D245s Hpil Op Manual 532b3a

D245S (HIGH PRESSURE - INSIDE LOADER) (Caterpillar T3 Engine)

OPERATION GUIDE November 2006 Serial Numbers 733014 and Up (Revised 6-08)

SANDVIK MINING and CONSTRUCTION

D245S

BLASTHOLE

733014 20,412 kg / 45,000 lb

C15 8,881 kg / 19, 580 lb 29, 484 kg / 65,000 lb 1814 kg / 4,000 lb

Sandvik Mining and Construction 13500 NW County Road 235 Alachua, Florida 32615 - USA Tel. (386) 462-4100 Fax. (386) 462-3247

The following three hazard signal words are used throughout this manual to emphasize important instructions. For the purpose of this manual, these signal words are defined as follows:

!

!

DANGER WARNING CAUTION

Indicates a hazardous situation which, if not avoided, will result in death or serious injury.

Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

Indicates a situation which, if not avoided, may result in damage to machinery or components. California Proposition 65

WARNING: This Product Contains And, When Used, Produces Chemicals Known To The State Of California To Cause Cancer, And Birth Defects Or Other Reproductive Harm.

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SAFE OPERATING PRACTICES FOR DRILLERS

Introduction SANDVIK MINING and CONSTRUCTION drilling equipment is carefully designed, tested and manufactured. When operated and serviced by trained and qualified personnel, this machine will give safe and reliable service. There are SANDVIK MINING and CONSTRUCTION offices world-wide to answer questions concerning the safe operation and maintenance of this equipment. To minimize the risk of accidents and injuries, all persons involved in the operation and servicing of this machine MUST read and understand the following safety precautions and the manuals developed for this machine. While we believe that we have properly identified several potential hazards that could result in property damage or injury or death to personnel, there are certain hazards which may be present that we have not contemplated. It therefore is the responsibility of the drill owner, operator and crew to be certain that the drill is properly equipped and safe to operate to assure accident free operation.

Management's Responsibilities It is the responsibility of management to: • See that all operators of this equipment are thoroughly trained (with special emphasis on safety), competent, physically fit and if required, licensed. • Assign specific crew specific safety responsibilities and instruct them how to report any unsafe conditions. • Enforce the use of protective clothing, eye and hearing equipment. • See that the operation and maintenance of this drill is in compliance with all Federal, State and local codes, regulations and standards. • Ensure that the work area is appropriately illuminated when drilling is performed at night. • Maintain a complete first aid kit at the drill site. At least two of the drilling crew or personnel in the area where the drill is operated should be familiar with first aid and Cardiac Pulmonary Resuscitation. • the utility companies for the exact location of underground transmission lines in the drilling area.

The Operator’s Responsibilities Safety must always be the operator's most important concern. The operator must refuse to operate the drill if an unsafe Safe Operating Practices for Drillers

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condition exists. It is the responsibility of the drill operator to ensure that the drill is properly equipped, safe to operate and that the site conditions make it possible for safe operation:

• The operator must see that all emergency stops, "operational aids" and "warning signals" are functional before operating.

• The operator must be alert, physically fit, and free from the influences of drugs, alcohol and medications that might impair eyesight, hearing or reactions

• The operator should not attempt to start, operate or service the drill unless he has been properly trained and read this manual.

• The operator should not operate this equipment if any of it's controls display a "lockout" tag. • If an unsafe condition exists, the operator must place a tag, identifying this condition, on the starting controls and alert other potential s of the drill.

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• The operator should not operate the drill without first checking that all personnel protection devices and machinery guards are in place.

Operator's Safety Check The operator must make a safety check before starting to work to ensure that the machine is in proper order for accident free operation. Somethings to check are:

• Check that there are no "lockouts" or "tagouts" attached to the controls. • Check the machine log book to see that periodic maintenance and inspections have been performed, and that all necessary repairs have been made. • After starting the engine, check all indicators, emergency stop, trip devices and gauges for serviceability.

• Check the fire extinguisher(s) for charge and accessibility. • Clean the cab interior windows if necessary. • Test all controls for proper operation. • Check access ladders and decking for damage and slipping hazards such as mud, oil or ice. • At the end of the shift, the operator must properly secure the drill to prevent the machine from being operated by unauthorized individuals. • The operator must never permit personnel to ride on the machine except in the enger compartment. • The operator should treat all power lines as live.

Safe Operating Practices for Drillers

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Planning the Job The person in charge must have a clear understanding of the work to be done and consider all the hazards at the site. He must develop a plan to do the job safely and explain the plan to the crew involved. Factors such as these should be considered: • Will the drilling take place in wet formations? • Are there utility lines or structures that must be moved or avoided? • Are there unusual or extreme weather conditions expected?

• Will drilling be done in night hours?

• Will the machine be propelled on inclines? • Will drilling be done into difficult formations? • Has a drilling pattern been developed? • What is the required depth of the drilling pattern? • Will special drilling tools be required to complete the job? • Will vertical or angle drilling be required? vi

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Operating Precautions

• Operating near or ing a power line with any part of the machine can result in electrocution. Do not raise the drilling mast or operate the machine in the vicinity of electrical power lines without checking the minimum safe operating perimeter set by local, state or federal regulations.

• Raising or lowering the mast, and drilling with an uned or unleveled machine can result in excessive structural stress to the machine frames or can cause the machine to overturn. Do not raise or lower the mast or attempt to drill until the machine is fully ed and leveled by the leveling jacks. • Drilling with an unlocked mast can result in excessive pressure at the mast raising cylinders causing the mast to fall. Do not attempt to drill until the mast locking pins are fully engaged. .

• Before leaving the operator's station, all controls must be in the neutral position with all locking and safety devices engaged. Do not allow the drill to operate unattended. • Do not park or position the machine on grades that exceed the tilt ratings. Park or position the machine on level ground or across (horizontal) grade

• Park or position the machine to allow the wind to carry engine exhaust fumes away from the operator. Exhaust fumes from diesel engines are lethal.

Safe Operating Practices for Drillers

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.

• Drill pipe that is free to slide through the opening in the top plate could be released from the loader while traveling. Before lowering the mast, index the loader to a position such that the top plate of the loader prevents all drill pipe from moving past the top plate

General Maintenance Safety Practices While operating and servicing this machine be aware of the following:

• The sudden release of a pressurized lid or hose can spray hot oil. Do not open hydraulic tanks, air reservoirs or hydraulic connections while the machine is running or the systems are under pressure.

• Before entering any enclosure, be sure that the door is secured open. Avoid entrapment, be sure that no one is inside any enclosure before closing and latching the doors. Enclosures can cause suffocation. • Before starting any service or maintenance work, always perform a safety/risk analysis of the task. Performing maintenance work without the proper tools and personal protection equipment can cause serious injury or death. • Climbing the mast is a crushing and falling hazard. Climbing the mast may cause serious injury or death. Stay off the mast at all times. • Hydraulic oil under extreme pressure from a small opening can penetrate the skin and inject oil into the body. Do not attempt to locate a hydraulic leak by using your hand. • Pressure in hydraulic systems can be retained for long periods of time. If not properly released before maintenance people attempt to work on the hydraulic system, this pressure can let components move or cause hot oil to spray and hose ends to shoot out at high speed. Release system pressure before attempting to make adjustments or repairs.

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• Carelessness in getting on and off equipment can result in serious injuries. Always wait until the machine has completely stopped. Do not jump on or off. Always use both hands and feet and use the 3-point rule.

• Riding the rotary head up and down the mast is a crushing hazard. Never ride the rotary head for any reason!!! It was not designed to be an elevator. When there is a need for an operator or helper to work on the rig in the working area or danger zone and this work involves activation of one or several machine functions, this work shall only be done under the following conditions: a. There must be two safety trained people present, one should supervise the safety of the other doing the servicing. Supervision should be done from the operator’s station to ensure immediate access to an emergency stop at all times. b. The area where the service work is to be done should be properly illuminated. c.

A reliable mode of communication should be establish between the servicing person and the supervisor.

d. The rig must be completely shut down and all methods of starting disabled before servicing work begins.

Fire Prevention

• Keep the machine clean of vegetation, coal dust and oily rags. • Clean-up any oil and fuel spills particularly around hot surfaces and heat producing components.

• Check the Fire Suppression System (FSS), if fitted, for damaged hoses or cylinders. • Check all electrical lines and connections including battery terminals for a tight fit, wear, abrasion, and corrosion. • Do not use the drilling machine in oil, gas or waterwell operations unless the well head is properly equipped with blowout preventers and safety equipment required by law or as recommended in the American Petroleum Institute's document API 54. Safe Operating Practices for Drillers

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• Check all machine ignition points (engine block, exhaust manifolds, mufflers, turbo-chargers, etc...) to make sure they are not in with any hoses. • Keep the batteries secured in their compartment and covered. • Never inject ether or other starting aids into the engine and compressor intake filter(s). Ether or other aids drawn into the compressor can cause an explosion. • Do not store flammable fluids on or in the immediate vicinity of the machine. • Engine oil, hydraulic fluid and compressor oil are flammable. Do not operate a machine with leaking or worn hoses or lines. • Do not clean washable filter elements with flammable solvents, diesel fuel, kerosene, or gasoline. • Do not attempt to perform welding repairs until all flammable materials including oil and fuel spills oily rags, and rock and coal dust, have been isolated or removed from the machine. • Disconnect the battery cables before welding on the machine. • Keep tools away from exposed live electrical parts such as terminals, to avoid arching. • If charging the batteries, always turn the charger off before making or breaking connections to the battery.

• The compound (ethyl ether) used in the engine starting aid system is extremely flammable. Changing the cylinders and servicing this system should be done in a well ventilated area. Do not store or install the cylinders in temperatures above 160° F (71° C). • The anti-freeze compound (methanol) used in the air line anti-ice systems is flammable. Refill the system with compound only in well ventilated areas, away from heat, open flames and sparks. Do not store or expose this system or the compound to temperatures above 150° F (65° C), or in direct sunlight.

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INCLEMENT WEATHER and SAFE DRILLING PRACTICES GENERAL The following safety precautions were developed to minimize the risk of injury during inclement weather when using Sandvik Mining and Construction drilling equipment. All persons involved in the planning, operation and servicing of Sandvik Mining and Construction equipment MUST read and understand the following safety precautions, the manuals developed for this machine and the Safe Operating Practices outlined in the front of this manual. While we believe that we have properly identified several potential hazards that could result in property damage or personnel injury, there are certain hazards which may be present that we have not contemplated. Bad weather conditions as they relate to this topic include lightning, thunderstorms and severe rainfall.

