5” and install a pressure test coupling to the fitting an check the pressure when the engine is running. Fit a 60bar / 870 psi pressure gauge to the test coupling. The gauge should register 50-53 bar / 725-775 psi. Replace item 35 if it is faulty and reset the pressure. • Locate the orifice 1.2mm M6 under the plug or fitting marked “ORF” and check that it is not blocked. • Check the pressure setting of item 45 by fitting a 150 bar /2175-psi pressure gauge to a test fitting ‘Tee’d into port”P9”. The gauge should read 100 bar /1450 psi. Adjust item 45 if required. 7. Fully increase the rotation speed control item 55. When the rotation speed control is fully increased the pilot pressure at the “X” port of the motor will be at the maximum pressure.

Actual pressure BAR A.P.R. 50- 53PSI A.P.R. 725- 77


DE710


190 (196) WI864-033 Revision 2

46.7.2 Rotation Chuck Operation

1. Fit an N size drill rod jaw set to the rotation head chuck. 2. Operate the control lever and check the following. 3. No mechanical fouling. 4. No hoses being nipped or pulled. 5. Fit a short length of N size drill rod to the rotation head and the chuck. Check for correct operation of the chuck versus the name-tag on the control panel. 6. Leave the short length of N size rod in the chuck for further commissioning of the rotation head.

46.7.3 Rotation Head Operational Checks

1. With the diesel engine at 800-850 rpm. Operate the rotation head control lever “FORWARD” and “REVERSE” and check the following. 2. Correct operation versus name tag drawing

46.7.4 Maximum Rotation Head Speed Setting

1. Set the maximum rotation speed at 1500 rpm with the following conditions 2. Diesel at 2200 rpm ARR2195-2200 3. Rotation speed control fully increased 4. Rotation pilot lever engaged “FORWARD”. 5. Check you can feel the rotation motor piston barrel resting firmly against the maximum speed adjustment screw as the screw is adjusted. 6. Check the rotation head rpm with a hand held tachometer.

ACTUAL ROTATION MAXIMUM RPM ARR 1500- 1505


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46.7.5 Motor Control End Regulator Setting

1. Fit a 60 bar / 870 psi pressure gauge to the pressure test coupling for the “X” port of the rotation head motor. The test coupling is located at the pressure flow control manifold at the rear of the hydraulic oil tank. 2. Run diesel at 1500 rpm. A.R.R. 1490 - 1500. 3. Engage the rotation pilot lever “FORWARD”. 4. Adjust the rotation speed control item 37 until the pressure gauge reads 30 bar, A.P.R. 30 - 30.5 bar / 435 psi A.P.R. 435-443 psi. 5. Undo the locknut of maximum speed adjustment screw, “FEEL” the screw. At the same time adjust the control regulator screw “OUT” slowly, until you feel the motor piston barrel just moving away from the maximum speed adjustment screw. 6. Lock the control regulator screw and check setting as follows: • Rotation speed control pressure = 31 bar A.P.R. 31-31.5 bar. = 450 psi A.P.R. 450-457 psi The motor piston barrel must be firmly against the maximum speed adjustment screw. The adjustment screw will be hard to turn. • Rotation speed control pressure = 29 bar A.P.R. 28.5 - 29 bar. = 420 psi A.P.R. 413-420 psi. The motor piston barrel has moved away from the maximum speed screw. The adjustment screw will be easy to turn. 7. Recheck the above by decreasing and increasing the pressure setting of the rotation speed control item 37.

8. Recheck the maximum rotation speed, reset if required.

46.7.6 Rotation Reverse Speed Interlock Valve Check procedure

1. Engage the rotation control lever into “REVERSE” and note the rotation speed with the diesel at 1500 rpm with the rotation speed control fully decreased. 2. Adjust the rotation head speed control to fully increased. Note the rotation rpm, there should not be any increase in rotation speed between fully decreased and fully increased.

46.7.7 Rod Spin Guard

1. With the rod spin “OPEN” and the valve at right side of the mast released. Check the rotation head rpm as follows: 2. Rotation torque control fully increased. Rotation head in high gear. 3. Diesel at 2000 rpm ARR 1900- 2000 RPM. 4. Rotation control lever fully engaged.

