LF90D

Manual Operation and Maintenance

 LF90D

COMMISSIONING PROCEDURE
DRAFT
Table of contents
1 VISUAL INSPECTION AND OTHER NOTES ............................................................................ 4
2 COMPONENT CLEANING......................................................................................................... 4
3 GREASE THE ITEMS LISTED BELOW ..................................................................................... 4
4 OIL FILTER CHART ................................................................................................................... 5
5 DIESEL ENGINE PREPARATIONS........................................................................................... 5
6 MISCELLANEOUS HYDRAULIC CHECKPOINTS .................................................................... 5
6.1 Oil cooler......................................................................................................................... 5
6.2 Main winch ......................................................................................................................5
6.3 Wire line winch motor...................................................................................................... 7
6.4 Rotation head motor ....................................................................................................... 7
6.5 Traverse cylinder ............................................................................................................ 7
6.6 Mast raise cylinders ........................................................................................................ 7
6.7 Mast dump cylinder......................................................................................................... 7
6.8 Control cabinet................................................................................................................ 7
6.9 Main control valve m4-15 ................................................................................................ 7
6.10 jack leg 4 sPOOL/ Mast raise / Mast dump 8 SPOOL VALVE....................................... 9
6.11 Water pump system ........................................................................................................ 9
6.12 Main control valve ........................................................................................................... 9
6.13 Hand pump ..................................................................................................................... 9
7 MISCELLANEOUS MECHANICAL CHECKPOINTS.................................................................. 9
8 PRIME THE HYDRAULIC PUMPS .......................................................................................... 10
9 LUBRICATING OIL CHART ..................................................................................................... 10
10 SHORT CIRCUIT THE MAIN SUPPLY HOSES OF THE FOLLOWING MOTORS............. 10
11 CONTROL ADJUSTMENT IN PREPARATION FOR FLUSHING........................................ 10
12 FIRST EVER DIESEL START-UP ....................................................................................... 11
13 boost pump setup (high altitude rigs) ................................................................................... 11
14 FLUSHING ........................................................................................................................... 12
14.1 Flushing Table. ............................................................................................................. 12
14.2 Flushing Circuit Pressure Checks................................................................................. 12
15 Pump 6c (Pilot pressure, cooling fan, boost pump) ............................................................. 13
15.1 THIRD STAGE PUMP 6C ............................................................................................. 13
1. Flow & Pressure Regulator Adjustment Procedure (Boost Pump installed).............. 13
2. PILOT Pressure Relief Valve Item 37.2 Adjustment Procedure................................ 14
3. Flow & Pressure Regulator Adjustment Procedure (Boost Pump not installed)........ 14
4.PILOT Pressure Relief Valve Item 37.2 Adjustment Procedure (no boost pump)..... 15 15.2
SECOND STAGE PUMP 6B......................................................................................... 15 15.2.1
Flow Regulator Adjustment Procedure...................................................................... 15 15.2.2
Pressure Relief Valve Item 4 Adjustment Procedure ................................................ 17 15.2.3
Pressure Regulator Adjustment Procedure............................................................... 17 15.3
FIRST STAGE MAIN PUMP 6A.................................................................................... 18
15.3.1 Flow and pressure and main control pressure regulator setting ............................... 19
15.3.2 MAXIMUM FLOW SETTING ..................................................................................... 19
15.3.3 Pump 6A and control valve 24 flow test .................................................................... 20
15.3.4 m4-15 diagram .......................................................................................................... 21
15.3.5 control valve m4-15 pressure relief adjustmet procedure ......................................... 22
16RECONNECT HOSES, PRIME HYDRAULIC MOTORS AND HYDRAULIC OIL TANK
LEVEL............................................................................................................................................. 22
17 Jack legs valve item 46 / 8 spool valve item 59 relief valve adjustment procedure ............. 23
17.1.1 pREPERATION FOR ADJUSTMENT ....................................................................... 23

UDR 200DLS BOARD LONGYEARCOMMISSIONING PROCEDURE REVISION A 6/2020 2

 17.1.2 Main relief valve adjustment...................................................................................... 23
17.1.3 Work port relief valve adjustment (8 SPOOL VALVE ITEM 59) ................................ 23
17.1.4 Front and Rear Jack legs Cylinders (if fitted) ............................................................ 24
17.2 Mast Raise Cylinders .................................................................................................... 24
17.3 Mast Dump Cylinder ..................................................................................................... 25
18 ROD CLAMP ........................................................................................................................ 26
19 HEAD TRAVERSE MICRO FEED, HOLD BACK, PULL DOWN, MICRO FEED SPEED
CONTROL ...................................................................................................................................... 27
19.1 Traverse System Operational Checks .......................................................................... 27
19.2 Head Traverse Holdings Valve ..................................................................................... 27
19.3 Pull Down Pressure Control Valve................................................................................ 27
19.4 Micro Feed System ....................................................................................................... 28
19.5 Hose Burst Valve Item 64 ............................................................................................. 29
19.6 Power Float Set Up Procedure ..................................................................................... 29
19.6.1 Power float down set up ............................................................................................ 29
19.6.2 Power float UP set up................................................................................................ 30
19.7 Control Valve Stroke Limit Adjustment ......................................................................... 30
19.8 Traverse Speed Checks ............................................................................................... 31
20 ROTATION........................................................................................................................... 32
20.1 Motor control location.................................................................................................... 32
20.2 Rotation Head Speed Control Item 37.1 ....................................................................... 33
20.3 Rotation Chuck Operation............................................................................................. 33
20.3.1 Chuck Release and rapid traverse up down check ................................................... 33
20.4 Rotation Head side rack................................................................................................ 33
20.5 Rotation Head Operational Checks .............................................................................. 34
20.5.1 Minimum Rotation Head Speed with maximum pump flow check............................. 34
20.5.2 Maximum Rotation Head Speed Setting ................................................................... 34
20.5.3 Motor Control End Regulator Setting ........................................................................ 34
20.5.4 REverse rotation maximum speed ............................................................................ 35
20.5.5 Reverse Rotation Speed Interlock Valve Check Procedure...................................... 35
20.5.6 Rod Spin Guard and rotation forward minimum speed ............................................. 35
20.5.7 Rotation Forward Pressure Check ............................................................................ 36
20.5.8 Main Filter Back pressure Checks............................................................................. 36
20.5.9 Speed Control Test ................................................................................................... 36
20.6 Rotation Head to Rod Clamp Alignment ....................................................................... 36
20.7 Rotation Torque Control................................................................................................ 37
20.8 Rotation/ Float Operational Check................................................................................ 37
20.8.1 FLOAT DOWN TO MAKE UP A ROD JOINT............................................................ 37
20.8.2 FLOAT up TO break out A ROD JOINT .................................................................... 38
21 MAIN WINCH ....................................................................................................................... 39
21.1 MAIN WINCH MANIFOLD BLOCK PART NO WU 11684 ............................................ 39
21.2 Brake Release pRESSURE REDUCING VALVE ITEM 72 Test................................... 40
21.3 Main winch base frame removable spacer ................................................................... 40
21.4 Main Winch Operational Checks................................................................................... 40
21.4.1 Main Winch Counter Balance Valve Setting.............................................................. 40
21.4.2 Main Winch Float System.......................................................................................... 41
21.4.2.1 Operational Checks............................................................................................ 41
21.4.3 Main Winch No load Pressure Check........................................................................ 41
21.4.4 Test the Winch with a Test weight............................................................................. 41
22 WIRE LINE WINCH.............................................................................................................. 43
22.1 Wire Line Winch Operational Check ............................................................................. 43
22.2 Double Counter Balance Valve Item 84 ........................................................................ 43
22.3 Maximum Speed Check and Adjustment ...................................................................... 43
22.4 Wire Line Winch Rope .................................................................................................. 44
23 WATER PUMP ..................................................................................................................... 44
24 MUD MIXER CIRCUIT ......................................................................................................... 45
25 DIESEL LOAD TEST ........................................................................................................... 46

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26 COMMISSIONING CHECK POINTS CHECK THE FOLLOWING ....................................... 47
27 SERIAL NUMBERS OF EQUIPMENT ................................................................................. 52
28 SIGNATURE FORM............................................................................................................. 53

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1 VISUAL INSPECTION AND OTHER NOTES
• Obtain a copy of the production order from the sales department and verify that the rig is
built to the production order.
• Obtain copies of the following drawings for the particular rig and use them as a reference
source;
• Hydraulic Circuit DR/Number 8040 Latest revision
• Water Circuit DR/Number Latest revision
• Fuel System Assembly DR/Number Latest revision
• Electrical Circuit DR/Number Latest revision
• The item numbers on the hydraulic circuit drawing will be used as reference numbers
through out this procedure.
• Refer to the UDR 200D operator’s manual when necessary
• ALL POINTS in this commissioning procedure MUST BE initialled and dated by
commissioning personnel.
• Please initial and date each line in the left- hand margin.
• The following abbreviations will appear throughout this procedure.
• A.P.R. = Acceptable Pressure Range in bar /psi.
• A.T.R. = Acceptable Temperature Range in degrees C.
• A.M.R. = Acceptable Measurement Range in mm / inch.
• A.R.R. = Acceptable Revolution Range in rpm.
• Use these letters for reference to what is an acceptable range to work in.
• While commissioning this rig, the hydraulic oil temp should be between 50°C to 60°C for
• Most of the procedure. Please note the hydraulic oil flow to the cooler has a thermal
valve fitted in the system, which will keep the oil temperature stable.
• The finished procedure must be sighted and signed by sales department and the
production manager following a visual and operational inspection with any points noted by
the sales inspection checked and corrected by production.

2 COMPONENT CLEANING
• Remove the hydraulic oil tank lid and check that the hydraulic tank has been cleaned out.
Thoroughly inspect for perfect cleanliness.

3 GREASE THE ITEMS LISTED BELOW

Description No. of Nipples
Rotation Head - air & water swivel 1
- top seal cover slinger 1
- chuck thrust bearing 1
- chuck rod jaw bowl 1
Rod Clamp - clamp rod jaw lever bearings 4
- sliding faces Apply by hand
Water pump - push rods 3 if fitted
Main winch - drum bearing pack with grease 1
Wire line winch - drum bearing pack with grease 1

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4 OIL FILTER CHART

ITEM ELEMENT MAKE & PARTNO

Hydraulic Tank Main Filter Hydac RFBN660 F10 A1.1
Hydraulic Tank Breather Hydac 0160 MG 010 P
Rotation Head Lube System Vickers 5203174
Rotation Head Breather As supplied by Marc Chile

5 DIESEL ENGINE PREPARATIONS

• Get reference drawings for the particular rig for following items, and check they are
correctly fitted.
• main drive assembly
• cooler, radiator assembly
• fuel tank assembly (if fitted)
• fuel system assembly (if fitted)
• Check the diesel engine oil level
• Check all coolant system piping and hoses are tight and correctly positioned.
• Check the radiator coolant level
• Check the anti-corrosion / antifreeze additive has been added
• Check the battery electrolyte level
• Check the air filter assembly, that both the primary and safety filter elements are fitted.
• Check the fan drive belt is tight
• Check the spin-on type oil filter is fitted and accessible
• Check the primary and secondary spin-on type fuel filters are fitted and accessible
• Racor primary fuel / water separator filter element on the fuel tank is correctly bled.
• Fuel line ball valve open if fitted.
• Diesel fuel in tank
• Fuel lines in and out correctly fitted
• Check valve fitted in fuel suction line (if fitted).
• Electronic engine electrical wiring loom correctly fitted
• Electrical system (battery and leads) correctly connected and functional
• Emergency stop switch correctly connected and functional
• Check the exhaust system is correctly fitted and functional.

6 MISCELLANEOUS HYDRAULIC CHECKPOINTS

1. OIL COOLER
• Check the oil cooler by pass check valve Item 10 is pipe in correctly and has a 3 bar / 44
psi cracking pressure
• Check the oil cooler, thermal valve item 8 is correctly piped in.
• Check the oil cooler fan drive motor by pass check valve item 17 is correctly piped in.

