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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:

Indicates a hazardous situation which,


! DANGER if not avoided, will result in death or serious injury.

Indicates a hazardous situation which,


! WARNING if not avoided, could result in death or serious injury.

Indicates a situation which, if not avoided,


CAUTION 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.
11-06

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, physi-
cally fit and if required, licensed.

Assign specific crew members 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, regula-
tions 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 members of the drilling crew or personnel in the area
where the drill is operated should be familiar with first aid and Cardiac Pulmonary Resuscitation.

Contact the utility companies for the exact location of underground transmission lines in the drilling area.

The Operators 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 iii


11-06

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 oper-
ating.

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 users of the drill.

iv
11-06

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 passenger compartment.

The operator should treat all power lines as live.

Safe Operating Practices for Drillers v


11-06

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 members 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
11-06

Operating Precautions

Operating near or contacting 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 mini-
mum safe operating perimeter set by local, state or federal
regulations.

Raising or lowering the mast, and drilling with an unsupported 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 supported and leveled by the lev-
eling 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 (hori-
zontal) 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 vii


11-06

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 sys-
tems 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 seri-
ous 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 peri-


ods of time. If not properly released before maintenance
people attempt to work on the hydraulic system, this pres-
sure 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.

viii
11-06

Carelessness in getting on and off equipment can result in seri-


ous 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 contact 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 operators 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 blow-
out preventers and safety equipment required by law or as recommended in the American Petroleum Institute's doc-
ument API 54.

Safe Operating Practices for Drillers ix


11-06

Check all machine ignition points (engine block, exhaust manifolds, mufflers, turbo-chargers, etc...) to make sure they
are not in contact 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 tempera-
tures above 160 F (71 C).

The anti-freeze compound (methanol) used in the air line anti-ice systems is flammable. Refill the system with com-
pound 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.

x
11-06

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 Prac-
tices 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 per-
sonnel 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.

MANAGEMENTS 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 supports.

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 loca-
tions 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 xi


11-06

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 calcu-
late lightning proximity.

The FLASH BANG method is determined by counting the seconds between the visible lightning and the sound of thun-
der. 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 per-
form 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 supports.
Understand that the mast in a vertical position with drill pipe in the ground is capable of attracting high volt-
age lightning.

NOTE !
If the operator and machine are inside or near a blast area follow procedures written in USA Federal Metal and Non-
metal 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.

xii
11-06

Equipment operators shall secure the machine, close doors and windows, leave the machine cabin and dismount
the machine in a proper 3 point contact 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, remember 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 contact 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 xiii


11-06

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)

xiv
TABLE OF CONTENTS

SAFE OPERATING PRACTICES FOR DRILLERS . iii Fire Suppression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii GENERAL PICTOGRAMS . . . . . . . . . . . . . . . . . . . . . . . . .2-3


Management's Responsibilities . . . . . . . . . . . . . . . . . . . . . . .iii
The Operators Responsibilities . . . . . . . . . . . . . . . . . . . . . . .iii DANGER, WARNING and CAUTION DECALS . . . . . . . . 2-3
Operator's Safety Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . v General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3
Planning the Job . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vi
Operating Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii OPERATORS STATION A PANEL . . . . . . . . . . . . . . . .2-7
General Maintenance Safety Practices . . . . . . . . . . . . . . . .viii
Fire Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ix OPERATORS STATION B PANEL . . . . . . . . . . . . . . . .2-9

OPERATORS STATION C PANEL . . . . . . . . . . . . . . .2-11


INCLEMENT WEATHER and SAFE DRILLING PRAC-
OPERATORS STATION D PANEL . . . . . . . . . . . . . . .2-13
TICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xi
OPERATORS STATION E PANEL . . . . . . . . . . . . . . .2-15
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xi
OPERATORS STATION F PANEL . . . . . . . . . . . . . . .2-17
MANAGEMENTS RESPOSIBILITIES . . . . . . . . . . . . . . . . xi
DRILL OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-21
RAINFALL AND FLOODING . . . . . . . . . . . . . . . . . . . . . . . . xi
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-21
THUNDERSTORMS AND LIGHTNING . . . . . . . . . . . . . . . . xii
Preparation Inspection and Adjustments . . . . . . . . . . . . . .2-21
Exceptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xiii
STARTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . .2-21
MACHINE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . xiii
Shutting Down the Machine . . . . . . . . . . . . . . . . . . . . . . . .2-22
Propelling the Machine (Tramming) . . . . . . . . . . . . . . . . .2-22
Levelling the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-25
TABLE OF CONTENTS Raising the Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-26
Lowering the Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-26

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 DRILLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-27


Adding Drill Pipe - Inside Loader . . . . . . . . . . . . . . . . . . . .2-27
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Returning Drilled Pipe - Inside Loader . . . . . . . . . . . . . . . .2-29
Using the Tong(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-31
MACHINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . 1-1 Propelling to the Next Hole . . . . . . . . . . . . . . . . . . . . . . . .2-32
Application of Rig . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Recommended Operating Conditions . . . . . . . . . . . . . . . . 1-1 LIFTING and TRANSPORTING the MACHINE . . . . . . . .2-32
Manners and Conditions In Which This Machine Should NOT Be
Used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 DUST SUPPRESSION SYSTEMS . . . . . . . . . . . . . . . . . .2-32
Sound Pressure and Power Levels . . . . . . . . . . . . . . . . . . 1-2 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-32
Vibration Value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 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
ELECTRONIC DEPTH COUNTER (EDC) . . . . . . . . . . . .2-35
GENERAL ARRANGEMENT . . . . . . . . . . . . . . . . . . . . . . 1-7 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-35
Component Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . .2-35
Indicator and Key Descriptions . . . . . . . . . . . . . . . . . . . . .2-36
OPERATOR CONTROLS and OPERATION . . . . . 2-1 Viewing Bit Position, Distance From Bottom, Accumulated Depth
And Penetration Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-39
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-39

FIRE AND SAFETY EQUIPMENT . . . . . . . . . . . . . . . . . . . 2-1 DRILL MONITOR SYSTEM (DMS) . . . . . . . . . . . . . . . . . 2-40
Fire Extinguisher Location and Operation . . . . . . . . . . . . . . 2-1 SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . .2-41
Cab Emergency Exits . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Emergency Stops and Battery Disconnect . . . . . . . . . . . . . 2-1

Table of Contents 1
2
SECTION 1

model and serial number of the machine, along


INTRODUCTION with the part number and description of the
items required, as their personnel are fully qual-
GENERAL ified to assist and advise you on any service or
operational problems that may be encountered.
This manual provides a step-by-step guide to Sandvik Mining and Construction Field Repre-
operating and performing scheduled lubrication sentatives are also available to you for advice
and maintenance for your drill. A thorough and assistance on special problems.
study of this manual is recommended before
operation or maintenance of the machine is MACHINE SPECIFICATIONS
attempted.
Application of Rig
Careful attention should be given to the service
The D245S machine is designed for construc-
and maintenance instructions for the various
tion and surface mine drilling.
components and systems of the machine.
Experience indicates that the procedures Recommended Operating Conditions
described herein are preferred practices and
that failure to comply with them can materially This machine was designed to operate at ambi-
shorten the useful life of the equipment and/or ent temperatures of -40C to +54C (-40F to
reduce its standard performance. +130F).
Some photographs in this manual may show Manners and Conditions In Which This
details or attachments that are different from Machine Should NOT Be Used
your unit, due to optional equipment and/or
advancement of product design. Contact your Inadequate training of operator.
andvik Mining and Construction dealer for Unathorized persons in working area.
details of lubrication or maintenance not cov-
Inadequate lighting.
ered in this publication.
Inadequate grading.
Transporting people.
The parts manual should be referred to when it
is necessary to order repair parts. For prompt Defective safety systems.
and efficient parts service, contact your Sandvik
Mining and Construction dealer, giving the

Introduction - Page 1-1


Sound Pressure and Power Levels

The measurement of the sound power and the


sound pressure levels at the operators cab
have been measured in accordance with Euro-
pean Drill Rig Standard EN791 and the EC
Machinery Directive 89/392/EEC and amend-
ments 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


operators cab have been measured in accor-
dance with European Drill Rig Standard EN791
and the EC Machinery Directive 89/392/EEC
and amendments thereof. Vibration does not
exceed 0,5m/s.

