Operator's Instructions for

CHRISTENSEN

CT 14
2
 Operator's Instructions for
CHRISTENSEN

CT 14
These instructions are intended for operators of the Atlas Copco diamond core drill
CHRISTENSEN CT 14.
Instructions are given for start and stop procedures, drilling, additional
instructions, maintenance, and service schedule to be carried out by the operator.
For further information concerning service measures for the drill rig, please contact
your nearest Atlas Copco representative.

Read carefully the INTRODUCTION- AND OPERATING SAFETY sections before

starting to use the rig.

All rights reserved.

The owner of the equipment is granted the permission to take copies of this
publication solely for internal use.
It is recommended, however, to order additional copies from Atlas Copco
representative in order to benefit from the latest revision.
Atlas Copco Craelius AB reserves the right to make changes in its products in order
to improve design or performance characteristict without notice.
The information in this publication is assumed to be accurate at the time of
publication, but is subject to changes in order to remedy detected deficiencies or
to follow changes in the product.
Any user of this publication is requested to inform Atlas Copco Craelius AB about
deficiencies found, particularly in matters concerning product safety.

ATLAS COPCO CRAELIUS AB

MÄRSTA - SWEDEN 2006-02

Printed Matter No 6991 1433 01b

3
Contents
Page Page

Introduction ........................................................ 5 Thread compensation .......................................43

Operating safety ................................................ 6
Organizational measures ................................... 6
Operation and maintenace ................................ 7
Special safety device .......................................... 9
Following signs are used .................................. 9
Environmental Instructions ...............................11
General ............................................................... 13
Hoisting and transport .................................. 14
Hoisting the drill and power unit .................... 14
Technical specification.......................................15
Drilling positions............................................... 16
Transport .............................................................18
Characteristict .................................................. 22
Mast .................................................................. 22
Rod holder ......................................................... 22
Power units ....................................................... 23
Performance specifications .......................... 24
Rotation units .................................................... 24
Mast extension.................................................. 26
Wire line hoists ................................................. 26
Design features ................................................ 27
Drill module....................................................... 27
Power unit ......................................................... 27
Control panel..................................................... 27
Controls ............................................................. 28
Control panel functions.................................... 28
Maneuvring ....................................................... 30
Pre-start procedure .......................................... 30
Start-up Diesel power unit............................... 31
Stopping Diesel power unit ............................. 32
Adding a drill rod and making a joint..............44
Breaking the joint.............................................. 44
Water pressure dump valve..............................44
Maintenance ...................................................... 45
General............................................................... 45
Cleaning the hydraulic system ........................ 45
Oil cooler .......................................................... 45
Hydraulic oil filters .......................................... 46
Changing hydraulic oil .................................... 47
Draining condensed water out of tank ........... 47
Periodic maintenance ....................................... 48
Lubricant recommendations ........................... 50
Daily safety check.............................................. 51
Hydraulic system ...............................................52
Drill head 3-1/2”, 4-5/8” spindle........................54
Oil filter ...............................................................55
Chuck bonnet......................................................56
Changing rod holder jaws and rod holder
guide bushings.................................................. 57
Flush pump.........................................................58
Wireline hoist .....................................................59
Main hoist ...........................................................60
Mast/Hoist Frame...............................................62
Mud mixer ..........................................................63
Basic hydraulics................................................ 64
Basic hydraulics, Trouble-Shooting ..............72
Rotation unit “P head”....................................86
Trouble shooting............................................... 94
Hydraulic schematic ........................................ 98

Setting up for drilling ..................................... 34

Leveling the drill ............................................... 34
Mast sections .................................................... 35
Mast raise procedure........................................ 36
Mast backstay legs............................................ 37

Drilling ................................................................. 38
Before drilling starts ..........................................40
Start the power unit.......................................... 40
Start the water pump ....................................... 40
Adjust the flow of flushing water.................... 40
Start rotation ..................................................... 40
Start drill feed.................................................... 41
Stop drilling....................................................... 41
Wireline ............................................................. 42
Controlled wireline lowering ............................42
Controlled wireline hoisting .............................42

4
 Introduction
This instruction book is part of the complete The information is divided into the
delivery of your new diamond core drill following chapters
CHRISTENSEN CT 14. It offers basic information on
Section 1: Operating safety
features and handling of the unit and contains
advice and measures necessary to keep the rig Section 2: General and technical
operational. It does not, though, replace thorough specification.
training of operator, helpers and service support. Section 3: Operation
It is the responsibility of the owner to make sure Section 4 Maintenance
that all personnel assigned to this CHRISTENSEN
CT 14 unit, have the skill necessary for the safe
operation, service and maintenance of the unit
before carring out any kind of work. Personnel
must have been given adequate time to assimilate
the information in this book. One copy of the
manual should be kept available for reference on
the rig at all times.
The following information is available, and
relevant for operating the CHRISTENSEN CT 14
drill rig.

CHRISTENSEN CT 14 Printed Matter No.

Operator’s manual 6991 1433 01
Spare parts list 6991 1432 50

Order from: Atlas Copco Craelius AB

S-195 82 Märsta
Sweden
Fax: +46 ( 8) 591 187 82

5
Operating safety
Dear operator,
Before putting your new equipment into use, we
would like to direct your attention to the safety
aspects. Drilling can be a hazard to you and to
the environment. Good order, training and well
maintained equipment are key factors to safe
operation. This instruction book is no
replacement for thorough training, but will, as a
training aid and a reference book, help you
maintain a safe working environment and keep
the rig in good operational condition.
Yours faithfully;
Atlas Copco Craelius AB
Fig.1 Read the instruction book carefully before
starting up the drill rig.
Intended use
1.3 Always use personal protective
The diamond core drill CHRISTENSEN CT 14 is
equipment, as required by circumstances
intended for surface exploration and
or demanded by regulations.
investigation drilling.
Any use going beyond this shall be considered 1.4 If, during operation of the unit, any
"not intended use". The manufacturer is then not abnormal action in the safety or
liable for damage incurred as a result. operational systems is observed; the unit
Unintentional use shall be at the owner's risk. should be stopped and the problem be
investigated and rectified.
Proper use also includes observing information
in operation-, service-, and maintenance books 1.5 Warning signs must be kept easily legible
as stipulated by the manufacturer. at all times. Damaged signs should be
The CHRISTENSEN CT 14 should be run, replaced immediately.
serviced and repaired by personnel properly
1.6 The daily safety check, as described in this
trained for their task. These personnel must have
instruction, must be carried out in addition
sound knowledge about hazards in their
to maintenance measures described in the
respective profession.
periodic maintenance section.
General safety regulations must be observed.
Personnel should be aware of dangers resulting 1.7 Hydraulic and electrical systems are of a
from abuse of drugs and alcohols as well as complex nature - and can cause injury or
effects of medicines legally prescribed, or damage if not handled with care. Repair
mixture of any of them. The manufacturer is not and service shall be carried out by
personnel with documented experience for
liable for any damage caused by unauthorized
these systems.
alterations made to the unit.
1.8 Welding repairs should only be carried out
1.0 Organizational measures: by an authorized welder in order to meet
the high standards that apply to Atlas
1.1 The diamond core drill CHRISTENSEN CT Copco products. Special attention must be
14 shall be operated only by personnel given to components which could cause
who have undergone theoretical and injury or serious damage.
practical training on the rig. Particular
emphasis shall be laid on safety 1.9 After repair make sure that the rig has
precautions and maintenance. been inspected and approved by the
proper authorities before being brought
1.2 Keep this instruction book as well as back to normal operation.
other books related to the equipment
available on the rig at all times.

6

1.10 Never make alterations or modifications to
components of the unit, particularly to the
safety systems, which might result in
hazardous consequences. The
manufacturer’s approval should be
requested for any modification done to the
unit.
2.0 Operation and maintenance.
2.1 In addition to this manual you should also
have a good knowledge of generally
recognized safety and accident prevention
regulations. If you follow these regulations
you stand a better chance of
accomplishing your task without harm to
either man or equipment.
2.2 Prior to starting up for the first time,
familiarise yourself with the rig's features,
its controls and their functions. Refer to
"Controls, Manoeuvring and Setting up for
drilling" pages for further information.
2.3 Various safety devices are built into the
system of the rig for your personal safety.
These devices must be checked at least
once at the beginning of each shift to
ensure that they are in full working order.
The equipment should not be used unless
safety checks and maintenance have been
carried out according to the schedule.
2.4 Operators and helpers should wear
helmets, (with ear protectors when called
for), safety glasses, safety shoes, gloves
and suitable clothing. Loose fitting clothing
and jewellery can get caught in the moving
2.9
parts of the machinery, causing serious
injury or even death.
2.5 Check the surroundings. During drilling
2.10 Use extreme caution while handling starter
and tramming no unauthorized person
should be allowed near the rig. Ask a
supervisor for assistance when moving the
rig into dangerous positions such as close
to the edge of a quarry bench. Make sure
the visibility is good. Do not drive the rig
into a dust cloud. Check the travel route if
you are unsure of the safety of the ground.
2.6 Set control levers and switches to the
neutral positions prior to starting up,
otherwise the rig could start
uncontrollably. Some of the levers are
spring-loaded so that the operation will
stop once released.
Operating safety
This is part of the safety system. Never
lock these levers into operating position
using strings, sticks or similar items. The
unit should always be started from the
control panel. On a Crawler mounted rig,
the operator should ride on the rig during
tramming. Any attempt to move the rig
while walking beside it could result in
injury.
2.7 Avoid sharp turns when tramming on
inclined ground. Take extreme care when
moving on wet, slippery ground. Secure
the rig with a suitable wire rope when
operating on slopes in excess of 10° from
horizontal.
2.8 Shut the rig down when refueling. Fuels
must be handled with care, and at a safe
distance from fire, sparks or electrical
systems. Smoking is not allowed within 10
metres of the fuel ! Do not fill the tank in
an enclosed space without ensuring
adequate ventilation. Fumes are
poisonous. Dispose of spilled fuel in
accordance with safety and environmental
regulations (Use absorbents or dig uot the
contaminated soil and transport it to an
approved storage) Do not overfill the fuel
tank. If you top up the tank in the morning,
the expansion of the fuel, as the
temperature increases later in the day,
may cause fuel to spill from the tank. Tank
ventilation easily clogs if the level of fuel is
too high. See the “Environmental
instructions” chapter for further
information.
Never leave the rig unattended with the
engine running. Carry the ignition key with
you.
batteries. Wear gloves and protective
glasses when servicing batteries. The
batteries contain strong acid, which can
seriously burn eyes, skin and damage
cloth, insulation and metal. First aid in
case of acid in the eyes: wash with plenty
of clean water and seek medical help.
Disconnect the earth cable from the battery
before carrying out service on the electrical
system.
The battery gas is explosive! Never use
matches when checking the acid level.
7
Operating safety
Be careful using tools made of iron near
the battery, a spark might set off an
explosion. Read the battery manufacturer’s
manual for further information as well as
the “Environmental instructions” chapter.

2.11 Hydraulic oils are poisonous. Use eye

protection and gloves. Hydraulic oils, like
fuel, must be treated in compliance with
safety and environmental regulations. See
the “Environmental instructions” chapter
for further information.

2.12 Before any repair or service is carried out

on the rig's hydraulic or water systems, GENUINE PARTS
make sure the engine is stopped and that
all systems are depressurized.

2.13 Be very careful while tracing leaks in the Fig. 2.16 Use only genuine Atlas Copco parts.
pressurized systems. Hydraulic oils, water
or air under pressure can penetrate the
skin and cause complicated injuries or
infection. If this happens, see a doctor at
once.

2.14 Dispose of engine oils, hydraulic oils, fuels,

filters and acids in a safe manner
according to environmental protection
regulations

2.15 Avoid the use of cleaning agents

containing solvents like carbon
tetrachloride. There are environmentally
better alternatives now available on the
market.

2.16 Use only authorized parts (Atlas

Copco parts). Any damage or
malfunction caused by the use of
unauthorized parts is not covered by
warranty.

2.17 Any warranty for work performed,

only covers Atlas Copco Products,
Atlas Copco components and work
performed by authorised personnel.

8
 Operating safety
4.0 Special safety signs
On the rig and in the manuals you will come
across the following warning signs. DANGER
4.1 The “DANGER” sign warns for immediate
hazards, which, when ignored, will Fig. 4.1
inevitably cause serious personal injury or
death!

4.2 The “WARNING” sign warns for hazards or

unsafe practices which, when ignored, WARNING
could lead to serious personal injury or
death.
Fig. 4.2
4.3 ThE “CAUTION” sign indicates hazards or
unsafe practice, which could lead to minor
personal injury or damage to equipment.

4.4 The “IMPORTANT” sign is used for CAUTION

recommendations such as how to run the
unit efficiently, economically and in
compliance with environmental Fig. 4.3
regulations.

IMPORTANT !
Fig. 4.4
5.0 Following signs are used on
your CHRISTENSEN CT 14
Description and where the sign is located:

5.1 Lifting points. This sign is located where

the sling is recommended to be attached.
Location: Each corner of the crawler.

5.2 Ear protectors. Ear protectors should

always be worn.
3716 5528 00 3716 5525 00

5.3 Risk of crush. Be aware of the risk from Fig. 5.1 Fig. 5.2
crushing.

5.4 Diesel fill. Location: On the diesel power

unit.

5.5 ATTENTION Before starting, oil must be

3716 5527 00 3716 5526 00

filled according to:

Lubricant Recommendations Fig. 5.3 Fig. 5.4

5.6 Drain water cooler. When there is a risk

of freezing, especially during storage of
the unit. ? -0°°C
-0

Fig. 5.5 Fig. 5.6

9
Operating safety

CAUTION!
It is recommended that the drill operator
checks that the mine disconnect system is
equipped with a ground fault/ground check
system. If the mine does not supply this type
of disconnect system, such a system can be
obtained through Atlas Copco.
WARNING!
The ground fault protection system located in
the mine disconnect system (and for CE
marked drills in motor starter panel), trips at
approximately 0.3 amp which is too high to
provide personnel protection. The driller and
helper should always use suitable electrically
insulating boots when operating an electrically
powered drill.

Fire protection!
A fire extinguisher is placed on the lefthand side of
the control panel

The drill rig is equipped with a portable fire extinguisher.

The fire extinguisher is located on the control panel at the
left hand side.

This fire extinguisher is suitable for fire in electrical cables,

fuel and engines and lasts for approximately one minute
when operated continuously.

For use; remove the safety pin and press handle. Direct the
jet towards the base of the fire.

• Check the function at least once a year.

This type of fire extinguisher puts out the fire by eliminating

access to oxygen. Ember might start the fire again. Use water
for fighting fire in wood, paper and similar materials.

10
 Environmental Instructions
Dear operator, Chemicals
Atlas Copco Craelius AB recognizes the Dispose of chemicals such as drilling additives,
importance of environmental issues. As part of other additives, glycol etc. according to the
our commitment to a better environment, we manufacturer’s instructions. Avoid the use of
want to inform you, the customer, of how you cleaning agents containing solvents like carbon
can minimize the effect on the environment tetrachloride. There are environmentally better
when using an Atlas Copco Craelius product. alternatives now available on the market.
These simple but important instructions will help Follow national regulations regarding handling
to preserve the environment. and disposal of wastes.
Metals (steel, aluminum, etc.)
These products are recyclable and should be
1.0 Operation, maintenance and
taken care of according to national regulations.
disposal
Plastict and rubber
Oil
These products are often labeled according to
Leaks of hydraulic and lubrication oils pose an different classes. In those cases they are
environmental threat. Changing lubricating and recyclable and should be taken care of according
hydraulic oils, hydraulic hoses and hydraulic to national regulations.
filter elements also pose a threat to the
Electrical components (cables, electronict, etc)
environment.
Used components should be taken care of
Collect all oil spills and waste (e.g. oil filter according to national regulations.
elements) contaminated with oil. Dispose of
according to national regulations.
Use biologically decomposable hydraulic oils
and lubricating oils for Atlas Copco products
wherever possible. Contact your nearest Atlas
Copco office for more information.
Engine
Engine emissions are toxic and pose an
environmental threat. Always provide for fresh
air when an engine is running. Well-maintained
air filters help keep emissions at a low level.
Fuel (Petrol/Gas, Diesel)
Fuel spillage poses an environmental threat.
Collect all wastes and fuel spillage and dispose
of according to national regulations.
Grease
Lubricating grease poses a threat to the
environment. Collect all wastes and spillage and
dispose of according to national regulations.
Batteries
Batteries contain acids and heavy metals. Used
batteries can therefore pose a threat to the
environment and to your health. Avoid all
contact with acids and dispose of used batteries
according to national regulations. See also the
“Operating safety” chapter for further
information.
Dust
Rock dust can pose a health danger. Use dust
binding oil.

