Maintenance Manual Vd5000 6000 8000

AVD DRILL RIG MAINTENANCE MANUAL

AVD DRILL RIG MAINTENANCE MANUAL Rev. October 2008 Last printed 29/04/2009 12:46:00 PM

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Contents PRELIMINA PRELIMINARY RY REMARKS................ REMARKS................................. .................................. .................................. .................................. .................................. .................................. ...................... ..... 5 MANUAL MANUAL ORGANIZA ORGANIZATION TION ................................ ................................................. .................................. .................................. .................................. .................................. ...................... ..... 6 1. SAFETY SAFETY............... ................................ .................................. ................................... ................................... .................................. .................................. .................................. .............................. ............. 7 1.1 GENERAL.......................... GENERAL........................................... .................................. .................................. ................................... ................................... .................................. ........................... .......... 7 1.2 MAINTENANCE PERSONNEL: PERSONNEL: TRAINING AND PERSONAL PROTECTIVE EQUIPEMENT (PPE). 7 1.3 FIRE PREVENT PREVENTION ION .................................. ................................................... .................................. .................................. .................................. .................................. ...................... ..... 8 1.4 DA DAILY ILY SAFETY SAFETY DRILL DRILL CHECK.............................. CHECK............................................... .................................. .................................. ................................... ......................... ....... 9 1.5 RISK ASSESS ASSESSMENT MENT ................................ ................................................. .................................. .................................. .................................. .................................. ...................... ..... 9 2. DRILL DRILL RIG TECHNIC TECHNICAL AL SPECIFICA SPECIFICATION TIONS S ................................. .................................................. .................................. ................................... ....................... ..... 10 2.1 GENERAL GENERAL DESCRIPT DESCRIPTION........................... ION............................................ .................................. .................................. .................................. ..................................10 .................10 2.2 VD5000/80 VD5000/8000 00 DRILL DRILL RIG................................ RIG................................................. .................................. .................................. .................................. ............................... ..............11 11 A) TECHNICAL SPECIFICATIONS.....................................................................................................11 B) WEIGHT WEIGHT AN AND D DIMENSIONS DIMENSIONS .................................. ................................................... .................................. .................................. .................................. .................... ... 12 2.3 VD6000PC VD6000PC DRILL DRILL RIG............................................ RIG............................................................. .................................. .................................. ................................... ....................... ..... 14 A) TECHNICAL SPECIFICATIONS.....................................................................................................14 B) WEIGHT WEIGHT AN AND D DIMENSIONS DIMENSIONS .................................. ................................................... .................................. .................................. .................................. .................... ... 15 2.3 VD6000PT VD6000PT DRILL DRILL RIG ................................. .................................................. .................................. .................................. .................................. ..................................17 .................17 A) TECHNICAL SPECIFICATIONS.....................................................................................................17 B) WEIGHT WEIGHT AN AND D DIMENSIONS DIMENSIONS .................................. ................................................... .................................. .................................. .................................. .................... ... 18 3. MAINTENA MAINTENANCE....................... NCE........................................ .................................. .................................. ................................... ................................... .................................. ......................... ........ 19 3.1 RECOMMENDED SERVICE SCHEDULE.........................................................................................19 3.2 HYDRAU HYDRAULIC LIC POWER POWER PACK PACK .................................. ................................................... .................................. .................................. ................................... ....................... ..... 20 3.2.1 DIESEL ENGINE (AS RECOMMENDED BY JOHN DEERE).....................................................20 3.2.2 TRIPLE PUMP DRIVE DRIVE WITH WITH CLUTCH CLUTCH ................................ ................................................. .................................. .................................. .................... ... 23 3.2.3 HYDRAUL HYDRAULIC IC MAIN PUMPS PUMPS ................................ ................................................. .................................. .................................. .................................. .................... ... 28 3.3 HYDRAU HYDRAULIC LIC SYSTEM SYSTEM................ ................................. .................................. .................................. .................................. .................................. ..................................29 .................29 3.3.1 HYDRAULIC TANK / RETURN FILTER.....................................................................................29 3.3.2 AIR AND WATER OIL COOLING SYSTEM...............................................................................35 3.3.3 GENERAL GENERAL ................................. .................................................. ................................... ................................... .................................. .................................. ............................ ........... 36 AVD DRILL RIG MAINTENANCE MANUAL Rev. October 2008 Last printed 29/04/2009 12:46:00 PM

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3.4 DRILL MAST.....................................................................................................................................37 3.4.1 VISUAL INSPECTION................................................................................................................ 37 3.4.2 DRILL HEAD .............................................................................................................................. 37 3.4.3 PULLEY LUBRICATION ............................................................................................................ 52 3.4.4 PULL CYLINDER STEEL CABLE INSPECTION ....................................................................... 53 3.4.5 MAST SLIDING TABLE (WEAR PLATE)...................................................................................53 3.4.6 VD6000 MAST DUMP (WEAR PLATE)......................................................................................55 3.4.7 HYDRAULIC CYLINDERS (PULL/FEED) ..................................................................................56 3.4.8 ROD CLAMP LUBRICATION.....................................................................................................66 3.4.9 LUBRICANT SPECIFICATIONS ................................................................................................ 66 3.5 WIRELINE WINCH ............................................................................................................................ 67 3.6 WATER PUMP/MUD MIXER............................................................................................................. 68 3.6.1 WATER PUMP ........................................................................................................................... 68 3.6.2 MUD MIXER ............................................................................................................................... 70 3.7 ROD HANDLER................................................................................................................................ 71 3.8 VD5000/8000 DRILL SHACK VISUAL INSPECTION ....................................................................... 73 3.9 VD6000 VISUAL CHECK FOR TRACK TENSION AND WEAR ....................................................... 75 4.0 QUICK REFERENCE............................................................................................................................ 76


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PRELIMINARY REMARKS

Before distribution, this manual should be checked and approved by proper user authorities.

This maintenance manual describes the suggested service and repair procedures based on information provided by MAJOR DRILLING GROUP INTERNATIONAL INC. The information is dedicated to drill rig version VD5000/VD8000

(shack) and VD6000PC/PT (platform), was current at the time of printing but is subject to change without notice or liability.

The manufacturer recommends, in the interests of safety and proper operating procedures, that all personnel engaged in operating or working around this rig be appropriately trained and familiarized with the contents of this manual.

You must follow your company procedure when you service or repair equipment. Be certain you understand all the procedures and instructions before you begin work on any part.

Drill rigs have been designed to handle diamond core drilling up to the rated capacities detailed in the technical specifications section (3.0) of this manual. For this reason, non manufacturer-approved structural or performance modifications could affect the certification and operation of the drill rigs.

SEEKING ASSISTANCE In the event that the given instructions in this manual: •

Are difficult to understand;

•

Are easily misinterpreted;

•

Produce unexpected outcomes when followed;

•

Do not cover eventualities or situations unanticipated at the time of writing…

Please refer to your company’s technical department.

APPROVED BY: __________________________________

DATE: _________________________________

SIGNATURE: __________________________________


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MANUAL ORGANIZATION

This manual is divided into four main sections. The first section, “SAFETY”, describes general safety rules that focus on working around a drill rig.