Page 1-2
NOMENCLATURE/TERMINOLOGY

The terms used on this illustration are used throughout this manual.

FRONT

BATTERY ROTARY HEAD


RECEIVER TANK BOX
COOLER
FEED CHAIN

AIR CLEANER

COMPRESSOR

DRILL PIPE

MAST
ENGINE

PUMP DRIVE
MAST
RAISING LUBRICATOR TANK
CYLINDERS

HYDRAULIC
TANK

JACK CAB
CYLINDER

LOADER
DUST COLLECTOR

CAB
CRAWLERS DUST HOOD

REAR

Introduction - Page 1-3


D245S (900 cfm) SPECIFICATIONS

DRILL RATING
Hole Size 5 to 7-7/8 (127 - 203 mm)
Max. 1st pass capacity (Std. tooling) 28 5 (8.65m)
Max. 1st pass capacity (Special tooling 30 9 (9.4m)
Total Depth Capacity (Outside Loader) 150 (46m)
Total Depth Capacity (Inside Loader) 90 (27.4m)

UNDERCARRIAGE
Type Caterpillar - Model 325
Length 14 4 (4.37m)
Pads (Shoes) Triple Grouser 23.6 (600 mm)
Travel Speed 2.1 mph (3.38 km/h)
Gradeability 50%
Drive HP each track 130 hp (97 kW)
Ground Bearing Pressure (Std. Equipment) 8.8 psi (60.7 kPa)
Width Over Tracks 11 0 (3.35 m)
Suspension Three Point Oscillating
Rollers 9 Lower - 2 Upper

DRILL POWER
Caterpillar Model C15 475 hp (354 kW)
Rated Speed 1800 rpm
Fuel Capacity 200 gallons US (757 l)

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

FEED SYSTEM
Type 1 Hydraulic Cylinder and Chains
Rated Bit Loading 45,000 lbs (20,412 kg)
Rated Pullback 19,580 lbs (8,881 kg)
Feed Rate 0-97 fpm (29.5 mpm)
Retract Rate 0-207 fpm (63 mpm)

ROTARY HEAD
Type Gear Case Type
Drive Motor Hydraulic Axial Piston
Maximum Rotary Horsepower 130 hp (97 kW)
Standard Rotary Speed/Torque 158 rpm @ 48,500 in-lbs (5,481 Nm)

TOOL HANDLING EQUIPMENT (Loaders)


Type Carousel (Outside Mast)
Number of Positions 4
Type Two Single Pod (Inside Mast)
Pipe Size 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) 44 7 (13.6 m)
Width (operating) 13 8 (4.16 m)
Height (mast up) 42 6 (12.9 m)

ELECTRICAL
Alternator 24VDC 100amp
Air Conditioner 24VDC
Batteries 2 @ 12 Volt

Page 1-4
D245S (1000 cfm) SPECIFICATIONS

DRILL RATING
Hole Size 5 to 7-7/8 (127 - 203 mm)
Max. 1st pass capacity (Std. tooling) 28 5 (8.65m)
Max. 1st pass capacity (Special tooling 30 9 (9.4m)
Total Depth Capacity 150 (46m)
Total Depth Capacity (Inside Loader) 90 (27.4m)

UNDERCARRIAGE
Type Caterpillar - Model 325
Length 14 4 (4.37m)
Pads (Shoes) Triple Grouser 23.6 (600 mm)
Travel Speed 2.1 mph (3.38 km/h)
Gradeability 50%
Drive HP each track 130 hp (97 kW)
Ground Bearing Pressure (Std. Equipment) 8.8 psi (60.7 kPa)
Width Over Tracks 11 0 (3.35 m)
Suspension Three Point Oscillating
Rollers 9 Lower - 2 Upper

DRILL POWER
Caterpillar Model C15 540 hp (402 kW)
Rated Speed 1800 rpm
Fuel Capacity 200 gallons US (757 l)

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

FEED SYSTEM
Type 1 Hydraulic Cylinder and Chains
Rated Bit Loading 45,000 lbs (20,412 kg)
Rated Pullback 19,580 lbs (8,881 kg)
Feed Rate 0-97 fpm (29.5 mpm)
Retract Rate 0-207 fpm (63 mpm)

ROTARY HEAD
Type Gear Case Type
Drive Motor Hydraulic Axial Piston
Maximum Rotary Horsepower 130 hp (97 kW)
Standard Rotary Speed/Torque 158 rpm @ 48,500 in-lbs (5,481 Nm)

TOOL HANDLING EQUIPMENT (Loader)


Type Carousel (Outside Mast)
Number of Positions 4
Type Two Single Pod (Inside Mast)
Pipe Size 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) 44 7 (13.6 m)
Width (operating) 13 8 (4.16 m)
Height (mast up) 42 6 (12.9 m)

ELECTRICAL
Alternator 24VDC 100amp
Air Conditioner 24VDC
Batteries 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 2. Pull the clamp release and remove the extin-
guisher from its mounting base.
OPERATION 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.
GENERAL
5. Squeeze the handle and sweep the hose
from side to side.
This section of the manual discusses safety
6. After use have the extinguisher refilled.
equipment the operator should be familiar with
before operating the machine as well as control
identification, machine limitations, and operat- RING HANDLE
PIN
ing procedures.
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 CLAMP
and note the location and understand the mean- RELEASE
ing of all DANGER, WARNING and CAUTION
decals.

Fire Extinguisher Location and Operation

Fire extinguishers are located at the front sides Cab Emergency Exits
of the rig as shown.
Operator cab emergency exits are the cab
doors and the side window.

KICK OUT
GLASS
245-59 TO EXIT

CAB DOOR

Read the operating instructions on the side of


the extinguisher and check to see that the Emergency Stops and Battery Disconnect
charge indicator needle is not in the red zone.

Operate the fire extinguisher as follows: The emergency stops were designed to
1. Shutdown the rig. 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.
The battery disconnect switch is
located on the battery box. Turn the key to the
Emergency stop #1 is located in the operators
OFF position to cut electrical power to the
cab. Push this button to stop the engine and all
machine.
machine operations. Pull the button out to reset.

Emergency stop #2 is located on the mast. Pull


this cord to stop the engine and all machine
operations. Push the reset button before restart-
ing 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.

EMERGENCY 22133s1 2. Quickly actuate the fire suppression system


STOP #2 by pulling the safety ring pin and pushing down
the plunger on the actuator.

RESET BUTTON 6120-s1

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 extin-
guisher.

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 WATER ONLY


yourself from windblown flames, explosions or
other dangers created by the fire.

Heat remaining from the fire could cause reigni- ALTERNATOR CIRCUIT BREAKER
tion after the fire suppression system has dis-
charged. Because of this, it is important that CRUSHING HAZARD
someone stand by, at a safe distance, with a
hand portable extinguisher. This standby should
be maintained until all possibility of reignition is
past.
MAIN CIRCUIT BREAKER

When a fire suppression system discharges,


there is considerable noise accompanied by WINCH CAPACITY
clouds of dry chemical. While breathing foreign
particles is not pleasant, the agent FORAY is
FEED (PULLDOWN) CYLINDER
non-toxic and exposure during a fire will not CAPACITY
harm you.