11
General

Fig. 1 CHRISTENSEN CT 14 is an all-hydraulic operated diamond core drill.

The CHRISTENSEN CT 14 is a complete, all- Recommendations

hydraulic diamond core drill for surface
exploration drilling. It is the perfect combination
of the proven Christensen CT concept, combined
with new and powerful components.
The CT14 is mounted on a frame to be mounted
on a truck.
To achieve the best results with regard to:
- high penetration
- optimal core recovery
- and low drilling costs
it is of primary importance that drill rods, core
barrels and coring bits are of the right type and
quality, matched to the rock drill and to the
prevailing rock conditions.

The CHRISTENSEN CT 14 uses well proven Bearing in mind the core drill’s speed of rotation,
technology for diamond core drills combined its rating and chuck diameter, the CHRISTENSEN
with new improvements in order to get easy drill CT 14 is best suited to drill holes in diameter
operation. Hydraulic jacks, mast dump, hinged (60 - 123) using both conventional as well as
top mast and all controls available at the new wire line rods.
control panel provide the driller an easy set-up.
Other features such as the strong main winch,
powerful direct feed cylinder, modern diesel
engine, long mast, new Rod Holder (option) and
more gives the CT14 capacity to drill deeper than
previous models.
Revision. b 2006-02-20
12
 Hoisting and transport
1.1 Hoisting the drill unit
1. Position the mast on the mast support.
2. Place the rotation unit above the main
hoist to obtain the best possible point of
balance and centre of gravity.
3. Place a sling around the mast and mast
support in the front of rig.
DANGER
– The sling must be dimensioned for lifting 9
tons (Drill unit) to provide a safety margin.
– Never use a damaged rope/sling.
– Always make sure that nobody is under or
anywhere near, a suspended load or within
the swing radius of the rope/sling.

DANGER
– The movement of the extention mast can
cause injury or death.

Note. When lifting, make sure that the

sling will not damage the hydraulic hoses,
mechanical components etc. Use a
spreader bar to lift the CT14.

Fig. 1.2 Hoisting the drill unit

13
Technical specifications

E F
C
D

1.0 Drill unit

Dimensions
mm in

A 9816 386.4
B 4119 162,1
C 86 3.4
D 641 25.2
E 1100 43.3
F 1680 66.1
G 2280 89.7

Dimensions
Length Width Height
Lower Mast:
5150 mm (202”) 580/740 mm (22.8/29.1”) 457.5 mm (18”)
Upper Mast:
4060 mm (159.8”) 560/730 mm (22.0/28.7”) 482 mm (18.9”)
Assembled Mast:
9665 mm (31.8 ft) with Crown wheel (9215 mm 30.1 ft without Crown wheel)
Drill Head:
Horizontal view 787 mm (31”) x 1118 mm (44”)
Vertical view 533 mm(21”) x 1118 mm (44”)
Engine Component:
1740 mm (68.5”) x 822 mm (32.4”) x 1600 mm (62.9”)
Weight: 9000 kg

14
Technical specifications

15
Technical specifications

16
Technical specifications

17
Technical specifications

18
 Characteristics
1.1 Mast
Feed Travel: . . . . . . . . . . 3.5 m (11,5 ft)
Feed Speeds: . . . . . . . .fast and slow with
. . . . . . . . . . . . . . . . . . . .variable control
Thrust: . . . . . . . . . . . . . .59,6 kN (13,390 lb)
Pull: . . . . . . . . . . . . . . . .138 kN (31 020 lb)
Drilling Angle: . . . . . . . .45 to 90 degrees
Rod pull length: . . . . . .6,09 m (20 ft)

1.2 Rod holder

The rod holder is hydraulically operated, and
closed by gas pressure.

Axial holding force: . . . . . . . . 133 kN (30000 lbf)

Jaws . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ( TC set)
Max. rod size: . . . . . . . . . . . . . . . . . . . . . 117,5 mm

Fig. 1.2 Hydraulically operated Rod holder

19
Characteristics
1.3 Power units Fuel drain line maximum restriction . . . . 69 kPa
Fuel inlet maximum temperature. . . . . . . . . 74°C
Power units with variable hydraulic pumps and Engine minimum cranking speed . . . . . . 150rpm
independent hydraulic circuits for rotation and
feed thrust. Prepared for auxiliary, hydraulically Lubricating oil system
driven flush pump. Oil pressure:
Complete with hydraulic tank, filters, oil cooler Low idle (minimum allowed). . . . . . . . . . 103 kPa
and starter panel. At rated speed (minimum allowed) . . . . 310 kPa
Regulated pressure. . . . . . . . . . . . . . . . . . 414 kPa
1.3.1 Diesel power unit
Oil capacity of standard engine
Powered by a Cummins diesel engine
Standard, total system . . . . . . . . . . . . . 16.4 liters
Manufacture: Cummins Deep sump, total system . . . . . . . . . . . 18.3 liters
Model: QSB5.0-C, 5.9 liter 6 cylinder
Power: 158 kW (212 hp) Cooling system
RPM: 1800 Coolant capacity (engine only) . . . . . . . 9.0 liters
Engine type: Diesel turbocharged/after cooled
Cooling: Water Std, modulating thermostat - range. . 84 to 91°C
Displacement . . . . . . . . . . . . 5.9 liters [359 C.I.D] Max. allowed operating temperature . . . . 100 °C
Max operating pressure . . . . . . . . . . . . . . . . . . . . Min. recommended operating temperature
- Main pump . . . . . . . . . . . . . . . . . . . 280 bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 °C
- Service pump . . . . . . . . . . . . . . . . 200 bar
- Auxiliary pump . . . . . . . . . . . . . . . . 215 bar Min. recommended pressure cap . . . . . . . 48 kPa

Max flow Air intake system

- Main pump. . . . . . . . . . . . . . . . . . 242 l/min
- Service pump . . . . . . . . . . . . . . . 122 l/min
- Auxiliary pump . . . . . . . . . . . . . . . 47 l/min
Engine weight . . . . . . . . . . . . . . . 458 kg [1010 lb]
Fuel system
Engine idle speed . . . . . . . . . . . 700 to 1000 rpm
Max. fuel inlet restriction to lift pump . . . 20 kPa
Max. fuel pressure at fuel filter outlet
(engine cranking) . . . . . . . . . . . 28 to 55 kPa
Min. fuel pressure at fuel filter inlet
(engine running) . . . . . . . . . . . 55 to 117 kPa
Max. pressure drop across fuel filter . . . . 34 kPa
Max. intake restriction (clean air filter element)
. . . . . . . . . . . . . . . . . . . . . . . . . 254 mm H2O
Max. intake restriction (dirty air filter element)
. . . . . . . . . . . . . . . . . . . . . . . . . 635 mm H2O
Exhaust system
Maximum back pressure from pipeing and
silencer (combined):
Hg . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 mm Hg
H2O . . . . . . . . . . . . . . . . . . . . . . . . . 1016 mm H2O
Exhaust pipe size (normally acceptable inside
diameter). . . . . . . . . . . . . . . . . . . . . . . . . . . 76 mm

Sound noise level

Drill unit with diesel power unit
Sound power emission . . . . . . . . . 100 dB (A)

Fig.1.3.1 Power Unit

20
 Characteristics
1.4 CT 14 Performance
Specifications Range selection: manual control from operator’s
station
Depth capacity coring (wire line or Hinged head: swing away
conventional)
Chuck assembly
B wire line 1 540 m (5 052 ft) Type: hydraulic open, spring closed
N wire line 1 200 m (4 042 ft) Maximum inside diameter: 117 mm (4 5/8 in)
H wire line 800 m (2 695 ft) Holding capacity: 18 143 kg (40 000 lb)
P wire line 475 m (1 558 ft)
Depth are based on vertical hole Drill base supports
Frame mounted rig designed to be mounted on
a truck
The above capacity values only serve as a
Support: 4 hydraulic jacks
guideline, and refer to vertical, downward Pad size: 210 x 210 mm (8,27x 8,27 in)
drilling in homogeneus rock. Travel length: 900 mm (35,43 in)

Main hoist (Single line) Weight

Capacity: Bare drum 80 kN (18 000 lb) Base drill: approx. 8 000 kg (17 635 lb)
Line speed: Bare drum 44 m/min (148 ft/min)
Cable size: 35 m (118 ft) x 16 mm (10/16 in) Dimensions (L – W – H)
In transport position:
Wire line L: 9 900 mm (32,48ft) W: 2 280 mm (7,48ft)
Capacity: 1 830 m (6 000 ft) of H: 4 050 mm (13,29ft)
4,76 mm (3/16 in)
Standard equipment
975 m (3 200 ft) of -Hydraulic mast dump
6,35 mm (1/4 in) -Hydraulic mast raise
Line pull: bare drum: 11,9 kN (2665 lb) -Mast in two sections
full drum: 3,0 kN (668 lb) -4 hydraulic levelling jacks
-Large crown sheave wheel
Line speed: bare drum 114 m/min (374 ft/min) -Tier II engine
full drum 453 m/min (1486 ft/min) -Towing package
-Wear liners on lower mast
Mast and feed system -Fuel tank 200 l (53 gal)
Feed travel: 3,5 m (11,5 ft) -Safety guards
-Hydraulic oil reservoir fill
Feed speeds: fast and slow with variable control -Fuel filter & water separator, pump & filtration
Thrust: 59,6 kN (13 390 lb) -Mast lightening kit
Pull: 138 kN (31 020 lb) -Hydraulic P-size rod holder
Drilling angle: 45 to 90 degrees -Hydraulic mud mixer
Rod pull length: 6,09 m (20 ft) -Hydraulic mud pump, Trido 140:
max flow: 140 l/min (37 gal/min)
Drill head and spindle speeds max pressure: 7 MPa (1 015 psi)
Power: hydraulic motor – variable -Water flow meter
speed/reversible -RPM meter

Final drive: 4 in chain driven in oil bath –

2,5 ratio All weights and dimensions are approximations
Spindle (inner diameter): 117 mm (4 5/8 in) and are subject to change

Spindle speeds:
Ratio Speed, rpm Torque, Nm (ftlb)
1st 6,63:1 117-196 5 113-3 011
(3 771-2 250)

2nd 3,17:1 245-410 2 445-1 459

(1 803-1 076)

3rd 1,72:1 451-756 1 326-792

(978-584)

4th 1,00:1 776-1300 771-460

(569-340) Revision. b 2006-02-20

21
Characteristics

Fig.1.4.1 Torque diagram

Revision. b 2006-02-20
22
 Characteristics
1.0 Mast top section
A mast extension (1) is mounted at the top of the 2
mast. With the standard foldable mast extension
, the total length of the mast extension is 4.5 m.
With the crown block , the total length is 10 m.
The crown block (2) is mounted on the extension
mast. 1
To brace the mast, 3 metre aluminium tubes (3,
Ø 49 mm) can be used.

3
1.1 Wire line hoist, 1800 m
Mounted on the stand for the mast. Does not 5
need to be moved when changing drilling angle.

Data
Bare Drum: 264kg (580 lb)
Full Drum: 995kg (2,190 lb)

Line Speeds:
4
Bare Drum: 119 m/min (390 ft/min)
Full Drum: 445 m/min (1,460 ft/min)
Cable Size: 976 m(3,200ft)
or 4.6 - 6 mm (3/16”)
Fig.1.0 CHRISTENSEN CT 14 equipped with mast
and hoist.
1. Mast top section
2. Crown block
3. Backstay leg bracket
4. Wire line hoist
5. Water pump

Fig.1.1 Wire line hoist, 1800 m

23
CHRISTENSEN CT 14 Design Features
1.1 Drill module
1. Feed frame
2. Rotation unit
3. Rod holder
4. Foot bracket 10
5. Control valves (panel)
6. Platform
7. Bracket for backstay legs
8. Main hoist
9. Wireline hoist
10. Crown block

2
5

4 6
9 8
24
 Controls
1.0 Control panel -Control functions, see Fig. 1.0
1) Start panel with ignition Switch – To start engine.
2) Gauge for hold back force (kN)
3) Gauge for feed force (kN)
4) Water Pressure – Indicates the pressure at the water pump outlet.
5) Main pump pressure gauge (Bar)
6) Rod holder gas pressure.
7) Rotation speed – Digital tachometer - indicates engine speed in revolutions per
minute. (Option)
8) Flow meter - Indicates water flow (l/min) (Option)
9) Emergency stop indicator

Read the safety instructions before start

9 2 3 4 5

1 8 7

Fig.1.0 Control panel

25
Controls

1 2 6

8 9 10 11
5
7

3 4
13
14

10
Fig.1.1.0 Drilling 16

1.1.0 Valve assembly (Drilling)

1. Rod kicker valve - moves rod kicker in and
out
2. Break out tool and rod lifter (Option)
3. Rod holder (Option)
4. Chuck - Open and closes the chuck
5. Fine feed, rotation unit
6. Thread compensation, make/break
7. Throttle control (Diesel engine) 15 17
8. Rotation unit (Drilling)
9. Fast feed, rotation unit
10. Main hoist - Controls the direction of the
main hoist up or down
11. Wire line - Controls the direction of the
wireline up or down
13. Emergency stop
14. Pressure knobs
15. Hold back force
16. Rotation speed - Controls rotation speed
from low to high speed. Must be at low
speed for rod breaking
17. Feed rate - Allows for adjustment of the
feed speed during slow feed operation
18. Water flow lever - Controls operation of the
water pump (on/off)

18

26
 Maneuvering
1.0 Pre-start procedure
1. Check hydraulic oil level in the oil tank.
Refill if oil level is too low Fig. 1.2.

2. Before starting motor, carry out

instructions given in Periodic Maintenance
pages.

Fig. 1.2. Hydraulic oil tank

DANGER 1. Level indicator & Temp gauge

Special care and attention should be paid to

damaged or worn components, which could
cause structural fatique, cracks or even
fracture in materials or welded joints.

27
Maneuvering
2.0 Start-up Diesel power pack
Before starting the diesel engine, certain checks
IMPORTANT
and measures must be carried out to prevent
accidents, unnecessary stops or breakdown.
When starting up in cold weather, (below +
Some of these measures must be carried out 5°C), run engine at 1000 rpm until the engine
regularly as a part of the preventive temperature is about +10°C.
maintenance schedule.

Pre-Start
A1 A2
Check that all controls are in neutral
position. Check that the emergency stop
button on the control panel is not
depressed.

4.1 Check the oil level in the diesel engine,

(A1, fig. 4.1) and fill when necessary. (A2,
fig. 4.1). Oil viscosity and quality
according to engine manufacturer manual.

4.2 Check cooler fluid level Fig. 4.1. Check level /A1). Fill when required (A2)

4.3 Check the engine air intake filter. Clean or

replace cartridge. (X, Fig. 4.2)

4.4 Check oil level in hydraulic oil tank (C1,

fig. 4.3) Add when required.

4.5 Check fuel level (D2, fig. 4.4) Top up

before beginning of each shift.
X

D1 D2 Fig. 4.2. Engine air intake filter. Remove coarse particles

daily at (X).
C2
C3

C1

Fig. 4.3. Check hyd. oil level

C1: Gauge: Temperature and level
Fig. 4.4. Filler cap D1, level indicator D2 fuel tank. C2: Hyd. oil filters
Fill when required. C3: Filler cap

28
 Maneuvering
H0 H1

4.6 Activate master circuit switch Q1 (fig.

4.5). Press and turn in clockwise
direction.

4.7 Turn the starter key (S1, fig. 4.5) to F1

position and press button (S2, fig. 4.5. F2 S1
Lamp functions H0 to H1 should light
up.
S2
Start
1 Move speed control lever to 1/2 speed
position.