2. MAIN WINCH
•Check all cartridges fitted to the main winch Counter Balance block part no WU11684, do not
have any damaged or missing ‘O’ rings or back up rings.
• Check the cartridges are fitted into the correct cavities in the main winch manifold block,
part no WU11684.
• Check the brake pressure control of the main winch final drive PD22978AL has been

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 preset to 172.41 bar / 2500 psi. This is located on the hydraulic tank facing forward.
• Check the holding valve item 71 has been preset to 278 bar / 4030 psi.
• Check that both shuttle valves item 73, for the following;
• Correctly piped in
• Are free of any debris eg sealing compounds, hose dust.
• Check the pilot open check valve item 34 has been correctly piped in.
• Check the external hosing is correct by the hydraulic circuit drawing.
•Check the main winch planetary has the external drain and fill points and is filled to the
correct level.

MAIN WINCH MANIFOLD BLOCK PART NO WU 11684

The manifold is comprised of the following items. Refer to the hydraulic circuit for further
details.
• Item 71 PD24464AU Counter Balance Valve Winch Over Run Control
▪ Item 81 PD24464AH Pilot Open Check Valve Winch Float System
▪ Item 82 PD22978AL Valve Body(Manifold Block)

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3. WIRE LINE WINCH MOTOR
• Check the holding valves item 77 have, been preset to 210 bar / 3045 psi.
• Check the external hosing is correct by the hydraulic circuit drawing.

4. ROTATION HEAD MOTOR

• Check the “HD” control end pressure setting of the motor item 78 has been preset to 25
bar / 362.5 psi.
• Check the external hosing is correct by the hydraulic circuit drawing.

5. TRAVERSE CYLINDER
• Check the holding valve item 66 has been preset to 207 bar / 3000 psi.
• Check the orifice plate has been removed from the hose burst valve, which is fitted to the
traverse cylinder or the restriction is set for 20LPM.
• Check the external hosing is correct by the hydraulic circuit drawing.

6. MAST RAISE CYLINDERS

• Check the mast raise cylinder holding valves item 63 for the following
• Have been preset to 230 bar / 3335 psi
• Correctly piped in

7. MAST DUMP CYLINDER

• Check the mast dump cylinder holding valves item 63 for the following
• Have been preset to 230 bar / 3335 psi
• Correctly piped in

8. CONTROL CABINET
•Check the cartridges items 35, 45 and check valve cartridges item 40, which are fitted to the
float control blocks item 113, 48, 42 do not have any damaged or missing ‘O’ rings or back up
rings.
•Check the pilot control valves items 25 & 26 have the correct pilot control curves (curve 06)
fitted to them.
• Check the rotation pilot control lever has the modified lockable control lever WU9388 has
been correctly fitted to it. And the detent locks the lever when pulled towards the operator.
• Check the pull down minimum back pressure check valve item 29 is a 5 bar / 72.5 psi
cracking pressure check valve and that the cartridge is in the correct location.
• Check the following directional control valve have detents fitted to them
• Micro-feed
• Float
• Check the winch float 3-way ball valve item 27 is correctly piped in.

6.9 MAIN CONTROL VALVE M4-15

1. Check that the port relief valves have been preset. If not remove the plastic caps and
tamper plugs from the relief valve adjustment points.
2. Loosen the relief valve lock nuts and turn counter clockwise each relief valve setting 1 turn.
3. Check all hoses are correctly connected to drawing MPL8815/ hydraulic piping for the
unit that is being commissioned.
4. Check that the 0.5 mm orifice ¼”BSPP- 9/16JIC has been fitted to the LS port.
5. Check that all plastic plugs have been removed and replaced with the correct steel plugs
on the auxiliary ports.
6. Check the valve is built to the correct model code and that the spool configuration is
correct. This can be checked by inserting compressed air in the work port, all sections
should be open when neutral with exception to the Traverse section.

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7. Refer to the diagram below which illustrates the valve connections and adjustment points.

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6.10 JACK LEG 4 SPOOL/ MAST RAISE / MAST DUMP 8 SPOOL VALVE
•Check the primary pressure relief valve of item 46 (4 SPOOL VALVE) has been preset to
200 bar / 2900 psi. Check the primary pressure relief valve of item 59 (8 SPOOL VALVE) has
been preset to 172 bar / 2500 psi.
• Check the mast raise port pressure relief valve cartridge has been preset to 172 bar / 2500
psi (up) and 70 bar / 1015 psi (down).
• Check the mast dump port pressure relief valve cartridge [port “A”], has been preset to 60
bar / 870 psi. This port supplies pressure to lower the mast on the dump slides.
• Check the mast dump port pressure relief valve cartridge [port “B”], has been preset to 70
bar / 1015 psi. This port supplies pressure to raise the mast on the dump slides.
6.11 WATER PUMP SYSTEM
• Check the primary pressure relief valve item 4 has been preset to 200 bar / 2900psi.
•Check the water pump “ON-OFF” ball valve item 32 has been piped correctly in. Check the
lever selector plate to have the lever match the name tags locations.
• Check the water pump fine and coarse speed control items 33 & 36 have been correctly
piped in.
• Check the water pump coarse control ball valve has been correctly piped in, lever “UP” ball
valve is shut.
• Check the external hosing is correct by the hydraulic circuit drawing.

6.12 MAIN CONTROL VALVE

• Check the spike protection pressure relief valve, in the inlet section of the main control
valve item 24, has been preset to 300 bar / 4350 psi.
• Check the “A&B” port pressure relief valves of the main winch valve section has been
preset to 240 bar / 3480 psi.
•Check the “B” port pressure relief valve of the wire line winch valve section has been
preset to 235 bar / 3400 psi.
• Check the “A” & “B” port pressure relief valves of the traverse valve section have been
preset to 290 bar / 4200psi.
• Check the external hosing is correct by the hydraulic circuit drawing.

6.13 HAND PUMP

• Check the hand pump outlet check valve Item 53 is correctly piped in.

7 MISCELLANEOUS MECHANICAL CHECKPOINTS

• Check the main winch drum bearing has been correctly fitted.
• Check the wire line winch drum to motor drive shaft shoulder has a minimum clearance of
1mm / 0.4”.
• Check the wire line winch drum bearing has been correctly fitted and the lock nut torque
up to the recommended torque.
• Check the mast raise cylinder pins are fitted and secured.
• Check the mast pivot pins are correctly fitted and secured.
• Check the mast dump cylinder pins are fitted and secured.
• Check the mast dump cylinder barrel “U” bolt is secured.
• Check all bolts and nuts have been torque up to the recommended torque.
• Check the mast sections fit together easily.
• Check the main and wire line winch rope sheave assembly has been assembled correctly.

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8 PRIME THE HYDRAULIC PUMPS
• Open the upper drain port of No.6A-6B-6C of pump assembly. Fill the cases of each pump
with clean hydraulic oil. Ensure that all air has been expelled from each pump case.

9 LUBRICATING OIL CHART

• Observe correct levels.

ITEM OIL TYPE QTY OIL LEVEL

LITRES

DIESEL AS RECOMMENDED BY THE DIPSTICK

ENGINE SUPPLIER TO SUIT THE
AIR TEMPERATURE WHEN
OPERATING

ROT. HEAD * VALVOLINE EPG 220 LEVEL PLUG

MAIN WINCH VALVOLINE EPG 220 OR LEVEL PLUG - MUST

GEAR BOX EQUIVALENT TO SUIT CLIMATE BE HORZONTAL AND
CONDITIONS. THE GEARBOX HALF
FULL

WATER PUMP SAE 40 2.5 LEVEL PLUG

HYDRAULIC OIL HYDRAULIC OIL TO SUIT TO UPPER LEVEL

TANK CLIMATE CONDITIONS. MARK ON SIGHT
GLASS

NOTE
8. Check the Rotation Head oil cooler lines are full with lubricating oil.

10 SHORT CIRCUIT THE MAIN SUPPLY HOSES OF THE

FOLLOWING MOTORS
• Main Winch Motor
• Rotation Head Motor
• Water Pump Motor
• Wire line winch motor
• Mud mixer motor if fitted or short circuit quick release couplings.
•Connect a suitable flow meter in line between the B port of pump 6A and the Port of
the Main control valve item 24. This will remain in place until Pump 6A and Valve 24 is
completely commissioned.
NOTE
▪ Close the motor ports with plugs, caps during flushing to prevent dirt and water
entering.

11 CONTROL ADJUSTMENT IN PREPARATION FOR FLUSHING

• Fully open the mud mixer speed control valve item 93
• Fully open the water pump fine and coarse control valves items 33 & 36.
•Water pump “ON-OFF” ball valve item 27.2 in the “ON” position. (Make sure the location
plate has been installed to match the name tag drawings)
• Drill / Make control item 31.1 in the “DRILL” position.
• Micro feed control lever in the neutral position.

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 • Chuck / clamp / float control lever in the neutral position.
• Rod spin guard interlock valve items 88 & 89 closed (drill position).
• Fit a 100 bar / 1450-psi pressure gauge to the pressure test point item 14 on the pressure
relief valve item 4 (Water Pump).
•Fit a 100 bar / 1450-psi pressure gauge to the pressure test point item 14 on the pilot
pressure control item 37 to check pump 6C pressure.
• Adjust by two full turns out the pressure regulator adjustment screw of pumps 6A-6B-6C
• Connect the “X” port of the rotation head motor to the case drain port via a 0.50 mm
0.019”orifice
• Fully increase the rotation speed control item 37.1.
• Remove the brake release hose from the main winch gearbox and connect the line via a
0.5mm 0.019”orifice to the drain hose of the main winch motor.
• Put the main winch float control item 27.1 into the float position.
• While commissioning this rig, the hydraulic oil temp should be between 50°C to 60°C for
most of the procedure. Please note the hydraulic oil flow to the cooler has a thermal valve
fitted in the system, which will keep the oil temperature stable.

12 FIRST EVER DIESEL START-UP

• Fit a piece of reflective tape to the fan of the hydraulic oil cooler
•Ring the engine supplier to commission the diesel engine if this has not been already
checked.
• Immediately after first kick over let the diesel idle at 800 to 850 rpm and check the
following:
• Diesel water temperature settles below 85°C
• Diesel fan is sucking air through radiator
• Diesel oil pressure minimum 1.03 bar/15psi idling
• Check that Rexroth pumps work properly, correct rotation
• Engine supplier representative to commission diesel
• Ensure the correct operation of diesel emergency shut down system.
• High water temperature.
• Low oil pressure
• Entire diesel installation is satisfactory
• Set the maximum no load speed of diesel at 2400 rpm.
• Check the fan speed of the hydraulic oil cooler it should operate between 630-650 rpm.

13 BOOST PUMP SETUP (HIGH ALTITUDE RIGS)

• Ensure item 120 PD24464BH priority flow control valve is preset to 20 LPM.
• Ensure Item 122 PD24464PR flow control pilot pressure circuit is preset to 7 LPM.
•At start up check that there is a minimum of 15 psi pressure showing at the boost pressure
gauge. Adjust item 120 and 122 to obtain sufficient boost pressure and pilot pressure.

12
14 FLUSHING
Note
1. During flushing no pressure to exceed 60 bar in any circuit.
2. Oil temperature in tank not to exceed 70°C
3. All flushing to be carried out at 2200 rpm A.R.R. 2200-2220
4. Make sure there is pilot pressure at TH6 pilot controls.
5. Pump 6c and item 37.2 pilot pressure relief may need to be set prior to flushing if.
6. Make sure there is at lease 150 lpm flow showing on the flow meter connected to
pump 6A when the rotation lever is fully forward.

14.1 FLUSHING TABLE.

Time in Minutes. Total flushing time 90 minutes

SELECT THE PARTICULAR PILOT CONTROL LEVER FOR THE OPERATION

0-15 15-30 30-45 45-60 60-75 75-90

ROTATION HEAD ROTATION MAIN WINCH MAIN WINCH WIRE LINE WIRE LINE
FORWARD HEAD RAISE LOWER WINCH RAISE WINCH LOWER
REVERSE
PUMP 6B WATER PUMP
PUMP 6C MUD MIXER
CHECK THE PILOT PRESSURE AT THE ‘P’ PORT OF THE PILOT CONTROL ITEMS 25 & 26
CHECK THAT THE PRESSURE AT THE BOOST PUMP GUAGE REMAINS ABOVE 15 PSI
NOTE: MAIN FILTER BACK PRESSURE AT START OF FLUSHING AND OIL TEMP.