AFTER THE FIRE IS OUT

Machinery should not be restarted until it has


been serviced and cleaned (water may be used DANGER, WARNING and CAUTION DECALS
to remove the dry chemical). Immediately
General
recharge the fire suppression system. You
needed it once, you may need it again.
The following illustrations show the general
placement of the Caution, Warning and Danger
decals found on this machine. These decals
GENERAL PICTOGRAMS
should make it clear to the operator where the
major risks for personal injury and machine
The following symbols can be found on this rig.
damage are, and what measures should be
taken to operate this equipment safely.

D245S (hpil) 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)


A2. RECEIVER AIR PRESSURE
A1 A2
This gauge indicates the air pressure as mea-
A3 sured at the air receiver tank. This gauge
should read slightly higher than the working air
A4
pressure gauge when drilling is taking place.

A5 A3. ROTATION PRESSURE


This gauge indicates hydraulic oil pressure as
measured at the rotary head motor. Pressure is
controlled by turning the rotation pressure con-
trol valve (F11).

A4. HYDRAULIC PRESSURE


This gauge indicates hydraulic oil pressure as
measured at the control valve bank operating
the feed cylinders (pulldown force).
OPERATORS STATION
A PANEL A5. OPERATOR STATION LIGHTS
This two-position toggle switch operates the
operator station lights.

A1. WORKING AIR PRESSURE Lift the switch up to turn the lights on.
This gauge indicates the air pressure as mea-
sured at the drill bit. Push the switch down to turn the lights off.

D245S (hpil) Controls and Operation - Page 2-7


Page 2-8 D245S (hpil)
B4. R JACK
B2
B1 B6 This indicator illuminates (GREEN) to confirm
B7 that the right rear jack (levelling) cylinder is fully
B8 B9 retracted.

B3 B10 B5. CHANGE COMPRESSOR FILTERS


B11 This indicator illuminates (red) when the filter is
B4 clogged and oil is bypassing the filter. Push to
B12 test the indicator.

B5 B13

B14
B6. FUEL
B15
This gauge indicates the level of engine diesel
B16 fuel.
B17
B18 B7. DISENGAGE - ANGLE LOCKING
B19 This indicator illuminates (RED) when the mast
locking pins are not engaged.
OPERATORS STATION
B PANEL B8. ENGAGED - ANGLE LOCKING
This indicator illuminates (GREEN) when the
mast locking pins are fully engaged.

B1. HEAD SPEED


This tachometer gauge indicates the drive B9. ENGINE RPM
speed of the rotary head and the drill string in
multiples of 10 with a maximum of 200 revolu- This tachometer gauge indicates the engine
tions per minute. rotation speed in multiples of 100s of rpms.

B2. L JACK
This indicator illuminates (GREEN) to confirm B10. WATER TEMPERATURE
that the left rear jack (levelling) cylinder is fully This gauge indicates the coolant temperature of
retracted. the engine. The normal operating temperature
is indicated by the green zone.

B3. F JACK
This indicator illuminates (GREEN) to confirm
that the front jack (levelling) cylinder is fully B11. DISCHARGE AIR TEMPERA-
retracted. TURE
This gauge indicates the temperature of the air
that is discharged by the compressor by mea-

D245S (hpil) Controls and Operation - Page 2-9


suring the temperature of the discharged oil.

B18. BY-PASS
This switch activates the engine shutdown sys-
tem by-pass. This by-pass system is needed
B12. OIL PRESSURE
when starting the engine while the engine and
This gauge indicates the engine lubricating oil compressor oil pressures have not reached
pressure. their operating levels. For more information on
the use of this switch refer to the topic Starting
the Engine.

B13. BATTERY
This voltmeter indicates the battery charge volt-
age. The normal voltage reading will be slightly
above 24V. B19. ENGINE - OFF/ON
When this key operated switch is placed in the
ON position the machines electrical system is
energized. The switch must be placed in the
B14. LIGHTS OFF position when the machine is shutdown to
prevent the batteries from discharging.
Pull this switch out to illuminate the work area
lights. Push the switch in to extinguish the
lights.

B15.CHANGE HYDRAULIC FILTERS


This indicator illuminates (red) when the filter is
clogged and oil is bypassing 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 infor-
mation on the use of this button.

Page 2-10 D245S (hpil)


C2. V-BLOCK - IN/OUT
C1 This lever controls the actuation of the V-block
cylinder.
C2
C2
C4
ARRANGEMENT Push up on the lever to position the V-block IN
C5 WITH POWER the drilling area.
-TONG
C6 C3
Pull down on the lever to retract the V-block
OUT of the drilling area.

C3. NOT USED

C4. SWING - IN/OUT

C1 Push up on this control to swing the powertong


mechanism in to position at the drill pipe.
C2
Pull down on this control to swing the power-
C3 tong mechanism away from the drill pipe.

C5. CLAMP - OPEN/CLOSE

Push up on this control to open the powertong


OPERATORS STATION jaws and release the drill string.

C PANEL Pull down on this control to close the tong jaws


and clamp the drill string.

C1. CURTAIN - UP/DOWN


This lever controls the movement of the dust C6. BREAK - IN/OUT
hood curtain cylinder.
Push up on this control to break the drill string
Push up on the lever to raise the curtain UP. connection.

Pull down on the lever to close the curtain. Pull down on this control to retract the cylinder
and prepare the wrench for the next break.

D245S (hpil) 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. COMPRESSOR AIR PRESSURE -


HIGH/LOW
D5 This two position switch controls the air pres-
D6 sure as measured at the receiver tank (gauge
D7 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
OPERATORS STATION to decrease air pressure to 150 - 160 psi (10 -
11 bars).
D PANEL

D1. CHECK ENGINE


This indicator illuminates (red) when the engine
is sending a diagnostic code at indicator D2.
D6. LUBRICATOR - ON/OFF
D2. DIAGNOSTIC CODE INDICATOR This toggle switch controls the injection of lubri-
This indicator will illuminate (red) coded pulses cating oil into the drill string.
when an engine problem has been detected by
the engines self-diagnostic system. Refer to
the Caterpillar engine Operation & Mainte- D7. PULSE RATE
nance Manual for more information on this sys- With the Lubricator switch (D6) in the ON posi-
tem. tion 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
E4. LOADER - RETRACT/LOAD (RH)
E7 This lever controls the swing functions of the
E3
E8 right side drill pipe loader.
E4

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.

OPERATORS STATION E5. EXHAUSTER/WATER


E PANEL This lever controls the dust suppression sys-
tems.

E1. WINCH - UP/DOWN


This lever controls the operation of the winch. Push forward on this lever to start the
dust collector.

Pull back on this lever to start the water


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

E6. WRENCH - IN/OUT


This lever controls the positioning motion of the
Pull this lever to lower (spool out) the
holding wrench.
winch rope.

E2. TONG Push the lever forward to slided the


wrench towards the drill pipe.
This lever controls the extend and retract
motions of the power-tong cylinder.

Pull back on this lever to extend the cylinder Pull the lever back to retract the
and break the drill pipe connection. 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 E8. AIR - ON/OFF
This lever controls the movement of the mast This lever controls the injection of working (bail-
locking cylinders. ing) 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. ROTARY/ LEFT TRACK LEVER
This lever regulates the speed and direction of
F2 F3
the drill strings rotational motor and the left side
F1
crawler track.