2 Check that none of the indicator lamps ( Q1

H0 - H1) is lit when the engine is running.
If any lamp remains on, switch off the
engine, investigate and remedy

3 Check the oil temperature on the Fig. 4.5 Startbox for diesel power unit.
combined temperature and level indicator
mounted to the oil tank. If the S1 Starter key. : Positions 0, 1, 2
temperature is below +20°C, let the S2 Start button
engine run a few minutes until this value
is reached before activating any control F1 Fuse
levers. Verify that hydraulic oil return line F2 Fuse
filter warning lamp is off after the
warming period. H0 Check lamp: Fuse tripped
H1 Check lamp: Fuse tripped

Display Parameters

The following are some of the engine and

Stopping the diesel engine
Allow the engine to idle for a few minutes before
switching it off. This particularly applies when the
rig has been operating for lengthy periods.
IMPORTANT
The diesel engine should only be shut down
directly from its operating rpm in the case of
emergency.
transmission parameters displayed by the
PowerView in English or Metric units (when
applicable), consult engine or transmission
manufacturer for SAE J1939 supported
parameters.
• Engine RPM
• Engine Hours
• Machine Hours
• System Voltage
• % Engine Load at the Current RPM
• Coolant Temperature
• Oil Pressure
• Fuel Economy
• Throttle Position
• Engine Manifold Air Temperature
• Current Fuel Consumption
• Transmission Gear Oil Pressure
• Transmission Gear Oil Temperature
• Transmission Gear Position
• Active Service Codes
• Stored Service Codes from the Engine
• Set Units for Display (English or Metric)
• View Engine Configuration Parameters

29
Setting Up for Drilling
1.0 Set Up - Start Up CHRISTENSEN CT 14:
Engine Start Up

The Engine is equipped with a Murphy high temperature, low oil pressure and a manual
emergency shut down. If any of these conditions exist, the engine will not run.

The manual emergency shut down switch is located on the instrument panel – pull out to run –
push in to stop.

Before start up of the CT 14 the following pre start checks should be made:

* Engine Oil Level – Check at the start of every 8-hour shift. Keep oil to the full level on the dip
stick.

* Coolant Level – Check radiator at the start of every 8-hour shift. Maintain level at bottom of filler
neck.

* Hydraulic Oil Level – Check hydraulic tank sight glass at the start of every 8-hour shift. Maintain
level at or near full level. When adding oil, use the transfer pump.

* Hydraulic Filters – Check hydraulic filter indicators every 8-hour shift after system is warmed to
operating temperature.

* Gear Box Oil Levels – Check oil levels at the start of every 8-hour shift.

* Grease Fittings – Grease all fittings for components that are in daily use.

* Fuel check

Before engine start up, check that all controls are in the neutral position.

The engine and all systems are designed to operate from 1800 RPM to 2000 RPM for best
efficiency.

30
 Setting Up for Drilling
1.1 Set Up – Leveling the Drill
Controls for hydraulic jacks
1. Start the power unit and check that all
hydraulic connections are tightened and
that no leakage appears.
2. Stabilize the rig with the hydraulic jacks (1).
Assemble mast and legs. Lower down
dump mast to the ground. Insert lock pins.
3. Raise the mast to the desired angle.
Anchor mast to the ground.
4. Anchor the support legs to the brackets on
the power unit frame.
WARNING
• Always stabilize / anchor the rig in a
proper way before drilling
commences.
• MAST MUST BE IN CONTACT WITH
FIRM GROUND OR TIMBERS.
Hydraulic jacks must be grounded and
stabilized, the feed cylinder creates
enough force to tip the rig.
• Make sure that no loose pieces of
equipment or objects are lying on the
feed.

• Before raising the mast look up to

check for overhead obstructions.
When overhead electrical power lines
exist at, or near a drilling site,
1 consider all wires to be alive and
dangerous.

• Always make sure no unauthorized

persons are within the working area
of the drill rig in use.

Fig. 1.0 Control levers - Driving panel

• Lock out positioning valve bank
before pins are removed from dump
1. Rear left jack plate.
2. Rear right jack
3. Front left jack
4. Front right jack
5. Mast raise - Raises or lowers the mast
from the resting position to drilling
position
6. Dump cylinder
7. Panel - In / out from the rig
8. Platform - Raise and lower

1 2 3 4 5 6 7 8

31
Setting Up for Drilling

WARNING
ENSURE THAT DRILL IS LEVELED ON
In order to prevent accidents, caused by
STABLE GROUND.
overturning the rig, strictly stabilize the rig /
crawler before starting to drill.

WARNING
• Mast must be horizontal before
attempting to fold.

• Make sure that no loose pieces of

equipment or objects are lying on the
feed.

• Before raising the feed (mast) look up to

check for overhead obstructions. When
overhead electrical power lines exist at,
or near a drilling site, consider all wires
to be alive and dangerous.
1.1 Set Up – Mast Sections
Bolt top mast section to mid section using (6)
M36 Grade 8 bolts and nuts. Torque nuts to 2.2
kNm.

32

1.5 Set Up – Mast Raise Procedure
1. Using mast lift valve in up position, raise
mast to desired position, lock mast
stiffening legs with the lock jaw bolts ¾-10
NC x 3” LG. Torque bolts to 376 ft/lbs.
Setting Up for Drilling
STAND CLEAR OF UNDER MAST AREA
UNTIL MAST IS RAISED TO THE DESIRED
ANGLE AND STIFFENING LEGS ARE
LOCKED IN PLACE.
MAST DUMP PROCEDURE
MAST MUST BE IN CONTACT WITH FIRM
GROUND OR TIMBERS.
DUMP PLATE PINS MUST BE IN PLACE.
SPECIAL NOTES FOR FOLDING MAST.
- FOR SHORT TRAMMING DISTANCE ONLY
- MUST BE LEVEL
- BEWARE OF CRUSHING DANGER
BETWEEN SECTIONS
33
Setting Up for Drilling
1.7 Set Up – Mast Backstay Legs
1. Raise mast to desired position (45 degrees
to 90 degrees) and pin stiffening legs with
(4) 3/4”-10 x 2” grade 8 bolts and nuts (pin DO NOT OPERATE THIS DRILL
part number 150270-179). Torque nuts to WITHOUT STIFFENING LEGS AND
376 ft/lbs. PINS IN PLACE.

34
 Drilling
Drilling methods

The CHRISTENSEN CT 14 is an all-hydraulic diamond core drill with a wide range of options and
accessories. The drill unit with power pack and a control console gives the operator a good view over the
rig from the working platform in front of the control panel.
It is suitable for a variety of drilling methods in surface operations such as core drilling, probing etc.
The drill unit is powered by a diesel engine. The drill rig is mounted on a platform suited for truck carrier.

The CHRISTENSEN CT 14 uses the best technology available for diamond core drills. All tube jointing,
thread breaking with adjustable thread compensation, feeding, wireline hoist sequences, are controlled
from a control console. Feed is by direct cylinder, eliminating the need for chains. This results in
smoother feed and reduced maintenance.
Recommendations
To achieve the best results with regard to:
- high penetration
- optimal core recovery
- less deviation
- and low drilling costs
it is of primary importance that drill rods, core barrels and coring bits are of the right type and quality,
matched to the rock drill and to the prevailing rock conditions. Reaming shell, back and stabilizer.
Bearing in mind the core drill’s speed of rotation, its rating and chuck diameter, the CHRISTENSEN CT 14
is best suited to drill holes in diameter (B - P, 60 mm-123 mm).

IMPORTANT

Always make sure the counter pressure valve

IMPORTANT:
Never try to remove the drill rod until the
rotation unit has passed over the open rod
joint and stopped.
has been correctly adjusted and set before rod
breaking starts.
If this valve is set too high, this will result in
much shorter life span for the rod threads and
consequential leakage.

When rod threads leak, it is difficult to judge

how much flushing water is reaching the drill
bit.

It is also necessary to occasionally check the

condition and diameter of the rods being used.
Worn rods can slide back and forth inside the
jaws.

35
Drilling

CT 14 Working platform

36
 Drilling
1.0 Before drilling starts
Make sure that the supply of water is adequate.
See to that the suction hose to the water pump
in good condition. Strainer clean and not Q1
clogged

1.1 Start the power unit

Activate master circuit switch (Q1, fig. 1.1).

Turn the starter key (S1, fig 1.1) clock-wise

direction. Push the start button (S2, fig 1.1). S1

S2
1.2 Start water pump

Water flow lever - Controls operation of the

Fig. 1.1 Startbox for diesel power unit.
water pump (on/off) (Fig 1.2 pos 2.)
S1 Starter key. : Positions 0, 1, 2
S2 Start button
1.3 Adjust the flow of the flushing Q1 Master circuit switch
water
1. Start the water pump with the control lever
(Fig 1.2 pos 2) at the front on the panel.

2. Read the water flow rate on the flow meter

(Fig 1.3 pos 1) on the control panel. 2

2. Read the water pressure on the gauge (Fig

1.3 pos 2) in the control panel.

1.4 Start rotation Fig.1.2 Start the water pump

Before starting the rotation select gear on

the rotation gear box that gives you the
right rpm range for the ITH equipment.
1 2
1. Position the drill string with the corebarrel
and the drill bit about 50 cm above the 0000

bottom of the drill hole.

0000

2. Open the rod holder 0000

3. Start the drill rotation with rotation lever.

4. Adjust the rotation speed to the desired

RPM control on the display.

The rotation speed must be adjusted as

the hole deepens so the maximum rotation
pressure remains at 240 bars. Fig.1.3 Adjusting the water flow

37
Drilling
1.5 Start the drill feed
1. Before the drilling operation can be 4 6
started, the rod weight must be 3
compensated so the actual feed force can
be read.

2. Adjust rpm and flow, with the fine feed

(Fig 1.6 pos 5) in the neutral position. The
feed pressure should be zero. The feed
force can be read on the gauge (Fig 1.5 pos
4) on the control panel.

3. Turn the hold back force knob (Fig 1.6 pos

14.1) clockwise. The holdback force can be
read on the gauge (Fig 1.5 pos 3) in the
control panel.

4. Regulate the holdback knob so that the

cradle is stationary - not moving up or
down. Now the rod weight is balanced.
Fig.1.5 Control panel
5. When the feed is balanced, the drill feed
can be activated with lever (Fig 1.6 pos 5) 3) Gauge for hold back force (kN)
4) Gauge for feed force (kN)
without any danger that the drill string will 6) Main circuit pressure
rush to the bottom of the drill hole and
damage the drill bit.

6. Increase the fine feed force slowly using 2 6

1
the fine feed knob (Fig. 1.6 pos 14:3) until
the drill string reaches bottom of the hole 8 9 10 11
or the face. 5
7
3 4
7. Continue to increase the feed force in
order to reach desired penetration rate for
chosen drill bit and formation.

8. Do not apply more feed force than is 13

recommended for the drill bit.
9. Continue drilling to the end of the feed
stroke, fill the inner tube, or until you get
coreblockage.
1.6 Stop drilling
1. Stop the drill feed by moving the drill feed
lever (Fig 1.6 pos 5) to the neutral position.
2. Stop the rotation by moving the drill
rotation lever (Fig 1.6 pos 8) to neutral.
3. It is recommended to flush the drill hole
for some minutes after stopping drilling to
avoid problems with cuttings and sludge
specially at the end of the work shift.
14
Fig.1.6 Controls
1. Rod kicker valve - moves rod kicker in and
out
2. Break out tool and rod lifter (Option)
3. Rod holder (option)
4. Chuck - Open and closes the chuck
5. Fine feed, rotation unit
6. Thread compensation, make/break
7. Throttle control (Diesel engine)
8. Rotation unit (Drilling)
9. Fast feed, rotation unit
10. Main hoist - Controls the direction of the
main hoist up or down
11. Wire line - Controls the direction of the
wireline up or down
13. Emergency stop
14. Pressure knobs
1. Hold back force
2. Rotation speed - Controls rotation speed
from low to high speed. Must be at low
speed for rod breaking
3. Feed rate - Allows for adjustment of the
feed speed during slow feed operation

38
 Drilling
Wireline Operation

2.0 Controlled wireline lowering

1. To spool out cable from the wireline drum

with the hydraulic motor, push the lever
slowly forward (away from you). The
drum will start to rotate.

2. To increase the speed, push the lever

further forward.

3. When the lever is dropped, the spring

force will move it back to neutral

2.2 Controlled wireline hoisting

1. To spool in cable rope from the wireline

drum with the hydraulic motor, move it
slowly backwards (towards you). The drum
will start to rotate.

2. To increase the speed, pull the lever

further backward.

3. Stop the winch smoothly.

If the winch comes to a sudden stop it can
cause a jump and the core can make the
core lifter to loosen it´s grip and go down
the hole.

4. When the lever is dropped, the spring

force will move it back to neutral, where it
locks automatically. Fig.2.0 Wire line

39
Drilling
3.0 Thread compensation
1. Thread compensation balances the weight
of the rotation unit and drill rod being
unscrewed and prevents the weight of
these components from loading the
threads when the joint is being unscrewed
for downhole drilling. The amount of
thread compensation should be adjusted
when starting with new drill rod size or
large change in drilling angle.
Whenmaking the joint, the feed cylinder is
moving downwards according to the
setting. It is recommended that the helper
turns the rod in at least one full turn before
the rest of the joint is made with the
rotation unit.
2. Turn the thread compensation adjustment
screw clockwise to increase the thread
compensation force or counterclockwise to
decrease the thread compensation force.
Tighten the lock screw after making the
adjustment.

40
 Drilling
3.1 Adding a drill rod and making 4.0 Water pressure dump valve
the joint
Dump valve relieves the water pressure in the
1. When adding a drill rod, ensure that the drill string. Push the lever down to open the
threads are properly engaged, by spinning valve.
the rod in one full turn by hand, before
making the remainder of the joint with the
machine.
2. To make the joint close the chuck and start
the rotation head to rotate clockwise. At
the same time the feed cylinder
disengages so the rod ends can screw
together without damage to the threads.

3.2 Breaking the joint

1. To break the joint with the rod holder
closed, start the rotation unit to rotate
counter- clockwise.

2. Do not unscrew the joint fully. Leave at

least one turn of the thread engaged.
When the rod is lifted out, the last thread
is screwed out by hand.

41
Maintenance
1.0 General
The performance and reliability of the
CHRISTENSEN CT 14 is largely dependent on the
amount of care and attention shown to it.
Regular checks and inspection of wearprone
components prevent breakdowns and costly
downtime.
Dirt is a primary cause for most malfunctions in a
hydraulic system.
Therefore:
- Always try and keep the core drill clean
and free from dirt and other pollutants. It is
much easier to detect faults or oil leakage
on clean equipment.
4 Use the rotation control to set the drill
location lever (10) in drilling position to
circulate the hydraulic system for about 5
minutes.
5. Disconnect the two main hoses from the
fitting and reconnect them to their correct
points on the hydraulic motor.
1.2 Oil cooler - air type
When required, clean the air oil cooler by
flushing dust out of the fins. Do not damage the
fins by using excessive water pressure.

- Never leave any part of the hydraulic

system open or exposed to external
influence.

- Always attach tight-fitting plugs to

disconnected hose ends and couplings.

- Always perform oil refills into the hydraulic

oil tank by using the hand pump supplied.

- Always store fresh oil stocks in sealed

containers.

- Always use TREDO-type seals for sealing

threads. Use of Teflon tape, oakum or
similar, could damage sensitive
components in the system if fragments
dislodge and enter the system.
1.1 Cleaning the hydraulic system
Following any major intervention in the hydraulic
system, systematic and through cleaning of the
system should be performed, before drilling is
allowed to continue.
Cleaning procedure
WARNING
Do not carry out any service and repair on
hydraulic equipment being under hydraulic
pressure. Stop the power unit, then operate
valves until pressure is relieved. Escaping
pressurized hydraulic oil can penetrate skin
which can cause serious inflammations. Seek
medical attention if injured. Small leaks are
practically invisible, so when searching for
them, Do not expose your face or hands but
use a piece of cardboard or wood.

1. Disconnect the two main hoses on the

hydraulic motor and put caps on the
fittings.

2. Reconnect the loose ends to the fittings

included in the tool kit.

3. Start up the power unit.

42
 Maintenance
1.3 Hydraulic oil filters
5
There are in total three filters on the
CHRISTENSEN CT 14 drill. Two returnfilters and 1,2,3
one breathing filter.

Power unit
Of the three on the power unit, one is a
breathing filter mounted on top of the tank, and
two are return filter mounted from the lid -
inside the hydraulic tank.
The breathing filter is all in one piece, unscrew
the filter and replace with a new one. Replace
once per year and more often in dusty
conditions.
The return filter is equipped with a clogging
4
indicator. The filter contains a bowl that holds
two filter elements. To change those elements,
Fig. 1.3 Filter change
unscrew the four hexagon nuts on top of the 1. Filter housing
filter and lift the bowl straight out. Once you 2. Filter cartridge (inside the container)
have have the bowl in your hand, push down the 3. Filter container (inside the housing)
lid, turn 90 degrees counter clockwise and lift the 4. Lid
lid out. Inside the bowl you see two filter 5. Clogging indicator
elements stacked on each other. Pull them out,
rinse the bowl if necessary and replace the
elements with fresh ones. Then put the lid back
on the bowl and reinstall the the bowl.
All filters in contact with oil on CHRISTENSEN
CT 14 drill have filter elements that are lifted
from a bowl. The advantage of this is that there
is no leakage when replacing the filter elements.
Even if the clogging indicators have not called
for a cartridge change, the cartridges should be
changed once every year.