Note
1. Do not operate the mast raise / micro-feed / chuck / clamp / traverse levers

14.2 FLUSHING CIRCUIT PRESSURE CHECKS

FUNCTION PUMP DIESEL PRESS PRESS BAR PRESS BAR OIL TEMP
RPM CHECK AT degree C
ACTUAL EXPECTED
ITEM
Rotation forward 6A 2200 50 30-35
Rotation reverse 6A 2200 50 30-35
Main winch raise 6A 2200 50 25-30
Main winch lower 6A 2200 50 25-30
Wire line winch raise 6A 2200 50 30-35
Wire line winch lower 6A 2200 50 30-35
Water Pump 6B 2200 Pump 3B 25-30

Mud Mixer 6C 2200 Pump 85 10-15

Pilot pressure 6C 2200 ‘P’ port of pilot 50-55
control

NOTE
1. During flushing check the following:
2. Diesel water temperature
3. Diesel oil pressure
4. Main filter back pressure - max. 2 bar
5. No pressure to exceed 60 bar
6. Note and report any anomalies
7. Hydraulic oil cooler fan speed should be between 630-650 rpm

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 • After 90 mins of operation note main filter back pressure and oil temp (item 25 at
• Panel) and the hydraulic oil cooler fan speed .

OIL TEMPERATURE °C ATR 60 - 65°C

ACTUAL PRESS BAR APR 0.- 0.2 BAR

OIL COOLER FAN SPEED RPM ARR 630-650 RPM

15 PUMP 6C (PILOT PRESSURE, COOLING FAN, BOOST

PUMP)
NOTE

1. THIRD STAGE PUMP 6C

FIGURE OF PUMP 6C

1. FLOW & PRESSURE REGULATOR ADJUSTMENT PROCEDURE (BOOST PUMP

INSTALLED)
1. Refer to the figure for pump 6C for the location of the pump control locations.
2. Remove the flow and pressure regulator cap nut and loosen the lock nut.
3. Using an Allen key, turn the flow regulator setting screw clockwise all the way in.
4. Disconnect the hose connected to the P port of the pilot pressure relief valve item 37.2
and plug and cap the hose and port.
5. Make sure that Item 120 priority flow control has been preset to 22 LPM.
6. Fit a 2000 psi gauge to the to the pressure test point connected to port 1 on the flow
control item 120.
7. With the diesel engine running at 1800 RPM, adjust the pressure regulator to achieve
1400 psi and tighten the locknut.
8. Turn the flow regulator adjustment counter clockwise until the pressure on the drops to
1160 psi.
9. Fit and tighten the cap nuts on the flow and pressure regulators and reconnect the hose
connected to the pilot pressure relief valve item 37.2.
10. When the cap and lock nuts are loosened, a slight oil weep will occur.

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2. PILOT PRESSURE RELIEF VALVE ITEM 37.2 ADJUSTMENT PROCEDURE
1. Fit the 1500 psi pressure gauge to the pressure test coupling item 14 for item 37.2 pilot
pressure relief valve connected to the drain manifold inside the control cabinet.
11. Adjust the Adjust item 37.2 to achieve 500 psi.
12. Tighten the lock nut and remove the adjustment handle.

Actual pressure relief valve setting BAR / A.P.R 34 – 34.5 BAR

PSI
A.P.R. 500 PSI
Actual diesel rpm A.R.R 1800-1820 RPM
RPM

3. FLOW & PRESSURE REGULATOR ADJUSTMENT PROCEDURE (BOOST PUMP NOT

INSTALLED)
13. Refer to the figure for pump 6C for the location of the pump control locations.
14. Remove the flow and pressure regulator cap nut and loosen the lock nut.
15. Using an Allen key, turn the flow regulator setting screw clockwise all the way in.
16. Disconnect the hose connected to the P port of the pilot pressure relief valve item 37.2
and plug and cap the hose and port.
17. Disconnect the hose connected to the cooling fan motor and plug and cap.
18. Fit a 1000 psi gauge to the to the pressure test point connected to port 1 on the flow
control item 120.
19. With the diesel engine running at 1800 RPM, adjust the pressure regulator to achieve 870
psi and tighten the locknut.
20. Turn the flow regulator adjustment counter clockwise until the pressure on the drops to
560 psi.
21. Fit and tighten the cap nuts on the flow and pressure regulators and reconnect the hose
connected to the pilot pressure relief valve item 37.2 and oil cooler fan motor.
22. When the cap and lock nuts are loosened, a slight oil weep will occur.

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15.1.4 PILOT PRESSURE RELIEF VALVE ITEM 37.2 ADJUSTMENT PROCEDURE (NO
BOOST PUMP)
2. Fit the 1000 psi pressure gauge to the pressure test coupling item 14 for item 37.2 pilot
pressure relief valve connected to the drain manifold inside the control cabinet.
23. Adjust the Adjust item 37.2 to achieve 650 psi.
24. Tighten the lock nut and remove the adjustment handle.

Actual pressure relief valve setting BAR / A.P.R 44 – 45 BAR

PSI
A.P.R. 650 PSI
Actual diesel rpm A.R.R 1800-1820 RPM
RPM

2. SECOND STAGE PUMP 6B

1. FLOW REGULATOR ADJUSTMENT PROCEDURE

1. Refer to the picture above to locate the regulator adjustment screw.
2. Remove the hydraulic oil pressure hose from the water pump motor. Cap the fitting and
plug the hose end with steel plugs.
3. Remove the flow regulator cap nut and loosen the lock nut.
Note
1. When the cap nuts are loosened, a slight oil weep will occur.

2. Fit a 40 bar / 580 psi pressure gauge to the pressure test coupling item 14 connected to
the pressure relief valve item 4, which is connected to the pump 6B pressure port.
3. At the control panel set the water pump hydraulic controls as follows:
• Water Pump on-off: “OFF”
• Water Pump fine control: “CLOSED” ( fully clockwise)
• Water Pump coarse control: “CLOSED” (lever up)
4. Start the engine and set the diesel rpm to 1800 to1850 rpm.
5. Operate the water pump on-off control to the “ON” position.
6. Adjust the flow regulator adjustment screw until the pressure gauge reads 14-15 bar /
205-220 psi.

16
 Actual flow regulator setting BAR A.P.R 14-15 BAR
PSI A.P.R. 205-220 PSI
Actual diesel rpm RPM A.R.R 1800-1850 RPM

7. Tighten the flow regulator lock nut and replace the cap nut.
8. Check the setting by operating the water pump on-off control “OFF-ON” several times.
Note
1. The flow regulator cannot be set correctly, if pressure relief valve or the water
pump on / off ball valve is faulty.
9. Operate the water pump on-off control to the “OFF” position. Stop the engine.

17
2. PRESSURE RELIEF VALVE ITEM 4 ADJUSTMENT PROCEDURE
1. Refer to the picture on page 21 for the location of the pump regulator setting screws.
1. Remove the pressure regulator cap nut.
2. Loosen the pressure regulator locknut.
3. Using an Allen key, adjust the pressure regulator adjustment screw of pump 6B clockwise
all the way in, then back out the screw by 1/2 turn tighten the locknut.
4. Fit a 250 bar / 3625 psi pressure gauge to the pressure test coupling item 14 at pressure
relief valve item 4, which is connected to the pump pressure port of pump 6B.
5. Remove the hydraulic oil pressure hose from the water pump motor. Cap the fitting and
plug the hose end with steel plugs.
6. Reduce the setting of the pressure relief valve item 4 by turning the adjustment screw out
two full turns.
7. Start the engine and set the diesel rpm to 1800 to1850 rpm.
8. Operate the water pump on-off control to “ON”.
9. Adjust the pressure relief valve adjustment screw until the 200 bar /2900 psi is indicated
on the pressure gauge.
10. Tighten the locknut of the adjustment screw of the pressure relief valve.
11. Check the setting by operating the water pump on-off control “OFF-ON” several times.

Actual pressure relief valve setting BAR / PSI A.P.R 198-200 BAR
A.P.R. 2871-2900 PSI
Actual diesel rpm RPM A.R.R 1800-1850 RPM

12. Operate the water pump on-off control to the “OFF” position. Stop the engine.
13. Refit the pressure hose onto the water pump motor if no further adjustment is required.
3. PRESSURE REGULATOR ADJUSTMENT PROCEDURE
1. Refer to the picture on page 21 for the location of the regulator setting screws.
14. Fit a 250 bar pressure gauge to the pressure test coupling item 4 at the pressure relief
valve item 4, which is connected to the pump 6B pressure port.
15. Remove the pressure hose from the water pump motor. Cap the fitting on the motor and
plug the hose end with steel plugs
16. At the control panel set the water pump hydraulic controls as follows:
• Water Pump on-off: “OFF”
• Water Pump fine control: “CLOSED” (fully counter clockwise)
• Water Pump coarse control: “OPEN” (lever down)
17. Remove the pressure regulator cap nut and loosen the lock nut.
Note
1. When the cap nuts are loosened, a slight oil weep will occur.
18. Start the engine and set the diesel rpm to 1800 to1850 rpm.
19. Using an Allen key set the pump pressure regulator adjustment screw (maximum system
pressure) by turning the adjustment screw as follows.
• Adjusting the pressure regulator setting screw clockwise increases the pressure.
• Adjusting the pressure regulator setting screw counter-clockwise reduces the
pressure.
• One turn of the setting screw corresponds to 50-bar pressure in the range 20 to 250
bar.
20. Observe the pressure reading on the gauge connected to the test coupling.
21. Operate the water pump on-off control to the “ON” position.

18
 22. Adjust the pressure setting to 180 bar. Tighten the lock nut and replace the cap nut.

Actual pressure regulator setting BAR / PSI A.P.R 178-180 BAR

A.P.R. 2581-2610 PSI
Actual diesel rpm RPM A.R.R 1800-1850 RPM

Note
1. Do not exceed the pressure relief valve setting, note that pump pressure regulator
setting is generally 15-20 bar lower than relief valve setting.
2. The pressure regulator cannot be set correctly, if the pressure relief valve or the
water pump on / off ball valve is faulty.
3. Check the setting by operating the water pump on-off control “OFF-ON” several times.
4. Operate the water pump on-off control to the “OFF” position. Stop the engine.
5. Refit the pressure hose onto the water pump motor if no further adjustment is required.

3. FIRST STAGE MAIN

PUMP 6A
FIGURE OF PUMP 6A
1. “X” port of pump 6A.
2. Flow regulator adjustment
screw under cover.
(Load sensing)
3. Suction port
4. Pressure regulator adjustment
screw under cover. (Pressure
cut off)
5. Constant Power adjustment
screw under cover.

NORMALLY THIS ADJUSTMENT

IS NOT SUPPLIED.

This adjustment is NOT used in

the 200D rig.
6. Minimum flow adjustment
screw.
Do not make any adjustments to
this screw.
7. “M” port for pressure gauge
connection.
8. Pressure port.
9. Maximum flow adjustment
screw. Do not make any
adjustments to this screw.
10. Case leakage use in the 200D
rig.

19
1. FLOW AND PRESSURE AND MAIN CONTROL PRESSURE REGULATOR SETTING
1. Check if the pump controls have been preset by the supplier.
2. Refer to the photos on the previous page to locate pump 6A control positions.
3. Check the pilot levers for the main drill functions (main winch, wire line winch, rotation and
traverse) are in the neutral position.
4. Tee a 350 bar / 5000-psi pressure gauge and a pressure test point into the “M” port of
pump 6A.
5.Start the engine and operate at 1800-1850 rpm. 6.
7. Loosen the flow and pressure regulator lock nut.
8. Using an Allen key, adjust the flow regulator adjustment screw fully clockwise.
9. Using an Allen key, adjust the main control valve pressure relief fully clockwise.
10. Using an Allen key, adjust the pressure regulator screw until the pressure gauge at the
“M” port indicates 300 bar / 4350 psi.
11. Using an Allen key, adjust the primary pressure relief valve on Item 24 until the valve
opens and the pressure gauge drops slightly.
12. Turn the adjustment clockwise ¼ turn.

Actual pressure regulator setting BAR / PSI A.P.R 300 BAR

A.P.R. 4350 PSI
Actual diesel rpm RPM A.R.R 1800-1850 RPM

13. Using an Allen key, adjust the pressure regulator screw of pump 6A until the pressure
gauge at the “M” port indicates 290 bar / 4200 psi.