Note If the flow regulator setting of the pump 6A is set to high this will affect the rotation head rpm.

5. Check the rod spin guard fits and operates correctly. Check the operation of the guard as follows. 6. No mechanical fouling when the head is traversed “UP” or “DOWN” the mast. 7. When the guard is “OPEN” the maximum rotation speed is 150 with the diesel at 2200 rpm. 8. When the guard is “CLOSED” the maximum rotation speed is 1500 with the diesel at 2200 rpm. 1. Adjusting the pressure cut off adjustment screw “IN” will increase the main pressure and rpm, screwing it “OUT” will decrease main pressure and rpm.

ACTUAL CONTROL REGULATOR SETTING BAR A.P.R. 30 - 30.5PSI A.P.R.435-443

ACTUAL ROTATION RPM A.R.R 150-155


DE710


192 (196) WI864-033 Revision 2

46.8 MAIN WINCH MOTOR 46.8.1 SET UP PROCEDURE FOR CONTROLS

MAIN WINCH MANIFOLD BLOCK PART NO WU 11684


WARNING• This procedure requires working around unguarded rotating machinery and can be in an elevated • position well above ground level. Observe all safety rules such as:• • Wear an approved safety harness• • Tuck in long hair• • Avoid loose clothing• • Watch all pinch points, especially the rope leading onto the drum.• • Climbing up to and moving down from the main winch.• Observe all safety procedures outlined in this manual.• Beware of drill components such as the rotation head, winches or others, which may be run • purposely or inadvertently during testing.

DE710


The manifold is comprised of the following items. Refer to the hydraulic circuit for further details. 1. Item 71 PD24464AU Counter Balance Valve Winch Over Run Control 2. Item 82 PD22978AL Valve Body(Manifold Block) 3. Item 81 PD24464AH Pilot Open Check Valve Winch Float System

46.8.2 MAIN WINCH COUNTER BALANCE VALVE SETTING 1. Tee a 400bar/ 5800 psi pressure gauge into the hose leading to the “B” port of the main winch manifold block. 2. Disconnect the hose going to port PL2 plug and cap the ports. 3. Make sure the winch float control is in the off position and the drill head is side racked into the mast. 4. Increase the pressure setting of counter balance valve cartridges items 71 by screwing each adjustment screw counter clockwise until fully adjusted. To increase the pressure settings of Sun counterbalance valves the adjustment screw must be screwed counter clockwise as viewed from the end of the cartridge. 5. With diesel at 1500 - 1600 rpm, slowly operate the main winch control lever “DOWN”. The winch drum should not turn and the pressure gauge ‘Tee’d into the “B” port of the main winch manifold block should indicate above 4000 psi. 6. Do not pull the main winch control lever on fully, you only need to engage the lever enough to attain a pressure reading on the pressure gauge ‘Tee’d into port “B” of the main winch manifold block. 7. Release the main winch control lever to neutral. Adjust the adjustment screw of counterbalance valve cartridge item 71 clockwise in 1/6 of a turn. After each adjustment engage the main winch control lever “DOWN”. You will have to release the main winch control lever to be able to turn the adjustment screw of the cartridge. 8. At some point in the adjustment process the main winch drum will just begin to turn and the pressure gauge ‘Tee’d into the “B” will indicate between psi. 9. The main winch drum should rotate between 4-5 rpm maximum, which is equal to one rev in 12 to 15 secs. 10. Tighten the lock nut of the adjustment screw of valve 71. Check the pressure adjustment of valve 71 several times by engaging and disengaging the main winch control lever. 11. Remove the tee and the 400bar/ 5800 psi pressure gauge from the “B” port of the main winch mani fold block.


ACTUAL DRUM A.R.R. 4 - 5 RPMACTUAL PRESSURE at “A” port for VALVE 71 A.P.R 4000- 4030 PSI

DE710


194 (196) WI864-033 Revision 2

46.8.3 Brake Release Pressure Reducing Valve.

1. Pressure reducing valve cartridge.

2. Brake release pressure test point.

46.8.4 Test Proceedure 1. Connect a 3000 psi pressure gauge at the brake release valve test port. 2. Remove the break pressure line from the main winch gear box. 3. With diesel at 850-875 rpm, check by very slowly engaging the main winch control lever “UP” and “DOWN”, that a pressure of 172.5 bar / 2500 psi reads on the gauge. 4. Re connect the break release hose to the port on the main winch gear box.