NOTE !
The operations controlled by the positioning of
F9 this control lever are dependent upon the posi-
F10
F11 tion of the DRILL/PROPEL selector switch (F7).
F12
With the DRILL/PROPEL selector switch (F7) in
the DRILL position:

Push the lever forward to rotate the drill


F4 string in a clockwise rotation. The further for-
ward this lever is pushed, the faster the rotation
F5 speed. The drill string speed is shown on the
F6 HEAD SPEED tachometer gauge (B1).
F7
Pull back on the lever to rotate the drill
F8
string in a counter-clockwise rotation. The fur-
ther this lever is pulled back, the faster the rota-
tion speed. The drill string speed is shown on
the HEAD SPEED tachometer gauge (B1).

With the DRILL/PROPEL selector switch (F7) in


F13 the PROPEL position (and the optional DEAD-
F14
MAN pedal F13 depressed):

Push this lever up to propel the left


OPERATORS STATION crawler tracks forward.
F PANEL
Pull this lever down to propel the left
F1. FEED - UP/DOWN crawler tracks in reverse.
This lever controls the rotary head pulldown and
Refer to the topic on propelling the machine for
raising.
more instructions on the use of this control.

Pull back on this lever to extend the feed NOTE!


cylinder and lower the rotary head. The engine will not start until this control is
placed in the center NEUTRAL position.
Push forward on this lever to retract the
feed cylinder and raise the rotary head. F3. FEED/ RIGHT TRACK LEVER
This lever controls the rotary head fast feed
system, and controls the speed and direction of

D245S (hpil) Controls and Operation - Page 2-17


the right side crawler track.

NOTE ! F5. TORQUE CONTROL - ROTARY


The operations controlled by the positioning of This knob regulates the hydraulic oil pressure
this control lever are dependent upon the posi- applied to the drill strings rotational motor.
tion of the DRILL/PROPEL selector switch (F7).
Turn the knob clockwise to increase hydraulic
With the DRILL/PROPEL selector switch (F7) in torque pressure.
the DRILL position and the FEED lever (F1) in
either the UP or DOWN position: Turn the knob counter clockwise to decrease
torque pressure as shown on the ROTATION
Depress the button and pull back on this lever to PRESSURE gauge (A3).
fast feed the rotary head (direction is deter-
mined by the positioning of FEED lever F1).

With the DRILL/PROPEL selector switch (F7) in


the PROPEL position (and the optional DEAD- F6. WATER CONTROL
MAN pedal F13 depressed): This control varies the amount of water injected
into the down the hole air supply. With the
This lever controls the propelling of the right EXHAUSTER/WATER control (E7) in the
crawler tracks. WATER position:

Rotate the knob clockwise to decrease the


Push this lever up to propel the right amount of water injected.
crawler tracks forward.
Rotate the knob counterclockwise to increase
the amount of water injected.
Pull this lever down to propel the right
Refer to the topic on the water injection opera-
crawler tracks in reverse. Refer to the topic on
tion for more instructions on the use of this con-
propelling the machine for more instructions on
trol.
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 ener-
gizes control levers F2 and F3.
F4. FEED PRESSURE CONTROL
This knob regulates the hydraulic oil pressure Position this switch to the DRILL position to
applied to the feed cylinder. Turn the knob operate the feed and rotation controls.
clockwise to increase (pulldown) force. Turn
the knob counter clockwise to decrease the Position this switch to the PROPEL position to
pressure as shown on the FEED PRESSURE operate the propel controls.
gauge (A4).

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 Push this lever up to retract (pick up) the cylin-
This lever controls the up and down motions of der. Indicator light B4 will illuminate to confirm
the drilling mast. that the jack is fully retracted.

Pull this lever down to extend (lower) the right


! DANGER rear jack cylinder.
Operating near or contacting a power line with
any part of the machine can result in electrocu- F13.PROPEL DEADMAN PEDAL
tion. Do not raise the drilling mast or operate
the machine in the vicinity of electrical power This optional foot pedal prevents the machine
lines without checking the minimum safe oper- from being propelled unless the operator is at
ating perimeter set by local, state or national the operators station.
regulations.
Depress this pedal before operating the propel
Pull back on this lever to raise the mast. control levers (F2 or F3).

Push this lever forward to lower the mast. Release this pedal after releasing the propel
control levers (F2 or F3).

F10.LEFT JACK - UP/DOWN


This lever controls the raising (extending) and
! CAUTION
lowering (retracting) of the left rear jack (level- Do not use this pedal for stopping the machine.
ling) cylinder. Serious damage to the propel components will
occur.
Push this lever forward to retract (pick up) the
cylinder. Indicator light B2 will illuminate to con-
firm that the jack is fully retracted.
F14. THREAD GREASER
Pull this lever back to extend (lower) the left rear
Depress this optional pedal to spray lubricant on
jack cylinder.
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 cylin-


der. 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 (level-
ling) cylinder.

D245S (hpil) Controls and Operation - Page 2-19


Page 2-20 D245S (hpil)
DRILL OPERATION
RECEIVER AIR
GENERAL PRESSURE GAUGE (A2)

The following operating suggestions are offered


as a reminder rather than as an attempt to
B16
instruct, since a machine of this size must not D4
be entrusted to anyone except a fully trained
D5
and qualified operator.
B17

Preparation Inspection and Adjustments


B18

Before operating the drill:


Read and understand the Safe Operating B19
Practices for Drillers at the front of this man-
ual.
Perform the 8 Hour or Shift Change Main-
tenance Checks outlined in this manual.
Adjust the operator seat to provide a com-
fortable and safe operating position. Step 1. ENGINE IDLE (D4)
Step 2. COMPRESSOR LOW (D5)
Step 4. IGNITION ON (B19)
STARTING THE ENGINE Step 5. HOLD BYPASS (B18) and
PUSH START (B17)
The engine will not start until:
ENGINE START-UP SWITCHES

All controls are in the "NEUTRAL" position.


The battery disconnect switch is in the ON 2. Place the COMPRESSOR switch (D5) in the
position LOW position.

3. Alert others in the vicinity of the machine


DISCONNECT
SWITCH 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 6. Push the BYPASS switch (B18) down and at
the IDLE position.
the same time push in the START button (B17).

D245S (hpil) Controls and Operation - Page 2-21


Once the engine starts, release the START but- 2. Move the compressor switch (D5) to LOW.
ton (B17) but continue to hold the BYPASS
switch (B18) up until the RECEIVER AIR PRES- 3. Set the engine speed switch (D4) to IDLE.
SURE gauge (A2) reads 110 psi.

NOTE !
If the BYPASS 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).

B9 B19

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 5. After engine has idled for 5 minutes, turn key
engine water temperature (B10) rises to a mini- switch (B19) To "OFF".
mum of 180F (82C).
6. Make certain all electric switches and radio
NOTE ! (if equipped) are "OFF", so not to drain the bat-
Hydraulic oil can be warmed by retracting the teries.
loader (E5 pushed forward) and stalling the cyl-
inder for no longer than 2 minutes at a time. 7. Remove keys from switch (if required by
During the winter months, a warm-up period company), lock cab doors and put keys in a safe
may take as long as 15 minutes. place.

Shutting Down the Machine 8. Turn the battery disconnect switch to the
When shutting the machine down at end of a OFF position.
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 Propelling the Machine (Tramming)
machine is restarted for the next shift.

1. Make certain all controls are in "NEUTRAL".


!! WARNING
Exceeding the maximum incline limits can

Page 2-22 D245S (hpil)


cause personnel injury or death. An alarm
will sound in the operators cab when the
pitch angle (front to rear) reaches 12 or !! WARNING
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.