The second section,

specifications for each drill rig. The third section,

“TECHNICAL DATA”, contains technical

“MAINTENANCE”, provides general explanations regarding

the maintenance of your drill rig and specific information regarding each model presented in this manual. The fourth section, “QUICK

REFERENCE”, provides a resumé of all scheduled maintenance.


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1. SAFETY Before you perform maintenance on your new equipment, we would like to direct your attention to the safety aspects. Good order, training and well-maintained equipment are the key factors for safe operation. This manual is not a replacement for thorough training and knowledge of company safety procedures. It should be used as a training aid and reference, helping you to maintain a safe working environment and keep the rig in good operational condition.

1.1 GENERAL Most accidents involving product operation, maintenance and repair are caused by failure to observe basic safety rules, company safety procedures or precautions. An accident can often be avoided by recognizing potentially hazardous situations before such accident occurs.

AVD ( Atelier Val D’Or inc.) cannot anticipate every possible circumstance that might involve a potential hazard. The advisories in this manual are therefore not all-inclusive. If a tool, procedure, work method or operating technique not specifically recommended by AVD is used, you must satisfy yourself that it is safe for you and others. You should ensure that the product will not be damaged or made unsafe by the operation, lubrication and maintenance or repair procedures you choose. The specifications, torque settings, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service given to the product. Obtain the complete and most current information before starting any job.

The safety recommendations contained in this manual were written to the best of our knowledge and according to the safe work practices generally agreed upon at the time of writing. Make certain you are aware of all of your company’s safety regulations, and any safety-related standards and practices in place at your work site. If these hazard warnings are not heeded, bodily injury or death could be the unfortunate outcome.

1.2 MAINTENANCE PERSONNEL: TRAINING AND PERSONAL PROTECTIVE EQUIPEMENT (PPE) Before attempting to work on this machine it is mandatory that you read the maintenance manual carefully and completely. Familiarize yourself with all controls, gauges, levers and accessories and know what each item is designed to perform, as well as its use, control and safety requirements. Follow company safety procedures and


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instructions as outlined in this manual paying particular attention to all advisories and cautionary notices. Again, all personnel should have the necessary training, skills and tools to perform these functions properly. Moreover, all personnel involved with the maintenance of this rig must be aware of and alert to all potential hazards.

Ensure that you and your assistants have appropriate personal protective equipment before starting work. Improper operation, use of safety devices, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death. For this reason please ensure that you are well-informed on the following points:

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Company procedures

-

Personal protective equipment: Always use personal protective equipment, as required by circumstance or demanded by regulation.

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Protective guards and covers: Make certain all protective guards and covers are fitted on the machine and securely installed.

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Clean machine: Keep the machine and the area around the machine, especially the deck, walkways and steps, clean, tidy and free of foreign material, such as debris, oil, tools etc.

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Use the storage device: Securely store all loose items.

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Never put maintenance fluids into glass containers.

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Use all cleaning solutions with care.

-

Report all needed repairs.

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Do not allow unauthorized personnel access to the machine or the work site.

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Have emergency procedures on hand and familiar to all.

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All machinery is secure before operating.

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The machine is set up properly.

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Ensure that cables and hoses are secure.

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Remember that working machines operate under high stress and loads.

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Ensure that your hand tools and equipment are laid out correctly and are properly maintained.

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Regularly carry out the pre-operational inspections and above all, report any obvious or suspected defects.

1.3 FIRE PREVENTION One or more readily accessible fire extinguishers should be fitted to the machine. Know their location and how to use them and have them serviced as recommended by their manufacturer, your company or local safety regulations. Verify all extinguishers before each use of the drill.


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1.4 DAILY SAFETY DRILL CHECK Ensure that: • • • • • •

All guards and safety pins are in place. All controls are functioning properly. All bolts are tight. There are no hydraulic leaks. There are no distorted, cracked or damaged safety components. The wireline winch and pull cylinder cables are not frayed.

1.5 RISK ASSESSMENT Generally risk assessment takes account of intended use, and foreseeable misuse, including maintenance requirements and process control. AVD has made every effort to minimize situations where personal injury or equipment damage might occur during the normal use of the drill rig. However, the operator still needs to take precautions when handling/using any part of the machine that is unfamiliar or that might present potential hazards.

Also refer to the appropriate section of the “SAFE WORK METHODS HANDBOOK”, published by:

Canadian Diamond Drilling Association City Centre Building, Suite 437 101 Worthington Street East North Bay, Ontario P1B 1G5 Tel: Fax:

(705) 476-6992 (705) 476-9494

Web:

http://www.canadiandrilling.com/

E-mail:

[email protected]


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2. DRILL RIG TECHNICAL SPECIFICATIONS 2.1 GENERAL DESCRIPTION

The VD5000/8000 drill rigs are skid mounted, in a closed shack. The main difference between the two models lies in the rod stacking capacity.

•

The VD5000 drill shack is 3 meters x 6 meters (10ft by 20ft) with a rod stacking capacity of around 1900m (6300ft) (“N” rods).

•

The VD8000 drill shack is 3 meters x 6 meters (10ft by 20ft) with a fold out section giving an extra meter (3ft) of rod stacking area. This puts the rod stacking capacity at around 2500m (8000ft) (“N” rods).

The VD6000 is a drill rig on a platform that can either be mounted on a truck (PT) or track-mounted (PC). Because the drill rig is self-propelled, the unit can be moved into position where access to the drilling area is limited or where one cannot use conventional drill rigs on skids because of the soil abrasiveness and/or configuration.

The 8.2m (27ft) long telescopic drill mast can drill between 90° and 45°. It is designed to pull and run in 3m (10ft) or 3.3m (11ft) strokes using its “H” or “P” drill head (as per customer choice). For transport purposes, the drill mast must sit on the mast rest, rear platform lifted and corner legs up for the VD6000 version.

IMPORTANT The rod rack is intended to be used with 9-meter (30 foot) sections for rod strings. During stacking operations, especially for rod lengths over 6 meters (20 feet), pay special attention to wind conditions. High or gusty winds could affect the stability of the stack. The rod rack is certified for a maximum wind speed of 70 km/h (43 mph) with rods stacked at 80º vertical.


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2.2 VD5000/8000 DRILL RIG A) TECHNICAL SPECIFICATIONS Model

VD5000 / VD8000

Type

Skid mounted, enclosed shack, all hydraulic chuck drive core drill, specially designed for diamond core drilling up to the rated specifications.

Drill mast

8.2m (27ft) long with a capacity to drill at angles between 90° and 45°.

Diesel Engine

The most frequently used power units are John Deere 200HP JD6068TF250 or John Deere 250HP JD6081AF001 with a normal operating speed of up to 2 200 RPM (operating RPM can vary depending on pump configuration/option).

Fuel tank capacity

170 liters (45 US gal.)

Pump drive

Funk triple pump drive (series 28000) with ratio 1.27:1

Rotation Head

AVD (Atelier Val D’Or inc.) type with chain drive head for hydraulic chuck ( as per customer choice) ratio 12/24 on “H” size head, and 12/29 on “P” size head.

Transmission

Funk 4 speed transmission (Ratio 1 6.63:1, 2 3.17:1, 3 1.72:1. 4 1:1)

Head

Hydraulic cylinder directly coupled to the Rotation Head table. The travel is 3m (10ft) or 3.3m (11ft). The pull down and pull up capacities are 13 555 kg (29 820 lbs) and 25 704 kg (56 550 lbs) both at a pressure of 4500PSI.