MANAGEMENT’S RESPOSIBILITIES High winds, rainfall and cloud cover are often precursors to actual cloud to ground strikes notifying individuals to take action. Many reported lightning accidents occur with sun, clear skies and no rain present at the beginning as the storm approaches because; people ignore these precursors. Generally the lightning threat diminishes with time after the last sound of thunder, but may persist for more than 30 minutes. It is the responsibility of management to: •

Be aware of daily weather conditions within a 100 mile (161 Km) radius of the mine property.

•

Determine a plan of action relating to expected bad or unexpected weather conditions.

•

Notify equipment operators of impending storms. Communication to equipment operators may be given via two way radio and/or in person.

•

Consider that drill operators need ample time: a. to retrieve drill pipe from blastholes and well bottom. b. lower masts to a horizontal position or position feed rails into feed s. c. give the drill engine an adequate cool down period prior to shutting machine down. d. leave machine cabin or operator platform and transport to central meeting location.

•

Give equipment operators an all clear signal after the storm has cleared the area.

Note To Supervisors! Recognize that equipment operators should be given adequate time to prepare the machine to move to specific locations for safe keeping. Crawler mounted drill machines have a maximum travel speed not exceeding 2.2 mph (3.5 kph).

RAINFALL AND FLOODING When notified of an impending storm, machine operators should: Safe Operating Practices for Drillers

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•Move the drill machine to higher ground conditions. Never leave a drill machine at the lowest floor position of a mine or quarry or in a low lying ditch that could trap water runoff. •Move the drill machine to stable ground and away from unstable crests or the face. Never leave a drill machine on the front face of the drill pattern while rain and severe weather pose a threat of loose ground falls or washouts.

•When operating machines in a construction application, equipment operators shall move the drill machine to higher stable ground. Never leave a drill machine in any construction zone roadway, river bed or drainage ditch. •Move the drill machine to stable ground away from high walls and any threat where rock or water erosion may allow unstable ground to fall or slide.

THUNDERSTORMS AND LIGHTNING A publication written in MSHA Holmes Safety Association Bulletin April 2001 gives a simple flash bang formula to calculate lightning proximity. The FLASH BANG method is determined by counting the seconds between the visible lightning and the sound of thunder. This delay in seconds when divided by 5 will give an approximate value in miles as to how close the active lightning is to your worksite. Example: when you see lightning and it takes (10) ten seconds to hear the thunder divide by (5) five. The approximate distance of lightning proximity is 2 miles (3.2 km). If the flash bang measurement is 30 seconds or less seek shelter immediately and remain indoors, away from electrical devices, water and metal components. Supervisors shall notify equipment operators in a timely manner. This is to allow the drill operator adequate time to perform the required operation principals needed and secure the machine in a safe manner. •

Equipment operators shall retrieve drill pipe from blastholes, secure drilling tools and lower mast to a horizontal position into the mast rest s. Understand that the mast in a vertical position with drill pipe in the ground is capable of attracting high voltage lightning.

NOTE ! If the operator and machine are inside or near a blast area follow procedures written in USA Federal Metal and Nonmetal Mine safety Standards 30CFR 56/57/58 manual. •

Equipment operators shall move the machine to secure ground as noted in the rainfall and flooding description.

•

Equipment operators shall give adequate engine cool down period prior to shutting machine down. Adequate engine cool down periods range between 3 to 5 minutes. Follow engine manufacture specifications as a standard.

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•

Equipment operators shall secure the machine, close doors and windows, leave the machine cabin and dismount the machine in a proper 3 point with the boarding ladder.

•

Equipment operators shall drive or be transported to a central meeting location away from bad weather and storm conditions.

There are exceptions to the rules when bad weather develops and time does not permit adequate machine preparation - shutdown principals.

Exceptions If you do get caught in an electircal storm and have little or no time to prepare, that, no place is absolutely safe from the lightning threat, however, some places are safer than others. When operators are inside a enclosed stable structure such as a machine cabin or the truck cab it is recommended that: •

all windows are closed

•

all doors closed

•

do not touch metal parts

•

do not use two way radio communication

NOTE! Wait inside the enclosed cab as long as it takes for the storm or lightning to subside. Do not attempt to dismount the machine when lightning is in your immediate work area. If lightning is present within a 20 mile (32 km) radius of your location be aware of your surroundings when outdoors. Seek adequate shelter immediately. If lightning is present within the 20 mile (32 km) radius, and a decision is made to dismount the machine, use a standard 3 point down the boarding ladder to dismount the machine. Move away from the machine quickly and into a enclosed vehicle or adequate shelter. Maintain a distance greater than 100 yards (92 m) to prevent electrical draw in the event lightning did strike the mining equipment. Static interference on AM radio channels is another indicator as to lightning proximity. Lightning detectors are available aftermarket as a measuring instrument to determine lightning proximity. Blasting crews are aware of lightning hazards and may have a lightning detector on site. If you are caught in the open with lightning nearby and shelter is not available the safest position to be in is to be crouched down on the balls of your feet. Keep your feet as close to one another as possible. Do not allow your hands (or other body parts) to touch the ground. Use your hands to cover your ears and brace for a loud thunderous bang. Lightning struck victims carry no electrical charge and should be given first aid treatment immediately!

MACHINE MAINTENANCE If lightning does strike a drill machine parked in any position (mast up or down) expect major component failures. A total machine inspection is in order. Safe Operating Practices for Drillers

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Electrical charge should dissipate immediately after impact. Prior to climbing on board a machine known to have been struck by lightning use the back side of either hand (knuckle side) to lightly touch the boarding ladder. Reference material MSHA Holmes Safety Association Bulletin April 2001 Federal Metal and Nonmetallic Mine Safety and Health Standards 30CRF 56/57/58 Ninth Edition (1999). National weather service (www.noaa.gov)

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TABLE OF CONTENTS SAFE OPERATING PRACTICES FOR DRILLERS . iii

Fire Suppression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii Management's Responsibilities . . . . . . . . . . . . . . . . . . . . . . .iii The Operator’s Responsibilities . . . . . . . . . . . . . . . . . . . . . . .iii Operator's Safety Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . v Planning the Job . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vi Operating Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii General Maintenance Safety Practices . . . . . . . . . . . . . . . .viii Fire Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ix

GENERAL PICTOGRAMS . . . . . . . . . . . . . . . . . . . . . . . . .2-3 DANGER, WARNING and CAUTION DECALS . . . . . . . . 2-3 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3 OPERATOR’S STATION “A” . . . . . . . . . . . . . . . .2-7 OPERATOR’S STATION “B” . . . . . . . . . . . . . . . .2-9 OPERATOR’S STATION “C” . . . . . . . . . . . . . . .2-11

INCLEMENT WEATHER and SAFE DRILLING PRACTICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xi GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xi MANAGEMENT’S RESPOSIBILITIES . . . . . . . . . . . . . . . . xi RAINFALL AND FLOODING . . . . . . . . . . . . . . . . . . . . . . . . xi THUNDERSTORMS AND LIGHTNING . . . . . . . . . . . . . . . . xii Exceptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xiii MACHINE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . xiii

TABLE OF CONTENTS

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 MACHINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . 1-1 Application of Rig . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Recommended Operating Conditions . . . . . . . . . . . . . . . . 1-1 Manners and Conditions In Which This Machine Should NOT Be Used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Sound Pressure and Power Levels . . . . . . . . . . . . . . . . . . 1-2 Vibration Value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

OPERATOR’S STATION “D” . . . . . . . . . . . . . . .2-13 OPERATOR’S STATION “E” . . . . . . . . . . . . . . .2-15 OPERATOR’S STATION “F” . . . . . . . . . . . . . . .2-17 DRILL OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-21 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-21 Preparation Inspection and Adjustments . . . . . . . . . . . . . .2-21 STARTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . .2-21 Shutting Down the Machine . . . . . . . . . . . . . . . . . . . . . . . .2-22 Propelling the Machine (Tramming) . . . . . . . . . . . . . . . . .2-22 Levelling the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-25 Raising the Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-26 Lowering the Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-26 DRILLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-27 Adding Drill Pipe - Inside Loader . . . . . . . . . . . . . . . . . . . .2-27 Returning Drilled Pipe - Inside Loader . . . . . . . . . . . . . . . .2-29 Using the Tong(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-31 Propelling to the Next Hole . . . . . . . . . . . . . . . . . . . . . . . .2-32 LIFTING and TRANSPORTING the MACHINE . . . . . . . .2-32 DUST SUPPRESSION SYSTEMS . . . . . . . . . . . . . . . . . .2-32 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-32 Dust Collector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-33 Water Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-34

NOMENCLATURE/TERMINOLOGY . . . . . . . . . . . . . . . . . 1-3 WINCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-34 D245S (1000 cfm) SPECIFICATIONS . . . . . . . . . . . . . . . 1-5 TOWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-34 CENTER OF GRAVITY & LIFTING POINTS . . . . . . . . . . . 1-6 GENERAL ARRANGEMENT . . . . . . . . . . . . . . . . . . . . . . 1-7

OPERATOR CONTROLS and OPERATION . . . . . 2-1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 FIRE AND SAFETY EQUIPMENT . . . . . . . . . . . . . . . . . . . Fire Extinguisher Location and Operation . . . . . . . . . . . . . . Cab Emergency Exits . . . . . . . . . . . . . . . . . . . . . . . . . . . . Emergency Stops and Battery Disconnect . . . . . . . . . . . . .

2-1 2-1 2-1 2-1

ELECTRONIC DEPTH COUNTER (EDC) . . . . . . . . . . . .2-35 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-35 Component Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . .2-35 Indicator and Key Descriptions . . . . . . . . . . . . . . . . . . . . .2-36 Viewing Bit Position, Distance From Bottom, Accumulated Depth And Penetration Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-39 Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-39 DRILL MONITOR SYSTEM (DMS) . . . . . . . . . . . . . . . . . 2-40 SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . .2-41

Table of Contents

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2

SECTION 1 INTRODUCTION GENERAL This manual provides a step-by-step guide to operating and performing scheduled lubrication and maintenance for your drill. A thorough study of this manual is recommended before operation or maintenance of the machine is attempted. Careful attention should be given to the service and maintenance instructions for the various components and systems of the machine. Experience indicates that the procedures described herein are preferred practices and that failure to comply with them can materially shorten the useful life of the equipment and/or reduce its standard performance. Some photographs in this manual may show details or attachments that are different from your unit, due to optional equipment and/or advancement of product design. your andvik Mining and Construction dealer for details of lubrication or maintenance not covered in this publication.