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 posi-
tion (horizontal).
Remove all drill pipe if tramming for long dis- 5m
tances. (15 ft.)
Fully retract the drill pipe loaders.
Refer to the topics on Lowering the Mast
and Propelling to the Next Hole.

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.

NOTE ! 5m
(15 ft.)
The engine needs to be at 1800 rpm for tram-
ming. While propelling, it is forbidden to be in the
propelling area.

4. If equipped, depress the DEADMAN pedal PROPELLING DANGER ZONE


(F13). The DEADMAN switch releases the tram any track driven machine:
brakes and must be depressed at all times dur-
ing tramming and released when the propel Push both controls (F2 and F3) forward an
controls are returned to the NEUTRAL position. equal amount to propel straight forward.

Pull both controls (F2 and F3) back an equal


5. Push or pull the propel controls (F2 and F3) amount to propel straight in reverse.
as required. Propel speed is determined by
how far forward or back the levers are posi- Position one control ahead of the other in
tioned during propelling. the same direction to obtain a large radius
turn.
Propelling this machine is typical of propelling in

D245S (hpil) 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 DEAD-
MAN switch (F13) as a brake.
17 30%

6. When propelling has been completed, return


the controls (F2 and F3) to the NEUTRAL posi-
tion and release the DEADMAN switch (F13).
With the deadman 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 supported by the machines 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
19 34% the LEVEL (F8) adjust for the side to side level-
ling.

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

4. Continue to alternately raise or lower the B8


jacks to obtain the lowest possible height con-
sistent with good drilling clearance.

E7
Raising the Mast

! DANGER F9

Operating near or contacting 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)
Before raising the mast check the following: Step 2. RAISE MAST (F9)
Step 3. LOCK PINS (E7)
The mast will not contact any overhead pow-
MAST RAISING
erlines.
The jack cylinders are deployed and the
3. Push forward on the MAST control lever
machine is levelled on firm ground.
(E7) to LOCK the mast into position. Indicator
All equipment is secured firmly in the mast
(B8) will illuminate when the pins are engaged
and will not fall.
(extended).
That the drill pipe has been retracted to a
point where the drill bit is just below the mast
table.
Lowering the Mast
The mast-side cab door is closed.
The operator remains in the cab and any
helpers maintain a 50 ft. (15 m) distance ! DANGER
from all sides of the machine.
Operating near or contacting a power line
with any part of the machine can result in
Raise the mast as follows: electrocution. Do not lower the drilling mast
or operate the machine in the vicinity of
1. Pull back on the MAST control lever (E7) to electrical power lines without checking the
UNLOCK (retract) the mast locking pins. Indi- minimum safe operating perimeter set by
cator B7 will illuminate to confirm that the pins local, state or federal regulations
are fully retracted.
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 The mast will not contact any overhead pow-
desired angle. erlines.
The outside loader is retracted and indexed
NOTE ! to a mid position to prevent pipe from falling
The mast locking lugs are spaced at 5 incre- out.
ments. The inside loaders are retracted.

Page 2-26 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. Indi- 8m
cator B7 will illuminate to confirm that the pins (25 ft.)
are fully retracted.
DRILLING DANGER ZONE
2. Push forward on the MAST control lever (F9)
to the DOWN position and slowly lower the Adding Drill Pipe - Inside Loader
mast to the desired angle if not stowing the
mast. The following procedure was written with the
assumption that the starter section of drill pipe
NOTE ! has been drilled and that additional drill pipe is
required.
The mast locking lugs are spaced at 5 incre-
ments. 1. Switch OFF the LUBRICATOR (D6),
WORKING AIR (E8), and the DUST COLLEC-
TOR or WATER INJECTION (E5).
3. Push forward on the MAST control lever
(E7) to LOCK the mast into position if not
2. Push the FEED control (F1) forward to the

D245S (hpil) Controls and Operation - Page 2-27


UP position and raise the rotary head high
enough to enable the holding wrench to engage ! CAUTION
CAUTION
on the drill pipe flats.
Be sure that the rotary head is raised fully to
3. If necessary, rotate the drill pipe to align the the top of the mast before swinging the
flats on the drill pipe with the holding wrench loader. Failure to do so will damage the
before pushing the WRENCH control (E6) to the rotary head, top sub, or loader.
IN position and engaging the holding wrench.
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
F3
gauge B1).
E6
F2
E8
E5 C2 B1

F1
F3
D6
F2 E3

E4

F1 E6

F5 E5

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. Step 7. HEAD SPEED (F2)
Step 8. V-BLOCK - IN (C2)
NOTE ! Step 9. LOWER FEED (F1)
Step 10. RAISE FEED (F1)
If the top adaptor does not start to unthread, Step 12. RETRACT LOADER (E3 or E4)
increase the rotation torque (F5). If this is uti- Step 13. GREASE THREADS (F14)
lized, once the top sub is unthreaded from the Step 14. LOWER FEED (F1)
Step 15. COUPLE JOINTS (F2 & F1)
drill pipe, reset the rotation torque back to the Step 17. WRENCH - OUT (E6)
drilling setting. Step 18. V-BLOCK - OUT (C2)

5. Push FEED control (F1) forward and pull ADDING DRILL PIPE (INSIDE LOADER) contd
back on the FEED control (F3) to raise the
rotary head to the top of the mast. 8. Push up on the V-BLOCK control lever (C2)
to hold the drill pipe in place.

Page 2-28 D245S (hpil)


not over-torque the pipe threads.
! CAUTION
CAUTION 17. Pull back on WRENCH control (E6) and
Excessive rotary head down pressure dur- retract the wrench.
ing joint coupling can damage pipe threads.
Feather the FEED control and stop feeding
when joints begin threading. ! CAUTION
CAUTION
Drilling with the V-block IN (extended) will
9. Pull back on FEED control (F1) and slowly damage the V-block and/or the rotary head.
begin to lower the rotary head. Begin threading Always be sure to position the V-block lever
the top sub to the drill pipe that is in the loader. in the OUT position before drilling.

As this is happening, watch the ROTATION 18. Pull down on the V-BLOCK control lever
PRESSURE gauge (A3) and when the gauge (C2) to retract the V-block OUT.
reading increases, stop the rotation.

10. Push the FEED lever (F1) forward to lift the Returning Drilled Pipe - Inside Loader
drill pipe up out of the loaders bottom pocket. The following procedure was written with the
assumption that drilling to the required depth
11. Push the ROTATION lever (F2) forward to has been completed and that one or both
rotate the drill pipe to align the top of the drill pieces of drill pipe were removed from the load-
pipe flat with the opening in the loader. This will ers.
permit the loader to swing out from under the
rotary head. 1. Retract the drill string by pushing the FEED
lever (F1) to the UP position until the pipe flats
12. Push the LOADER control (E3 or E4) and reach the holding wrench area.
fully swing the loader (RETRACT) until it stops.
2. Turn OFF the DUST COLLECTOR or
13. If equipped, depress the THREAD WATER INJECTION (E5) and WORKING AIR
GREASER pedal (F14) to spray thread grease (E8).
on the drill pipe threads.
3. Place the COMPRESSOR AIR PRESSURE
14. Pull FEED control F1 to the DOWN posi- switch (D5) in the LOW position.
tion and lower the drill pipe down over the drill
pipe in the table. 4. Lift the V-BLOCK lever (C2) to the IN posi-
tion to deploy the pipe centralizer.
! CAUTION
CAUTION
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 PRES-
SURE 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 prop-
erly aligned before swinging a loader. Fail-
ure to do so could damage these
C2 mechanisms.