IMPORTANT
If the oil temperature is normal (+50 to +60°C)
and the indicator (5) reactives a couple of
times, the filter cartridge has to be replaced at
once. Otherwise there is a high risk of the oil
bypassing the filter and dirt contained in the
oil being transported further into the hydraulic
system with the ultimate breakdown or
serious malfunction of hydraulic components
as the result.
When the oil temperature is low, the indicator
will activate through the pressure drop
caused by the high viscosity of the oil.

43
Maintenance
1.4 Changing the hydraulic oil.
The hydraulic oil should be changed after 2000
operating hours in normal worksite conditions, or
at least once a year.
If the quality of the oil has deteriorated for some
reason, either through extremely high
temperatures or contamination for example,
then it should be changed as soon as possible. In
such cases, the top part of the tank should also
be removed and the entire interior of the tank
cleaned thoroughly.

Oil change.
1. Drain off all the hydraulic oil by opening
the drain valve (1) underneath the tank.
2. Refill new oil (about 250 litres) using the
hand pump. As the oil is pumped into the
tank it passes through the filter so that any
impurities are strained out.

Fig. 1.3 Hydraulic oil tank

1.5 Draining condensed water 1. Drain valve
out of tank 2. Sight glass

The tank drain valve (1) is used to drain

IMPORTANT
condensed water out of the tank. Condensed
water can collect at the bottom of the tank. The The useful service life of the hydraulic oil can
amount of water collected depends on the be seriously reduced at high temperture.
humidity levels and the number of times the drill
is shut down and the oil tank cools down. High temperature can cause:
– Leaky gaskets
The tank drain should be checked regularly for
– Serious internal leakage in pumps and
the presence of condensed water. In conditions
valves, due to decreased viscosity and
of high humidity and tank cool down each shift,
lubricating properties of the oil.
condensed water may have to be drained out at
the beginning of each shift. If the power unit is
not level, try and position the drain on the low
side.

1.6 Hydraulic tank oil level

The oil level in the tank should be kept in the
sight glass at all times (2 on Fig. 1.3). There is a
low oil level guard which will trip the motor
when the oil level is about 50 mm below the
lowest sight glass level. This will prevent damage
to the hydraulic pumps.

44
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45
Maintenance
2.1 Periodic maintenance with Service schedule for CHRISTENSEN CT 14
The Service Schedule gives instructions to lubrication, inspection procedures and measures to take,
following a specific number of operating hours. Use this schedule to get the most out of your equipment
and always follow the instructions given.

6 7
8,9
12

5
5a

10
11

46
 Maintenance
2.1 Periodic maintenance with Service schedule for CHRISTENSEN CT 14

Ref. Check points Procedure Service interval in Notes

No. hours of operation

8 40 once/
month

1 Feed frame holder Tightening x

2 Slide shoes Lubrication x More often in bad conditions

3 Chuck jaw inserts Cleaning x Inspect and clean if necessary

4 Rotation unit Lubrication x See Lubr. Recommendations

4 Rotation unit and gear Check level and x See Rotation unit
case temperature

5 Rod holder (Bearing) Lubrication x See Lubr. Recommendations

5 Rod guide Cleaning x See Lubr. Recommendations

Lubrication x

5a Rod jaws Cleaning x Check for wear

Jaw holder Check, Clean x Grease behind jaws

Gas spring Check, Clean x

Adjustment x Adjust pressure

6 Hydraulic oil tank Level check x Fill oil when necessary (clean the
Oil temperature x tank once a year)

7 Hydraulic oil filters Inspection x See Hydraulic oil filters

8 Oil leakage Inspection x Continuous inspection of hydraulic

fittings, hoses and components

9 Complete drill rig Cleaning x When necessary

10 Wireline hoist Lubrication x Apply, on lube nipple.

Main hoist Lubrication x Apply, on lube nipple.

11 Oil cooler Cleaning x See Oil cooler

12 Emergency devices Test of function x On control panel, power unit and rig

47
Maintenance

2.2 Lubricant recommendations

Lubricant Check point No. Recommendation

1. Hydraulic oil 11 Use mineral-based hydraulic oil with good anti-wear, rust (oxidation)
and foam inhibiting properties, as well as effective air and water
separation abilities. The viscosity grade should correspond to the
ambient temperature and ISO 3448, as follows:

Ambient temp. °C (°F) Viscosity grade Viscosity index

+25 to +40 (77 to 104) ISO VG 68 Min. 150
0 to +25 (32 to 77) ISO VG 46 Min. 150
-30 to 0 (-22 to +32) ISO VG 32 Min. 150

Examples of oil grades in the temperature range 0 to + 25°C

Shell Tellus T46
BP Bartran HV 46
Castrol Hyspin T 46
Mobil DTE 15M
Texaco Rando HDZ 46
Exxon UNIVIS HP 46

Use of flame proof or biodegradable hydraulic oil, please contact

nearest Atlas Copco representative for information.

2. Grease 2,4,5,6,8,9,10 Universal grease NLG12....................Operating temperature °C (°F)

lithium/molybdenum ..................................Max. 100 (212)
additive
Synthetic sodium or Max. 140 (284)
calcium grease

Example of grease grades

Shell Retinax AM
Esso MP Grease
BP Energrease LS-EP 2

3. Engine oil Use engine oil according to diesel engine Instruction Manual

Example of grade
15W 40 Turbo oil

4. Transmission 4 Use transmission oil according to API

oil
Example of grade
80-90 weight API Classification GL5

48
 Maintenance
3.0 Daily safety check
Before each shift commences, an extra and thorough safetey check shall be carried out to detect:

— emergency stop failure (On panel and rig)

— cracks or fractures in materials or at 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11

welded points.

— damage, which could cause structural 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11

weakness or fracture

— wear, which could cause structural 5, 6, 8, 9, 10, 11

weakness or fracture

— loose junctions, loose threaded unions 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11

From the safety aspects therefore,

the following check points are
6
particularly important (see
illustration below)

1. Mast

2. Mast holder

3. Platform

4. Rotation unit, cradle & slides

10
5. Rod holder

6. Crown block

7. Wireline hoist, wire rope 1

8. Main hoist, wire shown 2

9. Water pump 11

10. Mast extension

4
11. Hydraulic tank

Fig. 3.0 5

9 8,7
3

49
Maintenance
Maintenance – Hydraulic System

1) Hydraulic Tank Oil Level

50
 Maintenance
2) Hydraulic Filters

Pos Designation
1 Cover assy

1a Cover with magnetic system

2 By-pass assy

3 Filter elements

4 Filter bowl

5 O-ring

6 O-ring

7 Flat gasket

8 Clip

9 Mesh screen element

10 O-ring

1 2

Oil Filter Change: every 500 hours or when indicators

show change.

One breathing filter mounted on top of the tank, and

two return filter mounted from the lid - inside the
hydraulic tank.
The breathing filter is all in one piece, unscrew the
filter and replace with a new one. Replace once per
year and more often in dusty conditions.
3
The return filter is equipped with a mechanical
1 Main Return Filters
clogging indicator. The filter contains a bowl that holds
two filter elements. To change those elements, unscrew
2 Secondary Return Filters
the four hexagon nuts on top of the filter and lift the
bowl straight out. Once you have have the bowl in 3 Clogging indicator
your hand, push down the lid, turn 90 degrees counter
clockwise and lift the lid out. Inside the bowl you see
two filter elements stacked on each other. Pull them
out, rinse the bowl if necessary and replace the
elements with fresh ones. Then put the lid back on the
bowl and reinstall the the bowl.

51
Maintenance
Maintenance – Drill Head 3-1/2” Spindle
Maintenance – Drill Head 4-5/8” Spindle

1) Oil Level

2 1

2.2
1.2
2.1

TWO Oil Levels

1) Funk Transmission – Filler Plug
1.2) Funk Transmission - Drain plug
2) Transmission – Filler Plug
2.1) Transmission - Drain plug
2.2) Transmission - Level check (place the rotation unit in vertical position)
Recommended Oil Change: 500 hours (250 hours preferred)
Recommended Oil: 80-90 weight API Classification GL5
1. Total amount is approx. 12 liter for complete unit. The Funk Transmission (1) holds about 4 liter
and housing (2) with chain about 8 liter.
2. Transmission is filled half the box until oil comes from plug on front cover near shift lever or
from clear plastic on left side near chuck.
3. Main housing with chain is filled to plug on right side of housing. This plug is located just to
right and bottom of round access cover for adjusting chain tension.
After the housings have been filled, the head should be rotated in low gear and lube pump
should be checked to see oil is moving thru 1/4 inch lines by cracking them open. Most times
the suction on pump needs to be opened to get air out and oil to pump. Suggest head is then
run until oil is returning from clear plastic line on side of transmission. Next to the chuck.
You can also fill spin on lube filter with oil which speeds up circulation when you start rotation.
NOTE; Make sure the case drain on drillhead hydraulic motor has been filled with clean hyd. oil before
rotation.

52
 Maintenance
Maintenance – Drill Head 3-1/2” Spindle
Maintenance – Drill Head 4-5/8” Spindle

2) Oil Filter

Oil Filter Change: every 500 hours

Filter: CBC# 155841-55, Fleetguard# HF 6510

WHEN HEAD IS ROTATING, OIL FLOW MUST BE

PRESENT IN LOWER CLEAR RETURN LINE. GEAR
BOX DAMAGE WILL RESULT IF NO OIL FLOW IS
PRESENT.

53
Maintenance
3) Grease Fittings

(2) Fittings on Chuck Bonnet

(1) Fitting on Chuck Bearing Retainer

Grease Daily

Recommended Grease: Multipurpose E.P. Grease

54
 Maintenance
1 4

3
5

7 2

10

8 11

Changing Rod Holder Jaws Fig. 11.0-11.2 Rod holder jaws and guide
And Rod Holder Guide bushing
Bushings 1 RH Housing
2 Rod holder insert
3 Liner
Changing Jaws
4 Front cover
Remove the two bolts holding the rod holder
5 Back cover
insert (2) in the rod holder housing. Pull out the
insert so the jaws (3) are clear of the housing, 6 Retainer
taking care not to damage or stretch the 7 Socket holder
hydraulic hose. The jaws can now be pulled out 8 Ball bearing
and replaced. 9 Circlip
10 Guide socket
Important: The jaws have a flange on one side. 11 Jaw
Ensure that the jaws are put in so that the flange
keeps the jaws from falling out of the jaw
For A and B size reainer, the bearing (8) is held
holders and down the drill hole when the rod
and centered in the back cover (5) by retainer (6).
holder insert is pulled out.
For N and H size bushings, the bushing (10) is
centered directly in the bearing (8) .
Rod Holder Guide Bushing
The diameter of the bushing (10) and retainer (7)
must be chosen to suit the drilling equipment to
be used (See spare parts list).
The retainer is replaced by prying it out of the
bearing (8). The new bushing is knocked into the
bearing (snap fit).
There are two sizes of bearings – one for A and B
size bushings, the other for N and H size
bushings.

55
Maintenance
Maintenance – Water Pump

1) Oil Level
1.1 Level plug
1.2 Drainage plug
1.3 Oil cap

2) Grease Fittings

1.3

1.2

1.1

Oil Level: Check Daily

Recommended Oil: 30 weight API Service SB.

Grease Fittings: Check Monthly

Recommended Grease: Multipurpose E.P. Grease

56
 Maintenance
Maintenance – Wireline Hoist

1) Grease Fittings
- (both sides of the drum)

Grease Daily.

Recommended Grease: Multipurpose E.P. Grease

57
Maintenance
Maintenance – Main Hoist

1) Oil Level

Check Oil Level Weekly.

Recommended Oil: 80 – 90 weight API

Classification GL5

Preventive maintenance
A regular program od preventive maintenance for your planetory winch is strongly recommended to
minimize the need for emergency servicing and promote safe, reliable winch operation.

Field experience, supported by engineering tests, indicate the three (3) service procedures listed below
are the MOST critical to safe, reliable winch operation and must be observed.

* Regular Gear Oil Changes - every 1000 hours or six (6) months
* Use of Proper Gear Oil - recommended type for prevailingambient temperature
* Annual Dissassembly and Inspection of All Wear Item - in compliance with American National
Standards Institute (ANSI) specification B30.5c 1987 and American Petroleum Institute (API)
recommended practice RP 2D section 3.

The following minimum service intervals are specified for operating hours of the prime mover.

1. Oil level
The gear oli level should be checked every 500
operating hours or three (3) months, whichever
occurs first. To check the oil level, remove the
large plug located in the center of the drum
support. The oil should be level with the bottom
of this opening. If additional oil is needed, refer
to “Recommended Planetory Gear Oil”
2. Oil change
The gear oil should be changed after the first
one hundred (100) hours of operation, then
every 1,000 operating hours or six (6) months,
whichever occurs first. The gear oil must be
changed to remove wear particles that impede
the reliable and safe operation of the brake
clutch and erode bearings, gears and seals.
Failure to change gear oil at these suggested
minimum intervals may contribute to intemittent
brake slippage which could result in property
damage, severe personal injury or death.
The gear oil should also be changed whenever
the ambient temperature changes significantly
and an oil from a different temperature range
would be more appropriate. Oil viscosity with
regard to ambient temperature is critical to
reliable brake clutch operation.

58

Our tests indicate that excessively heavy or thick
gear oil may contribute to intermittent brake
clutch slippage. Make certain that the gear oil
viscosity used in your winch is correct for your
prevailing ambient temperature.
Failure to use the proper type and viscosity of
planetary gear oil may contibute to brake clutch
slippage wich could result in property damage,
severe personal injury or death. Refer to
“Recommended Planetory Gear Oil” for
additinal information.
3. Vent plug
The vent plug is located in the drum support as
shown. It is very important to keep this vent
clean and unobstructed. Whenever gear oil is
changed, remove vent plug, clean in solvent and
reinstall.
Do not paint over the vent or replace with a
solid plug.
4. Hydraulic system
The original filter element should be replaced
after the first fifty (50) hours of operation, then
every 500 operating hours or three (3) months,
or in accordance with the equipment
manufacturer´s recommendations.
5. Wire rope
Inspect entire length of wire rope according to
wire rope manufacturer´s recommendations.
6. Mounting Bolts
Tighten all winch base mounting bolts to
recommended torque after the fisrt one hundred
(100) hours of operation, then every 1000
operating hours or six (6) months, whichever
occurs first.
7. Warm-up Procedures
A warm-up procedure is recommended at each
start-up and is essential at ambient
temperatures below +40ºF (4ºC)
The prime mover should be run at its lowest
recommended RPM with the hydraulic winch
control valve in neutral allowing sufficient time
to warm up the system. The winch should then
be operated at low speeds, forward and reverse,
several times to prime all lines with warm
hydraulic oil and to circulate gear lubricant
through the planetary gear sets.
Maintenance
WARNING
Failure to properly warm up the winch,
particularly under low ambient temperature
conditions, may result in temporary brake
slippage due to high back pressures attempting
to release the brake, which could result in
property damage, severe personal injury or
death.
8. Recommended Planetory Gear Oil
Field experience, supported by extensive
engineering tests, indicates the use of proper
planetary gear oil is essential to reliable and
safe operation of the brake clutch and obtaining
long gear train life.
WARNING
Failure to use the proper type and viscosity of
planetary gear oil may contribute to intermittent
brake clutch slippage which could result in
property damage, severe personal injury or
death. Some gear lubricants contain large
amounts of EP (extreme pressure) and anti-
friction additives which may contribute to brake
clutch slippage and damage to brake friction
disct or seals. Oil viscosity with regard to
ambient temperature is also critical to reliable
brake clutch operation. Our tests indicate that
excessively heavy or thick gear oil may
contribute to intermittent brake clutch slippage.
Make certain that the gear oil viscosity used in
your winch is correct for your prevailing
ambient temperature.
For simplicity, BRADEN has listed one (1) readily
available product in each temperature range
which has been tested and found to meet our
specifications. This is not to say that other
lubricant brands would not perform equally as
well.
If the following lubricant brands are not
available in your are, make certain your
lubricant vendor supplies you with oil that is
equivalent to those products listed below.
BRADEN planetary winches are factory filled
with Texaco Meropa 150 or equivalent AGMA
No. 4EP gear oil.
9. Inspection
In compliance with ANSI specification number
B30.5c1987 and API recommended practice RP
2D section 3, we recommend that the winch be
disassembled for a thorough inspection of all
wear items every 2,000 hours of operation or
twelve (12) months, whichever occurs first.
59
Maintenance
Maintenance – Mast/Hoist Frame

1) Grease Fittings

(1) Fittings on both sides of mast/hoist frame.