The parts manual should be referred to when it is necessary to order repair parts. For prompt and efficient parts service, your Sandvik Mining and Construction dealer, giving the

model and serial number of the machine, along with the part number and description of the items required, as their personnel are fully qualified to assist and advise you on any service or operational problems that may be encountered. Sandvik Mining and Construction Field Representatives are also available to you for advice and assistance on special problems. MACHINE SPECIFICATIONS Application of Rig The D245S machine is designed for construction and surface mine drilling. Recommended Operating Conditions This machine was designed to operate at ambient temperatures of -40°C to +54°C (-40°F to +130°F). Manners and Conditions In Which This Machine Should NOT Be Used •

Inadequate training of operator.

•

Unathorized persons in working area.

•

Inadequate lighting.

•

Inadequate grading.

•

Transporting people.

•

Defective safety systems.

Introduction - Page 1-1

Sound Pressure and Power Levels The measurement of the sound power and the sound pressure levels at the operator’s cab have been measured in accordance with European Drill Rig Standard EN791 and the EC Machinery Directive 89/392/EEC and amendments thereof. The average sound level emitted by machinery: 93.9 dB Sound level In Cab: 85 dB Vibration Value The measurement of the vibration value at the operator’s cab have been measured in accordance with European Drill Rig Standard EN791 and the EC Machinery Directive 89/392/EEC and amendments thereof. Vibration does not exceed 0,5m/s².

Page 1-2

NOMENCLATURE/TERMINOLOGY The used on this illustration are used throughout this manual.

FRONT

RECEIVER TANK

BATTERY BOX

ROTARY HEAD COOLER FEED CHAIN AIR CLEANER COMPRESSOR

DRILL PIPE

MAST ENGINE PUMP DRIVE MAST RAISING CYLINDERS

LUBRICATOR TANK

HYDRAULIC TANK

JACK CYLINDER

CAB

LOADER DUST COLLECTOR

CAB CRAWLERS

DUST HOOD REAR

Introduction - Page 1-3

D245S (900 cfm) SPECIFICATIONS DRILL RATING Hole Size Max. 1st capacity (Std. tooling) Max. 1st capacity (Special tooling Total Depth Capacity (Outside Loader) Total Depth Capacity (Inside Loader)

5” to 7-7/8” (127 - 203 mm) 28’ 5” (8.65m) 30’ 9” (9.4m) 150’ (46m) 90” (27.4m)

UNDERCARRIAGE Type Length Pads (Shoes) Triple Gro Travel Speed Gradeability Drive HP each track Ground Bearing Pressure (Std. Equipment) Width Over Tracks Suspension Rollers

Caterpillar® - Model 325 14’ 4” (4.37m) 23.6” (600 mm) 2.1 mph (3.38 km/h) 50% 130 hp (97 kW) 8.8 psi (60.7 kPa) 11’ 0” (3.35 m) Three Point Oscillating 9 Lower - 2 Upper

DRILL POWER Caterpillar® Rated Speed Fuel Capacity

Model C15 475 hp (354 kW) 1800 rpm 200 gallons US (757 l) COMPRESSOR

Type Manufacturer

2 Stage Oil Flooded Screw Type Sullair 900cfm (25.5m³m) @ 350 psi (24.1 bar) @ 1800 rpm

FEED SYSTEM Type Rated Bit Loading Rated Pullback Feed Rate Retract Rate

1 Hydraulic Cylinder and Chains 45,000 lbs (20,412 kg) 19,580 lbs (8,881 kg) 0-97 fpm (29.5 mpm) 0-207 fpm (63 mpm)

ROTARY HEAD Type Drive Motor Maximum Rotary Horsepower Standard Rotary Speed/Torque

Gear Case Type Hydraulic Axial Piston 130 hp (97 kW) 158 rpm @ 48,500 in-lbs (5,481 Nm)

TOOL HANDLING EQUIPMENT (Loaders) Type Number of Positions Type Pipe Size

Carousel (Outside Mast) 4 Two Single Pod (Inside Mast) 3” to 5-1/2” (76 to 140 mm)

WEIGHT Operating Weight w/Drill Pipe

65,000 lbs (29,484 kg)

DIMENSIONS Length (mast down) Width (operating) Height (mast up)

44’ 7” (13.6 m) 13’ 8” (4.16 m) 42’ 6” (12.9 m)

ELECTRICAL Alternator Air Conditioner Batteries

Page 1-4

24VDC 100amp 24VDC 2 @ 12 Volt

D245S (1000 cfm) SPECIFICATIONS DRILL RATING Hole Size Max. 1st capacity (Std. tooling) Max. 1st capacity (Special tooling Total Depth Capacity Total Depth Capacity (Inside Loader)

5” to 7-7/8” (127 - 203 mm) 28’ 5” (8.65m) 30’ 9” (9.4m) 150’ (46m) 90” (27.4m)

UNDERCARRIAGE Type Length Pads (Shoes) Triple Gro Travel Speed Gradeability Drive HP each track Ground Bearing Pressure (Std. Equipment) Width Over Tracks Suspension Rollers

Caterpillar® - Model 325 14’ 4” (4.37m) 23.6” (600 mm) 2.1 mph (3.38 km/h) 50% 130 hp (97 kW) 8.8 psi (60.7 kPa) 11’ 0” (3.35 m) Three Point Oscillating 9 Lower - 2 Upper

DRILL POWER Caterpillar® Rated Speed Fuel Capacity

Model C15 540 hp (402 kW) 1800 rpm 200 gallons US (757 l) COMPRESSOR

Type Manufacturer

2 Stage Oil Flooded Screw Type Sullair 1000cfm (28.3m³m) @ 350 psi (2412 kPa) (24.1 bar) @ 1800 rpm

FEED SYSTEM Type Rated Bit Loading Rated Pullback Feed Rate Retract Rate

1 Hydraulic Cylinder and Chains 45,000 lbs (20,412 kg) 19,580 lbs (8,881 kg) 0-97 fpm (29.5 mpm) 0-207 fpm (63 mpm)

ROTARY HEAD Type Drive Motor Maximum Rotary Horsepower Standard Rotary Speed/Torque

Gear Case Type Hydraulic Axial Piston 130 hp (97 kW) 158 rpm @ 48,500 in-lbs (5,481 Nm)

TOOL HANDLING EQUIPMENT (Loader) Type Number of Positions Type Pipe Size

Carousel (Outside Mast) 4 Two Single Pod (Inside Mast) 3” to 5-1/2” (76 to 140 mm)

WEIGHT Operating Weight w/Drill Pipe

65,000 lbs (29,484 kg)

DIMENSIONS Length (mast down) Width (operating) Height (mast up)

44’ 7” (13.6 m) 13’ 8” (4.16 m) 42’ 6” (12.9 m)

ELECTRICAL Alternator Air Conditioner Batteries

24VDC 100amp 24VDC 2 @ 12 Volt

Introduction - Page 1-5

CENTER OF GRAVITY & LIFTING POINTS

Page 1-6

GENERAL ARRANGEMENT Introduction - Page 1-7

Page 1-8

SECTION 2 OPERATOR CONTROLS and OPERATION GENERAL This section of the manual discusses safety equipment the operator should be familiar with before operating the machine as well as control identification, machine limitations, and operating procedures.

2. Pull the clamp release and remove the extinguisher from it’s mounting base. 3. Hold the extiguisher upright and pull the ring pin. 4. From 3 meters (9ft) away, direct the hose at the base of the fire. 5. Squeeze the handle and sweep the hose from side to side. 6. After use have the extinguisher refilled. RING PIN

HANDLE

CHARGE GAUGE

FIRE AND SAFETY EQUIPMENT Before operating this machine become familiar with the location and operation of all safety related equipment. Walk around the machine and note the location and understand the meaning of all DANGER, WARNING and CAUTION decals.

CLAMP RELEASE

Fire Extinguisher Location and Operation Fire extinguishers are located at the front sides of the rig as shown.

Cab Emergency Exits Operator cab emergency exits are the cab doors and the side window.

245-59

KICK OUT GLASS TO EXIT

CAB DOOR

Read the operating instructions on the side of the extinguisher and check to see that the charge indicator needle is not in the red zone.

Emergency Stops and Battery Disconnect

Operate the fire extinguisher as follows: 1. Shutdown the rig.

The emergency stops were designed to shutdown the machine in an emergency situa-

D245S (hpil)

Controls and Operation - Page 2-1

tion only. Before resetting an emergency stop, determine how to avoid the situation which caused the emergency stop to be used. Emergency stop #1 is located in the operator’s cab. Push this button to stop the engine and all machine operations. Pull the button out to reset.

The battery disconnect switch is located on the battery box. Turn the key to the “OFF” position to cut electrical power to the machine.

Emergency stop #2 is located on the mast. Pull this cord to stop the engine and all machine operations. Push the reset button before restarting the rig.

c245-27 EMERGENCY STOP #1

BATTERY DISCONNECT SWITCH

Fire Suppression

IN CASE OF FIRE! When a fire starts, the way you react is very important. As soon as you become aware of a fire, do the following four things: 1. Turn the machine off.

22133s1

2. Quickly actuate the fire suppression system by pulling the safety ring pin and pushing down the plunger on the actuator.

EMERGENCY STOP #2

6120-s1

RESET BUTTON

Page 2-2

D245S (hpil)

3. Get away from your machine. Take a hand portable extinguisher along if you can. EMERGENCY STOP

4. Stand by with the hand portable extinguisher. RESULTS

DIESEL FUEL ONLY

If you leave the machine running, it may add fuel to the fire or restart the fire with sparks.

ENGINE LUBRICATING OIL

React quickly so the fire is caught before it grows too large.

SIGNAL HORN

By leaving the immediate fire area, you protect yourself from windblown flames, explosions or other dangers created by the fire.

WATER ONLY

Heat remaining from the fire could cause reignition after the fire suppression system has discharged. Because of this, it is important that someone stand by, at a safe distance, with a hand portable extinguisher. This standby should be maintained until all possibility of reignition is past.

ALTERNATOR CIRCUIT BREAKER CRUSHING HAZARD

MAIN CIRCUIT BREAKER

When a fire suppression system discharges, there is considerable noise accompanied by clouds of dry chemical. While breathing foreign particles is not pleasant, the agent FORAY is non-toxic and exposure during a fire will not harm you.

WINCH CAPACITY

FEED (PULLDOWN) CYLINDER CAPACITY

AFTER THE FIRE IS OUT Machinery should not be restarted until it has been serviced and cleaned (water may be used to remove the dry chemical). Immediately recharge the fire suppression system. You needed it once, you may need it again.

GENERAL PICTOGRAMS The following symbols can be found on this rig.

D245S (hpil)

DANGER, WARNING and CAUTION DECALS General The following illustrations show the general placement of the Caution, Warning and Danger decals found on this machine. These decals should make it clear to the operator where the major risks for personal injury and machine damage are, and what measures should be taken to operate this equipment safely.