Actual pressure regulator setting BAR / PSI A.P.R 258-260 BAR

A.P.R. 3750-3780 PSI
Actual diesel rpm RPM A.R.R 1800-1850 RPM

14. Using an Allen key, adjust the flow regulator adjustment screw counter clockwise until the
pressure gauge at the “M” port indicates 28 – 28.5 bar / 406 - 413 psi. Note a 500 psi
pressure gauge will need to be installed at the M port of pump 6A for the final adjustment
of this setting.

Actual flow regulator setting BAR A.P.R 28-28.5 BAR

PSI A.P.R. 406-413 PSI

15. Tighten the flow regulator locknut and replace the cap nut.
16. Recheck the flow regulator pressure setting.

2. MAXIMUM FLOW SETTING

17. WITH a 300 lpm / 80 US gpm minimum 350 bar /5000 psi flow meter already connected to
the P port of Pump 6A and the rotation motor hoses already connected from the previous
flushing procedure.
18. Check the flow meter pressure control is fully decreased.
19. Start the engine and operate at 2200-2210 rpm.
1. Engage the rotation control lever into the forward position completely.
2. Check the flow meter reading it should indicate 200-201 lpm.
3. If the flow meter is indicating a flow Lower than 200 lpm, the maximum flow screw of the

20
 pump will have to be adjusted until the maximum flow reading is 200 lpm at 2200 rpm with
the oil at an operating temperature of 45-60 degrees C.

Actual flow meter reading LPM A.F.R 200-201 LPM

A.F.R. 52.6- 53 US GPM
Actual diesel rpm RPM A.R.R 2200-2210 RPM

15.3.3 PUMP 6A AND CONTROL VALVE 24 FLOW TEST

20. Use the chart below to set the main control valve item 24 stroke limiters for each function
listed on the chart. The stroke limiter is located on the valve cap covering the spool. The
hoses to these functions have been connected together during the flushing procedure.
The flow meter connected earlier in line with the main control valve will indicate the flow
from each function. This procedure will minimize repletion of removing and connection
hoses for each individual test. This procedure should be carried out at operation
temperature and with the engine running at 2200 RPM.
21. You will need an assistant to operate each function while this procedure is carried out.

FUNCTION PUMP DIESEL FLOW IN PRESS BAR OIL TEMP

RPM LPM degree C
EXPECTED
ACTUAL
Rotation forward 6A 2200 170 30-35
Rotation reverse 6A 2200 50 30

Traverse up 6A 2200 200 30

Traverse Down 6A 2200 100 30

Main winch raise 6A 2200 200 30

Main winch lower 6A 2200 200 30

Wire line winch raise 6A 2200 90 30

Wire line winch lower 6A 2200 90 30

L track forward 6A 2200 90 30

L track Reverse 6A 2200 90 30

R track forward 6A 2200 90 30

R track reverse 6A 2200 90 30

21
15.3.4 M4-15 DIAGRAM

22
5. CONTROL VALVE M4-15 PRESSURE RELIEF ADJUSTMET PROCEDURE
1. Remove hoses for all functions which were previously connected together for the flushing
procedure and plug each end of Rotation, Traverse, and Wire Line winch, Main Winch,
Left and Right Track (If fitted).
2. Refer to the chart below and the Diagram above to set the pressure relief valves for each
function.
3. You will need an assistant to operate each function while this procedure is carried out.

FUNCTION PUMP DIESEL PRESS BAR / PSI OIL TEMP

RPM degree C
EXPECTED

Rotation A PORT 6A 1800 265.5 BAR / 3850 45 - 60

PSI
Rotation B PORT 6A 1800 265.5 BAR / 3850 45 - 60
PSI
Traverse A PORT 6A 1800 186 BAR / 2700 45 - 60
PSI
Traverse B PORT 6A 1800 162 BAR / 2350 45 - 60
PSI
Main winch A PORT 6A 1800 290 BAR / 4200 45 - 60
PSI
Main winch B PORT 6A 1800 290 BAR / 4200 45 - 60
PSI
Wire line winch A 6A 1800 240 BAR / 3480 45 - 60
PORT PSI

Wire line winch B 6A 1800 240 BAR / 3480 45 - 60

PORT PSI

L track A PORT 6A 1800 230 BAR / 3335 45 - 60

PSI
L track B PORT 6A 1800 230 BAR / 3335 45 - 60
PSI
R track A PORT 6A 1800 230 BAR / 3335 45 - 60
PSI
R track B PORT 6A 1800 230 BAR / 3335 45 - 60
PSI

16 RECONNECT HOSES, PRIME HYDRAULIC MOTORS AND

HYDRAULIC OIL TANK LEVEL
• Reconnect the brake release hose to the main winch gearbox.
• Reconnect the “X” port hose to the rotation head motor.
• Reconnect the pressure hoses to the following motors.
• Main winch motor
• Rotation head motor
• Water pump motor
• Mud mixer motor if fitted
• Track motors
• Prime the motor cases with clean hydraulic oil if applicable.
• Check the hydraulic oil tank level, top up if required.
• Remove the flow Meter connected in line between Pump 6A and M4-15 valve item 24.

23
17 JACK LEGS VALVE ITEM 46 / 8 SPOOL VALVE ITEM 59
RELIEF VALVE ADJUSTMENT PROCEDURE
1. PREPERATION FOR ADJUSTMENT
1. Remove hoses plug and cap ports for the following functions
1. Mast rise.
2. Mast Dump
3. Upper Breaker.
4. Rod clamp.
5. Chuck
2. MAIN RELIEF VALVE ADJUSTMENT
1. Check that the lines from the auxiliary pump item 85 is connected to the 10.2 cc as per
the hydraulic circuit drawing and the tank line are correctly connected.
2. Check that the relief valves are installed in the correct location corresponding to the
function.
3. Turn counter clockwise 1 full turn the main Pressure relief valve on item 46 (4 spool valve)
and 59 (8 spool valve)
4. Fit a 3000 psi pressure gauge to the pressure test point connected to the p port of valve
item 59.
5. Start the engine and run it at 1800 rpm.
6. Have an assistant operate the chuck lever to the hold position.
7. Adjust the main pressure relief valve on Item 59 fully in (clockwise).
8. Adjust the main pressure relief valve on Item 46 to 200 bar / 2900 psi.
9. Adjust the main pressure relief valve on Item 59 to 172.5 bar / 2500 psi.
10. Operate the chuck lever to neutral.
2. WORK PORT RELIEF VALVE ADJUSTMENT (8 SPOOL VALVE ITEM 59)
1. Follow the chart and steps below for each function to set up the work port pressure relief
valves.
2. Operate the leaver to the up position this allow adjustment to the A port relief valve.
3. Operate the lever to the down position, this will allow adjustment to the B port pressure
relief valve.
4. Return the lever to the neutral position.
5. When Complete reconnect the hoses which were plugged earlier.

FUNCTION PUMP DIESEL PRESS BAR / PSI OIL TEMP

RPM degree C
EXPECTED

MAST RAISE A 85(10.2) 1800 172.5 BAR / 2500 45 - 60

PORT PSI
MAST RAISE B 85(10.2) 1800 70 BAR / 1015 45 - 60
PORT PSI

MAST DUMP A PORT 85(10.2) 1800 60 BAR / 870 PSI 45 - 60

MAST DUMP B PORT 85(10.2) 1800 70 BAR / 1015 45 - 60

PSI
BREAK OUT A PORT 85(10.2) 1800 100 BAR / 1450 45 - 60
PSI
BREAK OUT B PORT 85(10.2) 1800 100 BAR / 1450 45 - 60
PSI
UPPER BRAKER A 85(10.2) 1800 170 BAR / 2465 45 - 60
PORT PSI

ROD CLAMP A PORT 85(10.2) 1800 100 BAR / 1450 45 - 60

PSI
ROD CLAMP B PORT 85(10.2) 1800 120 BAR / 1740 45 - 60
PSI
CHUCK B PORT 85(10.2) 1800 120 BAR / 3335 45 - 60
PSI
11.

24
 12.
4. FRONT AND REAR JACK LEGS CYLINDERS (IF FITTED)
1. Raise and lower to ground level only each jack leg cylinder several times, do not raise the
rig, check as follows:
• Correct operation versus name tag drawing.
• Any mechanical fouling
• Any hydraulic oil leaks.
13. Jack the rig up clear of ground, level the rig both front and rear and side to side. Check for
any drift in cylinders, there must not be any drift in 15 minutes. Check during the day.

2. MAST RAISE CYLINDERS

1. Check the mast dump cylinder has been filled with oil before raising the mast.
2. Check the traverse cylinder is full of oil before raising the mast.
3. Check the mast raise counterbalance valves item 63 (x 4 off) have been preset to 230 bar
/ 3335 psi. If the counter balance valves have not been preset remove them and preset
them.
4. Check all 4 screws holding the 2 mast pivot pins shear plates are tight and the pivot pins
have been greased.
5. Check all 4 screws holding the 2 upper mast raise cylinder pivot pins shear plates are
tight and the pivot pins have been greased.
6. Check the lower mast raise cylinders pivot pins have been properly secured and that the
pivots have been greased.
7. Check all the fittings, steel pipes and the hoses connected to the double holding valves
the mast raise cylinders are tight.
8. Check the counter balance valve cartridges fitted to the valves are tight.
9. Set the mast up as follows.
• Rotation head in the drill position and at the top of the mast.
• All sections of the mast bolted together.
• Mast crown assembly fitted.
• Rod slide fitted
• Basket fitted (If applicable)
10. Operate the mast raise control lever and slowly raise the mast with the diesel at 1300
rpm.
11. Note the raising pressure at Item 14 at the inlet of valve 59, whilst raising the mast just as
the mast begins to rise above the mast cradle.

ACTUAL PRESSURE BAR APR 200- 210 BAR

PSI APR 2900- 2915 psi

12. Twice raise the mast to 60° then lower, the third time raise mast fully check as follows:
• Correct operation versus name tag drawing
• Any mechanical fouling
• Any hoses being nipped or pulled
• Any hydraulic oil leaks.
• Check that the mast goes “OVER-CENTRE” smoothly.
• Let mast go into vertical position under its own weight, do not apply pressure
• “LOWER” the mast from vertical position with diesel idling and note pressure
required to initially move it.
• Check at Item 14 at the inlet of valve 59
•

25
 ACTUAL PRESSURE BAR APR
PSI APR

13. Lower the mast fully check the mast alignment to the nylon wear pads on the tray.
14. Raise the mast to vertical position.

3. MAST DUMP CYLINDER

1. Check the mast dump cylinder has been filled with oil before operating the mast dump
control lever.
2. Lower mast to 45°.
3. Operate the mast dump control lever several times. Check as follows:
• For any mechanical fouling as the mast moves up - down inside the mast dump slides over
the complete length of the mast dump cylinder stroke.
• For any hoses being nipped or pulled particularly the hoses on the left-hand side of the
mast leading to and from the tray.
• Correct operation versus name tag drawing
• For any hydraulic oil leaks.
15.Check and record pressure to raise and lower mast (on dump slide). Check at item 14 at
the inlet of valve 59.

ACTUAL RAISE PRESSURE BAR APR 48-50 BAR

ACTUAL LOWER PRESSURE BAR APR 8-10 BAR

16. Raise the mast to highest position on mast dump slides.

17. Raise the mast to the vertical position. Check the mast dump for any drift over 60 minutes.

ACTUAL DRIFT MM AMR 0-5 MM ATR 0-60 MINS

26
18 ROD CLAMP
1. Connect the “C1” and “C2” ports of the double counter balance valve item 101 together with
a hose. Tee a 200 bar / 2900 psi pressure gauge into the hose.
2. Remove the lock nuts from the pressure adjustments of the valve.
3. Start the engine and operate between 1250-1300 rpm.
4. Operate the rod clamp control lever in both directions and adjust the pressure controls until
77 bar / 1126 psi is indicated on the pressure gauge for both directions of operation.