Grease weekly.

Recommended Grease: Multipurpose E.P. Grease

60
 Maintenance
Maintenance – Mud Mixer

Factory sealed, self contained, hydraulic propeller type mixer.

Check quick couplers periodically for leakage.

61
Basic hydraulics
1.0 Operation of hydraulic system
The system consists of three separate hydraulic circuits. The three pumps (main, water/mud* pump and
auxiliary) are driven directly from the power unit flywheel.

The pump is connected directly to the engine flywheel by a synthetic adapter and hub. The pump is an
axial piston load sense type. Suction oil comes directly from the reservoir. The pressure side of pump is
directed to the main valve block which control 4 functions-- drillhead rotation, fast feed, main hoist, and
wireline hoist. All hydraulic pressure from these 4 functions can be observed on the control panel.

The rotation section directs oil to the rotation motor on top of the drillhead. The rotation motor is a
variable displacement bent axis design with min. to max. displacement controled by a rotary hydraulic
control on the control panel. The fast feed section directs maximum volume (0-190 l/min) to the feed
cylinder for rapid movement up or down. The main hoist section controls the hydraulic winch.
Incorporated in this circuit is an automatic brake release which is activated from the fine feed pressure.
This allows the winch cable to unspool as the drillhead is feeding down. The brake system can also be
unlocked by a diversion valve located at the front of the control panel. See Braden service manual for
complete installation, maintenance, and service.

The wireline section controls the raising and lowering speed of wireline cable hoist. The hydraulic
section is similar on both hoists. The hydraulic motor has a counter-balance valve mounted directly to
the exhaust port to protect against overruns and act as a brake when stopping.

The water / mud* pump is piggybacked to the main pump and driven by a thru shaft. The pump is an
axial piston load sense type. Suction oil to this pump comes directly from the reservoir.

The auxiliary hydraulic pump is piggybacked to the water/mud* pump and driven by a thru shaft. The
pump is an axial piston pressure compensated type. This pressure can be observed constantly on
pressure gauge at the control panel. Suction oil to this pump comes directly from the reservoir.
Pressure oil is directed to the positioner valves (3VB) for the hydraulic jacks, the auxilliary valves (3VA)
that controls the water pump, rod kick cylinder, break out tool, and the rod lifter.
The auxilliary valves also control the hold back, feed and drilling valves.

The auxilliary pump controls the rod holder, chuck, feed cylinder (when drilling), rotation motor
displacement and thread compensation.

62
 Basic hydraulics
Diesel engine:
Powered by a Cummins diesel engine QSB5.9-C

Motor rating . . . . . 158 kW / 212 Hp at 1800 rpm

Displacement . . . . . . . . . . . . 5.9 liters [359 C.I.D]

Hydraulic Main Pump (0P1) Data:

Bosch Rexroth GMBH A1OVO 140 cc
Automatic adjusted by actuators, maximum;
Pressure: 280 bar
Flow (@1800 rpm): 242 l/min
Stand by setting: 25 bar

Hydraulic Secondary Pump (0P2) Data: Fig.1.1 CT 14 Diesel engine

Bosch Rexroth GMBH A1OVO 71 cc
Automatic adjusted by actuators, maximum;
Pressure: 200 bar
Flow (@1800 rpm): 122 l/min
Stand by setting: 20 bar

Hydraulic Auxilliary Pump (0P3) Data:

Bosch Rexroth GMBH A1OVO 28 cc
Automatic adjusted by actuators, maximum;
Pressure: 215 bar
Flow (@1800 rpm): 47 l/min

OP3 OP2 OP1

Fig.1.2 CT 14 Hydraulic pumps

0P3P1 8
T9
0P3P2 6

POWERUNIT 158 kW Main Pump 0P1LS2 Water/Mud Pump 0P2LS Auxilliary Pump
280 bar, 20 bar st-by 200 bar, 20 bar st-by 215 bar T7 T5 T4B
242 l/min @ 1800 rpm 122 l/min @ 1800 rpm 47 l/min @ 1800 rpm
3V19 13 l
B T6 T3

X 12
X X F
16 4

0P1P 0P2P1
M 3C1DR

8
T8
3C1
0P4
Hand Pump
T1 T2 0P4S 12
B B B 20 20

0P1 0P2 0P3 0P4P

12
0S1 0M1
0F1 0F2 0Z2 0F3
M

S L1 L S L1 L S L1 L
48 16 32 12 20 12

0P1S 0P1DR 0P2S 0P2DR 0P3S 0P3DR Drain

T1 0Z4 box

Fig.1.3 CT 14 Power Unit circuit

63
Basic hydraulics
Cooler (0Z1) (Fig 1.4)
On the CT 14 a air/oil cooler is mounted as
standard. A hydraulic motor drives the air/oil
cooler.

Filters (0F1, 0F2 and OF3) (Fig 1.5)

There are three filters in the hydraulic system;
they are Return filter with filter indicators for
clogging (Fig 1.6) (0F1, OF2 placed on the
hydraulic tank) Air filter (0F3, placed on the OZ1
hydraulic tank). Recommended change interval Fig.1.4 CT 14 Air/Oil cooler
on all filters is one year. The rig is equipped with
10 micron filter inserts from factory in return OF1, OF2 OS1 OF3
filter.

Hydraulic oil tank (TI) (Fig 1.5)

The tank size is 250 liter of oil; it is equipped
with a sight glass and thermometer (Fig 1.8). It
is equipped with air filters and has a combined
temperature and level guard sticking down from
the lid (0S1) (Fig. 1.5). On the front side there is
a drain box, this in order to get a controlled
drain oil flow into the tank. The drain box is
filled with oil, before disconnecting any drain
hose please empty the box. The drain box also
has a magnetic plug for indication and removal
of metal particles in the oil (0Z4)(Not shown).
T1

Filling of hydraulic oil (OP4) (Fig 1.6)

When filling oil into the system please fill Fig.1.5 CT 14 Oil tank
through the filter by using the handpump (OP4, OS1 = indicators on the control panel with two
fig 1.6) or some equivalent pump in the service lamps for temperature and level in tank.
shop.

OP4

Fig.1.7 CT 14 Visual filter indicators

Fig.1.6 CT 14 Hand pump Fig.1.8 CT 14 Sight glass and thermometer

64
 Basic hydraulics

0P2P1

MAST DUMP CYL

3A1E2 3A1F 4
MAST RAISE CYL
T4A

3V1EA1 T4B
6
0P1LS2

250
250

250
250
6
REAR LEFT JACK REAR RIGHT JACK FRONT LEFT JACK FRONT RIGHT JACK
3V1EA2 4 0P1LS1
3A1A 3A1B 3A1C 3A1D 4

3A1E1
3V1FA 3V1FB
4 Optional
CONTROL PANEL SLIDE PLATFORM TILT
0P3P12 3A1G 3A1H
4
4
3V1EB2
0P3P6 3N5
4
3N4 Ø0,7 Ø0,7
0P3P5 4 4 4 4 4

250

250
4 3V1AA 3V1BA 3V1CA 3V1DA 4 3V1GA 3V1GB 3V1HB
0P3P4 4 4 4
4
4
4
3V1AB 3V1BB 3V1CB 3V1DB 4
4 3V1EB1 3V1HA
3V2 B A B A B A B A B A B A B A B A
3V1A 3V1B 3V1C 3V1D 3V1E 3V1F 3V1G 3V1H S
P3B
8 P2 X

P1
1V2 T P

8
T1
T5 235

3V1I T3B
T2
3V1 Positioner valve
0P3P1

Fig.2.0 CT 14 Positioner valves for hydraulic jacks

1 2 3 4 5 6 7 8

3VB Positioner valves - Hydraulic Jacks

The system consists of a separate hydraulic circuit for manuovering of the hydraulic jacks driven by the
auxilliary pump circuit.
Valve (3V11) - Pressure relieving valve maximises the pressure in the circuit to 235 bar
1. Valve (3V1D) - Valve for rear left jack
2. Valve (3V1C) - Valve for rear right jack
3. Valve (3V1B) - Valve for front left jack
4. Valve (3V1A) - Valve for front right jack
5. Valve (3V1E) - Mast raise, raises and lowers the mast from resting position to drilling position
6. Valve (3V1F) - Dump cylinder
7. Valve (3V1G) - Control panel slide
8. Valve (3V1H) - Platform tilt

65
Basic hydraulics
Optional
GWP
WPG ROD HOLDER CHUCK
WPREL 3RH 3CH 3V3HB2
OUT
1FD IN
MUD Flow Meter
70

FEED CYLINDER
4 B OUT B HB A IN A FD
WPD 3V3FD2
MIXER WPP1
250 bar 1CV
4
Optional 2MM WPP2 1DM
WPWD B A

V DR B DR
WPS Water Swivel
4
3000 rpm
1CVDR
7,4 cc DRILL
MOTOR
3V8RH 6 12
1DMDR2 4
12
1DMDR1
3V3DM2
3V10CH1 6
3A14 ROD LIFT CYLINDER
3V10CH2 6

3A12 BREAK OUT GRIPPER

1VDDMB2 16
2WPDR 3A15
2WP ROD KICK CYLINDER CYLINDER
WATER PUMP Optional 1VDDMA2 16

3V12B2 4 Ø0,7
3V15DR
4 Optional 3N5
T7 2MMBP 3N4 3V13A2
12 3V12A2 Ø0,7
3V12B 4 3V3FD3 4
2V5 3V15 3V17DR 3V18DR
3N3 3V14 4
In
Ø0,7

100 bar 3N2 Ø0,7 A

Z
4

R P
3V12B1 B
4 4
6 4 1 1 1 GHB 3V3DR1 4 GFD
3V12A1 Optional 3
4
3
4
3
0-30 bar 15-30 bar 3V3HB1 3GHB 3V3DM1 3GFD 3V3FD1
30 bar
T6 3V15 2 2 2 4 4
2MMLS 0P3P13 Optional
6 6
3V17 3V18 G Hold G Drill Drill G Feed
0P2MMP Optional 3V13B1 4

4 2V4
2V2 3V12A 3V13 3V13B1 3V16 3V16B 3V3C 3V3D Feed
F 20 l

Out
4 4

In
In In 3V13A1 In 3V16A Hold B. A B 20-30 bar
knob
P B 4 P B P B
B
4 GRH 4

2WPP 12 Rot. Speed

4
R A
Out
R A
Out
3GRH R A
Out R P
2WPLS
0P3P16 4
3V3A 3V3B DR2
4 4 4 120 bar 3V3DR2 4
T5A12 T5A13 3V11
0P2LS C
P R Hold b. Feed

Ø1
T5A16 knob knob
2V3 2V1 3V10 3N1
4
0-180 bar 0-300 bar P
E
3V6 3V7 R
110 bar 4
0P2P2 In In 3V3 Drill ctrl. valve 0P3P5
6
4 P B P B P DR1
0P3P12 R A R A 4
3V7A
4

T5A6 4 0P3P7
0P3P6 4
4
T5A7

T9C T9 3V11DR 6

3V2 Auxilliary valves

The system consists of a separate hydraulic circuit for manuovering of feed cylinder, chuck, rod holder,
rod kick cylinder and break out cylinder / rod lift cylinder.

Valve (3V7) - Valve for chuck open / close

Valve (3V6) - Valve for rod holder open/close
Valve (3V12A) - Valve for rod kick cylinder
Valve (3V13) - Valve for break out cylinder
Valve (3V13) - Valve for rod lift cylinder

Pressure relieving valve keeps the pressure in the circuit to 235 bar
Valve for feed thread compensation when breaking and making rod joints

66
 Basic hydraulics

4
GHB 3V3DR1 4 GFD
3V3HB1 3GHB 3V3DM1 3GFD 3V3FD1
4 4

G Hold G Drill Drill G Feed

3V3C 3V3D Feed

Out
In
Hold B. A B 20-30 bar
knob

Rot. Speed
R P

3V3A 3V3B DR2

3V3DR2 4

Hold b. Feed
Ø1

knob knob
3N1
0-180 bar 0-300 bar P
4

3V3 Drill ctrl. valve

DR1 0P3P5

3V3 Drill ctrl. valves

The system consists of a separate hydraulic circuit for manuovering of feed/hold back pressure and
speed of rotation motor.

Valve (3V3B) - Knob for pressure adjustment, feed pressure range 30 - 300 Bar
Valve (3V3A) - Knob for pressure adjustment, hold back force range 30 - 180 Bar
Valve (3V3C) - Valve for enablying fine feed pressure to reach feed cylinder
Valve (3V3D) - Knob for pressure adjustment, rotation speed range 0-50 Bar
Valve (3GHB) - Pressure gauge for hold back force
Valve (3GFB) - Pressure gauge for feed force

67
Basic hydraulics
8
1MH
1MHDR
2 1BV3A 1WL
(BRAKE)
MAIN HOIST WIRE LINE

3A 2 1
1BV 175 bar
1AV

VA VB
7

260 bar

4
3V3FD3
4 9

16 1VDDMA1 16 1VCFDA 16 1VBMHA 12 1VAWLA

1VBMHB2 4 1VDDMB1 1VCFDB 1VBMHB1 1VAWLB

16 16 16 12

GP1
A B A B A B A B Z

A: 75 L/MIN
1GP
A, B: 180 L/MIN B: 190 L/MIN A, B: 190 L/MIN A, B: 115L/MIN
M
1V1D 1V1C 1V1B 1V1A
b b
b
P4=180bar P3=220bar
b P2=140bar
1V1E

P4 P3 P2 P1=300bar

P1

a a a a

LS LS DW
T
T
Z Z
P P
R R
R LS P
1V1
T3
20

0P1P
0P1LS1 6

Main valves
The system consists of a separate hydraulic circuit for manuovering of rotation unit, fast feed, Main hoist
and wire line.

Valve (1V1D) - Rotation unit circuit flow = 190 l/min

Valve (1V1C) - Fast feed circuit flow = 90 l/min, 190 l/min, pressure P4 = 180 bar
Valve (1V1B) - Main hoist circuit flow = 190 l/min, pressure P3= 220 bar
Valve (1V1A) - Wire line circuit flow = 115 l/min, pressure P2 = 140 bar

68
 Basic hydraulics
RETURN OIL CIRCUIT
Oil which has been circulated by the hyd. pumps
through the directional valves, to motors, hyd.
cylinders and valves is returned to the hydraulic oil
tank.

On its way back it passes through a air/oil cooler

(OZ1 ). In order to avoid damage to the cooling ducts
a check valve set at 5 bar permits oil to by-pass the
cooler when the flow of oil creates too high pressure
(when cold).

A hydraulic filter (OF1, OF2) with two easily

replaceable cartridge removes impurities and metal
chips from the hydraulic oil. An indicator connected to
the control panel alerts the operator when the function
of the filter is unsatisfactory.When the resistance in
the filter increases further, check valves will open and
the oil will by-pass the filter, however now without
being cleaned.

Replace cartridges as soon as the indicator gauges

alerts for clogging filter.
The system includes a hand operated pump (OP4) for
filling of the hyd. oil tank. This pump is permanently
connected to the system and supplies oil into the
system ahead of the filter (OF2) in order to prevent
ingress of impurities while adding or replacing
hydraulic oil.
OP3 . . . . . . . . . . . . . . . . . . . . . .Auxilliary pump
OP4 . . . . . . . . . . . . . . . . . . . . . .Hand pump
OZ1 . . . . . . . . . . . . . . . . . . . . . .Air/Oil Cooler
OZ2 . . . . . . . . . . . . . . . . . . . . . .Temp / oil level
OF1 . . . . . . . . . . . . . . . . . . . . . .Oil filter
OF2 . . . . . . . . . . . . . . . . . . . . . .Oil filter
OF3 . . . . . . . . . . . . . . . . . . . . . .Air Breathter

0P3P1 8
T9
6
0P3P2

Auxilliary Pump
215 bar T7 T5 T4B
47 l/min @ 1800 rpm
3V19 13 l
B T6 T3

X F
4

M 3C1DR

8
T8
3C1
0P4
Hand Pump
T1 T2 0P4S 12
B 20 20

0P3 0P4P
12

0F1 0F2 0Z2 0F3

S L1 L
20 12

0P2DR 0P3S 0P3DR Drain

0Z4 box

69
Basic hydraulics, TroubleShooting

INFORMATION
Potential problems and solutions

• The following guide is designed to help

you organize your solutions of hydraulic
problems. The explanations may not
provide all the answers but may direct
your train of thought toward solving the
problem.