Controls and Operation - Page 2-3

DANGER DECALS Page 2-4

D245S (hpil)

WARNING DECALS D245S (hpil)

Controls and Operation - Page 2-5

CAUTION DECALS Page 2-6

D245S (hpil)

A1

A2 A3 A4

A2. RECEIVER AIR PRESSURE This gauge indicates the air pressure as measured at the air receiver tank. This gauge should read slightly higher than the working air pressure gauge when drilling is taking place.

A3. ROTATION PRESSURE This gauge indicates hydraulic oil pressure as measured at the rotary head motor. Pressure is controlled by turning the rotation pressure control valve (F11).

A5

A4. HYDRAULIC PRESSURE This gauge indicates hydraulic oil pressure as measured at the control valve bank operating the feed cylinders (pulldown force).

OPERATOR’S STATION “A”

A1. WORKING AIR PRESSURE This gauge indicates the air pressure as measured at the drill bit.

D245S (hpil)

A5. OPERATOR STATION LIGHTS This two-position toggle switch operates the operator station lights. Lift the switch up to turn the lights on. Push the switch down to turn the lights off.

Controls and Operation - Page 2-7

Page 2-8

D245S (hpil)

B2

B1

B6

B7 B8

B9

B10

B3

B11

B4

B12 B5

B4. R JACK This indicator illuminates (GREEN) to confirm that the right rear jack (levelling) cylinder is fully retracted.

B5. CHANGE COMPRESSOR FILTERS This indicator illuminates (red) when the filter is clogged and oil is bying the filter. Push to test the indicator.

B13 B14 B15 B16

B6. FUEL This gauge indicates the level of engine diesel fuel.

B17 B18 B19

OPERATOR’S STATION “B”

B1. HEAD SPEED This tachometer gauge indicates the drive speed of the rotary head and the drill string in multiples of 10 with a maximum of 200 revolutions per minute.

B2. L JACK This indicator illuminates (GREEN) to confirm that the left rear jack (levelling) cylinder is fully retracted.

B3. F JACK This indicator illuminates (GREEN) to confirm that the front jack (levelling) cylinder is fully retracted.

D245S (hpil)

B7. DISENGAGE - ANGLE LOCKING This indicator illuminates (RED) when the mast locking pins are not engaged.

B8. ENGAGED - ANGLE LOCKING This indicator illuminates (GREEN) when the mast locking pins are fully engaged.

B9. ENGINE RPM This tachometer gauge indicates the engine rotation speed in multiples of 100’s of rpms.

B10. WATER TEMPERATURE This gauge indicates the coolant temperature of the engine. The normal operating temperature is indicated by the green zone.

B11. DISCHARGE AIR TEMPERATURE This gauge indicates the temperature of the air that is discharged by the compressor by meaControls and Operation - Page 2-9

suring the temperature of the discharged oil.

B12. OIL PRESSURE This gauge indicates the engine lubricating oil pressure.

B13. BATTERY This voltmeter indicates the battery charge voltage. The normal voltage reading will be slightly above 24V.

B14. LIGHTS Pull this switch out to illuminate the work area lights. Push the switch in to extinguish the lights.

B18. BY- This switch activates the engine shutdown system by-. This by- system is needed when starting the engine while the engine and compressor oil pressures have not reached their operating levels. For more information on the use of this switch refer to the topic “Starting the Engine”.

B19. ENGINE - OFF/ON When this key operated switch is placed in the ON position the machine’s electrical system is energized. The switch must be placed in the OFF position when the machine is shutdown to prevent the batteries from discharging.

B15.CHANGE HYDRAULIC FILTERS This indicator illuminates (red) when the filter is clogged and oil is bying the filter. Push to test the indicator.

B16. ETHER This pushbutton switch activates the cold weather starting system. Refer to the topic on starting the engine in cold weather for more instructions on using this switch.

B17. START Push this button in to start the engine. Release the button when the engine has started. Refer to topics on starting the engine for more information on the use of this button.

Page 2-10

D245S (hpil)

C1

C2. V-BLOCK - IN/OUT This lever controls the actuation of the V-block cylinder.

C2 C2 C4 C5 C6

ARRANGEMENT WITH POWER -TONG C3

Push up on the lever to position the V-block IN the drilling area. Pull down on the lever to retract the V-block OUT of the drilling area.

C3. NOT USED

C4. SWING - IN/OUT C1

C2 C3

Push up on this control to swing the powertong mechanism in to position at the drill pipe. Pull down on this control to swing the powertong mechanism away from the drill pipe.

C5. CLAMP - OPEN/CLOSE

OPERATOR’S STATION “C” C1. CURTAIN - UP/DOWN This lever controls the movement of the dust hood curtain cylinder. Push up on the lever to raise the curtain UP. Pull down on the lever to close the curtain.

D245S (hpil)

Push up on this control to open the powertong jaws and release the drill string. Pull down on this control to close the tong jaws and clamp the drill string.

C6. BREAK - IN/OUT Push up on this control to break the drill string connection. Pull down on this control to retract the cylinder and prepare the wrench for the next break.

Controls and Operation - Page 2-11

Page 2-12

D245S (hpil)

D4. ENGINE SPEED - RUN/IDLE With this toggle switch in the up (RUN) position, the engine rpm increases to 1800 rpm. With this switch in the down (IDLE) position, the engine rpm decreases to 1200 rpm. D2 D1 D3 D4

D5 D6 D7

OPERATOR’S STATION “D”

D5. COMPRESSOR AIR PRESSURE HIGH/LOW This two position switch controls the air pressure as measured at the receiver tank (gauge A2). Lift the switch in the HIGH position to increase air pressure to a maximum of 350 psi (24 bars). Lower the switch in the LOW position to decrease air pressure to 150 - 160 psi (10 11 bars).

D1. CHECK ENGINE This indicator illuminates (red) when the engine is sending a diagnostic code at indicator D2. D6. D2. DIAGNOSTIC CODE INDICATOR This indicator will illuminate (red) coded pulses when an engine problem has been detected by the engine’s self-diagnostic system. Refer to the Caterpillar® engine Operation & Maintenance Manual for more information on this system.

LUBRICATOR - ON/OFF

This toggle switch controls the injection of lubricating oil into the drill string.

D7. PULSE RATE With the Lubricator switch (D6) in the ON position this indicator will pulsate the rate at which oil is being injected into the bailing air system.

D3. EMERGENCY STOP Push this switch to stop all machine functions. Do not use this switch to shutdown the machine in a non-emergency situation.

D245S (hpil)

Controls and Operation - Page 2-13

Page 2-14

D245S (hpil)

E3. LOADER - RETRACT/LOAD (LH) This lever controls the swing functions of the left side drill pipe loader. Push the lever forward to retract the loader from under the rotary head. Pull the lever back to position the loader under the rotary head.

E5

E1 E2

E6 E7

E3

E8

E4

E4. LOADER - RETRACT/LOAD (RH) This lever controls the swing functions of the right side drill pipe loader. Push the lever forward to retract the loader from under the rotary head. Pull the lever back to position the loader under the rotary head.

OPERATOR’S STATION “E” E1. WINCH - UP/DOWN This lever controls the operation of the winch.

Push this lever forward to raise (spool in) the winch rope.

Pull this lever to lower (spool out) the winch rope.

E2. TONG This lever controls the extend and retract motions of the power-tong cylinder. Pull back on this lever to extend the cylinder and break the drill pipe connection.

E5. EXHAUSTER/WATER This lever controls the dust suppression systems.

Push forward on this lever to start the dust collector. Pull back on this lever to start the water injection system.

E6. WRENCH - IN/OUT This lever controls the positioning motion of the holding wrench.

Push the lever forward to slided the wrench towards the drill pipe.

Pull the lever back to retract the wrench.

Push this lever to forward to retract the cylinder and prepare for breaking the next connection. D245S (hpil)

Controls and Operation - Page 2-15

E7. MAST - LOCK/UNLOCK This lever controls the movement of the mast locking cylinders.

E8. AIR - ON/OFF This lever controls the injection of working (bailing) air into the drill string.

Push the lever forward to LOCK the mast. Pull this lever to bail the hole. Pull the lever back to UNLOCK the mast. Push this lever to stop the air flow.

Page 2-16

D245S (hpil)

F2

F2. ROTARY/ LEFT TRACK LEVER This lever regulates the speed and direction of the drill string’s rotational motor and the left side crawler track.

F3

F1

NOTE ! The operations controlled by the positioning of this control lever are dependent upon the position of the DRILL/PROPEL selector switch (F7).

F9 F10 F11 F12

With the DRILL/PROPEL selector switch (F7) in the “DRILL” position: Push the lever forward to rotate the drill string in a clockwise rotation. The further forward this lever is pushed, the faster the rotation speed. The drill string speed is shown on the HEAD SPEED tachometer gauge (B1).

F4 F5 F6 F7 F8

F13 F14

OPERATOR’S STATION “F” F1. FEED - UP/DOWN This lever controls the rotary head pulldown and raising. Pull back on this lever to extend the feed cylinder and lower the rotary head. Push forward on this lever to retract the feed cylinder and raise the rotary head.

D245S (hpil)

Pull back on the lever to rotate the drill string in a counter-clockwise rotation. The further this lever is pulled back, the faster the rotation speed. The drill string speed is shown on the HEAD SPEED tachometer gauge (B1). With the DRILL/PROPEL selector switch (F7) in the “PROPEL” position (and the optional DEAN pedal F13 depressed):

Push this lever up to propel the left crawler tracks forward.

Pull this lever down to propel the left crawler tracks in reverse. Refer to the topic on propelling the machine for more instructions on the use of this control. NOTE! The engine will not start until this control is placed in the center “NEUTRAL” position.

F3. FEED/ RIGHT TRACK LEVER This lever controls the rotary head “fast feed” system, and controls the speed and direction of Controls and Operation - Page 2-17

the right side crawler track. NOTE ! The operations controlled by the positioning of this control lever are dependent upon the position of the DRILL/PROPEL selector switch (F7). With the DRILL/PROPEL selector switch (F7) in the “DRILL” position and the FEED lever (F1) in either the “UP” or “DOWN” position: Depress the button and pull back on this lever to “fast feed” the rotary head (direction is determined by the positioning of FEED lever F1). With the DRILL/PROPEL selector switch (F7) in the “PROPEL” position (and the optional DEAN pedal F13 depressed): This lever controls the propelling of the right crawler tracks.

Push this lever up to propel the right crawler tracks forward.

Pull this lever down to propel the right crawler tracks in reverse. Refer to the topic on propelling the machine for more instructions on the use of this control.