9. Pull a LOADER control (E3 or E4) to swing


E6 LOAD the loader in under the rotary head until
F1 F2 E5 it stops.

10. Lower the drill pipe into the loader pod by


E8
pulling the FEED lever (F1) to the DOWN
D5 position.

11. Pull back on the ROTARY lever (F2) and


break the connection.

! CAUTION
CAUTION
Lowering the rotary head with the V-block
Step 1. RAISE DRILL PIPE (F1)
IN (extended) will damage the V-block and/
Step 2. WATER/DUST COLLECTOR or the rotary head. Always be sure to posi-
WORKING AIR - OFF (E5 & E8) tion the V-block lever in the OUT position
Step 3. COMPRESSOR AIR - LOW (D5)
Step 4. V-BLOCK - IN (C2) before lowering the rotary head.
Step 5. HOLDING WRENCH - IN (E6)
Step 6. BREAK PIPE JOINT (F2)
12. Push the V-BLOCK control (C2) down (OUT)
RETURNING DRILL PIPE TO THE INSIDE LOADER to retract this assembly.

13. Push the FEED lever (F1) to fully raise the


5. Rotate the pipe (F2) if necessary to align the rotary head to the top of the mast.
flats of the drill pipe before deploying the HOLD-
ING WRENCH with lever E6 IN. 14. Push the LOADER lever (E3 or E4) to
RETRACT the loader fully out.
6. Pull back on the ROTARY lever (F2) so that
the drill pipes break at the joint and start to 15. Retract (OUT) the holding wrench (E6) and
unthread. Continue to unthread the pipes. lower the rotary head and repeat the preceding
steps until both pipes are out of the ground and
NOTE ! placed in the loaders.
If the drill pipes do not break refer to the topic
Using the Tong in this section.

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

E6
F1 F2 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 JOINT (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 (contd)
5. Push the TONG lever (E2) to retract the cyl-
inder and prepare for the next deployment.

Using the Tong(s) 6. Signal to the helper to stand out of the drill-
ing area.
If the drill pipe does not break by reversing the
rotation, the tong or power-tong must be used POWER-TONG
as follows:
1. Deploy the holding wrench onto the drill pipe
TONG
wrench flats if not already done.
1. Deploy the holding wrench onto the drill pipe
2. Lift lever C4 up to swing the wrench into
wrench flats if not already done.
place.
2. Signal to a helper to swing the wrench into
3. Pull down on the CLAMP lever (C5) to
place.
secure the tong to the drill string.
3. Pull back on the TONG lever (E2) to break
4. Lift up on the BREAK lever (C6) to twist the
the pipe joint.
drill string and break the joint.

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 3. Position the mast in the horizontal position
lever C4 to prepare for the next break. (refer to the topic Lowering the Mast.

4. If lifting the machine, refer to the technical


Propelling to the Next Hole data plate to determine the machines weight
With all the drill pipe placed into the loader(s) (GVW). Lifting points (4 places) are marked on
prepare the machine to move to the next drill the machine.
hole as follows:
5. If propelling the machine onto a truck, refer
1. Push up on the CURTAIN control lever (C1) to the Propelling the Machine topic before
to raise (UP) the dust curtain. loading the drill onto the trailer.

2. Position the DRILL/PROPEL mode selector 6. Shutdown the machine as described in the
switch (F7) to the PROPEL position. 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

8. Using suitable chains and hold-downs, chain


F7 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.

LIFTING and TRANSPORTING the MACHINE 245-60


The following procedures are to be used as a
guide. The equipment you have and the regula-
tions 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. DUST SUPPRESSION SYSTEMS

2. Index the loader a half turn to prevent drill General


pipe from sliding out.
Two types of dust suppression systems are
Page 2-32 D245S (hpil)
DRIVE MOTOR
(HYDRAULIC)
BLOWER
FILTER
BACKFLUSHING
CLEAN AIR MODULE
DISCHARGE

WORKING AIR BACKFLUSHING


PRESSURE
FROM COMPRESSOR
REGULATOR

BURST
of
FLUSHING
DUST LADEN AIR AIR

FILTER

TABLE
BUSHING TABLE

DUST CURTAIN DUST


CUTTING
DEFLECTOR
ROCK
CHIPS

245-56

available on this machine; dust collector and when damp conditions exist. Doing so will
water injection. damage the dust collector elements.

Dust Collector Operate the dust collector as follows:

A hydraulic motor driven exhauster fan draws 1. Push up on CURTAIN lever (C1) to lower the
up dust laden working air from around the dust curtain.
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 collec-
tor where timed air blasts (3 to 6 seconds apart)
dislodge the dust and exhaust it (pressure regu-
lator set at 50 psi (3.5 bars) from the collector.

! 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

C1 E5

E5

2. Push forward on EXHAUSTER/WATER F6


lever (E5) to start the dust collector.
WATER INJECTION
3. After the drilling cycle is completed, position trol lever (E5) to the neutral position to purge
control (E5) in the neutral position and raise the working air lines of water. This practice pre-
the dust curtain (C1). vents freeze-up during cold weather.

WINCH
Water Injection The winch is used to lift accessories on and off
of the work deck. Before any lifting operations
Use only clean water to refill the tank. Flush begin, rope off the lifting area to ensure that
points may be added to the water supply during everyone is aware of the lifting about to take
cold weather to prevent freezing. 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 con-
trol 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 !
TOWING
Erratic or diminishing water flow indicates a
The following instructions are for moving a dis-
clogged strainer.
abled machine for a short distance, only a few
yards (meters), at a low speed, 1.2 mph (2 km/
3. Once the desired drilling depth has been
h).
reached, push the EXHAUSTER/WATER con-

Page 2-34 D245S (hpil)


6. Support ring gear (1) in place and loosen the
!! WARNING remaining two cover bolts (2). Using a hammer
and wedge, separate cover (4) from ring gear
Personal injury or death could result from (1).
improperly towing a machine.
7. Remove twelve bolts (3) and ring gear (5)
Shielding must be provided on the towing from final drive cover (4).
machine to protect the operator if the tow line
(wire rope) should break. 8. Install final drive cover (4) using all of cover
bolts (2).
All the different situation requirements cannot
be given, so always consult your dealer if ques- 9. Fill the final drive with clean oil of the type
tions arise. specified in Section 3.

1. Thoroughly clean the area around the 10. Repeat this procedure to the remaining final
crawler final drives including the track shoes drive.
positioned above the final drive. Block the
tracks to prevent the machine from free rolling.
ELECTRONIC DEPTH COUNTER (EDC)
2. Allow the final drive oil to cool before drain-
ing the oil from both final drives into a suitable General
container (refer to Section 4G of this manual).
This system has been made around a multi-
3. Remove all but two of the twenty final drive function counter which displays bit position, bit-
cover bolts (2). distance-from-bottom of hole, accumulated hole
depth and penetration rate. The counter has
NOTE ! one 6-digit red led-display to show one display
Do not leave a bolt in the top hole of cover (4). 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:

DC/DC CONVERTER
The converter switches 24 volts DC down to 12
volts DC. The 12 volt DC voltage is needed for
4. Insert an alignment dowel or other suitable the counter, optical encoder, * holding wrench
tool through the top hole of the final drive cover proximity switch and warning buzzer. The DC/
to support ring gear (1) while removing cover DC converter output ground is the same as the
(4). input ground. The maximum 12 volt current of
the EDC should be less than 1 amp.
5. Remove one track shoe to provide access to
the parting face between cover (4) and ring gear
(1). HOLDING WRENCH PROXIMITY SWITCH
This proximity switch has a nominal 10 mm