Pull Cylinder

Hydraulic cylinder with 16 868 kg (37 110 lbs) of maximum pull at 4500PSI.

Water Pump

Standard Bean 435 or Pratissoli KF40 (as per customer choice)

Rod clamp

Boyles style for “B” to “P” sizes.

Wireline winch

The capacity of the wireline winch is up to 3 500m (11,480ft) for 3/16” wireline rope, depending on the option chosen.

Hydraulic

Full flow 25 micron Beta rated return oil filtration; water/oil, air/oil hydraulically motorized (optional) and air/oil (optional, installed on the diesel engine) hydraulic coolers.

Hydraulic tank capacity


Maximum pull capacity

st

nd

rd

th

42 573 kg (93 660 lbs) @ 4500 PSI with feed and pull cylinder.

Rod Rack maximum stacking capacity Rod size Qty (9 meter sections) Depth in: meters feet

BQ (Ø2.19’’)* 243 2 187 7 175

VD5000 NQ (Ø2.75’’) HQ (Ø3.50’’) 216 140 1 944 1 260 6 376 4 132

PQ (Ø4.50’’) 88 792 2 597

Rod size Qty (9 meter sections) Depth in: meters feet

BQ (Ø2.19’’)* 368 3312 10866

VD8000 NQ (Ø2.75’’) HQ (Ø3.50’’) 288 196 2 592 1 764 8 500 5 786

PQ (Ø4.50’’) 121 1 089 3 573

* : comb configured for NQ rod AVD DRILL RIG MAINTENANCE MANUAL Rev. October 2008 Last printed 29/04/2009 12:46:00 PM

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B) WEIGHT AND DIMENSIONS

DIMENSION OF THE DRILL IN TRANSPORT POSITION


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VD5000

VD8000

DIMENSION OF THE DRILL RIG IN WORKING POSITION (mast at 90°)

Overall weight of drill rig on skids: approx. 13 640 kg (30 000 lbs)


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2.3 VD6000PC DRILL RIG A) TECHNICAL SPECIFICATIONS Type

Track-mounted, front driver console, rear operating platform, rod handler, all hydraulic chuck drive core drill, specially designed for diamond core drilling up to the rated specifications.

Track type

CATERPILLAR 320C L (500mm triple grouser track shoes)

Max. travel speed

3 mph (4.8 km/h)

Maximum slope

20%

Maximum cross fall

10%

Drill mast


Diesel Engine

The power unit is a John Deere 250HP JD6081AF001 with a normal operating speed of up to 2 200 RPM (operating RPM can vary depending on pump configuration and option chosen).

Fuel tank capacity


Pump drive


Rotation Head

AVD (Atelier Val D’Or inc.) type with chain drive head for hydraulic chuck ( as per customer choice) ratio 12/24 on “H” size head, and 12/29 on “P” size head.

Transmission


Head

Hydraulic cylinder is directly coupled to the Rotation Head carriage. The travel is 3m (10ft) or 3.3m (11ft). The pull down and pull up capacities are 13 555 kg (29 820 lbs) and 25 704 kg (56 550 lbs) both at a pressure of 4500PSI.

Pull Cylinder

Hydraulic cylinder with 16 868 kg (37 110 lbs) of maximum pull at 4 500PSI.

Water Pump

Standard Bean or Pratissoli (as per customer choice)

Rod clamp

Boyles style for “H” or “P” sizes.

Wireline winch

The capacity of the wireline hoist is up to 3 500m (11,480ft) for 3/16” wireline rope, depending on the option chosen.

Hydraulic






st

nd

rd

th


BQ (Ø2.19’’)* 299 2 691 8 829

VD6000PC NQ (Ø2.75’’) HQ (Ø3.50’’) 234 154 2 106 1 386 6 909 4 547

PQ (Ø4.50’’) 99 891 2 923


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DIMENSIONS OF THE DRILL RIG IN TRANSPORT POSITION


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DIMENSIONS OF THE DRILL RIG IN WORKING POSITION (mast at 90°) Overall weight of drill rig on tracks: approx. 22 800 kg (50 000 lbs)


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2.3 VD6000PT DRILL RIG A) TECHNICAL SPECIFICATIONS Type

Truck-mounted, rear operating platform, rod handler, all hydraulic chuck drive core drill, specially designed for diamond core drilling up to the rated specifications.

Platform weight

13 640 kg (30 000 lbs)

Drill mast


Diesel Engine

The standard power unit used is a John Deere 250HP JD6081AF001 with a normal operating speed of up to 2 200 RPM (operating RPM can vary depending on pump configuration and option chosen). John Deere 275HP JD6090HF485 is available on request.

Fuel tank capacity


Pump drive


Rotation Head

AVD ( Atelier Val D’Or inc.) type with chain drive head for hydraulic chuck (as per customer choice) ratio 12/24 on “H” size head, and 12/29 on “P” size head.

Transmission


Head

Hydraulic cylinder is directly coupled to the Rotation Head carriage. The travel is 3m (10ft) or 3.3m (11ft). The pull down and pull up capacities are 13 555 kg (29 820 lbs) and 25 704 kg (56 550 lbs) both at a pressure of 4500PSI.

Pull Cylinder

Hydraulic cylinder with 16 868 kg (37 110 lbs) of maximum pull at 4 500PSI.

Water Pump

Standard Bean or Pratissoli ( as per customer choice )

Rod clamp

Boyles style for “H” or “P” sizes.

Wireline winch

The capacity of the wireline hoist is up to 3 500m (11,480ft) for 3/16” wireline rope, depending on the option chosen.

Hydraulic






st

nd

rd

th


BQ (Ø2.19’’)* 299 2 691 8 829

VD6000PT NQ (Ø2.75’’) HQ (Ø3.50’’) 234 154 2 106 1 386 6 909 4 547

PQ (Ø4.50’’) 99 891 2 923


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DIMENSIONS OF THE DRILL RIG IN TRANSPORT POSITION

DIMENSIONS OF THE DRILL RIG IN WORKING POSITION (mast at 90°) Overall weight of drill rig mounted on a truck:

approx. 14 780 kg (32 500 lbs) AVD DRILL RIG MAINTENANCE MANUAL Rev. October 2008 Last printed 29/04/2009 12:46:00 PM

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3. MAINTENANCE Keep in mind that routine inspection and maintenance are usually performed by looking, listening and smelling. This basic routine is important in preventing breakdown and lengthening service life. Timely replacement of worn parts based on a maintenance inspection schedule also assures longevity and prevents breakdown. Use the hour meter installed on the main console as a guide. Perform all services at the hourly intervals suggested (see chart section 4).

ENGINE INSTRUMENT PANEL (VD6000 REAR CONSOLE SHOWN)

3.1 RECOMMENDED SERVICE SCHEDULE AVD recommends that users keep a Service Book in which all regular maintenance and all repair works is recorded. This will serve as a reminder and will also help keep track of repairs and their frequency.


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3.2 HYDRAULIC POWER PACK 3.2.1 DIESEL ENGINE (AS RECOMMENDED BY JOHN DEERE) The John Deere diesel engine is a part of the power unit that is directly mounted inside the drill rig. The power unit consists of a diesel engine, a triple pump drive and three hydraulic pumps. The pumps in combination with the consoles are used to feed different functions of the drill. Hydraulic oil is cooled down via the heat exchanger (oil/air, oil/water) to maximize performance. If required, a booster pump is also available as an option.