F5. TORQUE CONTROL - ROTARY This knob regulates the hydraulic oil pressure applied to the drill string’s rotational motor. Turn the knob clockwise to increase hydraulic torque pressure. Turn the knob counter clockwise to decrease torque pressure as shown on the ROTATION PRESSURE gauge (A3).

F6. WATER CONTROL This control varies the amount of water injected into the down the hole air supply. With the EXHAUSTER/WATER control (E7) in the WATER position: Rotate the knob clockwise to decrease the amount of water injected. Rotate the knob counterclockwise to increase the amount of water injected. Refer to the topic on the water injection operation for more instructions on the use of this control.

NOTE! The engine will not start until this control is placed in the center “NEUTRAL” position. F7. DRILL / PROPEL This two-position mode selector switch energizes control levers F2 and F3. F4. FEED PRESSURE CONTROL This knob regulates the hydraulic oil pressure applied to the feed cylinder. Turn the knob clockwise to increase (pulldown) force. Turn the knob counter clockwise to decrease the pressure as shown on the FEED PRESSURE gauge (A4).

Position this switch to the “DRILL” position to operate the feed and rotation controls. Position this switch to the “PROPEL” position to operate the propel controls.

F8. LEVEL Use this device to ensure that the machine is level after the jack cylinders have been lowered. Page 2-18

D245S (hpil)

F9. MAST - DOWN/UP This lever controls the up and down motions of the drilling mast.

!

DANGER

Operating near or ing a power line with any part of the machine can result in electrocution. Do not raise the drilling mast or operate the machine in the vicinity of electrical power lines without checking the minimum safe operating perimeter set by local, state or national regulations. Pull back on this lever to raise the mast. Push this lever forward to lower the mast.

F10.LEFT JACK - UP/DOWN This lever controls the raising (extending) and lowering (retracting) of the left rear jack (levelling) cylinder.

Push this lever up to retract (pick up) the cylinder. Indicator light B4 will illuminate to confirm that the jack is fully retracted. Pull this lever down to extend (lower) the right rear jack cylinder.

F13.PROPEL DEAN PEDAL This optional foot pedal prevents the machine from being propelled unless the operator is at the operators station. Depress this pedal before operating the propel control levers (F2 or F3). Release this pedal after releasing the propel control levers (F2 or F3).

!

CAUTION

Do not use this pedal for stopping the machine. Serious damage to the propel components will occur.

Push this lever forward to retract (pick up) the cylinder. Indicator light B2 will illuminate to confirm that the jack is fully retracted. Pull this lever back to extend (lower) the left rear jack cylinder.

F14. THREAD GREASER Depress this optional pedal to spray lubricant on the drill pipe threads.

F11.FRONT JACK - UP/DOWN This lever controls the raising (extending) and lowering (retracting) of the front jack (levelling) cylinder. Push this lever up to retract (pick up) the cylinder. Indicator light B3 will illuminate to confirm that the jack is fully retracted. Pull this lever down to extend (lower) the front jack cylinder.

F12.RIGHT JACK - UP/DOWN This lever controls the raising (extending) and lowering (retracting) of the right rear jack (levelling) cylinder. D245S (hpil)

Controls and Operation - Page 2-19

Page 2-20

D245S (hpil)

DRILL OPERATION RECEIVER AIR PRESSURE GAUGE (A2)

GENERAL The following operating suggestions are offered as a reminder rather than as an attempt to instruct, since a machine of this size must not be entrusted to anyone except a fully trained and qualified operator.

B16 D4 D5 B17

Preparation Inspection and Adjustments Before operating the drill: • Read and understand the “Safe Operating Practices for Drillers” at the front of this manual. • Perform the “8 Hour or Shift Change Maintenance Checks” outlined in this manual. • Adjust the operator seat to provide a comfortable and safe operating position. STARTING THE ENGINE The engine will not start until: • •

All controls are in the "NEUTRAL" position. The battery disconnect switch is in the ON position DISCONNECT SWITCH

B18

B19

Step 1. ENGINE IDLE (D4) Step 2. COMPRESSOR LOW (D5) Step 4. IGNITION ON (B19) Step 5. HOLD BY (B18) and PUSH START (B17) ENGINE START-UP SWITCHES

2. Place the COMPRESSOR switch (D5) in the LOW position. 3. Alert others in the vicinity of the machine that the machine will be starting.

!!

WARNING

Do not inject a starting aid into air cleaners. Personnel injury can occur from exploding gases.

c245-27 4. If the outside temperature is below 32° F (0° C) depress ETHER button (B16) and hold for 3 seconds. 5. Insert the ignition key into the ignition switch (B19) and turn the key to the ON position. 1. Place the ENGINE SPEED switch (D4) in the IDLE position.

D245S (hpil)

6. Push the BY switch (B18) down and at the same time push in the START button (B17).

Controls and Operation - Page 2-21

Once the engine starts, release the START button (B17) but continue to hold the BY switch (B18) up until the RECEIVER AIR PRESSURE gauge (A2) reads 110 psi.

2. Move the compressor switch (D5) to LOW. 3. Set the engine speed switch (D4) to IDLE.

NOTE ! If the BY switch (B18) is released before 110 psi is achieved, the engine will shut down. Before trying to restart the engine, make certain that the pressure reading on the RECEIVER AIR PRESSURE gauge (A2) is at 0.

D4 D5

The engine should be at low idle (1200 rpm) on the engine tachometer (B9).

B19

B9 B10

Step 2. COMPRESSOR LOW (D5) Step 3. SPEED IDLE (D4) Step 5. IGNITION OFF (B19) MACHINE SHUTDOWN SWITCHES ENGINE RPM and WATER TEMPERATURE

4. Let engine run at "IDLE" for 5 minutes. Continue to run the engine at idle until the engine water temperature (B10) rises to a minimum of 180°F (82°C). NOTE ! Hydraulic oil can be warmed by retracting the loader (E5 pushed forward) and stalling the cylinder for no longer than 2 minutes at a time. During the winter months, a warm-up period may take as long as 15 minutes. Shutting Down the Machine When shutting the machine down at end of a shift or overnight try to position the machine on level ground. This will permit you to get an accurate reading on fluid levels before the machine is restarted for the next shift. 1. Make certain all controls are in "NEUTRAL".

5. After engine has idled for 5 minutes, turn key switch (B19) To "OFF". 6. Make certain all electric switches and radio (if equipped) are "OFF", so not to drain the batteries. 7. Remove keys from switch (if required by company), lock cab doors and put keys in a safe place. 8. Turn the battery disconnect switch to the “OFF” position.

Propelling the Machine (Tramming)

!!

WARNING

Exceeding the maximum incline limits can Page 2-22

D245S (hpil)

cause personnel injury or death. An alarm will sound in the operator’s cab when the pitch angle (front to rear) reaches 12° or when the roll angle (side to side) reaches 17°. If this alarm sounds - stop propelling the machine and determine if it is safe to continue.

!!

WARNING

Before tramming the drill: • Determine if propelling should be done with the mast in the drilling position (vertical), or stowed for longer distance or transporting position (horizontal). • Remove all drill pipe if tramming for long distances. • Fully retract the drill pipe loaders. • Refer to the topics on “Lowering the Mast” and “Propelling to the Next Hole”.

5m (15 ft.)

1. Check the surrounding area that you will be propelling in for any obstacles.

2. Place the DRILL/PROPEL switch (F7) in the PROPEL mode.

3. Place the ENGINE SPEED switch (D4) in the RUN position. 5m (15 ft.)

NOTE ! The engine needs to be at 1800 rpm for tramming.

4. If equipped, depress the DEAN pedal (F13). The DEAN switch releases the tram brakes and must be depressed at all times during tramming and released when the propel controls are returned to the NEUTRAL position.

5. Push or pull the propel controls (F2 and F3) as required. Propel speed is determined by how far forward or back the levers are positioned during propelling. Propelling this machine is typical of propelling in D245S (hpil)

While propelling, it is forbidden to be in the propelling area. PROPELLING DANGER ZONE

any track driven machine: •

Push both controls (F2 and F3) forward an equal amount to propel straight forward.

•

Pull both controls (F2 and F3) back an equal amount to propel straight in reverse.

•

Position one control ahead of the other in the same direction to obtain a large radius turn.

Controls and Operation - Page 2-23

!!

WARNING

F3 F2

D4

245-57 12° 21%

F7

22° 40%

F13

PROPEL SWITCHES

•

Counter-rotate (one track forward one reverse) the tracks to make a pivoting turn.

! CAUTION CAUTION Do not stop the machine by using the DEAN switch (F13) as a brake.

17° 30%

6. When propelling has been completed, return the controls (F2 and F3) to the NEUTRAL position and release the DEAN switch (F13). With the dean switch released push the tramming controls forward and back to check that the switch is properly functioning. Also, check the emergency stop button to check that it too is functioning. 17° 30%

Never exceed the maximum inclination angles when parking, drilling or propelling. MAXIMUM MAST UP INCLINATION ANGLES Page 2-24

D245S (hpil)

Levelling the Machine

!!

WARNING

Before drilling, the weight of the machine must be firmly ed by the machine’s levelling jacks. The machine should be raised only enough to lift the crawlers off of the ground. Before lowering the jacks ensure that the jack pads will touch down on firm ground that will remain stable while drilling. Level the machine as follows:

25° 46%

1. With the engine running, set the ENGINE SPEED switch (D4) in the RUN position. 245-58

2. Pull back on the LEFT JACK and RIGHT JACK control levers (F10 and F12) until the jacks raise the crawlers off of the ground. Using the LEVEL (F8) adjust for the side to side levelling.

19° 34%

22° 40%

D4

22° 40%

F10 F11 F12

Never exceed the maximum inclination angles when parking, drilling or propelling. MAXIMUM MAST DOWN INCLINATION ANGLES

F8

Step 1. ENGINE SPEED RUN (D4) Step 2. REAR JACKS DOWN (F10 & F12) Step 3. FRONT JACK DOWN (F11)

LEVELING THE MACHINE

D245S (hpil)

Controls and Operation - Page 2-25

3. Pull back on the FRONT JACK control lever (F11) until the LEVEL (F8) indicates that the machine is level front to rear.

B7 B8

4. Continue to alternately raise or lower the jacks to obtain the lowest possible height consistent with good drilling clearance. E7

Raising the Mast

!

DANGER

F9

Operating near or ing a power line with any part of the machine can result in electrocution. Do not raise the drilling mast or operate the machine in the vicinity of electrical power lines without checking the minimum safe operating perimeter set by local, state or national regulations. Step 1. UNLOCK PINS (E7) Step 2. RAISE MAST (F9) Step 3. LOCK PINS (E7)

Before raising the mast check the following: • • • •

• •

The mast will not any overhead powerlines. The jack cylinders are deployed and the machine is levelled on firm ground. All equipment is secured firmly in the mast and will not fall. That the drill pipe has been retracted to a point where the drill bit is just below the mast table. The mast-side cab door is closed. The operator remains in the cab and any helpers maintain a 50 ft. (15 m) distance from all sides of the machine.