Saftey first

• Remember to observe saftey practices

when performing troubleshooting on
equipment make sure to support
heavy objects, hydraulic oil under
pressure is dangerous, and be careful
around rotating parts.

Type of fault Possible cause Remedy

1. Noisy pump caused A. Oil is too heavy A. Change to proper

by cavitation viscosity
B. Filter plugged
B. Clean or replace
C. Suction line plugged

C. Clean line

2. Noisy pump caused A. Oil supply low A. Fill reservior

by aeration
B. Air leaking into B. Tighten fittings
suction line

C. Foaming oil C. Drain reservoir and fill

with non-foaming
type oil. check that
return line oil is
directed into tank
properly and not
mixing with air first.

3. Hydraulic system A. Oil supply low A. Fill reservoir

overheating
B. Oil in system too light B. Drain reservoir and
refill with proper
viscosity oil

70
 Basic hydraulics, TroubleShooting
Type of fault Possible cause Remedy

3. Hydraulic system C. Excessive internal C. Connect a flow meter

overheating leakage to the pump pressure
port. Connect the
return to a adjustable
nozzle valve and then
run, if the valve
shown less then 90%
of the flow at 70%
pressure exchange
the pump.

D. Aeration of oil D. Tighten fittings

4. System not producing A. Excessive internal A. Check amount of flow

necessary pressure leakage according to spec.

B. Compensator spool B. Disassemble, inspect,

stuck open clean, or replace
compensator

C. Compensator spring C. Check spring in

weak or broken compensator

D. No flow to D. Check signal line for

compensator signal damage, size, and
port length

E. Load sense line E. Connect and bleed of

disconnected or filled the system
with air

5. System does not A. Excessive internal A. Check amount of flow

produce proper flow leakage according to spec.

B. Compensator spool B. Disassemble, inspect,

stuck open clean, or replace
compensator
C. Compensator spring
broken C. Check spring in
compensator

D. Pump cavitation D. Check proper oil

viscosity, suction
strainer, and suction
line

E. No signal to E. Check signal line and

compensator ports at valve

F. Load sense line

disconnected or filled F. Connect and bleed of
with air the system

71
TroubleShooting (specific functions), Auxiliary pump circuit

Type of fault Possible cause Remedy

1. Little, erratic, or no A. Hydraulic plumbing is A. Check schematic in parts book and correct
feed pressure not according to plumbing if necessary.
schematic

B. Pressure gauge B. Check the face and needle in pressure gauge for
defective (false damage replace if necessary
reading)

C. Quick disconnect C. Make sure quick disconnects go together freely

fitting not connected and no broken parts.
or pilot inside is
broken.
D. Check oil flow back to tank
D. Return line from
manifold is blocked
E. Check for worn or damaged parts
E. Spool in lever assy is
worn or damaged
F. Check for worn or damaged parts
F. Rotary control valve
for feed pressure is
worn or damaged
G. If main pump is ok check where water/mud and
G. Thru shaft from main auxiliary pump is piggybacked at thru shaft.
pump is broken or
damaged
H. Check auxiliary pump for excessive case drain
H. Pump or compensator flow (more than 2.5 gpm), pressure setting, and
is bad or out of compensator for dirt and worn or broken parts.
adjustment
1. position control levers in neutral.

2. start engine.

3. loosen jam nut on compensator adjustment

screw located at the rear of pump.

4. while observing pressure on gauge turn

adjustment screw clockwise to increase and
counterclockwise to decrease auxiliary
pressure. Retighten jam nut.
I. Contamination in I. Disassemble, clean, and inspect for broken parts
control valve or
auxiliary manifold
ports.

J. External problem such J. Disconnect winch cable and check condition of

as winch brake or sliding parts and structure. troubleshoot
structural parts are automatic brake release system if necessary.
affecting the feed
process.

K. Feed cylinder or feed K. Check o-rings in block at ram end of cylinder (p4
cylinder seal kit is and p6. also check if oil is bypassing at piston
defective or worn cups. check internal condition of cylinder.

72
 TroubleShooting (specific functions), Auxiliary pump circuit

Type of fault Possible cause Remedy

2. Automatic-chuck A. Relief valve for auto- A. Remove relief valve and inspect for damage and
opens partially, not at chuck (located below dirt. make sure relief valve was not overtightened
all, or leaking the control valve lever) into housing. set pressure at 90 bar.
hydraulic oil (not is stuck, contains
grease) at chuck body. contamination,
damaged, or pressure
setting is not correct.

B. Control valve spool is B. Check for worn or damaged parts in control valve.
damaged or broken.

C. Auxiliary pump or C. Check auxiliary pump for excessive case drain

compensator problem. flow (more than 10 liters), pressure setting, and
compensator for contamination and worn or
broken parts.

D. Disassemble chuck, clean all parts, and inspect for

D. Damage to internal galling, wear, or broken parts. use caution when
sliding parts of auto- removing 7/16 bolts at top plate. remove evenly
chuck. due to spring pressure below.

E. Remove piston ram from cylinder and install new

E. Seal kit, cylinder ram, seal kit. Inspect piston ram and cylinder for wear
or cylinder, is worn or or damage. make sure relief setting is not too
damaged. high if cylinder is bulged.

3. Automatic-chuck jaws A. Incorrect chuck jaw A. Inspect jaws and check part numbers according to
not holding drillrod or size, worn jaws, or parts book if possible. make sure the correct size
slipping. damaged. rod bushings (upper an lower) are being used if
damage to carbide is ocurring.

B. Hydraulic pressure B. Install 250 bar gauge at chuck and determine

entering chuck cylinder when pressure is entering chuck cylinder. if only a
when chuck control small amount is enterning when auto-chuck
valve is in the closed control valve is in closed position then check the
position. valve for wear or damage.

C. Internal parts of C. Disassemble chuck, clean, and inspect for

cylinder or chuck are damaged parts.
not moving properly.

D. Excessive D. Clean carbide inserts and sliding areas of jaws.

contamination inside
chuck and jaws.

73
TroubleShooting (specific functions), Water/Mud pump circuit

Type of fault Possible cause Remedy

1. Mud mixer not A. Quick disconnect not A. Check quick disconnect for damage or does not
rotating, rotating connected properly. go together freely.
slow, or erratic.
B. Auxiliary valve B. Check the drawing in parts book for correct
cartridge on auxiliary mounting according to lettering on valve.
manifold is mounted
incorrectly.

C. Auxiliary control valve C. Check the spool and housing at control valve for
is worn or damaged. wear or damage.

D. Hydraulic motor at D. Troubleshoot hydraulic motor for damage or

mixer assembly is internal leakage.
defective.

E. Sequence valve E. Make proper ajustment to sequence valve. install

(located below control a 250 bar gauge in the " a" port hose. move the
valve on back side of mud mixer valve to the on position. the
manifold) is out of adjustment is under the valve inside the operators
adjustment. panel. loosen the locknut and turn the screw
clockwise to lower and counterclockwise to raise
the pressure. the pressure should be set at 100
bar.

F. Water/Mud pump or F. Troubleshoot pump for proper settings, excessive

compensator is bad or internal wear, and compensator problem.
out of adjustment.

TroubleShooting (specific functions), Additional auxiliary

control valve circuits

Type of fault Possible cause Remedy

1. Hydraulic jacks, rod A. Auxiliary valve A. Check the drawing in parts book for correct
kicker, mast lift, etc. cartridge is mounted mounting according to lettering on valve.
will not operate at all incorrectly.
or erratic.
B. Hydraulic cylinder B. Troubleshoot the cylinder.
leaking internally or
damaged.

C. Control valve is worn C. Inspect control valve spool and housing for wear
or damaged. or damage.

D. Pump or compensator D. Check auxiliary pump for excessive case drain

is bad or out of flow (more than 10 liters), pressure setting, and
adjustment. compensator for contamination and worn or
broken parts.

74
 TroubleShooting (specific functions), Auxiliary pump circuit

Type of fault Possible cause Remedy

1. Rotation speed (hi to A. Main pump or A. check the other functions on main valve bank for
low) is erratic or not compensator problem. correct operation. If they are working properly
changing r.p.m. when continue troubleshooting b thru i. If some
turning rotory control problem exists troubleshoot the main valve or
valve in or out. main pump circuit.

B. No pressure from B. Check the auxiliary pump and compensator

rotory control valve

C. Swivel angle C. See rexroth service manual procedure for setting

adjustment screw is min. to max. displacement or simply try turning
not properly set the adjustment screw slightly and observe if
(located at the top of r.p.m. changes. check the parts book for correct
drillhead on the front r.p.m. setting and using hand photo-tachometer
side of hydraulic set the engine speed and head rotation to
motor). spec.the engine speed is set at 2500 r.p.m. and
the head high speed is 1250 r.p.m. its .not
recommended to overspeed either.

D. Rotory valve cartridge D. Remove the rotory control valve cartridge from
is worn, damaged, or housing and check for wear, damage, or
contamination inside. contamination.

E. Hydraulic controlvalve E. Carefully disassemble valve and check for wear,

at hydraulic motor is broken parts, or contamination. use caution when
worn, damaged, disassembling as some parts may be spring
contains loaded.
contamination, or not
adjusted properly.

F. Internal wear or F. Troubleshoot the hydraulic motor according to

damage to rexroth troubleshooting guide manual.
displacement parts
inside hydraulic motor.

G. Erratic r.p.m. can be G. Disconnect the drillhead from drill string and
caused by problems observe if rotation improves.
beyond the hydraulic
system such as
problems in the
drilling process,
transmission, or the
drillhead.

75
TroubleShooting (specific functions), Main pump circuit

Type of fault Possible cause Remedy

1. Rotation section in A. Main pump or A. Troubleshoot main pump and compensator. check
main valve bank compensator problem. for proper suction, contamination, pressure
producing slow settings, and excessive case drain leakage (more
r.p.m., no revolutions, than 10 l/min is excessive for this pump). Check
or lack of pressure. compensator spools for wear, damage, and
contamination. High pressure setting for main
pump is 280 bar. The standby pressure is 2o to 30
bar. these are set at the compensator on the main
pump. The adjustment closest to the pump
housing is standby. The larger adjustment and
furthest from the pump is the maximum pressure
adjustment. The high pressure can be seen on the
rotation gauge.

Procedure for checking or setting the compensator

low pressure standby requires the following:

1. stop engine.

2. install 50 bar gauge in the high pressure

line from the main pump before the high
pressure filter.

3. make sure all controls are in the neutral

position and restart the engine.

4. if standby requires adjustment - loosen the

jam nut on the compensator and turn the
screw clockwise to increase and
counterclockwise to decrease pressure.

5. after adjustment is completed, stop engine,

retighten jam nut, remove test gauge, and
tighten all fittings.

Procedure for checking or setting the compensator

high pressure requires the following:

1. stop engine.

2. disconnect quick-coupler fittings going to the

drillhead motor. (if quick couplers are not
used, disconnect male and female hose ends
and install steel plugs and caps).

3. engage the rotory control lever in forward or

reverse and observe the pressure on gauge..

4. if adjustment is necessary, loosen the jam nut

on the compensator and turn the screw
clockwise to increase and counterclockwise to
decrease pressure.

5. after adjustment is completed, stop engine,

retighten the jam nut on compensator, and
reconnect pressure lines to drillhead. See
eaton manual located in parts book for more
information.

76
 TroubleShooting (specific functions), Main pump circuit

Type of fault Possible cause Remedy

1. Rotation section in B. Problem in primary or B. Remove, clean, and inspect primary and
main valve bank secondary shuttles. secondary shuttles in rotation section. If their ok
producing slow check the shuttles in remaining valve sections as
r.p.m., no revolutions, they may affect this function. Use caution when
or lack of pressure. removing secondary shuttle due to loose ball
behind shuttle. Install proper o-rings and backups.
note primary and secondary shuttles are located
in each valve section of the main valve bank. See
the main control valve manual for description.

C. Main relief valve in C. Remove and inspect main relief valve for
mp-18 is stuck or
damaged. (located at
the top left side of
valve bank under
control panelcover.)
contamination, wear, damage, and proper
pressure setting. early model units did not have a
main relief in main valve bank. the later models
do. (the main relief is located at the top left side
of valve bank under the control panel cover).
pressure setting for the main relief is 280 bar.
Follow the procedure in this section solution c for
setting high pressure on compensator. After
setting this, loosen the jam nut on main relief and
turn the adjusting screw counterclockwise until
the pressure falls slightly below 250 bar, stop and
turn the screw clockwise half a turn.this will set
the main relief at approximately 280 psi.

D. Manual control valve D. Check manual spool and housing for wear,
spool is worn or contamination,or damage.
damaged.
E. Troubleshoot rotory control valve (for two speed)
E. Rotory control valve at the control panel and the auxiliary circuit. See
(for two speed head) solution a thrud under problem 1 rotation speed
on auxiliary circuit is (hi to low) is erratic or not changing r.p.m. when
not working properly. turning rotory control valve in or out.

F. Flow compensator F . Carefully remove compensator spool and check

spool in rotory valve for wear, damage, or contamination.
section blocked or
stuck.

G. No signal to ls port on G. Check the ls signal line from mp-18 valve to main
pump from main valve pump for obstruction in hose or blocked orfice
bank. fittings.

H. Problem in hydraulic H. See rexroth service manual procedure for setting

motor on drillhead.
min. to max. displacement or simply try turning
the adjustment screw slightly and observe if
r.p.m. changes. Check the parts book for correct
r.p.m. setting and using hand photo tachometer
set the engine speed and head rotation to spec.
the engine speed is set at 3250 r.p.m. and the
drillhead high speed is 1300 r.p.m. its not
recommended to overspeed either.

I. disconnect hydraulic motor from transmission and

I. Problem in see if problem still exists.
transmission or
drillhead housing.

77
TroubleShooting (specific functions), Main pump circuit

Type of fault Possible cause Remedy

2. Fast feed section in A. Main pump or A. Troubleshoot main pump and compensator. check
main valve bank compensator problem. for proper suction, contamination, pressure
does not move feed settings,and excessive case drain leakage (more
cylinder, too slow, or than 1,5 g.p.m. is excessive for this pump).
erratic.
Check compensator spools for wear, damage, and
contamination. Check metallic gasket and o-ring
between compensator and pump for wear. high
pressure setting for main pump is 280 bar.

The standby pressure is 20 to 30 bar. these are set

at the compensator on the main pump. the
adjustment closest to the pump housing is
standby.

The larger adjustment and furthest from the

B. Problem in primary or B. Remove, clean, and inspect primary and
secondary shuttle.
pump is the maximum pressure adjustment. see
previous section solution c for procedure on
setting and checking high pressure and low
pressure standby on compensator. see eaton
manual located in parts book for more
information.
secondary shuttlesin fast feed section. if their ok
check the shuttles in remaining valve sections as
they may affect this functionuse caution when
removing secondary shuttle due to loose ball
behind shuttle.

Install proper o-rings and backups. note primary

and secondary shuttles are located in each valve
section of the main valve bank. see the main
control valve manual for description.
C. Main relief valve in
main or the two relief C. Remove and inspect main relief for
valves located in the contamination, wear, damage, and proper
fast feed section are pressure setting. ( the main relief is located on the
stuck or damaged. inlet section.

Check the load sense limiting valve by running

the cylinder intoend position and read system
pressure gauge

D. Manual control valve D. Remove and check spool for wear or damage.
spool is worn or
damaged.

E. Flow compensator E. Carefully remove compensator spool and check

spool in fast feed for wear, damage, or contamination.
section is blocked or
stuck.

F. No signal to ls port on F. Check the ls signal line from the main valve to the
pump from the main main pump for obstruction in hose or blocked
valve bank. orfice fittings.
G. Problem in feed G. Troubleshoot the feed cylinder checking for worn
cylinder. seal kit or damage to cylinder.
H. Problem in the sliding H. Do inspection of slides, rollers, and lift chain.
parts of the drillhead
mounting plate, roller
parts, or lift chain.

78
 TroubleShooting (specific functions), Main pump circuit

Type of fault Possible cause Remedy

3. Main winch section in A. Quick disconnect A. Make sure quick disconnect fittings go together
main valve bank fittings are not freely and no broken parts inside.
producing slow hoist, connected.
no hoisting, erratic, or
winch not holding B. High pressure filter B. Remove and inspect high pressure filter. install
load. between pump and the proper filter element.
main valve is blocked.