D245S (hpil) Controls and Operation - Page 2-35


sensing distance. It is a Normally Open (NO) CONTROL RELAY
type switch. It is connected and mounted so The control relay is used on the warning circuit
that it is normally open when the holding wrench because of different voltage levels used on the
is not engaged. When the holding wrench is indicator light and buzzer. Also, the load level
engaged the circuit is closed. The supply volt- would exceed the proximity switch rating.
age for the proximity switch is 12 volts DC.
When the holding wrench is engaged the bit
position counter is stopped at that position. BUZZER
When the wrench is disengaged the bit position The buzzer is solid state electronics which auto-
counter will follow the movement of the rotary matically adjusts its own volume up or down
head gearbox. maintaining a minimum of 5dB (A) above envi-
ronmental noise level. Sound level ranges from
82dB thru 103dB.
OPTICAL ENCODER
The encoder is mounted beside the timing shaft Indicator and Key Descriptions
with a specific gear ratio sprocket and chain.
The encoder supplies two signals to the counter KEY 1 - PRESET HOLE DEPTH
which determines the distance, speed and The preset hole depth feature on the counter is
direction from these signals. Bit position is an indicator to advise the driller when he has
increased when the rotary head is moving drilled to a predefined depth. The preset hole
down. If the bit position counter counts in the depth is the depth from ground level to the bot-
wrong direction, the A and B signal can be tom of the hole. The operator should reset the
swapped from counter terminals no. 11 and 12. bit position (actual hole depth) counter for
proper operation starting at ground level. An
indicator light will indicate when the drill bit
ROTARY HEAD UP PROXIMITY SWITCH reaches the preset hole depth. The light will
The rotary head proximity switch has a 10 mm stay ON as long as drill bit position is greater
sensing distance. It is a Normally Closed (NC) than preset measurement. The preset hole
type switch. When the rotary head is moved to depth can be changed anytime before or after
a higher position the sensing plate mounted in drilling has started. The preset hole depth can
the feed system opens the sensor output. The be defined with an accuracy in centimeters
proximity switch is connected to the pipe in the (meters with two decimals).
hole warning circuit so that the closed output
will produce a warning signal if jack or mast
control levers are moved. KEY 2 - PRESET WARNING DEPTH
This is the depth used for the warning system.
It is factory set to provide maximum bit position
PRESSURE SWITCH measurement without sounding the alarm. The
This pressure switch is mounted on the lower warning signal is given if the bit position mea-
stacker valve to sound the alarm if the leveling surement is larger than the setting of the preset
jacks or mast raising control levers are oper- warning depth or the rotary head position is too
ated. The pressure switch is an adjustable type low.
preadjusted to switch ON at 900 PSI. The
switch is connected to the pipe in the hole warn- It is recommended to set the hole depth before
ing circuit as Normally Open (NO) switch. If starting to drill. The operator can set hole depth
either the jack or mast control levers are oper- from the counter keyboard. To view an old Pre-
ated, the activated output will allow the warning set Hole Depth measurement:
devices to activate the alarm if the bit position is
greater than the PRESET warning depth setting Press key # 1 (PRESET HOLE DEPTH)
or the rotary head is not in the proper position.

Page 2-36 D245S (hpil)


The old preset hole depth is displayed as long depth is displayed.
as the key is pressed and for 10 seconds after
key is released. The LED on the PROGRAM 3. To enter a new measurement for the hold
key will light when ever a preset is displayed. depth will require two 0s to be entered after the
new measurement is entered. For example, to
To program a new Preset Hole Depth measure- enter a preset depth of 25 ft. will require 2, 5, 0
ment: and 0 to be entered for English models. For
metric models the two 0s would be entered
1. Press the PROGRAM key. The Led on the unless the measurement required did contain a
Program key will flash. The main display is not two place decimal. If the measurement required
affected. 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 position counter is now reset.


Before drilling a new hole the bit position
counter should be reset. This requires that the If the RESET key has been pressed accidently,
drill bit be set on the ground and the counter the user may wait 10 seconds for the unit to
reset as follows: clear the flashing without affecting the counters.

1. Press RESET key. The main display will The system will automatically take care of cor-
begin to flash. This flashing is to indicate to the rect bit position if drill pipe is added. The bit
user that the bit position counter can be reset. position will stop counting when the holding
wrench is engaged. Not applicable for D90K-
2. Press key # 6 (BIT POSITION). The bit SP machines.

D245S (hpil) Controls and Operation - Page 2-37


NOTE! This will reset the accumulated depth counter.
The bit position is displayed in meters with two
decimals.
KEY 9 - PENTRATION RATE DISPLAY
The penetration rate is displayed in meters or
KEY 7 - BIT-DISTANCE-FROM-BOTTOM-DIS- feet per minute and it is updated every half sec-
PLAY ond. The penetration rate is displayed with one
Distance form bottom display indicates how far decimal number.
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 PIPE IN THE HOLE WARNING INDICATOR
distance. If the bit is lowered back to the bot- This push to test type indicator light is con-
tom, the display will switch back to bit position nected to the control relay which is controlled by
display. When retracting from the hole, the the warning circuit. The test push button will
counter is normally showing the distance form control the control relay voltage so it will test the
bottom display. Another display can be relay at the same time as the warning devices.
selected at anytime. The distance from bottom
display is switched automatically only once. The counter is equipped with an indicator light
The distance from bottom display will naturally and warning buzzer to help in preventing the
show the hole depth measurement when the machine from being moved with the drill pipe
drill bit is raised back to ground level. still in the hole.

The distance from bottom display will be reset ! CAUTION


CAUTION
automatically at the same time as the bit posi-
tion counter will be reset. If the operator wants This system only warns the operator if the
to reset the distance from bottom, he can use drill pipe is in the hole, if the operator tries
the same procedure shown as for bit position to operate any jack control level either up or
above, except press key # 7 (DISTANCE FROM down, or the mast control level either up or
BOTTOM) instead of key # 6 (BIT POSITION). down, or the mast control level either up or
down.

KEY 8 - ACCUMULATED DEPTH DISPLAY The pipe in the hole warning light and buzzer
Accumulated hole depth records the hole depth will operate only if the operator tries to raise or
drilled since the last reset. This allows the user lower the jacks and/or raise or lower the mast.
to use this counter as a record of shift, week or No warning will be given unless the jack or mast
month for total hole depth drilled. The accumu- controls are operated. The machine can be
lated hole depth is updated each time that dis- moved with the drill pipe still in the hole if the
tance from bottom measurement is equal to jack or mast controls are not operated before
zero. If using the accumulated depth counter as trying to propel the machine.
hole depth counter, the user has to reset the
accumulated depth counter separately after NOTE !
every hole. D90K-SP single pass machine has the optional
tram lock interface which disconnects the power
To RESET the accumulated depth counter: from tramming circuits if the rotary head position
is too low.
3. Press RESET key. The main display will
begin to flash. This flashing is to indicate to the
user that the counter can be reset. PRESET HOLE DEPTH LIGHT INDICATOR
Indicator light is connected to the counter output
4. Press Key # 8 (ACCUMULATED DEPTH). number 1. When the counter bit position is

Page 2-38 D245S (hpil)


greater than the preset hold depth the indicator wrench. The electric signal from the proximity
light will be lit. switch is connected to counter terminal number
10.
Viewing Bit Position, Distance From Bottom,
Accumulated Depth And Penetration Rate
PROPER COUNTING DIRECTION
To view the bit position, hole depth and accumu- The positive bit position counter measurement
lated depth, or penetration rate proceed as fol- should increase when the rotary head is moved
lows: down and decrease when moved up. If the
counter is counting in the wrong direction, swap
5. Press key # 6 (BIT POSITION) to view bit the optical encoder signal wires from counter
position. terminal numbers 11 and 12.