Raise the mast as follows: 1. Pull back on the MAST control lever (E7) to “UNLOCK” (retract) the mast locking pins. Indicator B7 will illuminate to confirm that the pins are fully retracted.

MAST RAISING

3. Push forward on the MAST control lever (E7) to “LOCK” the mast into position. Indicator (B8) will illuminate when the pins are engaged (extended).

Lowering the Mast

!

DANGER

Operating near or ing a power line with any part of the machine can result in electrocution. Do not lower the drilling mast or operate the machine in the vicinity of electrical power lines without checking the minimum safe operating perimeter set by local, state or federal regulations Before lowering the mast check the following:

2. Pull back on MAST control lever (F9) to the UP position and slowly raise the mast to the desired angle.

• •

NOTE ! The mast locking lugs are spaced at 5° increments. Page 2-26

•

The mast will not any overhead powerlines. The outside loader is retracted and indexed to a mid position to prevent pipe from falling out. The inside loaders are retracted. D245S (hpil)

stowing the mast. Indicator (B8) will illuminate when the pins are engaged (extended). B7 B8

DRILLING

!!

E7

WARNING

While drilling, it is forbidden to be in the drilling area. F9

Step 1. UNLOCK PINS (E7) Step 2. RAISE MAST (F9) Step 3. LOCK PINS (E7) MAST LOWERING

•

• •

That the drill pipe has been raised to a point where the drill bit is just below the mast table. The mast-side cab door is closed. The operator remains in the cab and any helpers maintain a 50 ft. (15 m) distance from all sides of the machine.

Lower the mast as follows: 1. Pull back on the MAST control lever (E7) to “UNLOCK” (retract) the mast locking pins. Indicator B7 will illuminate to confirm that the pins are fully retracted.

8m (25 ft.) DRILLING DANGER ZONE

2. Push forward on the MAST control lever (F9) to the “DOWN” position and slowly lower the mast to the desired angle if not stowing the mast. NOTE ! The mast locking lugs are spaced at 5° increments. 3. Push forward on the MAST control lever (E7) to “LOCK” the mast into position if not D245S (hpil)

Adding Drill Pipe - Inside Loader The following procedure was written with the assumption that the starter section of drill pipe has been drilled and that additional drill pipe is required. 1. Switch “OFF” the LUBRICATOR (D6), WORKING AIR (E8), and the DUST COLLECTOR or WATER INJECTION (E5). 2. Push the FEED control (F1) forward to the Controls and Operation - Page 2-27

“UP” position and raise the rotary head high enough to enable the holding wrench to engage on the drill pipe flats. 3. If necessary, rotate the drill pipe to align the flats on the drill pipe with the holding wrench before pushing the WRENCH control (E6) to the “IN” position and engaging the holding wrench.

Be sure that the rotary head is raised fully to the top of the mast before swinging the loader. Failure to do so will damage the rotary head, top sub, or loader. 6. Pull the LOADER control (E3 or E4) and fully LOAD (swing) the loader in under the rotary head until it stops. 7. Push the ROTARY control (F2) to set the speed at 40 rpm's (as shown on HEAD SPEED gauge B1).

F3 E6

F2

! CAUTION CAUTION

E8

C2

E5

B1

F1 F3 D6 F2

E3 E4 E6

F1 E5

F5 Step 1. WORKING AIR OFF (E8) Step 2. RAISE FEED (F1) Step 2. WRENCH IN (E6) Step 4. UNTHREAD PIPE (F2) Step 5. RAISE FEED (F1 & F3) Step 6. SWING LOADER IN (E3 or E4) ADDING DRILL PIPE (INSIDE LOADER) F14

4. Pull back on the ROTARY control (F2) so that the top adaptor starts to thread off of the drill pipe. NOTE ! If the top adaptor does not start to unthread, increase the rotation torque (F5). If this is utilized, once the top sub is unthreaded from the drill pipe, reset the rotation torque back to the drilling setting. 5. Push FEED control (F1) forward and pull back on the FEED control (F3) to raise the rotary head to the top of the mast.

Page 2-28

Step 7. HEAD SPEED (F2) Step 8. V-BLOCK - IN (C2) Step 9. LOWER FEED (F1) Step 10. RAISE FEED (F1) Step 12. RETRACT LOADER (E3 or E4) Step 13. GREASE THREADS (F14) Step 14. LOWER FEED (F1) Step 15. COUPLE TS (F2 & F1) Step 17. WRENCH - OUT (E6) Step 18. V-BLOCK - OUT (C2) ADDING DRILL PIPE (INSIDE LOADER) cont’d

8. Push up on the V-BLOCK control lever (C2) to hold the drill pipe in place. D245S (hpil)

! CAUTION CAUTION Excessive rotary head down pressure during t coupling can damage pipe threads. “Feather” the FEED control and stop feeding when ts begin threading. 9. Pull back on FEED control (F1) and slowly begin to lower the rotary head. Begin threading the top sub to the drill pipe that is in the loader.

not over-torque the pipe threads. 17. Pull back on WRENCH control (E6) and retract the wrench.

! CAUTION CAUTION Drilling with the V-block “IN” (extended) will damage the V-block and/or the rotary head. Always be sure to position the V-block lever in the “OUT” position before drilling.

As this is happening, watch the ROTATION PRESSURE gauge (A3) and when the gauge reading increases, stop the rotation.

18. Pull down on the V-BLOCK control lever (C2) to retract the V-block “OUT”.

10. Push the FEED lever (F1) forward to lift the drill pipe up out of the loader’s bottom pocket.

Returning Drilled Pipe - Inside Loader The following procedure was written with the assumption that drilling to the required depth has been completed and that one or both pieces of drill pipe were removed from the loaders.

11. Push the ROTATION lever (F2) forward to rotate the drill pipe to align the top of the drill pipe flat with the opening in the loader. This will permit the loader to swing out from under the rotary head. 12. Push the LOADER control (E3 or E4) and fully swing the loader (RETRACT) until it stops. 13. If equipped, depress the THREAD GREASER pedal (F14) to spray thread grease on the drill pipe threads. 14. Pull FEED control F1 to the “DOWN” position and lower the drill pipe down over the drill pipe in the table.

! CAUTION CAUTION

1. Retract the drill string by pushing the FEED lever (F1) to the “UP” position until the pipe flats reach the holding wrench area. 2. Turn “OFF” the DUST COLLECTOR or WATER INJECTION (E5) and WORKING AIR (E8). 3. Place the COMPRESSOR AIR PRESSURE switch (D5) in the “LOW” position. 4. Lift the V-BLOCK lever (C2) to the “IN” position to deploy the pipe centralizer.

Lowering (feeding) the drill pipe sections together will damage the pipe threads. 15. When the drill pipe is down over the threads, push the ROTARY control lever (F2) forward and simultaneously lower (F1) the drill pipe down stopping the feed when there are 3 threads showing. 16. Continue rotation of the drill pipe and as this is happening, watch the ROTATION PRESSURE gauge (B1) and when the gauge reading comes to the set pressure, stop the rotation. Do D245S (hpil)

Controls and Operation - Page 2-29

! CAUTION CAUTION Be sure that the rotary head is raised fully to the top of the mast and the drill pipe is properly aligned before swinging a loader. Failure to do so could damage these mechanisms.

C2

9. Pull a LOADER control (E3 or E4) to swing “LOAD” the loader in under the rotary head until it stops.

E6 F1

F2

E5

E8 D5

10. Lower the drill pipe into the loader pod by pulling the FEED lever (F1) to the “DOWN” position. 11. Pull back on the ROTARY lever (F2) and break the connection.

! CAUTION CAUTION Step 1. RAISE DRILL PIPE (F1) Step 2. WATER/DUST COLLECTOR WORKING AIR - OFF (E5 & E8) Step 3. COMPRESSOR AIR - LOW (D5) Step 4. V-BLOCK - IN (C2) Step 5. HOLDING WRENCH - IN (E6) Step 6. BREAK PIPE T (F2) RETURNING DRILL PIPE TO THE INSIDE LOADER

5. Rotate the pipe (F2) if necessary to align the flats of the drill pipe before deploying the HOLDING WRENCH with lever E6 “IN”. 6. Pull back on the ROTARY lever (F2) so that the drill pipes break at the t and start to unthread. Continue to unthread the pipes. NOTE ! If the drill pipes do not break refer to the topic “Using the Tong” in this section.

Lowering the rotary head with the V-block “IN” (extended) will damage the V-block and/ or the rotary head. Always be sure to position the V-block lever in the “OUT” position before lowering the rotary head. 12. Push the V-BLOCK control (C2) down (OUT) to retract this assembly. 13. Push the FEED lever (F1) to fully raise the rotary head to the top of the mast. 14. Push the LOADER lever (E3 or E4) to “RETRACT” the loader fully out. 15. Retract (“OUT”) the holding wrench (E6) and lower the rotary head and repeat the preceding steps until both pipes are out of the ground and placed in the loaders.

7. Push forward on the FEED lever (F1) to raise the rotary head to the top of the mast. 8. If necessary, rotate the pipe until the flats on the drill pipe will enable the pipe to be loaded into the loader. Page 2-30

D245S (hpil)

POWERTONG CONTROLS C4 C2 C5 C6

F1

F2

E6 E3

TONG CONTROL E8 D5

E2

Step 7. RAISE DRILL PIPE (F1) Step 9. SWING LOADER - LOAD (E3 or E4) Step 10. LOWER PIPE (F1) Step 11. BREAK PIPE T (F2) Step 12. V-BLOCK - OUT (C2) Step 13. RAISE ROTARY HEAD (F1) Step 14. RETRACT LOADER (E5) Step 15. HOLDING WRENCH - OUT (E6)

4. Signal to the helper to remove the wrench. RETURNING DRILL PIPE TO INSIDE LOADER (cont’d)

5. Push the TONG lever (E2) to retract the cylinder and prepare for the next deployment. Using the Tong(s)

6. Signal to the helper to stand out of the drilling area.

If the drill pipe does not break by reversing the rotation, the tong or power-tong must be used as follows:

POWER-TONG

TONG

1. Deploy the holding wrench onto the drill pipe wrench flats if not already done.

1. Deploy the holding wrench onto the drill pipe wrench flats if not already done. 2. Signal to a helper to swing the wrench into place. 3. Pull back on the TONG lever (E2) to break the pipe t.