ACTUAL BAR APR 77-78 BAR

PSI APR 1126-1141 PSI

ACTUAL BAR APR 77-78 BAR

PSI APR 1126-1141 PSI

5. Refer to drawing 21811 sheet 2 & 3 of 4

6. Fit an N size rod jaw set to the rod clamp.
7. Operate the control lever and check the following.
• Check for correct operation of the rod clamp versus nametag on the control panel.
• No mechanical fouling especially with the guard that fits over the cylinder levers.
• No hydraulic oil leaks.
• No hoses nipped or pulled.
8. Fit a short length of N size rod to the rod clamp.
9. Operate the rod clamp to clamp the short length of N size rod in the jaws.
10.Check how level the jaws are with each other.
11.Operate the rod clamp to open position to be able to level the jaws.
12.Level the jaw holder if necessary, by removing the connecting link clevis pin from the
cylinder lever and rotating the clevis on the connecting link. Then reassemble the clevis to
the cylinder lever.
Note
1. The clevis on either end of the connecting link can be rotated one complete turn
each time an adjustment is made, this is required to align the radius in the clevis
with the radius in the left or right hand cylinder lever.
2. Recheck the rod jaws are level by clamping the N size rod in the jaws.
3. Check the height of the jaws above the base frame is within tolerance on drawing
• 95 mm will allow a long service life.
• 75 mm is a height that will not allow a long service life
4. Open the rod clamp
Note
The alignment of the rod clamp with the rotation head will be covered in the rotation
section.

27
19 HEAD TRAVERSE MICRO FEED, HOLD BACK, PULL DOWN,
MICRO FEED SPEED CONTROL
1. TRAVERSE SYSTEM OPERATIONAL CHECKS
1. With the diesel engine at 800-850 rpm. Operate the traverse lever “UP” and “DOWN”
several times at various lever deflections and check the following;
• Correct operation versus the name tag drawing
• No mechanical fouling as the head moves up / down the mast.
• No hoses connected to the rotation head and traverse cylinder being nipped or pulled
5. Carry out the above test again but with the micro feed lever.
6. Carry out the above test again but with the power float lever.

2. HEAD TRAVERSE HOLDINGS VALVE

1. Set the head traverse holding valve item 66 as follows:
• Fully increase the pull down pressure control.
• Slowly engage the head traverse lever “DOWN” with the diesel engine at 900 RPM, so that
the rotation head just creeps down the mast.
• Adjust the counter balance valve item 66 until 26.5 bar / 385 psi reads on the pull down
pressure gauge item 51.

ACTUAL PRESSURE BAR A.P.R. 26.5 BAR

PSI A.P.R. 385 PSI

3. PULL DOWN PRESSURE CONTROL VALVE

1. Traverse the rotation head down to the bottom of the mast.
2. Fully decrease the pull down pressure control item 39 at the control panel. Micro feed
control lever engaged “DOWN”, micro feed speed control item 41 fully increased. Hold back
pressure control Item 39 fully decreased, diesel at 2200 rpm. Note the pressure reading on
the pull down pressure gauge item 51.

ACTUAL PRESSURE BAR A.P.R. 5-6 BAR

PSI A.P.R. 72-87 PSI

2. Slowly increase and decrease the pull down pressure control item 39, observe the pull
down gauge readings follows the operation of the pull down control smoothly.
3. Pull down pressure control fully increased. Note the pressure at the pull down gauge item
51 at the panel.

ACTUAL PRESSURE BAR A.P.R. 172.5 BAR

PSI A.P.R. 2500 PSI

4. Engage the head traverse lever “DOWN”, as well as the micro feed. Note the pressure
reading on the pull down gauge item 51 at the panel.

ACTUAL PRESSURE BAR A.P.R 186 BAR

PSI A.P.R. 2700 PSI

28
19.4 MICRO FEED SYSTEM
1. Traverse the head to the top of the mast.
2. Pull down pressure control item 39 fully decreased, hold back pressure control item 39 fully
decreased, micro feed speed control item 41 fully increased.
3. Engage the micro feed lever “DOWN”, diesel at 2200 rpm. Slowly increase the pull down
pressure control if required. Note the pressure to just lower the head on the pull down
pressure gauge.

ACTUAL PRESSURE BAR A.P.R. 5-6 BAR

PSI
A.P.R. 72-87 PSI
ACTUAL OIL TEMPERATURE °C ATR 55-60°C

4. Slowly increase the hold back-pressure control and balance, stop the head movement with
the hold back. Note the pressure at the pull down pressure gauge and hydraulic oil temp.

ACTUAL PRESSURE BAR A.P.R 6-7 BAR

PSI A.P.R. 87-101 PSI
ACTUAL OIL TEMPERATURE °C ATR 55-60°C

5. As head moves down the mast, play with various hold back; pull down and diesel rpm
settings, the head movement must be smooth.
6. Increase the pull down control to maximum, stop the head movement with hold back
control.

29
 7. Balance the rotation head as follows;
• Traverse the head to the top of the mast.
• Fully decrease (turned fully counter-clockwise) the pull down pressure control item 39.
• Fully decrease (turned fully counter-clockwise) the hold back pressure control item 39.
• Micro feed speed control item 41 fully increased.
• Engage the micro feed control lever “DOWN” and balance the mass of head with the
holdback control.
8. Use the head traverse lever to move the head fully down the mast, leave the micro feed
engaged “DOWN” and set the pull down pressure to 100 bar / 1450 psi.
9. Disengage the micro feed lever.
10. Move the head to the top of the mast with the “HEAD TRAVERSE”.
11. Engage the micro feed lever “DOWN”.
12. Let the head come down with the micro feed.
13. Adjust the micro feed speed control item 41 and set the head speed at 50.8mm / 2” per
minute.
14. As the head moves down the mast check for the following;
• Head movement must be smooth.
• No spikes on the pull down pressure gauge to indicate the head is jerky in operation.
• Pull down pressure should be stable through out the travel of the head down the mast.
15. Fully decrease (turned fully clockwise) the micro feed control item 41 and stop the head,
check for zero drift in one minute.

ACTUAL DRIFT MM A.M.R. 0-5 MM

INCH A.M.R. 0-0.196”

19.5 HOSE BURST VALVE ITEM 64

1. The valve cannot be tested safely under work-shop conditions.
2. The valve could be tested at a hydraulic repair shop where a flow in excess of 80 lpm could
be passed through the valve.

6. POWER FLOAT SET UP PROCEDURE

1. POWER FLOAT DOWN SET UP
Note
1. The controls for the power float down operation use item 45 (PBDB-1 located on the
lower left side of the control cabinet) and item 35 (RPEC-2 located inside the control
cabinet)
3. The power float down settings of 18 bar 260 psi (connected to the cylinder rod end)
and 12 bar 175 psi (connected to the piston end) should be enough to allow for the
weight and the weight of 1 x 6 meter H size drill rod in the rotation head chuck etc.
1. A gauge 500 psi will need to be connected to both sides of the cylinder.
2. Traverse the head to the bottom of the mast.
3. Fully decrease the pressure setting item35 (RPEC-2) and item 45 (PBDB-1).
4. Engage the float lever to the “DOWN” position with the diesel at 1500-1550.
5. Adjust item 45 (PBDB-1) until 18 bar / 260-psi reads on the pressure gauge connected to
the rod end of the cylinder.
6. Disengage the float control lever.
7. Operate the traverse lever and traverse the rotation head to the top of the mast.
8. Engage the float lever to the “DOWN” position.
9. Adjust item 35 (RPEC-2) until the rotation head just stops moving. Tighten the lock nut of
item 35 (RPEC-2).
10. Check the setting by decreasing and increasing the pressure setting of the float control
valve item 45 (PBDB-1).
• Decreasing the pressure setting of item 45 (PBDB-1) should stop movement of the
rotation head.

30
 • Increasing the pressure setting of item 45 (PBDB-1) will allow the rotation head to move
down the mast.
• Carry out the above at various diesel engine rpm, the power float down operation
should be smooth at all times
2. POWER FLOAT UP SET UP
Note
1. The controls for the power float up operation use item 45 (PBDB-2) and item 35
(RPEC-1).
4. The power float up operation does not require any back pressure to support the
weight of the rotation head or supported drill rods. This means that item 35 (RPEC-1)
is basically set to a nominal setting as described below.
5. The power float up settings of item 45 (PBDB-2) will have to be adjusted to suit the
type of drill rod used.
1. Fully increase (turned fully clockwise) the pull down pressure control item 39.
2. Fully decrease (turned fully counter-clockwise) the pressure setting item35 (RPEC-1) then
turn the adjustment screw clockwise “IN” two full turns. Tighten the lock nut of item 35
(RPEC-1).
3. Traverse the head to the bottom of the mast.
4. Engage the float lever to the “UP” position with the diesel at 1500-1550 rpm.
5. Adjust item 45 (PBDB-2) until the head begins to move up.
6. Disengage the float control lever.
7. Operate the traverse lever and traverse the rotation head to the bottom of the mast.
8. Engage the float lever to the “UP” position.
9. Check the setting by decreasing and increasing the pressure setting of the float control
valve item 45 (PBDB-2).
• Decreasing the pressure setting of item 45 (PBDB-2) should stop movement of the
rotation head.
• Increasing the pressure setting of item 45 (PBDB-2) will allow the rotation head to move
up the mast.
• Carry out the above at various diesel engine rpm, the power float down operation
should be smooth at all times
19.7 CONTROL VALVE STROKE LIMIT ADJUSTMENT
1. Adjust the “B” port stroke limit adjustment until it contacts the spool. Back the adjustment
out 2 full turns.
2. Traverse the head to the bottom of the mast. Mark a line on the mast 1.5 metres from the
top of the carriage.
3. Engage the traverse control “UP” completely with the diesel engine at 2175-2200 rpm.
Check the time to traverse the head 1.5metres “UP” the mast. It should be 3 seconds A.T.M
3-3.5 seconds. Re adjust the “B” port stroke limiter until the correct time is achieved.
Tighten the lock nut on the stroke limit adjustment.

TRAVERSE UP TIME SECS A.T.R. 3-3.5 SECS

4. Adjust the “A” port stroke limit adjustment until it contacts the spool. Back the adjustment
out 2 full turns.
5. Traverse the head to the top of the mast. Mark a line on the mast 1.5 metres from the
bottom of the carriage.
6. Engage the traverse control “DOWN” completely with the diesel engine at 2175-2200 rpm.
Check the time to traverse the head 1.5metres “DOWN” the mast. It should be 3 seconds
A.T.M 3-3.5 seconds. Re adjust the “A” port stroke limiter until the correct time is achieved.
Tighten the lock nut on the stroke limit adjustment.

TRAVERSE DOWN TIME SECS A.T.R. 3-3.5 SECS

31
19.8 TRAVERSE SPEED CHECKS
1. Balance the rotation head as follows;
• Traverse the head to the top of the mast.
• Fully decrease (turned fully counter-clockwise) the pull down pressure control item 39.
• Fully decrease (turned fully counter-clockwise) the hold back pressure control item 39.
• Micro feed speed control item 41 fully increased (turned fully counter-clockwise).
• Engage the micro feed control lever “DOWN” and balance the mass of head with the
holdback control.
• Use the head traverse lever to move the head fully down the mast, leave the micro feed
engaged “DOWN” and set the pull down pressure to 100 bar / 1450 psi.
• Disengage the micro feed lever.
• Move the head to the top of the mast with the “HEAD TRAVERSE”.
• Engage the micro feed lever “DOWN”.
• Let the head come down with the micro feed.
• Adjust the micro feed speed control item 41 and set the head speed at 50.8mm / 2” per
minute.
2. Operate the rig with diesel rpm at 2200. Fill in table.

ACTUAL MEASUREMENTS

MICRO HEAD TIME TO TRAVERSE FULL LENGTH OF MAST

FEED TRAVERSE
Time Pull Down Main Oil
Mins Secs Gauge pump Temp
Pressure
Gauge

Down -

Up -

- Down

- Up

REFER TO NEXT TABLE FOR A.P.R., A.T.R.

USE TWO MEN TO TAKE MEASUREMENTS
TRAVERSE SPEED CHECKS COMPARISON CHART

MICRO HEAD TIME TO TRAVERSE FULL LENGTH OF MAST

FEED TRAVERSE
Time Pull Main Pump Oil Temp
Down Pressure
Mins Secs

Down - 1 07 60 / 65 20 / 25 45 - 60°C

Up - 0 57 0/5 20 / 25 45 - 60°C

- Down 7 60 / 70 65 / 75 45 - 60°C

- Up 7 0/6 90 / 95 45 - 60°C

32
20 ROTATION
1. MOTOR CONTROL LOCATION
• Refer to photograph below to identify the various motor controls.
• Adjust the height of the maximum speed adjustment screw to 15mm above the maximum
speed screw lock nut.
• Refer to stamped rotation head serial number. Check with the rotation head assembly
section if head has been tested. If not, get a photocopy of test procedure for the rotation
head assembly and test the rotation head.
•Check the rotation head is filled with lube oil to the correct level and the lube oil system
has been primed with oil.
• Fit an external filter to the inlet of the lube oil sight glass at the rotation head.
•Short cut the hoses going to the interlock valve on the side of the mast. This operation
would act as though the rod spin guard is “CLOSED”.