The diesel engine also provides electrical power (12 volts) for the control system, lighting and electrical connections (remote lighting for example) of the drill rig.

At each scheduled maintenance interval, perform all previous maintenance operations in addition to the ones specified. Refer to the John Deere Operator’s Manual for detailed instructions at each step regarding safety rules and maintenance. For example:

Section 25: Lubrication and maintenance (DAILY) 1- Check oil level on dipstick. Add as required, using seasonal viscosity grade oil.

IMPORTANT: DO NOT fill above the top mark on the dipstick. Oil levels anywhere within the crosshatch are considered to be in the acceptable operating range.

IMPORTANT: If you use a side PTO, you should pay special attention to the oil level. If there is a problem coming from the pump seals, it could affect the oil level (level too high, sump overflow). In this case, we recommend that you inspect the pump seals, change the oil and check the filter.

2-

Check coolant level when engine is cold

3-

Check fuel filter for water or debris

4-

Check air intake restriction indicator gauge and determine if air cleaner needs to be serviced AVD DRILL RIG MAINTENANCE MANUAL Rev. October 2008 Last printed 29/04/2009 12:46:00 PM

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IMPORTANT: Maximum air intake restriction is 25 in. H2O. A clogged air cleaner element will cause excessive intake restriction and reduced air supply to the engine. 5-

Make a thorough inspection of the engine compartment. Look for oil or coolant leaks, fan wear and accessory drive belt, loose connections and trash build-up.

Section 30: Lubrication and maintenance (6 MONTHS / 250 HOURS, whichever comes first) 1- Change engine oil and replace filter

IMPORTANT: Immediately after completing any oil change, crank engine for 30 seconds without permitting engine to start. This will help insure adequate lubrication to engine components before engine starts. 2- Check engine mounts 3- Check battery 4- Visually inspect coolant pump

Section 35: Lubrication and maintenance (12 MONTHS / 500 HOURS, whichever comes first) 1- Clean crankcase vent tube 2- Check air intake system

IMPORTANT: The air intake system must not leak. Any leak, no matter how small, may result in internal engine damage due to abrasive dirt and dust entering the intake system. ALWAYS REPLACE primary air cleaner element when the air restriction indicator either shows a vacuum of 25in. H2O, is torn, or is visibly dirty.

AIR INTAKE CLEANER INDICATOR AVD DRILL RIG MAINTENANCE MANUAL Rev. October 2008 Last printed 29/04/2009 12:46:00 PM

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3- Replace (rectangular) final fuel filter

CAUTION: Escaping fluid under pressure can penetrate the skin causing serious injury. Relieve pressure before disconnecting fuel or other lines. Tighten all connections before applying pressure. Keep hands and body away from pinholes and nozzles which eject fluids under high pressure. Use a piece of cardboard or paper to search for leaks. Do not use your hand. 4- Replacing (round) primary fuel filter/water separator 5- Check belt tensioner spring tension and belt wear 6- Check cooling system 7- Check and adjust engine speed 8- Check crankcase vibration damper 9- Check engine ground connection

Section 40: Lubrication and maintenance (24 MONTHS / 2000 HOURS, whichever comes first) 1- Flush and refill cooling system 2- Check and adjust engine valve clearance

Section 45-Service as required 1- Drain fuel/water separator 2- Add coolant 3- Replace air cleaner filter element 4- Replace fan/alternator belt 5- Check fuses 6- Check electrical wiring and connections 7- Bleed fuel system

Section 50-Troubleshooting 1- Engine wiring diagram 2- Engine troubleshooting 3- Electrical troubleshooting 4- Lubrication system troubleshooting 5- Cooling system troubleshooting 6- Air intake system troubleshooting 7- Diagnostic trouble code procedure


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3.2.2 TRIPLE PUMP DRIVE WITH CLUTCH

FUNK TRIPLE PUMP DRIVE SERIES 28000

A) General visual inspection procedures Look for oil leaks and damage. Thoroughly clean the outside before doing anything else. If for any reason you need to handle machined parts, handle them carefully to prevent nicking or burring of machined surfaces.

B) Check Oil Level

IMPORTANT:

Check oil level at the beginning of each shift in which the machine is used. Inspect the Pump Drive for leaks or visible damage.

1. Run the Pump Drive until the lubricating oil is warm 2. Ensure that the Pump Drive is near level 3. Stop engine before servicing Pump Drive 4. Clean around the dipstick gauge 5. Check oil level


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NOTE: Keep the oil level near the “FULL” mark.

IMPORTANT: Too much oil in the Pump Drive may be an indication that an oil seal on a pump has failed and must be repaired. The oil should be changed whenever it shows traces of dirt, contamination by other fluids or the effects of high temperature evidenced by discoloration or strong odour. Under no circumstances should the gear case oil go unchanged for more than six months. Condensation may contaminate the oil, reducing its effectiveness. 6. Add oil or change oil if necessary

IMPORTANT: Do not overfill. Too much oil will cause the Pump Drive to overheat.

C) Change Oil First oil change Change oil after the first 100 hours of use or six months, whichever comes first.

Routine oil changes Change oil every SIX MONTHS or 2000 HOURS of use, whichever comes first.

Oil change procedure: 1. Run the Pump Drive until the lubricating oil is warm 2. Ensure that the Pump Drive is near level 3. Stop engine before servicing the Pump Drive 4. Ensure that the main switch on the engine is at "OFF" and locked out (padlock) 5. Clean around the oil drain, fill, and check locations 6. Look for oil leaks and damage 7. Place a container that is large enough to hold all of the oil in the Pump Drive under the drain location 8. Remove the drain plug 9. Look for metal particles on the magnetic end of the drain plug

IMPORTANT: If you find any metal particles on the magnetic end, immediately advise your service department and await instructions.


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10. Clean and replace drain plug 11. Remove the fill plug and breather as an assembly 12. Clean, inspect, and check the function of the breather

NOTE: The breather should allow pressure to equalize inside the gear case as it heats and cools all the while keeping out dirt and water. IMPORTANT: Do not overfill. Too much oil will cause the Pump Drive to overheat.

13. Refill the gear case to proper level using one of the recommended oils 14. Replace the fill plug and breather assembly 15. Operate the Pump Drive for several minutes. Look for oil leaks and listen for unusual sounds

D) Lubricate Clutch and Remote Input Grease Fittings Grease Specifications: Use lithium soap base grease NLG1 No.2 or equivalent, containing antioxidant and EP additives.

NOTE: This grease is for normal operating conditions. If severe conditions are expected, contact a FUNK distributor with specific information, and await recommendations. Application: Refer to the “LUBRICATION AND MAINTENANCE SERVICE INTERVAL CHART” for quantities.

Every 10 hours of operation: Lubricate the bronze throw-out collar for the clutch. The grease fitting is located on the clutch housing near the inspection plate and is connected to the throw-out collar by a flexible hose.

IMPORTANT: Do not over lubricate the bronze throw-out collar. Excess grease may get into the clutch assembly causing slippage and damage. For this reason, remove the plate shown below and grease the collar until you see a small quantity of grease coming out of the bearing. Usually, 1-2 strokes from a hand operated grease gun will suffice.