46.8.5 Main Winch Operational ChecksWith the diesel engine at 850-875 rpm. Operate the main winch control lever “UP” and “DOWN” and check the following. • Correct operation versus name tag drawing • No mechanical fouling on the winch components • Proper brake function.


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46.9 MISCELLANEOUS HINTS46.9.1 Rotation, Main Winch And Wire Line Winch Generally applies to all operations • Check the hydraulic oil level in the hydraulic oil tank. The minimum oil level is when you can see the oil level above the bottom edge of the sight glass. • Check the maximum pilot pressure at the test fitting on the pilot pump is between 50-55 bar. • Flow and pressure test the pilot oil gear pump. • Check the main control valve pressure relief valve setting. • Check the pressure and flow regulator adjustment settings as outlined in the main pump set up procedure. • Flow and pressure test the main pump.

46.9.2 Rotation • Check the lube oil level and oil pressure. • Check the rotation head is in the correct gear. • Check the rotation torque limiter has been correctly adjusted. • Check the operation of the rotation head motor control regulator. • Check the operation of the rotation head motor pressure cut off. • Check the operation of the rod spin guard interlock valve. This valve must be fully engaged by the rod spin guard striker bolt to achieve high-speed rotation. • If you require high speed (50 to 200 rpm) when the rotation head is in low gear the over ride pin must be fitted to engage the rod spin guard interlock valve.

46.9.3 Unusually Slow Rotation Whilst Diamond Drilling, Very High Torque Reading (Main Pump Pressure Very High) 1. Check the lube oil level and lube oil pressure. 2. Check the output shaft of the rotation head for excessive end float. 3. With the engine off, the rotation head in high gear and a short length of drill rod gripped in the chuck, attach a hand held pipe wrench and try to rotate the head backwards and forwards. The hydraulic oil and rotation head lube oil must be at operating temperature. 4. Check the rotation head for any unusual noises when operating the head at various operating speeds in high and low gear, with a short length of drill rod gripped in the chuck. 5. Check if the hydraulic oil temperature is above normal (60°C) say 70-85°C, when compared with the temperature under good drilling conditions. 6. Clamp the drill string, break it at the rotation head starter rod and spin the head without any rods at top speed. Provided the hydraulic oil is at operating temperature the main pump pressure should now be 80-90 bar (1160-1305 psi).

If Steps 1 to 6 check out, the problem could be a down the hole problem. It could be one or any combination of the following problems: • Incorrectly set hold back and pull down controls. • Bent drill rods • The rig may not be aligned to the hole • Drill rods need greasing • Insufficient or incorrect drilling fluid in the sump.


DE710


196 (196) WI864-033 Revision 2


46.9.4 Main winch • Check the gearbox and brake lube oil levels. • Check the operation of the main winch park brake. • Check the operation of the main winch motor control regulator. • Check the operation of the main winch motor pressure cut off. • Carry out a case leakage test.

46.9.5 Wire line winch • Check the wire line winch drum is not rubbing on the winch frame. • Check the double holding valve is correctly set. • Carry out a case leakage test.

46.9.6 Diesel engine • Inspect the fuel rack or fuel pump solenoid is correctly set and operational. • Inspect the fuel system of the diesel engine for contamination. • Carry out a diesel load test.

46.9.7 Water Pump • Check the hydraulic oil level in the hydraulic oil tank. The minimum oil level is when you can see the oil level above the bottom edge of the sight glass. • Carefully check the water pump suction hose and foot valve, observe guidelines as per Water Pump Section. • Check the condition of the ball or check valves and any gaskets or seals in the wet end of the pump. • Check the condition of any packing or piston seals used in the pump. • Check the operation of the water pressure relief valve. Check the operation of the water pump hydraulic oil pressure relief valve.

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