Rotation Head Motor

1. “X” port on motor control

block
2. Control regulator screw
3. Maximum speed screw

33
2. ROTATION HEAD SPEED CONTROL ITEM 37.1
1. Check the rotation “DRILL/MAKE “lever is in the off position.
2. Fully increase (turned fully clockwise) the “ROTATION TORQUE” control.
3. Leave items 1 & 2 in this position until required to test or adjust the rotation torque control.
4. Tee a 60 bar / 870 psi pressure gauge into the hose connected to the “X” port of the
rotation head motor.
5. Start the diesel engine and set the engine speed to 1200-1250 rpm.
6. Slowly increase (turned clockwise) and decrease (turned counter-clockwise) the pressure
setting of rotation speed control item 37 and observe the pressure gauge reading.
7. The gauge reading should follow the change in movement of the rotation speed control and
be smooth in operation.
8. Fully increase (turned fully clockwise) the rotation speed control and note the maximum
reading.

ACTUAL PRESSURE BAR A.P.R. 50-55 BAR

PSI A.P.R. 725-780 PSI

9. Adjust the rotation speed control to a maximum pressure of 35 bar / 508 psi, Shim between
the knob and the lock nut until a maximum of 35 bar is achieved with the rotation speed
control fully increased (turned fully clockwise).
10. Fully decrease (turned fully counter-clockwise) the rotation speed control item 37.1.

20.3 ROTATION CHUCK OPERATION

1. Fit an N size rod jaw set to the rotation head chuck.
2. Operate the control lever and check the following.
• The chuck opens to the maximum required distance.
• No mechanical fouling.
• No hoses being nipped or pulled.
• Fit a short length of N size drill rod to the rotation head and the chuck. Check for correct
operation of the chuck versus the nametag on the control panel.
• Operate the chuck control lever into the hold and release positions several times to check
the operation of the chuck.
1. CHUCK RELEASE AND RAPID TRAVERSE UP DOWN CHECK
1. Operate the chuck lever into the release position and hold in this position. Operate the
traverse control lever into the “UP” position and then into the “DOWN” position, check the
head will traverse up and down the mast with the chuck in the release position.
2. Fit a short length of N size drill rod to the rotation head and the chuck. Leave the short
length of N size rod in the chuck for further commissioning of the rotation head.

3. ROTATION HEAD SIDE RACK

1. Check the rotation head side shifts freely on the slide plate.
2. Check this will operate at mast angles 45 through 90 deg.
3. Check that the name tag is correct to the operation.
4. Make sure the hoses are routed correctly.
5. Check the alignment of the chuck to the centre of the mast when fully racked in.

34
20.5 ROTATION HEAD OPERATIONAL CHECKS
1. With the diesel engine at 850-875 rpm. Operate the rotation head control lever
“FORWARD” and “REVERSE” and check the following.
• Correct operation versus name tag drawing.
6. Engage the rotation pilot lever into the forward position and check the lube oil system of the
rotation head as follows;
• Lube oil can be seen flowing through the lube oil sight glass.
• Crack each lube hose connection at the nipple nearest to the bearing and check the lube
oil is coming out of each hose.
1. MINIMUM ROTATION HEAD SPEED WITH MAXIMUM PUMP FLOW CHECK
1. Disconnect and plug the “X” port hose from the rotation head motor
2. Rotation head in high gear (3 :1)
3. Rod spin guard “CLOSED” or interlock valve “OPENED” by an override device.
4. Engage the rotation pilot lever into the “FORWARD” position completely
5. Diesel engine at 2200 rpm A.R.R 2195 – 2200

ACTUAL ROTATION RPM A.R.R 354-355

6. Refit the hose to the “X” port of the rotation head motor.
2. MAXIMUM ROTATION HEAD SPEED SETTING
1. Run the rotation head up to maximum speed in stages and hold each stage for 1-2 minutes
to allow the head and rotation motor to warm up to operating temperatures.
2. Check the lube oil sight glass for lube oil flowing through the sight glass
3. Set the maximum rotation speed at 1450 rpm with the following conditions;
• Diesel at 2200 rpm ARR 2195-2200
• Rotation pilot lever engaged “FORWARD”.
• Slowly increase (turned clockwise) the Rotation speed control fully
• Check you can feel the rotation motor piston barrel resting firmly against the maximum
speed adjustment screw as the screw is adjusted.
• Check the rotation head rpm with a hand held tachometer.

ACTUAL ROTATION MAXIMUM RPM ARR 1450 RPM

20.5.3 MOTOR CONTROL END REGULATOR SETTING

4. Tee a 50 bar / 725-psi pressure gauge into the hose connected to the “X” port of the
rotation head motor.
5. Run the diesel at 1500 rpm. A.R.R. 1490 - 1500.
6. Engage the rotation pilot lever “FORWARD” completely.
7. Adjust the rotation speed control (turned clockwise) item 37 until the pressure gauge reads
30 bar / 435 psi
8. Undo the locknut of maximum speed adjustment screw, “FEEL” the screw. If the motor has
been preset correctly the maximum speed screw should be hard to turn because the motor
barrel is pressing against the screw.
9. If the maximum speed screw is easy to turn the motor barrel will not be pressing against the
screw. If this is the case adjust the control regulator screw “OUT” until you feel the motor
piston barrel just touching the maximum speed adjustment screw. Lock the control
regulator screw and check setting as follows:
• Rotation speed control pressure = 31 bar A.P.R. 30.5-31 bar.
• = 450 psi A.P.R. 442-450 psi
• The motor piston barrel must be firmly against the maximum speed adjustment screw. The
adjustment screw will be hard to turn.
• Rotation speed control pressure = 29.5 bar A.P.R. 29-29.5bar.

35
 • = 428 psi A.P.R. 420-428 psi.
• The motor piston barrel has moved away from the maximum speed screw. The adjustment
screw will be easy to turn.
10. Recheck the above by decreasing (turned counter-clockwise) and increasing (turned fully
clockwise) the pressure setting of the rotation speed control item 37.

ACTUAL CONTROL REGULATOR SETTING BAR A.P.R. 29.5 – 30.5 BAR

PSI A.P.R. 428 - 442 PSI

11. Recheck the maximum rotation forward speed as previously stated, reset if required.
4. REVERSE ROTATION MAXIMUM SPEED
1. Engage the rotation control lever into “REVERSE” and note the rotation speed with the
diesel at 1500 rpm with the rotation speed control item 37 fully decreased.
2. Adjust the “B” port stroke limit adjustment screw until it contacts the spool.
3. Adjust the “B” port stroke limiter adjustment screw until the rotation reverse speed is 100-
105 rpm. Tighten the lock nut of the stroke limit adjustment screw.

ACTUAL ROTATION RPM A.R.R 100-105 RPM

4. Check at various diesel rpm that the rotation reverse speed is between 100-105 rpm.
20.5.5 REVERSE ROTATION SPEED INTERLOCK VALVE CHECK PROCEDURE
2. Engage the rotation control lever into “REVERSE” and note the rotation speed with the
diesel at 1500 rpm with the rotation speed control item 37 fully decreased (turned fully
counter-clockwise).
5. Adjust the rotation head speed control item 37 to fully increased (turned fully clockwise).
Note the rotation rpm. There should not be any increase in rotation speed between fully
decreased and fully increased.
20.5.6 ROD SPIN GUARD AND ROTATION FORWARD MINIMUM SPEED
3. Remove the override tool from the rod spin guard valve on the side of the mast. This would
mean that the rod spin guard is “OPEN”.
6. Set the rotation head rpm as follows:
• Rotation speed control item 37 fully decreased (turned fully counter-clockwise). Rotation
head in high gear.
• Diesel at 2000 rpm ARR 1900- 2000 RPM.
• Rotation control lever fully engaged into the “FORWARD” position.
• Adjust item 98 (pressure relief valve) until the rotation head is doing 100-105 rpm.
• Check the setting by disengaging and engaging the rotation control lever several times

ACTUAL ROTATION RPM A.R.R 100-105 RPM

7. Refer to MPL10592 and drawing number 10592 (latest revision of each) check the rod spin
guard conforms to these drawings. Check the rod spin guard fits and operates correctly.
8. Check the operation of the guard as follows.
• No mechanical fouling when the head is traversed “UP” or “DOWN” the mast with the
rotation head in the drill position.
•When the guard is “OPEN” the maximum rotation speed is 100 with the diesel at 2200
rpm.
• When the guard is “CLOSED” the maximum rotation speed is 1500 with the diesel at 2200
rpm.

36
7. ROTATION FORWARD PRESSURE CHECK
• Diesel at 2200 rpm ARR 2195-2200
• Rotation pilot lever engaged “FORWARD” completely.
• Slowly increase the Rotation speed control fully
• With diesel at 2200 rpm fill in table.

Gear Head Main Pump Pressure

(rpm)
High 1500 Main Pump Press. A.P.R bar Hyd.Oil A.T.R °C
Psi Temp °C

80/ 85 55/65
1160-1232

8. MAIN FILTER BACK PRESSURE CHECKS

• Run machine as follows:
• Diesel at 2200 rpm
• Rotation at top speed forward
Run for 5 minutes, fill in table.

MAIN FILTER BACK PRESSURE BAR HYDRAULIC

OIL TEMP °C
ACTUAL A.P.R. 0.0-0.2 bar ACTUAL °C
BAR A.P.R 0.0-2.9 psi A.T.R. 50 - 65°C
PSI

20.5.9 SPEED CONTROL TEST

1. Fit a piece of “N” size drill rod to the chuck before rotating the head.
Rotation speed control fully decreased
2.Engage the rotation pilot lever into “FORWARD” completely. 3.
Diesel rpm 2200 rpm A.R.R.2180-2200.
4. Slowly increase (turned clockwise) the rotation speed control.
5. Check the following:
• Check for a smooth raising and lowering of rotation rpm is possible
• Check that rpm stays stable at any rotation speed control pressure setting.
NOTE
1. The dimension of maximum speed adjustment screw is from the top of adjustment
nut to the end of the screw.

ACTUAL LENGTH MM

INCH

20.6 ROTATION HEAD TO ROD CLAMP ALIGNMENT

1. Fit an N size rod jaw set to the rotation head chuck and rod clamp.
2. Fit the rod guide bushes to the rotation head.
3. Fit a short length of N size rod to the rotation head chuck and to the rod clamp. The rod
should be straight and long enough to protrude out of the rotation head and chuck by 200
mm / 8”. The same should apply to the rod clamp.
4. Align the two pieces of rod to within 0.4mm / 0.015” over 600mm / 24” both front to back an
side to side of the rod.

37
 5. This can be achieved by packing under the rod clamp base with shim material.
6. When the rod clamp base bolts has been torque up, re-inspect for alignment.

20.7 ROTATION TORQUE CONTROL

1. Operate the “DRILL-MAKE” control lever item 31, to the “ON” position.
2. Fully decrease (turned fully counter-clockwise) the “ROTATION TORQUE” pressure control
item 44.
3. Fully increase (turned fully clockwise) the rotation head speed control item 37.
4. Operate the chuck and clamp control levers to the “RELEASE” position.
5. Fit an “N” size drill rod to the chuck and rod clamp.
6. Operate the chuck and clamp control levers to the “HOLD” position.
7. Check the rotation head is in high gear.
8. Slowly engage the rotation head lever into “FORWARD” position.
9. Slowly increase (turned clockwise) the pressure setting of the rotation torque control item
44. Observe the pressure reading on the main pump pressure gauge item 50. Check the
pressure increases gradually with the movement of the rotation make torque control item
44.
10. Fully increase (turned fully clockwise) the rotation make torque pressure control, and note
the maximum pressure reading.

MAXIMUM PRESSURE BAR A.P.R. 205-210 BAR

PSI A.P.R. 2972-3045 PSI

11. Fully decrease (turned fully counter-clockwise) the rotation torque pressure control
12. Release the rotation control lever to neutral.
13. Operate the chuck and clamp control levers to the “RELEASE” position and remove the “N”
size drill rod from the chuck and the clamp.