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BRONZE THROW-OUT COLLAR

Every 50 hours of operation:

Lubricate the clutch operating shaft (cross shaft). There are two grease fittings provided. One fitting is located on each side of the clutch housing under the operating shaft bores.


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E) Oil and Grease Specifications recommended by FUNK manufacturing company Grease fittings: Use lithium soap base grease NLG1 No.2 or the equivalent, containing antioxidant and EP additives. NOTE: This grease is for normal operating conditions. If severe conditions are expected, contact your maintenance department for instructions.

Oils recommended by FUNK manufacturing company Gear Case Use any oil that meets or exceeds EP Gear Lubricant Spec Mil-L-2105C , API Classification GL-5 or the equivalent. In applications where oil operating temperature may exceed 180°F (82 °C) FUNK approves the use of a synthetic oil meeting the above specifications.

Oil Grades 1. Temperature below -10°F (-23°C): use 75W 2. Temperature above -10°F (-23°C) and up to 100 °F (37.8 °C): use 85W90 3. Temperature above 100 °F (37.8 °C): use 85W140

NOTE: Refer to Air Temperature Range Chart in this group for other recommendations regarding oil.

4. All FUNK forced lube units utilize JDM J20C oil.

The drills are shipped from the factory with gear cases filled with SuperGear 80W90 from “Lubrifiants SaintLaurent” for the gear case and greased with ESSO Unirex EP 2 .

Note:

The previous information is an abstract of the “Pump Drive Service Manual” from FUNK manufacturing company. Before each use, always refer to this manual or to your service department for detailed instructions regarding safety rules and maintenance.


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3.2.3 HYDRAULIC MAIN PUMPS

A) VD5000/8000 drill rig The hydraulic unit is divided into three circuits: Closed circuit #1: Open circuit #2: Open circuit #3:

Jackleg, rod handler, mast tilt, wireline winch, water pump. Thread follower, joystick control, manual clamp, chuck/rod clamp, feed cylinder. Head rotation, pull cylinder, fast feed

Three independent pumps are used to supply oil to each circuit. Each pump is installed directly on the pump drive described previously.

B) VD6000PC drill rig The hydraulic unit is divided into five circuits: Open circuit #1: Open circuit #2: Open circuit #3: Closed circuit #4: Closed circuit #5:

Left track, jackleg, rod handler, wireline winch, water pump. Thread follower, joystick control, rod rack, manual clamp, chuck/rod clamp, feed cylinder. Right track, drill head rotation, pull cylinder, fast feed. Oil cooling motor fan. Booster pump motor.

Five independent pumps are used to supply oil to each circuit. The three major pumps are installed directly on the pump drive described previously and two others are installed on the side PTO (oil cooler, booster pump).

C) VD6000PT drill rig The hydraulic unit is divided into five circuits: Open circuit #1: Open circuit #2: Open circuit #3: Closed circuit #4: Closed circuit #5:

Thread follower, joystick control, rod rack, manual clamp, chuck/rod clamp, feed cylinder. Jackleg, rod handler, wireline winch, water pump, rear platform jackleg and tongue. Drill head rotation, pull cylinder, fast feed. Oil cooling motor fan. Booster pump motor.

Five independent pumps are used to supply oil to each circuit. The three major pumps are installed directly on the pump drive described previously and two others are installed on the side PTO (oil cooler, booster pump).

Note:

For detailed information regarding pump configuration refer to your Parts Catalogue.


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3.3 HYDRAULIC SYSTEM 3.3.1 HYDRAULIC TANK / RETURN FILTER

VD5000/8000 HYDRAULIC TANK

VD6000 HYDRAULIC TANK


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A) Check oil Level

IMPORTANT: Check oil level at the beginning of each shift before the machine is used. Inspect the reservoir for leaks or visible damage. 1. Run the hydraulic system until the oil reaches its operating temperature 2. Be certain the tank is near level 3. Stop the engine before servicing the hydraulic tank 4. Clean around the gauge 5. Check oil level NOTE: Keep the oil level close to the “full” mark.

IMPORTANT: The oil should be changed whenever it shows traces of dirt, contamination by other fluids or the effects of high temperature evidenced by discoloration or strong odour. Under no circumstances should the hydraulic oil be used for more than 6 MONTHS without change. Condensation may contaminate the oil, reducing its effectiveness. If you find any metal particles on the magnetic end, immediately advise your service department and await instructions. 6. Add or change oil if necessary

NOTE: Oil should be drained while the unit is still warm and the used oil examined for contamination or metal particles. After draining the oil, clean the tank and the magnetic drain plug before replacing.


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VD 6000 HAND PUMP

VD5000/8000 HAND PUMP

. IMPORTANT: Extreme care should be taken when adding or changing hydraulic oil so as not to contaminate the system. Add fluid to the tank only with the fill pump installed on the drill. The experience of hydraulic system designers and maintenance supervisors has shown that about 75% of the downtime on hydraulically operated machinery is caused by dirt in the hydraulic fluid. Particular care should be taken when disconnecting and reconnecting any hoses or “quick disconnects” on the hydraulic system. If dirt has entered the connection, it must be carefully cleaned.


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B) Change Oil/Filter First oil/filter change Change oil and filters after the first SIX MONTHS or 100 HOURS of service, whichever comes first.

Routine oil/filter changes Change filters every 3 MONTHS or 1 500 HOURS of service, whichever comes first. Change oil every 6 MONTHS or 2 500 HOURS of service, whichever comes first.

FILTER VISUAL CLOGGING INDICATOR

Note:

On the latest drill rig version, there is a visual clogging indicator that will show when it is time to service the filter.


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Oil change procedure: 1. Run the hydraulic unit until the oil is warm 2. Ensure that the hydraulic tank is near level 3. Stop engine before servicing the hydraulic unit 4. Ensure that the main switch on the engine is "OFF" and locked-out (padlock) 5. Clean around the oil drain valve 6. Look for oil leaks and damage 7. Connect a hose to the drain valve and use the appropriate container to collect the used oil 8. Open the drain valve to empty the tank 9. Remove the return filters NOTE: The return filter actually filters all oil returning to the tank except for the drain lines of the cases. It has three or four elements, one per pump. The oil flows through the three elements in parallel. It is recommended that the filter elements be changed a minimum of every 3 months to keep a smooth flow.

IMPORTANT:Based on your company maintenance policy, check the used filters for any unusual contaminants. 10. Check the breather for functionality and cleanliness 11. Open the clean-out covers to inspect and clean thoroughly the inside of the tank 12. Re-install the clean-out covers, close the drain valve and use new return filters 13. Refill the tank to proper level using one of the recommended oils 14. Operate the unit for several minutes. Look for oil leaks and listen for unusual sounds 15. Check for oil level and refill the tank to proper level if necessary


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C) Recommended hydraulic oil The hydraulic fluid must be of a high-grade petroleum based fluid meeting the DENISON HF-0 standard. The viscosity range recommended are ISO VG 22 (winter) and ISO VG 32 (summer).

The drills are shipped from the factory with the hydraulic unit filled with HYDRAULIQUE 22 or 32 from “Lubrifiants Saint-Laurent” depending upon where the drill is operating. Check with your usual company supplier to ensure that the hydraulic oil you use is equivalent to or compatible with the one supplied.

Please contact your company for any questions on fluids if operating conditions are not within your standard conditions.