C. Main pump or C. Troubleshoot main pump and compensator. check

compensator problem. for proper suction, contamination, pressure
setting, and excessive case drain leakage ( more
than 10 l/min is excessive for this pump).

Check compensator spools for wear, damage, and

contamination. Check metallic gasket and o-ring
between compensator and pump for wear. high
pressure setting for main pump is 280 bar. the
standby pressure is 20 to 30 bar.

The adjustment closest to the pump housing is

standby. the larger adjustment and furthest from
the pump is the maximum pressure adjustment.
See previous section solution c for procedure on
setting and checking high pressure and low
pressure standby on compensator.

D. Problem in primary or D. Remove, clean, and inspect primary and

secondary shuttles.
secondary shuttles in winch section. If their ok
check the shuttles in remaining valve sections as
they may affect this function.use caution when
removing secondary shuttle due to looseball
behind shuttle.

Install proper o-rings and backups.note primary

and secondary shuttles are located in each valve
section of the main valve bank.

E. Remove and inspect main relief valve for

E. Main relief valve or contamination,wear, damage, and proper
relief valve in winch pressure setting.
section is stuck,
damaged, or setting is
incorrect. (the winch
section contains only
one relief valve located
on the hoist side of the
work port).

79
TroubleShooting (specific functions), Main pump circuit

Type of fault Possible cause Remedy

3. Main winch section in E. Main relief valve or E. The main relief valve setting is 280 bar and the
main valve bank relief valve in winch one relief valve in the winch section is set at 2800
producing slow hoist, section is stuck, psi on p4. the p6l with 12000 lb. winch requires
no hoisting, erratic, or damaged, or setting is the one relief to be set at 3250 psi.
winch not holding incorrect. (the winch
load. section contains only Load sense limiting and plugging
one relief valve located
on the hoist side of the
work port).

F. Manual control valve F. Check manual spool and housing for wear,
is worn or damaged. contamination, or damage.
G. Flow compensator G. Carefully remove compensator spool and check
spool in the winch is for wear, damage, or contamination.
blocked or stuck.

H. No signal to ls port on H. Check the ls signal line from main valve to the
pump from the mp-18 main pump for obstruction in hose or blocked
valve. orfice fittings.
I. Problem with I. If any pressure signal is evident at hoist and if not
automatic brake check that diversion valve at control panel is
release signal. receiving pressure from feed circuit.
J. Problem in braden J. Troubleshoot braden winch according to
winch. installation, maintenance, and service manual
located in parts book
K. Problem in structural
or mounting parts of K. Check structural area where winch is mounted.
braden winch make sure mounting platform is strong and
mounting surface is even.

80
 TroubleShooting (specific functions), Main pump circuit

Type of fault Possible cause Remedy

4. Wireline section in A. Quick disconnect
main valve bank fittings are not
producing slow, connected properly or
erratic, or no rotation pilot is damaged
of the wireline hoist inside.
drum.
B. Main pump or
compensator problem.
A. Make sure quick disconnect fittings go togther
freely and no broken parts inside.
B. Troubleshoot main pump and compensator..
check for proper suction, contamination, and
excessive case drain leakage (more than 10 liters
is excessive for this pump).
Check compensator spools for wear, damage,
contamination. Check metallic gasket and o-ring
between compensator and pump for wear. High
pressure setting for main pump is 280 bar. The
standby pressure is 20 to 30 bar.

The adjustment closest to the pump housing is

standby. The larger and furthest from the pump is
the maximum pressure adjustment. see previous
section solution c for procedure on setting and
checking high pressure and low pressure standby
on compensator.

C. Problem in primary or C. Remove, clean, and inspect primary and

secondary shuttles.
secondary shuttles in wireline section. If their ok
check the shuttles in remaining valve sections as
they may affect this function. use caution when
removing secondary shuttle due to loose ball
behind shuttle. Install proper o-rings and backups.
note primary and secondary shuttles are located
in each valve section of the main valve bank.

D. Main relief valve in D. Remove and inspect main relief valve and the two
main valve bank or the
two relief valves
located in the wireline
section are stuck or
damaged.
relief valves located in wireline valve section for
contamination, wear damage, and proper
pressure settings.
The load sense limiting valve in the wireline
section can be set by completely closing the
speed control valve for wireline hoist and
engaging the control lever up or down. The quick
couplers can also be disconnected to set this
pressure.

E. Check spool and housing for wear, contamination,

E. Manual control valve or damage.
spool is worn
damaged.
F. Carefully remove compensator spool and check
F. Flow compensator for contamination. wear, or damage.
spool in wireline
section is blocked or
stuck.
G. Check the ls signal line from main valve to main
G. No signal to ls port on pump for obstruction in hose or blocked orfice
pump from main valve fittings.
bank.
H. Troubleshoot hydraulic motor and counterbalance
H. problem in hydraulic valve mounted on the hoist drum. see eaton
motor mounted to manual in parts book for information.
hoist drum.
I. Inspect internal parts of speed control valve for
I. check wireline speed contamination or broken parts.
control valve located
on the right side of the
control panel
J. Check assembly and mounting area of hoist to
J. damage to structural main frame and condition of sheave wheels and
or mounting parts on crown block.
hoist.

81
TroubleShooting (specific functions), Secondary unit

Type of fault Possible cause Remedy

1. The water pump will A. Hydraulic hose A. Check the parts book hydraulic schematic for
not turn or stalls at plumbing is incorrect. correct plumbing. important the motor on the
low pressure. mud pump is designed to turn in one direction
only. (counterclockwise when viewed from the
shaft end of the motor). if the direction is
reversed, hydraulic pump and motor damage will
occur.

B. Hydraulic pump B. Check the pump pressure. Remove both the

problem. pressure and the return hoses going to the mud
pump motor and plug them. Connect load sense
signal to the hose before the plug and a 400 bar
gauge.

The pressure should read 175 bar. This is non-

adjustable and if the pump cannot build 175 bar
either the pump or the pump drive is bad.
Troubleshoot the pump for suction problem,
excessive case drain leakage, charge pressure
low, charge relief problem, or high pressure relief
is stuck or damaged. see Rexroth pump manual
for more information.

F. Hydraulic motor F. Check for proper hose plumbing. troubleshoot

problem. two-speed pilot line on auxiliary circuit. refer to
eaton service manual for more information.

G. Problem beyond G. Inspect hydraulic motor adapter and mud pump

hydraulic motor. for damage.

82
83
Rotation Unit ”P head”
1.1 DRILLHEAD ASSY. P HEAD
Part # 025161-104 4
"CHAIN ASSEMBLY PROCEDURE REFER TO
DRAWING # 025161-105"
#1 Thoroughly inspect housing (Part #
362926-0) Remove all burrs and weld
spatter. Check tapped holes for proper size
and thread quality .
#2 Wash housing with clean solvent and blow
dry. Make sure all tapped holes are free of
chips.
#3 Lay housing (Part # 362926-0) on work
bench, back side down, with spindle
opening on the left.
#4 Install the race for bearing (Part # 091578-
1) in the bottom spindle opening. (Tapered
side in first.)
#5 Inspect and clean cap. (Part # 162843-0)
Plug both lube oil holes, bottom hole with
a 1/4" NPT socket head plug, (Part #
0901233-02) and the side hole with a 1/8"
NPT socket head plug, (Part # 0901233-01)
Apply hydraulic sealant on threads.
#6 Install thin section roller bearing (Part #
162764-2) in cap, (Part # 162843-0)
#7 Apply a thin bead of silicone sealant on
cap, Lay 1 each 151174-110 gasket (.062'')
on cap and apply a thin bead of silicone on
gasket. Attach cap (Part # 162843-0) to
bottom of housing (Part #362926-0) with 8
each (Part # 090214-214) ½" 13 X 2 ¼" bolts
and ½" lock washers (Part #090343-7)
Lubricate threads and torque bolts to 85
foot pounds.
#8 Set housing upright on work bench stand
with inspection hole facing out.
#9 Inspect and clean spindle (Part # 162838-0)
#10 Place spindle (Part # 162838-0) on work
bench with split ring groove on lower side.
#11 Apply a generous amount of anti-seize to
split ring groove, split ring, spacer, key
ways and keys during assembly
procedure.
#12 Install split ring (Part # 162840-0) into split
ring groove in spindle. Make sure the split
ring bottoms completely in the groove.
#13 Install 2 Each keys (Part # 142614-4) into
key ways in spindle.
84
#14 Line up keys and install spacer (Part #
150035-500) Split ring groove down on
spindle. Make sure split ring seats
COMPLETELY into groove on spacer. THIS
IS IMPORTANT, IF THE SPACER IS NOT
SEATED COMPLETELY, THE SPINDLE END
PLAY WILL LOOSEN UP AFTER THE HEAD
HAS BEEN RUN.
#15 Apply a generous amount of anti-seize on
the spindle and inside the spindle sprocket
(Part # 150040-223) Install spindle sprocket
chamfered end up, on spindle and push it
on until it bottoms COMPLETELY against
the spacer (Part # 150035-00) THIS IS
IMPORTANT, IF THE SPROCKET IS NOT
SEATED COMPLETELY, THE SPINDLE END
PLAY WILL LOOSEN UP AFTER THE HEAD
HAS BEEN RUN.
#16 Install spindle bearings, 2 each, (Part #
091578-1) tapered side toward end of
spindle, 1 on each end of spindle. MAKE
SURE THE SPINDLE BEARINGS ARE
SEATED COMPLETELY AGAINST THE
SPINDLE SPROCKET, IF THEY ARE NOT,
THE SPINDLE END PLAY WILL LOOSEN UP
AFTER THE HEAD HAS BEEN RUN.
#17 Install retaining rings, 2 each, (Part #
0900202-600) in groove above spindle
bearing 1 on each end of spindle.
ASSEMBLY
INSTRUCTIONS
• Drillhead must be assembled in a clean
area free of any contaminants that can
accidently get into this assembly.
• All parts must be clean and free of any
dust, dirt, paint, metal chips, burrs, weld
slag, weld splatter, or any foreign material
before assembly.
• After assembly is completed and
before installing front cover, inspect
inside of box to insure that no foreign
materials have entered the box during
assembly.
 Rotation Unit ”P head”
4" 51 REF.

15

MOUNT 43 AS SHOWN

VIEW A-A
(1/2 SCALE) 16

162839-1 (REF.)
2 PLACES 162838-1 (REF.)
INSTALL WITH
1-9/16 TYP. LOCTITE #609
BOTH ENDS

1/2 SCALE

REMOVE INSTALLATION LIP.

MAKE SURE THERE
ARE NO SHARP EDGES.

LUBRICATE MOTOR AND

TRANSMISSION SPLINED
SHAFTS WITH HIGH QUALITY
GREASE BEFORE ASSEMBLY.

47
46 55

14

B 39
** 18 38

13
62 68
2 REQD.
6 REQD.

41
42
2 REQD.

***
A 28
34 ***
31
23
7
2 REQD. 40

19 22
2 REQD.
4 25
24 4" HV CHAIN

57 T. 23 T.

9
2 REQD.

12
21 15/16
8

48
44

28 REF. 47

32

49 59 66
43
2 REQD. 8 REQD.
72

60 66 17
53 GUARD 4-5/8 CHUCK
16 REQD. 20
2 REQD. NOT SHOWN FOR CLARITY PURPOSES

** INSTALL 18 BEFORE MOUNTING CAP 49 5

4 REQD.

*** A A
ADDITIONAL SHIMS MAY BE REQUIRED ON TOP CAP
151174-118 .002 RED
A

A 151174-118 .005 BLUE

A 151174-118 .010 BROWN
SERVICE IN SEAL KIT 041040-42

DRILLHEAD HOUSING TRANSMISSION HYD. MOTOR REMARKS

ASSY. NO. PART. NO. PART. NO. PART. NO.
025161-104 362926-0 025001-65 025052-110 CT-3000
VOLVO MOTOR
025161-105 362926-0 025001-65 025052-104 CT-1000
REXROTH MOTOR
025161- 363028-0 025001-46 LESS MOTOR CT-2000
(025052-29 REF.) HYD. HINGE
025161- 362926-0 LESS TRANS. LESS MOTOR CT-1000
MANUAL HINGE
025161- 363028-0 LESS TRANS. LESS MOTOR CT-1000
HYD. HINGE
025161- 363028-0 025001-65 025052-104 CT-1000 - REXROTH
MOTOR, HYD. HINGE

85
Rotation Unit ”P head”
#18 Install speedy sleeve, 2 each, (Part #
162839-1) 1 each on each end of spindle as
per manufactures instructions, supplied
with the speedy sleeve. Apply red Locktite
262 to the inside of the speedy sleeves
before installation. Using special
installation tool (Part # 163692-6), Position
the top of the speedy sleeve 1 9/16'' from
the end of the spindle. Remove the
installation lip from the speedy sleeves.
REMOVE ALL SHARP EDGES, IF ANY,
FROM THE SPEEDY - SLEEVES. ANY
SHARP EDGES WILL CAUSE SEAL
DAMAGE.
#19 Before installing the chain, count the
number of links in the chain. (There should
be 96 links only) Check to see if there is a
painted link on the chain, if so, its installed
painted side up during chain installation.
#20 Install chain (Part # 025287-8) in housing.
Position the chain so the spindle assembly
can be lowered into the housing coming to
rest on the bottom cap.
#21 Apply a generous amount of assembly
lube to each of the bearings. Lubriplate 105
or equivalent. THIS IS IMPORTANT, THE
HEAD WILL ROTATE FOR A SHORT TIME
BEFORE LUBE OIL WILL GET TO THE
BEARINGS.
#22 Lower spindle assembly through top
opening in housing, through chain and
into bottom cap assembly. MAKE SURE
THE SPINDLE IS COMPLETELY SEATED IN
THE BOTTOM CAP, IF IT IS NOT, THE
SPINDLE END PLAY WILL LOOSEN UP
AFTER THE HEAD HAS BEEN RUN.
#23 Apply assembly lube (Lubriplate 105 or
equivalent) on bearing surface of outer
race. Install the outer race for spindle
bearing (Part # 091578-1) into top of
housing (Tapered end in first.)
#24 Install thin section roller bearing (Part #
162764-2) on spindle, make sure it is
seated against the snap ring.
86
#25 Clean and inspect top cap (Part # 162843-0)
apply hydraulic thread sealant on threads
and install 1 each (Part # 0901233-01) 1/8''
pipe plug, in side lubrication oil hole, and
1 each (Part # 91124-604) JIC fitting in the
top lubrication oil hole. Apply a thin bead
of silicone on top cap (Part # 162843-0)
place 1 each shim (Part #151174-110 .062"
thick) and any combination of shims, (Part
#'s 151178-118 .002'' 151174-118 .005"
151174-118 .101") to achieve a total shim
pack thickness of .085" to .095". Apply a
thin bead of silicone to the last shim and
install the top cap, positioned on the
housing with the lubrication oil port
positioned at 4:00 o'clock using 8 each
(Part # 090214-214) ½''13 X 1 ½'' bolts and
8 each (Part # 090343-7) ½'' lock washer.
Lubricate threads and torque bolts to 87
foot pounds. MAKE SURE ALL THE BOLTS
ARE INSTALLED AND TORQUED, SPINDLE
END PLAY WILL NOT BE SET CORRECTLY
IF THEY ARE NOT.
#26 Spindle end play must be established at
this time. Spindle end play set up
procedure:
Attach Special tool (Part # 163692-2) on top
of spindle. With 2 each 7/16'' 20 x 1 1/2''
bolts. Torque bolts to 40 foot pounds.
Install 2 each ½'' 20 x 9'' all thread bolts
through tool with 1 nut below tool and 1
nut above tool.
Screw ½'' all thread bolts into the jacking
holes in the top cap. Back the lower ½''
nuts away from the tool. Tighten the upper
½'' nuts until the spindle is bottomed
tightly in the lower cap.
Hit the top of the tool with a large soft
faced hammer a few times and retighten
the top ½'' nuts. (This will assure that all
the end play is out of the spindle.) Install a
dial indicator on the top cap with the
indicator shaft resting on the top of the
spindle.
Zero the dial indicator. Loosen the top ½''
nuts a few turns and tighten the bottom
½'' nuts against the tool until the dial
indicator quits moving. This is the spindle
end play. It must be .010'' to .015''. If the
end play is not correct, add or remove
shims from under top cap until the correct
end play is achieved. THIS IS IMPORTANT,
THE LIFE OF THE DRILL HEAD DEPENDS IN
THIS BEING CORRECT.
 Rotation Unit ”P head”

MINIMUM DISPLACEMENT SCREW

STEP # 64

63 69 6 SILICONE SEALANT

2 REQD.

52

74

10
LOCTITE TWO (2) BEARINGS INTO
2 REQ D. TRANSMISSION HOUSING BEFORE
ASSEMBLY WITH DRILLHEAD
USE LOCTITE #680
71 61 67

4 REQD.

1/8 NPT LUBE PORT

REF.