2. Lift lever C4 up to swing the wrench into place. 3. Pull down on the CLAMP lever (C5) to secure the tong to the drill string. 4. Lift up on the BREAK lever (C6) to twist the drill string and break the t. 5. Lift up on the CLAMP lever (C5) pull down

D245S (hpil)

Controls and Operation - Page 2-31

on BREAK lever (C6) and pull down on SWING lever C4 to prepare for the next break.

Propelling to the Next Hole With all the drill pipe placed into the loader(s) prepare the machine to move to the next drill hole as follows:

3. Position the mast in the horizontal position (refer to the topic “Lowering the Mast”. 4. If lifting the machine, refer to the technical data plate to determine the machine’s weight (GVW). Lifting points (4 places) are marked on the machine.

1. Push up on the CURTAIN control lever (C1) to raise (“UP”) the dust curtain.

5. If propelling the machine onto a truck, refer to the “Propelling the Machine” topic before loading the drill onto the trailer.

2. Position the DRILL/PROPEL mode selector switch (F7) to the “PROPEL” position.

6. Shutdown the machine as described in the topic “Shutting Down the Machine”. 7. Turn the battery disconnect switch to the “OFF” position and remove the key. BATTERY DISCONNECT SWITCH

C1

245-27

F7

8. Using suitable chains and hold-downs, chain the rear of the machine down as shown and chain the front in a similar manner.

3. Refer to the topic “Propelling the Machine” in this section.

245-60

LIFTING and TRANSPORTING the MACHINE The following procedures are to be used as a guide. The equipment you have and the regulations for lifting and transporting this type of equipment will vary. 1. Clean the machine to remove any rocks or dirt that might dislodge during transporting. 2. Index the loader a half turn to prevent drill pipe from sliding out. Page 2-32

DUST SUPPRESSION SYSTEMS General Two types of dust suppression systems are D245S (hpil)

DRIVE MOTOR (HYDRAULIC) BLOWER FILTER BACKFLUSHING MODULE

CLEAN AIR DISCHARGE

WORKING AIR FROM COMPRESSOR

BACKFLUSHING PRESSURE REGULATOR

DUST LADEN AIR

BURST of FLUSHING AIR FILTER

TABLE BUSHING

TABLE DUST CURTAIN

CUTTING DEFLECTOR

DUST

ROCK CHIPS

245-56

available on this machine; dust collector and water injection.

when damp conditions exist. Doing so will damage the dust collector elements.

Dust Collector

Operate the dust collector as follows:

A hydraulic motor driven exhauster fan draws up dust laden working air from around the drilled hole. A dust curtain surrounds the hole and dust is sucked into a separator where large particles are dropped out of the side. Finer dust is drawn to filter elements inside the dust collector where timed air blasts (3 to 6 seconds apart) dislodge the dust and exhaust it (pressure regulator set at 50 psi (3.5 bars) from the collector.

1. Push up on CURTAIN lever (C1) to lower the dust curtain.

! CAUTION CAUTION Never operate the dust collector system D245S (hpil)

Controls and Operation - Page 2-33

Step 1. CONTROL ON (E5) Step 2. VARY FLOW (F6) DUST COLLECTOR CONTROLS

E5

C1

E5

2. Push forward on EXHAUSTER/WATER lever (E5) to start the dust collector.

F6 WATER INJECTION

3. After the drilling cycle is completed, position control (E5) in the “neutral” position and raise the dust curtain (C1).

Water Injection Use only clean water to refill the tank. Flush points may be added to the water supply during cold weather to prevent freezing.

trol lever (E5) to the neutral position to purge the working air lines of water. This practice prevents freeze-up during cold weather. WINCH The winch is used to lift accessories on and off of the work deck. Before any lifting operations begin, rope off the lifting area to ensure that everyone is aware of the lifting about to take place.

At shutdown, turn off the valve in the suction line and operate the pump for at least one minute to purge the system of water. WINCH CONTROLS

This procedure was written with the assumption that drilling has begun. E1

1. Pull back on the EXHAUSTER/WATER control lever (E5) to begin injecting water into the working air. . 2. Turn WATER CONTROL knob (F6) to vary the amount of water being injected. NOTE ! Erratic or diminishing water flow indicates a clogged strainer. 3. Once the desired drilling depth has been reached, push the EXHAUSTER/WATER conPage 2-34

TOWING The following instructions are for moving a disabled machine for a short distance, only a few yards (meters), at a low speed, 1.2 mph (2 km/ h). D245S (hpil)

!!

WARNING

Personal injury or death could result from improperly towing a machine. Shielding must be provided on the towing machine to protect the operator if the tow line (wire rope) should break. All the different situation requirements cannot be given, so always consult your dealer if questions arise. 1. Thoroughly clean the area around the crawler final drives including the track shoes positioned above the final drive. Block the tracks to prevent the machine from free rolling.

6. ring gear (1) in place and loosen the remaining two cover bolts (2). Using a hammer and wedge, separate cover (4) from ring gear (1). 7. Remove twelve bolts (3) and ring gear (5) from final drive cover (4). 8. Install final drive cover (4) using all of cover bolts (2). 9. Fill the final drive with clean oil of the type specified in Section 3. 10. Repeat this procedure to the remaining final drive.

ELECTRONIC DEPTH COUNTER (EDC) 2. Allow the final drive oil to cool before draining the oil from both final drives into a suitable container (refer to Section 4G of this manual). 3. Remove all but two of the twenty final drive cover bolts (2). NOTE ! Do not leave a bolt in the top hole of cover (4).

General This system has been made around a multifunction counter which displays bit position, bitdistance-from-bottom of hole, accumulated hole depth and penetration rate. The counter has one 6-digit red led-display to show one display at a time. Different displays can be selected with push buttons on the counter at anytime. The counter can be set to display all the data either in International units (meters, m/min) or English units (foot, ft/min). Component Descriptions

245-55 The following components are used in the EDC system:

4. Insert an alignment dowel or other suitable tool through the top hole of the final drive cover to ring gear (1) while removing cover (4). 5. Remove one track shoe to provide access to the parting face between cover (4) and ring gear (1). D245S (hpil)

DC/DC CONVERTER The converter switches 24 volts DC down to 12 volts DC. The 12 volt DC voltage is needed for the counter, optical encoder, * holding wrench proximity switch and warning buzzer. The DC/ DC converter output ground is the same as the input ground. The maximum 12 volt current of the EDC should be less than 1 amp.

HOLDING WRENCH PROXIMITY SWITCH This proximity switch has a nominal 10 mm Controls and Operation - Page 2-35

sensing distance. It is a Normally Open (NO) type switch. It is connected and mounted so that it is normally open when the holding wrench is not engaged. When the holding wrench is engaged the circuit is closed. The supply voltage for the proximity switch is 12 volts DC. When the holding wrench is engaged the bit position counter is stopped at that position. When the wrench is disengaged the bit position counter will follow the movement of the rotary head gearbox.

OPTICAL ENCODER The encoder is mounted beside the timing shaft with a specific gear ratio sprocket and chain. The encoder supplies two signals to the counter which determines the distance, speed and direction from these signals. Bit position is increased when the rotary head is moving down. If the bit position counter counts in the wrong direction, the A and B signal can be swapped from counter terminals no. 11 and 12.

ROTARY HEAD UP PROXIMITY SWITCH The rotary head proximity switch has a 10 mm sensing distance. It is a Normally Closed (NC) type switch. When the rotary head is moved to a higher position the sensing plate mounted in the feed system opens the sensor output. The proximity switch is connected to the pipe in the hole warning circuit so that the closed output will produce a warning signal if jack or mast control levers are moved.

PRESSURE SWITCH This pressure switch is mounted on the lower stacker valve to sound the alarm if the leveling jacks or mast raising control levers are operated. The pressure switch is an adjustable type preadjusted to switch “ON” at 900 PSI. The switch is connected to the pipe in the hole warning circuit as Normally Open (NO) switch. If either the jack or mast control levers are operated, the activated output will allow the warning devices to activate the alarm if the bit position is greater than the PRESET warning depth setting or the rotary head is not in the proper position. Page 2-36

CONTROL RELAY The control relay is used on the warning circuit because of different voltage levels used on the indicator light and buzzer. Also, the load level would exceed the proximity switch rating.

BUZZER The buzzer is solid state electronics which automatically adjusts its own volume up or down maintaining a minimum of 5dB (A) above environmental noise level. Sound level ranges from 82dB thru 103dB. Indicator and Key Descriptions KEY 1 - PRESET HOLE DEPTH The preset hole depth feature on the counter is an indicator to advise the driller when he has drilled to a predefined depth. The preset hole depth is the depth from ground level to the bottom of the hole. The operator should reset the bit position (actual hole depth) counter for proper operation starting at ground level. An indicator light will indicate when the drill bit reaches the preset hole depth. The light will stay ON as long as drill bit position is greater than preset measurement. The preset hole depth can be changed anytime before or after drilling has started. The preset hole depth can be defined with an accuracy in centimeters (meters with two decimals).

KEY 2 - PRESET WARNING DEPTH This is the depth used for the warning system. It is factory set to provide maximum bit position measurement without sounding the alarm. The warning signal is given if the bit position measurement is larger than the setting of the preset warning depth or the rotary head position is too low. It is recommended to set the hole depth before starting to drill. The operator can set hole depth from the counter keyboard. To view an old Preset Hole Depth measurement: Press key # 1 (PRESET HOLE DEPTH)

D245S (hpil)

The old preset hole depth is displayed as long as the key is pressed and for 10 seconds after key is released. The LED on the PROGRAM key will light when ever a preset is displayed. To program a new Preset Hole Depth measurement: 1. Press the PROGRAM key. The Led on the Program key will flash. The main display is not affected.

depth is displayed. 3. To enter a new measurement for the hold depth will require two 0’s to be entered after the new measurement is entered. For example, to enter a preset depth of 25 ft. will require 2, 5, 0 and 0 to be entered for English models. For metric models the two 0’s would be entered unless the measurement required did contain a two place decimal. If the measurement required only 7 meters, 7, 0 and 0 would be required to be entered to cover the decimal places.

2. Press key # 1 (PRESET HOLE DEPTH). The Current measurement for the preset hole

KEY 6 -BIT POSITION DISPLAY Before drilling a new hole the bit position counter should be reset. This requires that the drill bit be set on the ground and the counter reset as follows:

position counter is now reset.

1. Press RESET key. The main display will begin to flash. This flashing is to indicate to the that the bit position counter can be reset.

The system will automatically take care of correct bit position if drill pipe is added. The bit position will stop counting when the holding wrench is engaged. Not applicable for D90KSP machines.