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3.3.2 AIR AND WATER OIL COOLING SYSTEM

The air-oil cooler (radiator) is located at the front of the diesel engine radiator and utilizes the cooling power coming from the engine fan.

For maximum efficiency, pay special attention to the cleanliness of the radiator fins. For the air/oil cooler on hinges (all drill rigs), clean the area between the engine radiator and the hydraulic radiator.

By following the above maintenance procedures, the customer will ensure that the machine is in top operating condition and avoid unnecessary down time due to oil contamination.

The shell and tube heat exchanger doesn't require any particular maintenance.

SHELL AND TUBE HEAT EXCHANGER


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VD5000/8000 AIR/OIL COOLER

VD6000 AIR/OIL COOLER

3.3.3 GENERAL

Check for premature wear, damaged hoses and connections for oil leaks. If found, replace the hoses, retighten the loose fitting or replace it to stop the leak. AVD DRILL RIG MAINTENANCE MANUAL Rev. October 2008 Last printed 29/04/2009 12:46:00 PM

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3.4 DRILL MAST 3.4.1 VISUAL INSPECTION Make a visual inspection of the mast structure, checking for any cracked or deformed structural parts (structural integrity). Special attention should be directed to the following parts: - Mast pivot, - Tilt cylinders and stiff leg attachments, - Feed and pull cylinder attachments, - Drill head base or base guiding slide.

Check also the hose connections, the hydraulic cylinders, the hydraulic motor, the FUNK transmission, the head gear case, the chuck and the rod clamp for oil leaks or mechanical defects.

3.4.2 DRILL HEAD

DRILL HEAD AVD DRILL RIG MAINTENANCE MANUAL Rev. October 2008 Last printed 29/04/2009 12:46:00 PM

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TRANSMISSION DETAILS


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HEAD LUBRICATION POINTS A) Lubricate the chuck and the upper bearings of the drill head. First use Ensure that the bearing and the chuck bowl are properly greased.

Refer to your service department for

instructions.

Application: Refer to the “Lubrication and maintenance service interval chart” for quantities.


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Every 12 HOURS of operation: Lubricate the bearing inside the lower part of the chuck. The grease fitting is located at the front of the chuck and is directly connected to the bearing. The rotating part of the chuck containing the jaws must be greased (2 grease fittings) at the same frequency.

IMPORTANT: Do not over-lubricate the bearing. Excess grease may cause permanent damage.

B) Check Oil Level

IMPORTANT: Check oil level at the beginning of each shift the machine is used. Inspect the motor, the transmission, the gearbox and the chuck for leaks or visible damage. 1. Run the drill head until the lubricating oil is warm 2. Stop engine before servicing the drill head 3. Clean around the sight glass and the hoses 4. Check oil level on the transmission and the drill head gearbox NOTE: Keep the oil level as shown in the previous illustration

IMPORTANT: Too much oil in the transmission may be an indication that an oil seal on the hydraulic motor has failed and must be changed. Too much oil in the drill head (overflow from drill head breather) may be an indication that an oil seal between the transmission and the head has failed and must be changed. If the oil within the drill head is also of an off-white color, this indicates the presence of water. The oil must be changed and the spindle upper seals (2) checked. The oil should be changed whenever it shows traces of dirt, contamination by other fluids or the effects of high temperature as evidenced by discoloration or strong odour. Under no circumstances should the gearbox and transmission oil go unchanged for more than six months. Condensation may contaminate the oil and reduce its effectiveness. 5. Add oil or change oil if necessary

IMPORTANT: Do not overfill. Too much oil will cause overheating of the transmission and head gearbox.


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C) Change Oil on drill head First oil change Change oil after the first SIX MONTHS or 100 HOURS of service, whichever comes first.

Routine oil changes Change oil every SIX MONTHS or 250 HOURS of service, whichever comes first.

Oil change procedure: 1. Run the drill head until the lubricating oil is warm 2. Stop engine before servicing the drill head 3. Make absolutely certain that the main switch on the engine is “OFF” and locked out (padlock) 4. Clean around the oil drain, fill, and check locations 5. Look for oil leaks and damage 7. Under the drain location, place a container that is large enough to hold the combined volumes of oil in both the transmission and head gearbox 8. Remove the drain plug 9. Look for metal particles on the magnetic end of the drain plug

IMPORTANT: If you find any metal particles on the magnetic end, immediately advise your service department and await instructions. 10. Remove the cover plate of the gearbox to clean the inside thoroughly 11. Inspect the chain and sprockets for any premature wear or damage 12. Clean and replace the drain plug 13. Remove the fill plug (drill head) and the hose breather clamp (transmission) 14. Clean, inspect, and check the function of the breather

NOTE: The breather should allow pressure to equalize inside the gear case as it alternately heats and cools all the while keeping out dirt and water. IMPORTANT: Do not overfill. Too much oil will cause the transmission/gearbox to overheat.


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15. Refill the transmission/gearbox to the proper level using one of the recommended oils. 16. Replace the fill plug and breather assembly. 17. Operate the drill head for several minutes. Look for oil leaks and listen for unusual sounds.

IMPORTANT: The thrust bearing (top bearing) inside the drill head is “splash” lubricated. Lubrication comes from the immersion and movement of the chain in an oil bath. th

Run the drill head for at least one minute at maximum RPM ( 4 gear on FUNK transmission). This will ensure proper lubrication for the drill head bearing. When drilling at low RPM the thrust bearing is not lubricated sufficiently because the chain doesn’t create any oil projection inside the head. To overcome this problem, two solutions exist. First, at a frequency predetermined by your company, disengage the chuck from the drill rod to have the head free for rotation. Then run the drill head for at least one minute at th maximum RPM (4 gear on FUNK transmission). This will insure proper lubrication of the drill head bearing. The second solution is to install a lubrication pump (optional). This device will insure continuous lubrication of the bearing independently of the working conditions.

LUBRICATION PUMP


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D) Drill head overhaul 1.

Run the drill head until the lubricating oil is warm

2.

Stop the engine before servicing the drill head

3.

Ensure that the main switch on the engine is on "OFF" and locked-out (padlock)

4.

Clean around the oil drain, fill, and check locations

5.

Look for oil leaks and damage

7.

Under the drain location, place a container that is large enough to hold the combined volumes of oil in both the transmission and head gearbox

8.

Remove the drain plug

9.

Look for metal particles on the magnetic end of the drain plug

IMPORTANT: If you find any metal particles on the magnetic end, immediately advise your service department and await instructions.


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10. Remove the transmission and the transmission adaptor plate

TRANSMISSION REMOVAL


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11. Remove the retaining ring and Gib head keys (3) that lock the spindle to the chuck.

CHUCK REMOVAL


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12. Unscrew all nuts identified in the picture 13. Remove the chuck from the gearbox

Note:

To remove the chuck, you will require three eyebolts and the chuck removal tool. Install the eyebolt and attach the chuck to a bridge crane or any other device that will support the weight of the chuck (Chuck “P” 210kg (460lbs), Chuck “H” 114kg (250lbs)). Use the removal tool to unscrew the chuck from the spindle.