8. ROTATION/ FLOAT OPERATIONAL CHECK

1. FLOAT DOWN TO MAKE UP A ROD JOINT
1. Operate the rod clamp lever into the “RELEASE” position and fit a short length of N size rod
to the rod clamp with the box end (female thread) about 200 mm / 8” above the rod clamp.
Operate the rod clamp lever into the “HOLD” position.
2. Operate the traverse lever and traverse the rotation head until the bottom of the chuck is
about 600mm / 24 inches above the rod clamp.
3. Operate the float control lever into the “DOWN” position and adjust item 45 (PBDB-1) on
the float control manifold until the head just moves down.
4. Lubricate the drill rod threads with suitable rod thread grease.
5. Operate the chuck control lever into the “RELEASE” position and fit an N size rod through
the rotation head spindle and screw the rod into the rod clamped in the rod clamp. Do the
threads up by hand.
6. Operate the chuck lever into the “HOLD” position.
7. Engage the drill / make, control lever item 31 into the “ON” position.
8. Decrease fully (turned fully counter-clockwise) the rotation torque pressure control item 44
9. Engage the float control lever into the “DOWN” position and at the same time engage the
rotation control lever “FORWARD”.

38
 10. The rotation head should rotate and the head travel down at the same time. If necessary
adjust the rotation make torque control item 44 until the rod thread shoulders butt up
together. Release the rotation lever and operate the float lever to the “NEUTRAL” position.
11. Operate the chuck control lever into the “RELEASE” position.
12. Break the drill rod apart with a 915mm 36” pipe wrench, but do not screw the rod joint
apart.
13. Check there is a minimum distance of 600mm / 24 inches between the chuck and the rod
clamp.
14. Operate the chuck control lever into the “HOLD” position.
15. Repeat steps 8 to 13, several times and check the operation of the float / rotation system.
16. Leave the drill rod in the chuck and the rod clamp.
2. FLOAT UP TO BREAK OUT A ROD JOINT
1. Operate the chuck control lever into the “RELEASE” position.
2. Operate the float control lever into the “UP” position and adjust item 45 (PBDB-2) on the
float control manifold until the head just moves up.
3. Make up the drill rod joint with a 915mm 36” pipe wrench, until the shoulders on the rod
joint butt up to each other.
4. Operate the chuck lever into the “HOLD” position.
5. Engage the drill / make, control lever item 31 into the “ON” position.
6. Decrease fully (turned fully counter-clockwise) the rotation make torque pressure control
item 44
7. Engage the float control lever into the “UP” position and at the same time engage the
rotation control lever “REVERSE”.
8. The rotation head should rotate and the head travel up at the same time. If necessary
adjust the rotation make torque control item 44 until the rod thread shoulders break away
from each other. Release the rotation lever and operate the float lever to the “NEUTRAL”
position.
9. Operate the chuck control lever into the “RELEASE” position.
10. Make up the drill rod joint with a 915mm 36” pipe wrench, until the shoulders on the rod
joint butt up to each other.
11. Check there is a minimum distance of 600mm / 24 inches between the chuck and the rod
clamp.
12. Operate the chuck control lever into the “HOLD” position.
13. Repeat steps 7 to 12, several times and check the operation of the float / rotation system.

39
21 MAIN WINCH

1. MAIN WINCH MANIFOLD BLOCK PART NO WU 11684

The manifold is comprised of the following items. Refer to the hydraulic circuit for further
details.
• Item 71 PD24464AU Counter Balance Valve Winch Over Run Control
▪ Item 81 PD24464AH Pilot Open Check Valve Winch Float System
▪ Item 82 PD22978AL Valve Body(Manifold Block)

40
2. BRAKE RELEASE PRESSURE REDUCING VALVE ITEM 72 TEST
1. Connect a 3000 psi pressure gauge at item 72 brake reducing valve.
2. Remove the break pressure line from the main winch gear box.
3. With diesel at 850-875 rpm, check by very slowly engaging the main winch control lever
“UP” and “DOWN”, that a pressure of 172.5 bar / 2500 psi reads on the gauge.
4. Re connect the break release hose to the port on the main winch gear box.

3. MAIN WINCH BASE FRAME REMOVABLE SPACER

Refer to drawing number WU11680 Main winch base frame removable spacer installation bolt
tensioning procedure.

4. MAIN WINCH OPERATIONAL CHECKS

5. With the diesel engine at 850-875 rpm. Operate the main winch control lever “UP” and
“DOWN” and check the following.
• Correct operation versus name tag drawing
• No mechanical fouling on the winch components

1. MAIN WINCH COUNTER BALANCE VALVE SETTING

1. Tee a 400bar/ 5800 psi pressure gauge into the hose leading to the “B” port of the main
winch manifold block.
2. Disconnect the hose going to port PL2 plug and cap the ports.
3. Make sure the winch float control is in the off position and the drill head is side racked into
the mast.
4. Increase the pressure setting of counter balance valve cartridges items 71 by screwing
each adjustment screw counter clockwise until fully adjusted. To increase the pressure
settings of Sun counterbalance valves the adjustment screw must be screwed counter
clockwise as viewed from the end of the cartridge.
5. With diesel at 1500 - 1600 rpm, slowly operate the main winch control lever “DOWN”. The
winch drum should not turn and the pressure gauge teed into the “B” port of the main winch
manifold block should indicate above 4000 psi.
6. Do not pull the main winch control lever on fully, you only need to engage the lever enough
to attain a pressure reading on the pressure gauge teed into port “B” of the main winch
manifold block.
7. Release the main winch control lever to neutral. Adjust the adjustment screw of
counterbalance valve cartridge item 71 clockwise in 1/6 of a turn. After each adjustment
engage the main winch control lever “DOWN”. You will have to release the main winch
control lever to be able to turn the adjustment screw of the cartridge.
8. At some point in the adjustment process the main winch drum will just begin to turn and the
pressure gauge teed into the “B” will indicate between psi.
9. The main winch drum should rotate between 4-5 rpm maximum, which is equal to one rev
in 12 to 15 secs.
10. Tighten the lock nut of the adjustment screw of valve 71. Check the pressure adjustment of
valve 71 several times by engaging and disengaging the main winch control lever.

ACTUAL DRUM RPM A.R.R. 4 - 5 RPM

ACTUAL PRESSURE at “A” port for VALVE 71 PSI A.P.R 4000- 4030 PSI

41
 11. Remove the tee and the 400bar/ 5800 psi pressure gauge from the “B” port of the main
winch manifold block.

2. MAIN WINCH FLOAT SYSTEM

1. Operational Checks
Note
Do not operate the main winch control lever during this test
1. Tee a 100 bar 1450-psi pressure gauge into the brake release pressure port of the main
winch gearbox..
2. Operate the main winch float control item 27 to the “ON” position with the diesel at 850-rpm
A.R.R. 850-875.
3. You should have a 35-40 bar / 507-580 psi reading on the pressure gauge at the brake
port.
4. Check the pressure drains out of the brake cavity and pressure gauge by operating the
winch float control to the “OFF” position.
5. Carry out the above operations several times to check the gauge reading builds to 35-40
bar / 507-580 psi when the winch float control is “ON” and drains when “OFF” and with the
diesel engine at various rpm.
6. Operate the main winch float control item 27 to the “ON” position,
7. Operate the winch float control to the “ON” position. Operate the chuck control lever item
21 to the “RELEASE” position, the pressure reading on the gauge at the brake port should
drain.
8. Operate the rotation head side rack to the out position, the pressure reading on the gauge
at the brake port should drain.
9. Operate the chuck control lever to the “HOLD” position and check the pressure reading at
the gauge at the brake port. It should build to 35-40 bar / 507-580 psi.
10. Carry out the above operations several times to check the gauge readings builds to 35-40
bar / 507-580 bar when the chuck control lever is in the “HOLD” position and drains when
the lever is in the “RELEASE” position and with the diesel engine at various rpm.
11. The main winch rope will need to be connected to the drill head connected to a suitable
hoist plug with a drill rod in the chuck. Engage the micro feed down and slowly increase
the pull down to make sure the float works correctly.
3. MAIN WINCH NO LOAD PRESSURE CHECK
1. Operate the main winch control “UP”-“DOWN”, with no rope fitted and with the diesel at
2200 rpm A.R.R 2195-2205. Fill in the table.

MAIN WINCH SYSTEM PRESSURE HYDR OIL TEMP °C

ACTUAL A.P.R. ATR 55-65°C

“UP” 80-85 bar ACTUAL

1160-1233 psi

“DOWN” 140-145 bar ACTUAL

2030-2102 psi

4. TEST THE WINCH WITH A TEST WEIGHT

1. Fit the main winch rope to the drum.
12. Reeve the main winch rope through the sheave block at the top of the mast.
13. With a test 200 Kg / 440 lbs weight suspended from the main winch rope and at any
possible diesel rpm and main winch control lever position, check for:
14. Any surging as the weight is raised or lowered
• Any excessive response delay
• Excessive run out when the control lever is released to the neutral position.

42
• Brake holding, cut diesel, check if weight drifts, beware that if weight drifts that it will free
fall.

43
22 WIRE LINE WINCH
1. WIRE LINE WINCH OPERATIONAL CHECK
1. With the diesel engine at 850-900 rpm, engage the wire line winch control lever “UP” and
“DOWN” slowly, and check the following.
• Correct operation versus the nametag.
• The wire line winch drum slowly starts and stop and is not jerky in operation as the control
lever is slowly engaged and disengaged.
• No mechanical fouling.
• The drum runs reasonable true and does not have any excessive run out.

2. DOUBLE COUNTER BALANCE VALVE ITEM 84

1. The wire line winch counter balance valve cartridges Item 77 should have been preset to
210 bar / 3045 psi. With a pilot ratio of 3:1, if set correctly 70 bar / 1015 psi, is required to
move the wire line winch drum slowly “UP” or “DOWN”.
2. With the diesel rpm at 800rpm A.R.R 800-850 rpm, engage the wire line winch lever “UP”
and “DOWN” slowly until the drum just rotates. Adjust the counter balance valves item 77
until 70 bar / 1015 psi A.P.R. 68-72 bar / 986-1044 psi reads on the main pump pressure
gauge.
3. Hydraulic oil temperature 60°C ATR 55 -65°C

ACTUAL PRESSURE “UP” BAR A.P.R.68-72 BAR

PSI A.P.R. 986-1044 PSI
ACTUAL PRESSURE “DOWN’ BAR A.P.R.68-72 BAR
PSI A.P.R. 986-1044 PSI

22.3 MAXIMUM SPEED CHECK AND ADJUSTMENT

1. Diesel rpm 2200 A.R.R. 2195 – 2200
2. Engage the wire line lever “UP” and then “DOWN” and adjust the stroke limiter fitted to
caps of the wire line winch spool of the main valve assembly item 24. Adjust the stroke
limiter until the drum rpm “UP” and “DOWN” is 275-rpm A.R.R 274-276 rpm. Check the
drum speed with a hand held tachometer.
NOTE
1. If the flow regulator setting of the main pump is set to high this will affect the wire
line winch motor rpm.

OIL SYSTEM SYSTEM DRUM DRUM

TEMP PRESSURE PRESSURE RPM RPM
BAR A.P.R. A.R.R.
PRESSURE 100-105 BAR 274-276
“UP” 1450-1522 PSI
PRESSURE 100-105 BAR 274-276
“DOWN” 1045-1522 PSI

2. Check that when engaging the wire line winch control lever at any diesel rpm or lever
position combination that no surging continues more than 5 seconds.
3. Check that when engaging the wire line winch control lever at any diesel rpm that there is a
steady increase or decrease in drum rpm especially at the start of control.

44
22.4 WIRE LINE WINCH ROPE
1. Fit the wire line winch rope using the rope pre tension device.

23 WATER PUMP
1. Connect an air-tight suction line to the water pump suction port, and submerge it into a 205
litre drum filled with water.
2. Fit a modified drill rod (water swivel one end and a high pressure ball valve attached to the
other end of the rod) to the Rotation Head.
3. Set the water pressure relief valve at water pump to the minimum setting.
4. Fit a 200 bar / 2900 psi pressure gauge to the pressure test coupling item 14 on pressure
relief valve item 4.
5. Run a suitable sized hose from modified drill rod to the water drum.
6. Set the water valve and the vent valve to the following positions;
• Water Valve - “ON” position
• Vent Valve - “OFF” position
7. Water pressure gauge connected to water manifold.
8. With diesel at 2200 rpm, water “ON-OFF” control valve item 27 in the “OFF” position, water
pump coarse flow control item 36 fully increased, ball valve connected to the drill rod fully
open.
NOTE
1. During this test the water pressure relief valve setting will have to be increased.