30
54

57 65
6 REQD.

45

70
OIL LEVEL PLUG

50

33 58 65
12 REQD.
56 64
3 REQD. 29

11 2
8 REQD.

SERVICE IN SEAL KIT 041040-42

87
Rotation Unit ”P head”
See attached drawing for detailed end play
tool set up. This completes the set up
procedure portion on the spindle. The
following steps detail the set up procedure
of the pinion shaft.
#27 Clean and inspect the pinion sprocket (Part
# 150040-223) Check the lubrication oil
pump (Part # 025014-107) drive shaft in the
bottom of the pinion sprocket. Lubricate
the pump shaft with gear oil, it should
slide freely in the pinion sprocket. Bearing
surface to spline concentricity must be
checked at this time. This is accomplished
by installing a spline plug, (Part # 163692-
5) in the input spline , then place the
sprocket in a two point live center fixture,
(Part # 163692-7) set up a dial indicator in
the bearing surface nearest the oil pump
drive end, then on the bearing surface on
the input splined end, then on the spline
plug.
The run out on any of these surfaces must
be .003'' or less (see drawing # 150040-
222) IF THE RUN OUT EXCEEDS .003'' DO
NOT USE THE PINION SHAFT. (Pinion
shafts have been through quality
assurance, but they need to be rechecked
before installation.) Remove pinion shaft
from live center fixture and remove spline
plug .
Lubricate the input spline, (top of pinion
sprocket) with (Optimol grease Part #
08464-215 or equivalent.) Insert the out put
shaft from the Funk transmission (Part #
025001-65) into the input spline in the
pinion sprocket . It must slide free without
any binding. Check the bearing fit (Part #
090013-221) 4 each on the pinion sprocket.
(The fit needs to be a tap fit. This is
necessary for ease of installation.) If
bearing fit is not correct, polish the shaft
area until it fits right. When bearing fit is
correct, hand pack each bearing with
assembly lube, (Lubriplate 105 or
equivalent.) THIS IS IMPORTANT AS THE
PINION SPROCKET WILL TURN FOR A
SHORT TIME BEFORE LUBRICATION OIL
FLOW IS ESTABLISHED. Install 1 bearing, 1
spacer (Part # 150035-481) and 1 bearing
on each end of pinion sprocket. Set the
sprocket aside, it will be installed later.
#28 Install tensioner pin (Part # 050270-180)
with key (Part # 16614-4) Into tensioner
housing. Secure tensioner pin with
retaining ring. (Part # 090203-98)
88
#29 Install tensioner assembly into the
housing. (the tensioner assembly pin is
offset from center, install the tensioner
assembly with the shorter offset down.)
#30 The next 5 steps are necessary to
determine the correct width of the stop
spacer. (Part # 150035-505) The stop spacer
has to be fit to each individual case
because of variances in the housing
manufacturing. The stop spacer is installed
to prevent excessive pinion bearing side
loading in the event the adjuster nut is
over tightened.
#31 Install Lubrication pump mount (Part #
162830-0) as shown in view A-A drawing #
025161-105, with 8 each ½'' 13 x 1 ½''
bolts, (Part # 090214-144) without a gasket
on the bottom of the housing. Bolts need
to be looseenough so mount can slide
freely.
#32 Install pinion sprocket assembly into the
tensioner housing assembly and seat
lower pinion sprocket bearing into
lubricationpump mount. (The chain is not
on the pinion sprocket at this time.)
#33 Install transmission mount (Part # 162829-
0) with 6 each 5/8'' 11 x 1 ¾'' bolts, (Part #
090214-173) without a gasket on the top of
the housing. Bolts need to be loose
enough so mount can slide freely.
#34 Move tensioner assembly to the right
(away from spindle) until the mounting
bolts bottom in the adjusting slots on the
transmission and lubrication pump mount
plates. Measure the distance between the
tensioner housing and the weldment plate
that the tensioner pin goes through. This
dimension plus .030'' is the width that the
spacer, (Part #150035-505) needs to be.
#35 Check the width of the spacer (Part #
150035-505) Machine it to the dimension
that has been determined in step 36.
#36 Disassemble transmission and lubrication
pump mount, remove the pinion sprocket
assembly from the tensioner housing,
remove the tensioner housing assembly.
#37 Reinstall tensioner housing with the spacer
(Part # 150035-505) on the tensioner pin.
(The spacer goes on the tensioner pin
between the out side of the tensioner
housing and the weldment plate, make
sure the recessedend of the spacer is
towards the snap ring) Install lock nut 1'' 8
NC
 Rotation Unit ”P head”
(Part # 090356-9) on tensioner pin. (Leave #44 Tighten the transmission mount bolts to
this nut as loose as possible.) 175 foot pounds of torque, and the
lubrication pump mount bolts to 87 foot
#38 Position the chain (Part # 025287-8) in the
pounds of torque. Wipe away excess
tensioner housing so the pinion assembly
silicone and Hylomar from assembled
will fit past it. Install pinion sprocket
parts.
assembly into tensioner housing.
#45 Pinion sprocket end play must be
#39 Turn the housing so it is laying on it's back
established at this time. Pinion sprocket
on the work bench.
end play procedure:
#40 Apply a thin bead of silicone to the inside
Install special tool (Part # 163639-2) to the
face of the lubrication pump mount (Part #
top of the transmission mount with 2 each
162830-0) and install gasket (Part # 151174-
5/8'' 18 x 6 ½'' all thread bolts with nuts.
114) Apply a thin coat of Hylomar gasket
Tighten 5/8 nuts against tool. (This will
maker (Part # 710xx264 medium) to gasket
push the pinion sprocket to the lower limit
and mating surface on housing. Install
of it's travel.) Remove the tool and install a
lubrication pump mount to the housing
dial indicator with the pointer resting on
with 8 each ½'' 13 x 1 ½'' bolts (Part #
the top of the pinion sprocket. Install
090214-144) 8 each ½'' lock washer (Part #
special tool (Part # 163692-3) to the bottom
090343-7) and 8 each ½'' flat washers (part
of the lube pump mount with 2 each 1/2''
# 090347-20) Snug the bolts up hand tight
16 x 4 ½'' all thread bolts with nuts.
so the lubrication pump mount can slide
Tighten the 1/2'' nuts against tool until the
for chain adjustment. (Hylomar gasket
pinion sprocket is pushed to the upper
maker is the preferred sealant to be used
limit of it's travel. The dial indicator should
between the gasket and the housing
read .030'' minimum. If the end play is
because it stays pliable and wont leak
more than .035 this is acceptable, if it is
when chain is adjusted if it is not available
less than .030'' this is unacceptable. Add 1
silicone is the next best thing to use.)
each steel transmission mount gasket (Part
#41 Apply a thin bead of silicone to the inside # 151174-117) to transmission mount to
face of the transmission mount (Part # achieve the correct pinion sprocket end
162829-0) and install steel gasket (Part # play.
151174-117). Apply a thin bead of silicone
THIS END PLAY IS CRITICAL, PINION
to the face of the steel gasket, and install
SPROCKET BEARINGS WILL FAIL IF IT'S
plastic transmission mount gasket (part #
NOT RIGHT.
151174-122). Apply a thin coat of Hylomar
gasket maker to the face of the plastic #46 Install key (part # 090796-3) in shaft of
transmission mount gasket and the mating lubrication pump
surface on the housing. NOTE: APPLY
HYLOMAR GASKET MAKER SPARINGLY
SO IT WONT GET INTO THE HOUSING
AND CONTAMINATE THE LUBRICATION
SYSTEM. CAUTION
#42 Install transmission mount on housing
with 6 each 5/8'' 11 x 1 ¾'' bolts (part # LUBRICATION OIL FLOW IS
090214-173) 6 each 5/8'' lock washers (Part ABSOLUTELY NECESSARY
# 090343-8) and 6 each 5/8'' flat washers
(part # 090347-23) Snug these bolts up AT ALL TIMES WHEN THE
hand tight so the transmission mount can HEAD IS ROTATING.
slide for chain adjustment.
FAILURE TO MAINTAIN LUBE
#43 Adjust the chain. Tighten 1''8 NC self OIL FLOW WILL CAUSE
locking nut (1 ½'' socket) until the
chain has 1" of deflection from front to CATASTROPHIC DAMAGE TO
back . (see chain adjusting procedure THE HEAD AND OR THE
drawing # 163963-8)
TRANSMISSION.
DO NOT OVER TIGHTEN CHAIN. THE LIFE
OF THE ROTATION HEAD DEPENDS ON
THIS ADJUSTMENT BEING CORRECT.
89
Rotation Unit ”P head”
(Part # 025014-107) Put a thin layer of
silicone on lubrication pump gasket (part
#151174-115) and install gasket to face of
lubrication pump. Apply a thin layer of
silicone on mating surface of lubrication
pump mount (part # 162830-0) Install
lubrication pump into mount with 3 each
¼'' 20 x ¾'' bolts (part # 090214-85) with
¼'' lock washers (part # 090343-4)
Tighten bolts to 7 foot pounds of torque.
Lubrication pump relief valve adjustment
procedure. Remove the acorn nut (5/8''
wrench) from the relief valve, loosen the
lock nut (7/16'' wrench) and turn the
adjusting screw clockwise until three
threads are showing above the lock nut .
Tighten lock nut and reinstall acorn nut.
This adjustment will assure lubrication oil
flow during warm up. The lube system
depends more on oil volume, than oil
pressure to lubricate the bearings.
#47 Install lower spindle oil seal (part # 090363-
424) lip up as shown in drawing (# 025161-
105) Apply a thin layer of silicone to the
inside mating surfaces of the seal. Install
seal with special tool (part # 163692-1)
#48 Install oil tube (part # 364286-0) in the ¼''
NPT hole in the center bottom of the
housing. Make sure the oil spray holes in
the tube face the rear side of the pinion
sprocket.
#49 Reposition housing upright on bench with
chain opening facing forward.
#50 Install the spindle top seal (part # 090363-
424) in the top cap with the lip up. (view A
of drawing # 025161-105) Apply a thin layer
of silicone in the inside mating surfaces of
the seal. Install seal with special tool (part
# 163296-1) This seal is installed up side
down to prevent contaminates from
entering the housing from the top of the
spindle.
#51 Install seal excluder (part # 155971-9) (wide
side down) over spindle and on top of top
seal.
#52 Install speedy sleeve (part # 162839-2) on
top section of pinion shaft. (splined end)
Coat mating surfaces with red loctite (Part
# 262) Tap speedy sleeve into place with
the installation tool provided in the speedy
sleeve kit. Leave the installation lip in
place, there is no need to remove it.
90
#53 Install oil seal (part # 090365-203) Apply a
thin layer of silicone on the mating
surfaces of the seal, install seal with the lip
up, in the transmission mount plate. Install
seal with special tool (part # 163692-4)
MAKE SURE THE SEAL IS INSTALLED LIP
UP, AS SHOWN IN (DRAWING # 025161-
105.) THIS SEAL HOLDS THE LUBRICATING
OIL IN THE TRANSMISSION. IF IT IS NOT
INSTALLED CORRECTLY, THE
LUBRICATION OIL WILL DRAIN FROM THE
TRANSMISSION INTO THE CHAIN CASE,
CAUSING PREMATURE TRANSMISSION
FAILURE AND CHAIN CASE
OVERHEATING.
#55 Recheck pinion sprocket run out one last
time at this point. Install spline plug (part #
163692-5) into female spline in pinion
sprocket. Check the run out on the side of
the spline plug with a dial indicator. It
should be .003'' to .005'' or less.
#56 Apply a thin film of silicone to both sides
of side cover gasket (part # 151174-112)
install gasket and side cover (part #
162833-0) with 6 each (part # 090214-59)
3/8'' 16 x ¾'' bolt and 6 each (part #
090343-6) 3/8'' lock washers. Tighten bolts
to 36 foot pounds of torque.
#57 Apply a thin bead of silicone to both sides
of transmission gasket (part # 151174-122).
#58 Transmission installation procedure. Make
sure the transmission has been reworked
from a (part # 025001-43) into a (part #
025001-65) Rework consists of:
Transmission adapter modified as shown
on (drawing # 160303-5.)
Transmission to motor coupler modified as
shown on (drawing # 164356-0.)
Transmission input shaft bearing (part #
90017-210) shown in (drawing # 025001-
65.) The input shaft must be removed from
the transmission and the oil shields
removed from both sides of the input
bearing. THIS IS DONE TO ALLOW FOR
LUBRICATION OIL FLOW THROUGH THE
TRANSMISSION.
Transmission out put shaft, (part # 15896-6)
shown in (drawing # 025001-65) must be
removed and reworked as shown in
(drawing # 163692-9.) THE SNAP RING IS
ADDED TO THE OUT PUT SHAFT TO
MAINTAIN CLEARANCE BETWEEN THE
INPUT AND OUT PUT SHAFT TO PROVIDE
LUBRICATION OIL FLOW TO
 Rotation Unit ”P head”
THE POCKET BEARING BETWEEN THE #66 Install lubrication system. There are
TWO SHAFTS. basically two types of lubrication systems
used on this head assembly. One with an
#59 Apply a liberal coating of Optimol grease # oil cooler (drawing # 025282-13) and one
08464-215 to transmission out put shaft. without an oil cooler (drawing # 025283-
Install transmission into pinion sprocket. 11). Refer to the drawing that applies to
Attach transmission to transmission mount your application.
with 4 each (part # 090214-154) 9/16'' 12 x
1 ½'' bolts and 4 each (part # 090343-19) ALWAYS PRIME THE FILTER AND THE
9/16'' lock washers. Tighten bolts to 125 ENTIRE LUBRICATION SYSTEM BEFORE
foot pounds of torque. START UP. THE LOWER TRANSMISSION TO
CHAIN CASE DRAIN LINE (CLEAR PLASTIC
#60 Apply a liberal coating of Optimol grease LINE) WILL SHOW OIL FLOW AFTER THE
on the splines of motor to transmission HEAD HAS BEEN ROTATED FOE A MINUTE
coupling (part # 164356-0) and install on OR SO. IF NO OIL FLOW IS ESTABLISHED,
transmission input shaft. Make sure the CHECK THE LUBE SYSTEM TO DETERMINE
coupling has been reworked as shown on THE CAUSE. THE UPPER DRAIN LINE WILL
(drawing # 164356-0) The top of the ONLY SHOW LUBRICATION OIL FLOW IN
coupling has a recess cut in to it, to create COLD WEATHER START UP.
an oil dam to cut down on coupler and
shaft fretting.
#61 Install oil tube (part # 364335-0) in top left
side hole in transmission adapter (part #
160303-5) as shown in view B-B (drawing #
025282-13.)
#62 Install O ring (part # 090108-104) with a
little assembly lube on mating flange of
hydraulic motor (part # 025052-104).
#63 Install hydraulic motor onto transmission
adapter with 2 each (part # 090214-215)
5/8'' 11 x 2 bolts and 2 each (part # 090343-
8) 5/8'' lock washers. Tighten bolts to 175
foot pounds of torque.
#64 Check the length of the minimum
displacement screw on the hydraulic
motor. See (drawing # 025161-105) . The
screw should be 3 ¼'' long overall. IF IT IS
NOT THE CORRECT LENGTH, MODIFY IT,
REASON BEING, THAT THERE IS A
POSSIBILITY OF MOTOR OVER SPEED
WITH THE FACTORY LENGTH BOLT THAT
COMES IN THE MOTOR.

THE INITIAL SETTING OF THIS SCREW IS 3

THREADS SHOWING ABOVE THE LOCK
NUT. THE FINAL SPEED WILL HAVE TO BE
FINE TUNED TO EACH INDIVIDUAL DRILL
DURING START UP.
#65 Apply a thin bead if silicone to both sides
of front cover gasket (Part # 151174-111)
and install on mating surface of front cover
(part # 162847-0) Install front cover on
housing with 12 each (part # 090214-87)
3/8'' 16 x 1'' bolts and 12 each (part #
090343-6) 3/8'' lock washer . Tighten bolts
to 36 foot pounds of torque.

91