CHUCK REMOVAL


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14. Remove the gearbox cover plate 15. Remove the chain and check it for premature wear or damage 16. Disassemble the drill head transmission shaft assembly

COVER PLATE AND DRILL HEAD TRANSMISSION SHAFT ARRANGEMENT


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17. Remove drill head lower spindle retaining ring 18. Remove drill head upper spindle retaining ring

DRILL HEAD LOWER SPINDLE ASSEMBLY


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DRILL “P” HEAD UPPER SPINDLE ASSEMBLY

19. Clean thoroughly the inside of the gearbox and parts with the appropriate product 20. Re-assemble the drill head with the new bearings


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IMPORTANT: The spindle and transmission thrust bearing must be installed in a specific manner to function properly. Refer to your maintenance department for instructions.

To ensure longer life it is very important to keep the new bearings and seals clean during installation. Pack the new bearing with a liberal amount of bearing grease before installation. To prevent oil leakage: apply any gasket-related product (ex. Loctite Gasket Eliminator 518 ) on the sprocket bearing cap, lower, upper spindle retaining ring and screws before assembly. Control the amount of product you use to prevent overflow inside the drill head. Check or replace the oil seal and “O”-ring with new ones to prevent oil leakage coming from used/damaged seals.

21. Re-install the chuck

IMPORTANT: Do not forget to replace the retaining ring and the gib head keys (3) that lock the spindle with the chuck. 22. Use the spindle adjustment nut to tighten the spindle and the thrust bearing assembly 23. Use the locking nut and the cap nut to finalize the assembly

IMPORTANT: Pay special attention during this operation to ensure that the nuts are welltightened. If not, the spindle thrust bearing could be seriously damaged. During AVD DRILL RIG MAINTENANCE MANUAL Rev. October 2008 Last printed 29/04/2009 12:46:00 PM

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normal operations, this should be repeated several times during the first shift. Then, once at the beginning of each shift should be sufficient. 24. Clean all parts and install the cover plate and the drain plug.

IMPORTANT: To prevent oil leakage, apply any gasket-related product (ex. Loctite Gasket Eliminator 518) between the cover plate and the drill head. Limit the amount of product you use to prevent overflow inside the drill head.

25. Re-install the transmission and adaptor plate

IMPORTANT: To prevent oil leakage, apply any gasket-related product (ex. Loctite Gasket Eliminator 518) between the adaptor plate and t he drill head. Limit the amount of product you use to prevent overflow inside the drill head through the bearing.

26. Refill transmission and gearbox with oil.

IMPORTANT: Do not overfill. Too much oil will cause the transmission/gearbox to overheat. th

Run the drill head for at least one minute at maximum RPM ( 4 gear on FUNK transmission). This will ensure proper lubrication of the drill head bearing. 27. Operate the drill head for several minutes. Look for oil leaks and listen for unusual sounds.


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3.4.3 PULLEY LUBRICATION

MAST PULLEY ARRANGEMENT

Application: Use several strokes from a hand operated grease gun until grease is released from the bearing. This will allow new grease to replace old grease and expulse debris or any grease contaminants. Refer to the “Lubrication

and maintenance service interval chart” for approximate quantity.

Twice per week: Lubricate the bearing inside the wheel pulley. The grease fittings are located at each end of the pulley-greasing pin.


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3.4.4 PULL CYLINDER STEEL CABLE INSPECTION A thorough inspection should be carried out ONCE PER MONTH. If broken wires or other damages have been detected the intervals should be revised to a more frequent basis.

3.4.5 MAST SLIDING TABLE (WEAR PLATE) Do a visual inspection of the mast table, to check for any cracked or deformed structural parts (structural integrity). Ensure that the mast table moves freely on the mast side slides and check for excessive wear, and for missing or damaged wear plates. Ensure that the table is properly aligned with the mast.

If the mast table needs to be aligned, and the wear plates look OK, use side set screws to align the sliding table with the mast.

IMPORTANT: Do not overtighten the set screws. Use “locknut” to prevent the set screws from loosening.


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Otherwise, replace any missing wear plates or parts showing excessive wear (±1/16 for top and bottom wear plates). Always refer to your service department for detailed instructions or to help determine if it is time to change the wear plates.

WEAR PLATE ADJUSTMENT/ REPLACEMENT


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3.4.6 VD6000 MAST DUMP (WEAR PLATE) Perform a visual inspection of the sliding guide, to check for any cracked or deformed structural parts (structural integrity). Verify that the mast dump table moves freely on the mast side slide and that there is no excessive wear, or missing or damaged wear plates.

Replace any missing wear plate or parts showing excessive wear (±1/16 for top and bottom wear plates). Always refer to your service department for detailed instructions or to help determine if it is time to change the wear plates.

MAST DUMP WEAR PLATE REPLACEMENT


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3.4.7 HYDRAULIC CYLINDERS (PULL/FEED) A) Feed cylinder 1. Using the mast dump control and feed cylinder control align the head holding plate with the holes 2. Remove the head holding plate

HOLDING PLATE REMOVAL

3. Lower the drill head 4. Retract the mast with the mast dump control 5. Lower the drill mast on the mast rest


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6. Stop the engine before removing the drill head 7. Ensure that the main switch on the engine is on "OFF" and locked-out (padlock) 8. Clean around the mast to prevent any injuries 9. Look for oil leaks and damage 10. Disconnect hydraulic hoses from the drill head and use plug to close it 11. Remove the drill head 11.1 Loosen the swing bolts (2) 11.2 Remove drill head hinge pin 12. Flip the rod clamp

DRILL HEAD AND ROD CLAMP REMOVAL


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13. Remove the mast table

MAST TABLE REMOVAL


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14. Remove the feed cylinder pin 15. Move feed cylinder downward to have access to the feed cylinder guide

FEED CYLINDER REMOVAL STEP 1


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16. Disassemble the guide assembly from the feed cylinder 17. Remove the feed cylinder from the mast

FEED CYLINDER REMOVAL STEP 2

Note:

Perform a visual inspection of the cylinder, checking for any cracked or damaged parts. Special attention to leaks should be taken during inspection of the cylinder head, connections and rods. If necessary, refer to your service department for instructions regarding seal changeover or repairs.


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B) Pull cylinder 1. Use mast tilt control to place the drill m ast at 90° 2. Lower the drill head 3. Use mast dump control to move the drill mast completely up 4. Stop the engine before removing the drill head 5. Ensure that the main switch on the engine is on "OFF" and locked-out (padlock) 6. Clean around the mast to prevent any injuries 7. Check for oil leaks and damage 8. Disconnect hydraulic hoses from the pull cylinder and plug to close it 9. Disassemble the pulley from the pull cylinder

PULL CYLINDER PULLEY REMOVAL AVD DRILL RIG MAINTENANCE MANUAL Rev. October 2008 Last printed 29/04/2009 12:46:00 PM

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10. Remove the hose protection channel

HOSE PROTECTION CHANNEL REMOVAL


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11. Remove the retaining collar

RETAINING COLLAR REMOVAL


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12. Remove pull cylinder pin

PULL CYLINDER PIN REMOVAL


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13. Rotate the cylinder 90° to clear the hydraulic h ydraulic fitting 14. Lift the cylinder to clear the mast base

PULL CYLINDER REMOVAL AVD DRILL RIG MAINTENANCE MANUAL Rev. October 2008 Last printed 29/04/2009 12:46:00 PM

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3.4.8 ROD CLAMP LUBRICATION Lubricate the rod clamp Application: Use several strokes from a hand operated grease gun.