2. Check as follows:
• Start and stop the water pump with water pump “ON-OFF” control valve at the control
panel.
• Control the rpm of water pump from maximum to minimum with the water pump fine and
coarse flow controls at the control panel.
• Check for any excessive vibrations at the water pump, which could indicate a
misalignment between the water pump and the motor drive shaft.
• Check for leaks in the water piping, water pump and valves.
• With water pump at max. speed note the following:

PRESSURE AT VALVE 4 BAR A.P.R.[ ]-[ ] BAR

PSI A.P.R. PSI
WATER PUMP MOTOR RPM A.R.R. [ ] –[ ] RPM
WATER PRESSURE PSI A.P.R. 0-10 PSI

3. With the water pump controls set as described above, slowly close the ball valve on starter
rod until 60 bar / 870 psi shows on the water pressure gauge. Check as follows:
• Adjust the water pressure relief valve as required.
• Water pressure gauge follows the opening and closing of the ball valve.
• Adjust the water pump speed control from maximum to minimum and back to maximum.
• Any excessive vibrations.
• Leak in the water piping, water pump and valves.
• Fill in the table below

45
 NOTE
1. Hydraulic circuit pressure at Item 14 valve 4.
2. During this test the water pressure relief valve setting will have to be increased.

PRESSURE AT VALVE 4 BAR A.P.R. [ ]-[ ] BAR

A.P.R. PSI
PSI
WATER PUMP MOTOR RPM A.R.R. [ ]-[ ] RPM
WATER PRESSURE PSI A.P.R [ ]-[ ] PSI

2. Check the rotation head is fully commissioned. Remove the ball valve from the drill rod.
3. Fit a modified drill rod sub, which has a 7/16 JIC nipple on it. To the drill rod.
4. Engage the water pump speed control item 33 and have water running through the 7/16
nipple. Adjust the water pump flow control until 400-600 psi water pressure reads on the
water pressure gauge.
5. Run the rotation head up to maximum rpm Check the following:
• Water swivel for leaks
• Hoses and valves from water pump to water swivel for leaks.
6. Disconnect the water pump test equipment and reduce the water pressure valve setting to
minimum.

24 MUD MIXER CIRCUIT

1. Back the adjustment screw of item 86 mud mixer pressure relief valve out by 2 turns
2. Remove the pressure hose from the mud mixer motor. Plug the pressure hose and cap the
motor.
3. Check the flow control item 93 is set to allow the flow from pump 85 direct to tank.
4. Start the engine and set the engine speed at 2200 rpm
5. Set the mud mixer pressure relief valve item 86 to 138 bar/ 2000 psi by engaging the flow
control item 93 to maximum flow to the mud mixer.
6. Check the setting by operating the flow control to divert the oil flow to tank and then back to
the mud mixer motor.

ACTUAL ITEM 86 PRV PRESSURE BAR A.P.R. 136-138 BAR

PSI A.P.R. 1970-2000 PSI

46
25 DIESEL LOAD TEST

RIG TYPE 200D

DIESEL TYPE JOHN DEERE 6068HF250

IDLING SPEED 850

MAX. NO LOAD SPEED 2375

FULL LOAD SPEED 2200 A.R.R. 2195-2205

FULL LOAD POWER ( CONTINUOUS) AT 175 hp 2400 rpm

CHECK FULL LOAD SPEED AS FOLLOWS

Mud Mixer Circuit

• Connect a bi directional 100 lpm / 26 US gpm minimum 350 bar /5000 psi flow meter into
the pressure and tank return lines of the mud mixer system.
Pump 6B
• Connect a bi directional 200 lpm / 52 US gpm minimum 350 bar /5000 psi flow meter into
the pressure and tank return lines of the water pump system.
Traverse system
• Traverse the rotation head to the top of the mast.
Rotation speed control
• Fully decrease the rotation speed control item 37.
Start Diesel and Run at 2200 rpm
• Engage the water pump “ON-OFF” valve item 27 to the “ON” position and adjust the flow
meter pressure control to 165 bar / 2390 psi.
• Engage the traverse lever “UP”.
• Engage the mud mixer flow control to maximum flow and adjust the flow meter pressure
control to 120 bar / 1740 psi.

The engine should hold the load generated by the traverse system, water pump system, mud mixer
system, pilot pressure system and rotation speed control.
The engine may pull down to below 2200 rpm, if it does adjust the rpm to bring it back to 2200 rpm.

ACTUAL PRESSURE PRV ITEM 4 bar A.P.R. 160-165 bar

psi A.P.R 2320-2390 psi
ACTUAL MAIN PUMP PRESSURE GAUGE bar A.P.R. 210-215 bar
psi A.P.R 3045-3117 psi
ACTUAL MUD MIXER CIRCUIT bar A.P.R. 120-125 bar
psi A.P.R 1740-1812 psi

With the system set up as above the calculated power requirements is 107kW 143.4hp.

47
26 COMMISSIONING CHECK POINTS CHECK THE FOLLOWING
• Before the rig is handed over to the sales department, check the following list for any items
that may have not been covered or have been forgotten during the commissioning
procedure.

Item Description Checked, BY

and When
By When
Grease Points 7. Refer to section 3 and regrease all grease
points
Lubricating Oils 1. Refer to section 5 and recheck all oil levels and
top up if required.
Wire Line Winch 1. Correct operation
2. No oil leaks
3. Check all bolts, nuts & hose ends are tight
4. Rope is fitted and secured to the drum

Main Winch 5. Correct operation

6. No oil leaks
7. Check all bolts, nuts & hose ends are tight
8. Winch rope clamps are tight
9. Rope is fitted and secured to the drum
10. Tamper proof covers fitted where applicable
11. Lube oil level correct in gearbox is correct
12. Winch rope guard is fitted.

Mast Raise 13. Operation

Cylinders 14. No oil leaks
15. Check all bolts, nuts & hose ends are tight
16. Cylinder pivot pins are correctly secured and
have been greased.
17.

48
Item Description Checked, BY
and When
By When
Diesel Engine 18. Check coolant level
19. No coolant leaks
20. Check radiator inhibitor / antifreeze been put
into the cooling system
21. Check lube oil level
22. No lube oil leaks
23. Alternator and fan drive belt correctly tensioned
24. Correct operation of all engine controls and
gauges
25. Check tightness of all bolts, nuts & hose clamps
26. Emergency shut down operates correctly
27. Battery acid level is correct
28. All electrical connections have been sprayed
with sealant.
29. Check the radiator guard has been fitted
30. Check all components and connections for the
air inlet system of the engine are tight and
correctly fitted
31. Check all components and connections for the
exhaust system of the engine are tight and
correctly fitted
32. Drain any water from fuel filters

Pump Group 33. Correct operation of all pumps

34. No oil leaks
35. Check all bolts, nuts & hose ends are tight
36. All adjustment are securely tighten and correctly
adjusted
37. Tamper proof covers fitted where applicable.
38. Pump inlet piping connections are tight

Hydraulic Oil Tank 39. No oil leaks

40. Check all bolts, nuts & hose ends are tight
41. Correct oil level
42. Drain valves have been sealed with steel plugs
43. Bleed and check operation of the hand pump.

49
Item Description Checked, BY
and When
By When
Control Cabinet 44. Correct operation of all functions versus name
tag drawing
45. No oil leaks
46. Check all bolts, nuts & hose ends are tight
47. All pressure gauges are straight
48. All adjustable valves have knobs fitted to the
adjustment screws.
49. All control levers are tight
50. All electrical connections have been sprayed
with sealant
51. Removable sections is easily removed from the
cabinet assembly and is securely pinned in
place when in the cabinet assembly
Mast Assembly 52. Upper section of mast has been fitted to the
lower section.
53. Rod slide has been fitted and operated with the
traverse system of the rig
1. Rod side roller works and the stop rod is fitted
and the threads are covered with anti seize
compound.
2. If the mast is dissembled the correct bolts to
reinstall the mast must be put back and
tightened.
Crown Assembly 3. Check MPL8535-4 MAST CROWN ASSEMBLY
to ensure all components are fitted.
4. Check all bolts, nuts & are tight
5. Wire line sheaves rotate freely and has been
greased
6. Wire line sheave frame (crown
assembly)correctly fitted
7. Main winch sheaves rotate freely and has been
greased
8. Main winch sheave frame (crown assembly)
correctly fitted
Mast Platform 1. Refer to MPL and drawings for the stay rods and
(basket) Assembly check all of the components listed on the MPL
are available and have been trail fitted to the rig.
Platform Stay Rod
2. Make sure all pins are protected with anti seize
Assemblies and
and rotate freely. All the pins must be included
Mast Stay Rods
with the rig and secured.

50
Item Description Checked, BY
and When
By When
Mast Dump Cylinder 3. Correct operation
4. No oil leaks
5. Check all bolts, nuts & hose ends are tight
6. Cylinder pivot pins are correctly secured and
have been greased.
7. Check the “U” bolt supporting the cylinder is
correctly fitted.
8. The mast slides easily up and down on the mast
dump slides with no mechanical fouling as the
mast moves.
Traverse Cylinder 9. Correct operation
10. No oil leaks
11. Check all bolts, nuts & hose ends are tight
12. Cylinder pivot pins are correctly secured
13. Lock nuts fitted where applicable and tight
14. No misalignment of components

Drill Head Carriage 15. Correct operation

16. Check all bolts, nuts are tight
17. The drill head carriage slides easily up and
down on the mast with no mechanical fouling as
the carriage moves.
18. Rotation head Racks to the side easily.

Rotation Head 19. Lube Oil level correct

20. Correct operation
21. No oil leaks
22. All adjustment are securely tighten and correctly
adjusted
23. Tamper proof covers fitted where applicable
24. Rod spin guard has been fitted and operates
correctly
25. All guards have been fitted
26. Check the hoses to / from the rotation head and
traverse cylinder travel in a neat group when the
rotation head is moved “UP”-“DOWN” the mast
regardless of mast angle

51
Item Description Checked, BY
and When
By When
Rod Clamp 27. Correct operation
28. No oil leaks
29. Check all bolts, nuts & hose ends are tight
30. Clamp pivot pins are correctly secured
31. The guard has been fitted over the rod clamp
operating mechanism and clears all
components.
Water Pump 32. Correct lube oil level
33. Correct operation
34. No oil leaks
35. Check all bolts, nuts & hose ends are tight
36. Water relief valve has been reset to the
minimum setting
37. The water pump has been drained of all water
38. Suction fitting has been plugged

General Points 39. Check all standard accessories have been fitted
to the rig and operate correctly
40. Check all standard accessories fit are painted
and in the standard accessories box
41. Match drill all name tags
42. Safety and warning stickers have been fitted
43. Check the rig has the latest up date
modifications fitted
44.

52
27 SERIAL NUMBERS OF EQUIPMENT
CLIENT: RIG NO.:

ITEM DESCRIPTION SERIAL NO. ADJUSTMENT

NO. SCREW LENGTH

MIN MAX
1 Rig Engine Type
2 Rig Engine No.
3 Rig Engine Model No.
4 Hydraulic Pump No. 85
5 Hydraulic Pump No. 6A
6 Hydraulic Pump No. 6B
7 Hydraulic Pump No. 6C
8 Rotation Head
9 Rotation Head Motor
10 Main Winch Gearbox
11 Main Winch Motor
12 Wire Line Winch Motor
13 Water Pump
14 Water Pump Motor
15 Rig Hydraulic Oil Cooler
16 Mud Mixer Motor

53
28 SIGNATURE FORM

1. All points in this procedure have been commissioned as per procedure and have been
initialled and dated.

Commissioning Personnel

Name Date

Name Date

28.2 A visual and operational inspection by sales has been done and any points noted by sales
corrected by production.

Sales Department Personnel

Name Date

Name Date

3. Production Manager has sighted finished procedure and sales correction list.

Production Manager

Name Date

4. Finished procedure must be filed with Rig Build Record.

54
Revision list

Revision 1 10/2019 RDB

Revision 2 2/8/20 RDB

Item 22.2.8.1 now operational checks was counter balance valve item 80,
Counter balance valve item 80 deleted.
Revision A 200DLS UPGRADES 19/6/2020 KM

55