6. Press key # 7 (DISTANCE FROM BOTTOM)


to view present distance from bottom of the BIT POSITION COUNTER
hole. Bit position display is always following bit and
rotary head movement. To check the bit posi-
7. Press key # 8 (ACCUMULATED DEPTH) to tion counter you have to know the actual length
view accumulated depth. of the feed stroke. Reset the bit position
counter when the rotary head is completely at
8. Press key # 9 (PENETRATION RATE) to the top of the stroke. Run the rotary head down
view penetration rate. and check the bit position counter measure-
ment. It should equal the measured feed stroke
The counter will show the latest display until (meters or feet). If the error is more than an
another display is selected. The LED indicators inch or maximum of two, repeat the measure-
on the right side of the display indicate which ments and check the programming for that type
display is on. Distance from bottom display is machine and model. Different kind of feed
switched automatically on display when the drill chains (not standard), sprocket or timing shaft
bit is raised from the bottom of the hole. The bit can require a change to the programmed val-
position is resumed when the drill bit is lowered ues.
back to the bottom of the hole.
PENETRATION RATE DISPLAY
Tests Penetration rate display is showing feet/minute
When the system has been installed and pro- or meters/minute depending on destination
grammed the following test routines will be (country). Display is with one decimal accuracy.
needed to confirm that the counter operates
properly. There is no special calibration
required as these tests are only to ensure that FEED / MINUTE METERS / MINUTE
programming is correct for the respective
1 0.3
machine models and the counter and its instal-
lation are OK. 2 0.6

3 1

BIT POSITION COUNTING 5 1.5


When the holding wrench is engaged the bit 10 3.0
position counter display should remain at its
20 6.0
present display. When disengaging the wrench,
the bit position counter should resume counting.
If this is not happening, check the proximity Lower the rotary head down at a constant speed
switch mounting and sensor on the holding and check to see that the penetration rate dis-

D245S (hpil) Controls and Operation - Page 2-39


play is showing properly. A 30 feet stroke is 10 Speed Display
meters, so if drilling down 30 feet in one minute Update Time 0.5 seconds
with constant speed it would equal about a 10 Display 6-digit, 0.56 red LED display
meters/minute penetration rate. Try to drive the
rotary head distance in a half minute or in one Front Panel 4 LED status indicator
14-key membrane switch keyboard
minute to make calculations easier. Splash proof polyester overlay
Environment 32 to 132 F, operating
-40 to 160 F, storage
ACCUMULATED DEPTH DIP Switches 1 = OFF
Accumulated depth will be increased every time 2 = ON
the rotary head is moved down and distance 3 = OFF
4 = ON
from bottom display equals zero (0). This
5 = OFF
means that the drill bit is at the bottom of the 6 = OFF
hole. Otherwise the accumulated depth should
I/O Terminals Used 10 = Stop counting
work the same way as bit position. It has its 11 = Signal A
own programming measurement, so it should 12 = Signal B
be tested to insure that it counts distance cor- 13 = Ground
rectly. 15 = Power voltage, +12 V power
16 = Power voltage, ground
24 = Output 2 NO
25 = Output 2 common
PRESET HOLE DEPTH 27 = Output 1 NO
28 = Output 1 common
The unit is equipped with an indicator light for
preset hole depth. Program some measure-
ment to the preset hole depth register (see user
instructions) and test to see that the indicator PIPE IN THE HOLE WARNING LIGHT and
light works properly. An indicator light will indi- BUZZER
cate when the drill bit reaches the presetted The test button will test the wiring and the func-
hole depth. The light will stay ON as long as tion of those warning devices. The counter
drill bit position is greater than the preset mea- compares the bit position measurement and the
surement. The preset hole depth light is con- preset warning depth. If the pressure switch
nected to counter output terminal number 27 (mounted on the lower stacker valve) is pressur-
and the other side of light to the ground. Termi- ized to 900 PSI this will activate the alarm.
nal number 28 is connected 24 volt.
The same warning circuit can be activated if the
rotary head gearbox is lowered too low in the
EDC mast. The proximity switch and its sensing
SPECIFICATION plate have been mounted in the mast so that the
Counter Range -9999.99 to +9999.99 meters or
first pipe with the drill bit has to be above
-9999.99 to +9999.99 feet ground level to eliminate the alarm. The prox-
imity switch and the counter have been con-
Presets One, 6-digit preset
-9999.99 to +9999.99 meters or
nected parallel in the warning circuit so that if
-9999.99 to +9999.99 feet either of the circuits detect improper drill posi-
tion the alarm will be activated.
Counting Quadrature X4

Counts 10095 pulses/meter (D90K-SP)


7318 pulses/meter (D90K)
7610 pulses/meter (D75K)
DRILL MONITOR SYSTEM (DMS)
10978 pulses/meter (D40K/D50K) The Drill Monitor System provides warning sig-
15857 pulses/meter (D245S) nals to the operator or automatically shuts down
Speed Range 0.00 to 113.00 meters/min (D25)
the machine (for critical out-of-limit conditions)
0.00 to 246.00 meters/min (D90) in the event that the monitored conditions are

Page 2-40 D245S (hpil)


not within safe limits. The system is provided NOTE !
with a thirty second delay for start up, a system Engine oil and coolant temperatures are also
test push button, audible alarm, and a "first out" monitored by the engine electronic control mod-
indication for shut downs. ule (ECM).

There are three different levels of fault sensing:

Level 1. Flashing amber light.


L
Compressor
E Air Filter Alternator
Level 2. Flashing amber light and audible V
alarm. E Engine
Air Filter
Engine
Coolant Level
L
Level 3. Flashing red light, audible alarm, and 1 Fuel Level Compressor
Separator
machine shutdown.
LAMP ALARM Hydraulic
Oil Level
L
The audible alarm can be silenced at any time E Hydraulic
by means of a silence push button. The light V TEST SILENCE Oil Temp.

will continue to flash until the fault condition is E


Hydraulic
cleared. Only one level three fault will be indi- L Oil Filter
2
cated at any one time (first out). This will allow
ALARM
the cause of the shutdown to be easily deter-
Power On Engine Oil
mined. Level three faults can be converted to Temperature

alarm only, if desired, by an external wiring L Compressor


Air Temp.
change. E
V Compressor
E Oil Pressure
The items monitored are:
L
3 Compressor Engine
inter-stage F Coolant Flow
Level 1

Compressor air filter pressure


Engine air filter pressure
Fuel level There are a total of sixteen items sensed. All
Alternator charging Level 3 sensors are normally closed to ground
Engine radiator coolant level under normal operating conditions. An open cir-
Air/oil separator pressure differential cuit will cause machine shutdown. The alterna-
tor charging warning is activated by a voltage of
less than 10 volts at the alternator R terminal.
Level 2
SYSTEM OPERATION
Hydraulic oil level
In the event of a machine shutdown, after the
Hydraulic oil temperature
problem is rectified, it is necessary to turn off
Hydraulic oil filter pressure
the key switch at the start panel momentarily to
Engine oil temperature
reset the system and restart the 30 second time
delay to start the engine.
Level 3
The system operation should be checked once
per shift by turning on the key switch and wait-
Compressor discharge temperature
ing 30 seconds to verify that a shutdown fault is
Compressor inter-stage temperature
indicated and that the fuel system is de-ener-
Compressor oil pressure
gized.
Engine coolant flow

D245S (hpil) Controls and Operation - Page 2-41


NOTE !
The click of the shutdown relay (SDR) contacts
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 verify 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.

Page 2-42 D245S (hpil)