Every 12 HOURS of operation: Lubricate the jaws inside the rod clamp using the grease fitting located at the front of the clamp.

3.4.9 LUBRICANT SPECIFICATIONS Recommendation regarding grease Use premium quality industrial grade grease, according to your company standard. The drills are shipped from the factory greased with ESSO Unirex EP 2 . Check with your supplier to ensure that the grease you you use is equivalent to or compatible with this grease.

Recommendation regarding oil Based on your company standard, the oil should be of a recognized brand name from a major oil company such as ESSO, SHELL, TEXACO, etc. This will ensure consistent quality. qua lity.

The drills are shipped from the factory with gear cases filled with SuperGear 80W90 from “Lubrifiants SaintLaurent”.

Should any problems or questions regarding oil characteristics or oil choices arise, refer to your service department.


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3.5 WIRELINE WINCH Perform a visual inspection of the wireline winch, checking for any cracked or deformed structural parts (structural integrity). Special attention should be paid to the steel cable. A thorough inspection should be carried out

MONTHLY. If broken wires or other damage has been detected the intervals should be revised to a more frequent basis.

The wireline winch is shipped from the company with sealed bearings and does not require any particular maintenance intervention.

On the other hand, the cable guide mechanism must to be checked and lubricated with a hand-operated grease gun at least ONCE PER SHIFT (12 HOURS). Use industrial grade premium quality grease, according to your company standard.

The wireline winch is shipped from the factory greased with ESSO Unirex EP 2 . Check with your supplier to ensure that the grease you use is equivalent to or compatible with this grease.

WIRELINE WINCH AVD DRILL RIG MAINTENANCE MANUAL Rev. October 2008 Last printed 29/04/2009 12:46:00 PM

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3.6 WATER PUMP/MUD MIXER 3.6.1 WATER PUMP

“PRATISSOLI”

“BEAN” 1.

Oil level indicator

2.

Magnetic plug

3.

Fill plug

For each use, refer to the “Pratissoli” or “Bean” manuals for detailed instructions regarding safety rules and maintenance.


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A) Check Oil Level

IMPORTANT: Check oil level before use EACH WORKING DAY. Inspect the motor, the coupling and the crankcase for leaks or visible damage. 1. Run the water pump until the lubricating oil is warm 2. Stop the engine before servicing the pump 3. Clean around the sight glass and the hoses 4. Check oil level on the water pump crankcase

IMPORTANT: If the oil within the crankcase is of an off-white color, this indicates the presence of water. The oil must be changed and pump inspected. Refer to the pump manual for detailed instructions. The oil should be changed whenever it shows traces of dirt, contamination by other fluids or the effects of high temperature evidenced by discoloration or strong odour. Under no circumstances should the crankcase oil go unchanged for more than twelve months. Condensation may contaminate the oil reducing its effectiveness. 5. Add oil or change oil if necessary

B) Oil Changes First oil change Change oil after the FIRST MONTH or 50 HOURS of service, whichever comes first.

Routine oil changes Change oil every 12 MONTHS or 500 HOURS of service, whichever comes first.

Oil change procedure: 1. Run the water pump until the lubricating oil is warm 2. Stop the engine before servicing the water pump 3. Ensure that the main switch on the engine is "OFF" and locked-out (padlock) AVD DRILL RIG MAINTENANCE MANUAL Rev. October 2008 Last printed 29/04/2009 12:46:00 PM

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4. Clean around the oil drain, fill, and check locations 5. Look for oil leaks and damage 7. Place a container that is large enough to hold all of the crankcase oil under the drain location 8. Remove the drain plug 9. Look for metal particles on the magnetic end of the drain plug

IMPORTANT: If you find any metal particles on the magnetic end, immediately advise your service department and await instructions. 10. Before filling the pump with new oil, wash the crankcase and crankshaft mechanism 11. Clean and replace the drain plug 12. Remove the fill plugs (3) 13. Refill the crankcase to the proper level using one of the recommended oils (3.8 liters) 14. Replace the fill plug 15. Operate the water pump. Check for oil leaks and listen for unusual sounds

3.6.2 MUD MIXER Perform a visual inspection of the mud mixer impeller and hydraulic motor. A thorough inspection should be carried out DAILY.


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3.7 ROD HANDLER Perform a visual inspection of the sliding table, to check for any cracked or deformed structural parts (structural integrity). Check if the mast table moves freely and for excessive wear, and missing or damaged wear plates. Replace all missing wear plates or worn parts (±1/16 for top and bottom wear plate). Always refer to your service department for detailed instructions or for help to determine if it is time to change the wear plates.

Perform a visual inspection of the manipulator hand, mast frame, ropes (frayed, premature wear or improper tension) and pulley arrangement. Check for any cracked or deformed structural parts (structural integrity) or premature wear.

ROD HANDLER


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Every 50 HOURS of operation: Lubricate the hand swivel and pivot pins. The grease fittings are located at each extremity for the swivel shaft and under the hand for the pivot.

Application: Apply several strokes from a hand-operated grease gun.

ROD HANDLER CABLE ARRANGEMENT Cable changeover/tension adjustment:

For cable installation, mast should be fully retracted. Refer to the previous illustration for cable arrangement (blue: 135” long cable, Red: 163” long cable). Using a wrench stretch the cables to remove any sagging. Move the mast back and forth several times and check again for cable tension. If necessary, repeat procedure and check if the cable is sufficiently tight.


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3.8 VD5000/8000 DRILL SHACK VISUAL INSPECTION Perform a visual inspection of the structure to check for any cracked, deformed structural parts (structural integrity) or premature wear. Also, verify that all door hinges work properly. If not, use a hand-operated grease gun to grease hinges.

Special attention should be paid to the following sections of the shack.

a) Floor under and around the mast bases b) Rod rack structure (rod rack, support legs, extension leg and ground extension leg (VD-8000)) c)

Mast stiff leg attachments (floor and mast pins)

d) Skid wear plate (check after move) e) Overall structure


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DOOR HINGE GREASE FITTINGS (VD 8000 SHOWN)

SKID WEAR PLATE (VD 8000 SHOWN) AVD DRILL RIG MAINTENANCE MANUAL Rev. October 2008 Last printed 29/04/2009 12:46:00 PM

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3.9 VD6000 VISUAL CHECK FOR TRACK TENSION AND WEAR Perform a visual inspection of the platform structure, the dozer, the track tension and wear to check for any cracked, or deformed structural parts (structural integrity) or premature wear.

VD6000 TRACK INSPECTION

Special attention should be paid to the following section of the drill rig.

a) Main platform under and around the mast bases. b) Rod rack structure (Rear platform floor, rod rack, support legs, extension legs and ground extension leg). c)

Mast stiff leg attachments (platform floor and mast pins).

d) Undercarriage.

NOTE:

The most important factor in undercarriage wear is proper track-train adjustment. Before each visual check, follow the instructions given in your Caterpillar Operator’s Manual or check with the dealer for correct measurement of the track sag and for detailed information regarding safety rules and pre-op checks. The operator checks and manually adjusts the track tension, greasing if necessary.

e) Main platform tilt pin. f)

Overall structure. AVD DRILL RIG MAINTENANCE MANUAL Rev. October 2008 Last printed 29/04/2009 12:46:00 PM

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4.0 QUICK REFERENCE


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Maintenance Manual Vd5000 6000 8000

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