2. Press key # 6 (BIT POSITION). The bit D245S (hpil)

If the RESET key has been pressed accidently, the may wait 10 seconds for the unit to clear the flashing without affecting the counters.

Controls and Operation - Page 2-37

NOTE! The bit position is displayed in meters with two decimals.

KEY 7 - BIT-DISTANCE-FROM-BOTTOM-DISPLAY Distance form bottom display indicates how far the drill bit is from the bottom of the hole. If the drill bit is raised from the bottom of the hole, the display will automatically switch to display this distance. If the bit is lowered back to the bottom, the display will switch back to “bit position” display. When retracting from the hole, the counter is normally showing the distance form bottom display. Another display can be selected at anytime. The distance from bottom display is switched automatically only once. The distance from bottom display will naturally show the hole depth measurement when the drill bit is raised back to ground level. The distance from bottom display will be reset automatically at the same time as the bit position counter will be reset. If the operator wants to reset the distance from bottom, he can use the same procedure shown as for bit position above, except press key # 7 (DISTANCE FROM BOTTOM) instead of key # 6 (BIT POSITION).

KEY 8 - ACCUMULATED DEPTH DISPLAY Accumulated hole depth records the hole depth drilled since the last reset. This allows the to use this counter as a record of shift, week or month for total hole depth drilled. The accumulated hole depth is updated each time that “distance from bottom” measurement is equal to zero. If using the accumulated depth counter as hole depth counter, the has to reset the accumulated depth counter separately after every hole. To RESET the accumulated depth counter: 3. Press RESET key. The main display will begin to flash. This flashing is to indicate to the that the counter can be reset. 4. Press Key # 8 (ACCUMULATED DEPTH). Page 2-38

This will reset the accumulated depth counter.

KEY 9 - PENTRATION RATE DISPLAY The penetration rate is displayed in meters or feet per minute and it is updated every half second. The penetration rate is displayed with one decimal number.

PIPE IN THE HOLE WARNING INDICATOR This push to test type indicator light is connected to the control relay which is controlled by the warning circuit. The test push button will control the control relay voltage so it will test the relay at the same time as the warning devices. The counter is equipped with an indicator light and warning buzzer to help in preventing the machine from being moved with the drill pipe still in the hole.

! CAUTION CAUTION This system only warns the operator if the drill pipe is in the hole, if the operator tries to operate any jack control level either up or down, or the mast control level either up or down, or the mast control level either up or down. The pipe in the hole warning light and buzzer will operate only if the operator tries to raise or lower the jacks and/or raise or lower the mast. No warning will be given unless the jack or mast controls are operated. The machine can be moved with the drill pipe still in the hole if the jack or mast controls are not operated before trying to propel the machine. NOTE ! D90K-SP single machine has the optional tram lock interface which disconnects the power from tramming circuits if the rotary head position is too low.

PRESET HOLE DEPTH LIGHT INDICATOR Indicator light is connected to the counter output number 1. When the counter bit position is D245S (hpil)

greater than the preset hold depth the indicator light will be lit.

wrench. The electric signal from the proximity switch is connected to counter terminal number 10.

Viewing Bit Position, Distance From Bottom, Accumulated Depth And Penetration Rate To view the bit position, hole depth and accumulated depth, or penetration rate proceed as follows: 5. Press key # 6 (BIT POSITION) to view bit position. 6. Press key # 7 (DISTANCE FROM BOTTOM) to view present distance from bottom of the hole. 7. Press key # 8 (ACCUMULATED DEPTH) to view accumulated depth. 8. Press key # 9 (PENETRATION RATE) to view penetration rate. The counter will show the latest display until another display is selected. The LED indicators on the right side of the display indicate which display is on. Distance from bottom display is switched automatically on display when the drill bit is raised from the bottom of the hole. The bit position is resumed when the drill bit is lowered back to the bottom of the hole. Tests When the system has been installed and programmed the following test routines will be needed to confirm that the counter operates properly. There is no special calibration required as these tests are only to ensure that programming is correct for the respective machine models and the counter and its installation are OK.

BIT POSITION COUNTING When the holding wrench is engaged the bit position counter display should remain at its present display. When disengaging the wrench, the bit position counter should resume counting. If this is not happening, check the proximity switch mounting and sensor on the holding D245S (hpil)

PROPER COUNTING DIRECTION The positive bit position counter measurement should increase when the rotary head is moved down and decrease when moved up. If the counter is counting in the wrong direction, swap the optical encoder signal wires from counter terminal numbers 11 and 12.

BIT POSITION COUNTER Bit position display is always following bit and rotary head movement. To check the bit position counter you have to know the actual length of the feed stroke. Reset the bit position counter when the rotary head is completely at the top of the stroke. Run the rotary head down and check the bit position counter measurement. It should equal the measured feed stroke (meters or feet). If the error is more than an inch or maximum of two, repeat the measurements and check the programming for that type machine and model. Different kind of feed chains (not standard), sprocket or timing shaft can require a change to the programmed values. PENETRATION RATE DISPLAY Penetration rate display is showing feet/minute or meters/minute depending on destination (country). Display is with one decimal accuracy.

FEED / MINUTE

METERS / MINUTE

1

0.3

2

0.6

3

1

5

1.5

10

3.0

20

6.0

Lower the rotary head down at a constant speed and check to see that the penetration rate disControls and Operation - Page 2-39

play is showing properly. A 30 feet stroke is 10 meters, so if drilling down 30 feet in one minute with constant speed it would equal about a 10 meters/minute penetration rate. Try to drive the rotary head distance in a half minute or in one minute to make calculations easier.

Speed Display Update Time

0.5 seconds

Display

6-digit, 0.56” red LED display

Front

4 LED status indicator 14-key membrane switch keyboard Splash proof polyester overlay 32 to 132 F, operating -40 to 160 F, storage

Environment

ACCUMULATED DEPTH Accumulated depth will be increased every time the rotary head is moved down and distance from bottom display equals zero (0). This means that the drill bit is at the bottom of the hole. Otherwise the accumulated depth should work the same way as bit position. It has its own programming measurement, so it should be tested to insure that it counts distance correctly.

PRESET HOLE DEPTH The unit is equipped with an indicator light for preset hole depth. Program some measurement to the preset hole depth (see instructions) and test to see that the indicator light works properly. An indicator light will indicate when the drill bit reaches the presetted hole depth. The light will stay ON as long as drill bit position is greater than the preset measurement. The preset hole depth light is connected to counter output terminal number 27 and the other side of light to the ground. Terminal number 28 is connected 24 volt.

EDC SPECIFICATION Counter Range

-9999.99 to +9999.99 meters or -9999.99 to +9999.99 feet

Presets

One, 6-digit preset -9999.99 to +9999.99 meters or -9999.99 to +9999.99 feet

Counting

Quadrature X4

Counts

10095 pulses/meter (D90K-SP) 7318 pulses/meter (D90K) 7610 pulses/meter (D75K) 10978 pulses/meter (D40K/D50K) 15857 pulses/meter (D245S)

Speed Range

Page 2-40

0.00 to 113.00 meters/min (D25) 0.00 to 246.00 meters/min (D90)

DIP Switches

1 = OFF 2 = ON 3 = OFF 4 = ON 5 = OFF 6 = OFF

I/O Terminals Used

10 = Stop counting 11 = Signal A 12 = Signal B 13 = Ground 15 = Power voltage, +12 V power 16 = Power voltage, ground 24 = Output 2 NO 25 = Output 2 common 27 = Output 1 NO 28 = Output 1 common

PIPE IN THE HOLE WARNING LIGHT and BUZZER The test button will test the wiring and the function of those warning devices. The counter compares the bit position measurement and the preset warning depth. If the pressure switch (mounted on the lower stacker valve) is pressurized to 900 PSI this will activate the alarm. The same warning circuit can be activated if the rotary head gearbox is lowered too low in the mast. The proximity switch and its sensing plate have been mounted in the mast so that the first pipe with the drill bit has to be above ground level to eliminate the alarm. The proximity switch and the counter have been connected parallel in the warning circuit so that if either of the circuits detect improper drill position the alarm will be activated.

DRILL MONITOR SYSTEM (DMS) The Drill Monitor System provides warning signals to the operator or automatically shuts down the machine (for critical out-of-limit conditions) in the event that the monitored conditions are D245S (hpil)

not within safe limits. The system is provided with a thirty second delay for start up, a system test push button, audible alarm, and a "first out" indication for shut downs.

NOTE ! Engine oil and coolant temperatures are also monitored by the engine electronic control module (ECM).

There are three different levels of fault sensing: Level 1. Flashing amber light. Level 2. Flashing amber light and audible alarm. Level 3. Flashing red light, audible alarm, and machine shutdown.

L E V E L 1

Compressor Air Filter Engine Air Filter

Engine Coolant Level

Fuel Level

Compressor Separator

LAMP

The audible alarm can be silenced at any time by means of a silence push button. The light will continue to flash until the fault condition is cleared. Only one level three fault will be indicated at any one time (first out). This will allow the cause of the shutdown to be easily determined. Level three faults can be converted to alarm only, if desired, by an external wiring change. The items monitored are: Level 1 Compressor air filter pressure Engine air filter pressure Fuel level Alternator charging Engine radiator coolant level Air/oil separator pressure differential Level 2 Hydraulic oil level Hydraulic oil temperature Hydraulic oil filter pressure Engine oil temperature

Level 3 Compressor discharge temperature Compressor inter-stage temperature Compressor oil pressure Engine coolant flow D245S (hpil)

L E V E L 2

Alternator

ALARM

TEST SILENCE

Hydraulic Oil Level Hydraulic Oil Temp. Hydraulic Oil Filter

ALARM Engine Oil Temperature

Power On

L E V E L 3

Compressor Air Temp. Compressor Oil Pressure Compressor inter-stage F°

Engine Coolant Flow

There are a total of sixteen items sensed. All Level 3 sensors are normally closed to ground under normal operating conditions. An open circuit will cause machine shutdown. The alternator charging warning is activated by a voltage of less than 10 volts at the alternator “R” terminal. SYSTEM OPERATION In the event of a machine shutdown, after the problem is rectified, it is necessary to turn off the key switch at the start momentarily to reset the system and restart the 30 second time delay to start the engine. The system operation should be checked once per shift by turning on the key switch and waiting 30 seconds to that a shutdown fault is indicated and that the fuel system is de-energized. Controls and Operation - Page 2-41

NOTE ! The click of the shutdown relay (SDR) s and the fuel system should be audible both ON and OFF (DMS pins 20 and 21). Periodically a more comprehensive test should be made to that the sensors actuate at the proper settings and that disconnecting or grounding (depending on whether the sensor is normally open or normally closed) a sensor will indicate a fault.

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D245S (hpil)