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Atlas Copco Exploration Products

CS3001 Core Drill RigOperator’s Instruction ManualUniversal Deck Version

Printed Matter No. 6991 1458 01

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Operator's Instruction Manual for

CHRISTENSEN

CS3001 Universal Deck

This instruction manual is intended for operators of theChristensen CS3001 (Universal Deck Version) high capacitydiamond core drill.

Instructions are given for set up, drilling, and maintenanceprocedures to be carried out by the operator andmaintenance personnel. For further information concerningservice measures for the drill rig, please contact yournearest Atlas Copco representative.

Safety instructions applicable to operating and maintainingthe drill are given in the section 2, Product SafetyInstructions . This section must be read carefully and fully

understood before starting to use the rig. Any questionsregarding these instructions should be referred to yournearest Atlas Copco representative.

All rights reserved.

The owner of the equipment is granted the permission totake copies of this publication solely for internal use.It is recommended, however, to order additional copies fromyour nearest Atlas Copco representative in order to benefitfrom the latest revision.

Atlas Copco Exploration Products reserves the right to make

changes, without notice, in its products in order to improvedesign or performance characteristics.

The information in this publication is assumed to be accurateat the time of publication, but is subject to changes in orderto remedy detected deficiencies or to follow changes in theproduct.

Users of this publication are requested to inform Atlas CopcoExploration Products about deficiencies found, particularly inmatters concerning product safety.

ATLAS COPCO EXPLORATION PRODUCTS

NORTH BAY, CANADA 2007-8

Printed Matter No 6991 1458 01Issue Date December 6, 2007

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Contents

Page Page

1 Introduction______________________ 1

2 Safety Instructions ________________ 3

2.1 Organizational Measures ___________3

2.2 Operation (General) _______________5

2.3 Moving The Drill __________________7

2.4 Set-Up Of Drill____________________8

2.5 Drilling __________________________9

2.6 Tear-Down Of Drill_______________10

2.7 Maintenance and Servicing ________11

2.8 Special Safety Signs_______________12

2.9 Safety Decals ____________________13

2.10 Fire Extinguisher________________14

3 Environmental Instructions ________ 15

4 Hoisting the Drill ________________ 17

5 Specifications ___________________ 19

5.1 General _________________________19

5.2 CS3001 Technical Specifications ____20

5.3 Dimensions ______________________22

6 Design Features _________________ 25

6.1 Mast And Feedframe______________25

6.2 Rotation Unit ____________________26

6.3 Crown Block ____________________26

6.4 Control Console__________________27

6.5 Wireline Winch __________________27

6.6 Main Winch _____________________28

6.7 Hydraulic Tank __________________29 6.8 Mechanical Guards _______________30

6.9 Optional Spin-Out Tool ___________30

7 Controls ________________________ 31

7.1 Main Control Panel (Pilot Operated) 31

7.1 Engine Control Panel _____________37

7.2 Secondary Control Panel__________ 37

8 Diesel Engine Start-Up ____________ 39 8.1 Pre-Start _______________________ 39

8.2 Engine Start ____________________ 42

8.3 Engine Shut-Down _______________ 42

9 Drill Set-Up _____________________ 43

9.1 Start-Up _______________________ 43

9.2 Secondary Controls ______________ 44

9.3 Levelling The Drill _______________ 45

9.4 Operator’s Platform _____________ 46 9.5 Mast Slide ______________________ 46

9.6 Ground Support & Wind Conditions 47

10 Drilling _______________________ 51

10.1 Before Drilling Starts____________ 52

10.2 Start the Power Unit ____________ 52

10.4 Adjust the Flow of Mud/Water____ 53

10.5 Start Rotation__________________ 53

10.6 Start Drill Feed_________________ 54

10.7 Stop Drilling ___________________ 54

10.8 Controlled Wireline Lowering ____ 56

10.9 Controlled Wireline Winching ____ 56

10.10 Thread Compensation __________ 56

10.11 Adding a Drill Rod_____________ 57

10.12 Removing a Drill Rod __________ 57

10.13 Water Pressure Dump Valve ____ 58

10.14 Operating Main Winch _________ 58

10.15 Rod Handling _________________ 59

10.16 Drill Rod Break-In Procedure ___ 61

11 Maintenance And Servicing _______ 63

11.1 General _______________________ 63

11.2 Periodic Maintenance and Service

Schedule __________________________ 63

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Contents

Page Page

11.3 Lubricant Recommendations ______65

11.4 Service Point Detailed Instructions _66 11.5 Periodic Inspections _____________75

11.6 Hydraulic Hoses & Fittings Inspection

___________________________________77

12 Hydraulic Circuit Description _____ 79

12.1 Hydraulic Pumps________________79

12.2 Filtration ______________________80

12.3 Main Pump Circuit ______________82

12.5 Secondary Pump Circuit__________90

12.6 Return Oil Circuit And Hydraulic

Tank ______________________________91

12.7 Hydraulic Oil Cooler_____________92

13 Electrical Circuit Description______ 93

13.1 Electrical Fault Panel ____________93

13.2 Safety Systems (Electrical Circuit)

Description _________________________94

14 Trouble-Shooting _______________ 95

14.1 Trouble-Shooting - General ______ 96 14.2 Trouble-Shooting Auxiliary Pump

Circuit ____________________________ 98

14.3 Trouble-Shooting Main Pump Circuit

_________________________________ 102

14.4 Trouble-Shooting Secondary Pump

Circuit ___________________________ 105

15 Hydraulic Set-Up Procedure _____ 107

16 Spin-Out Tool Option ___________ 119

16.1 Safe-T-Spin Wireline Rod Make/BreakTool _____________________________ 119

16.2 Safe-T-Spin Operator’s Manual__ 120

16.3 Safe-T-Spin Maintenance _______ 127

17 Addendum Sheets ______________ 129

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1 Introduction

1

1 Introduction

Thank you for choosing the CS3001as your nextcore drill. The team at Atlas Copco ExplorationProducts is certain that it will provide you withyears of productive service.

This operator’s instruction manual containsinformation and safety instructions to assist inthe safe operation and maintenance of theCS3001 in the standard configuration. SomeCS3001 drills have special customer orderedfeatures that differ from the standard drillconfiguration. These are described inSection 18 – Addendum Sheets

Core drilling by its nature can be dangerouswork. Care must be exercised when operatingand servicing this product. Never operate thismachine without all guards, pins and safetydevices in place and in good working order.

A safe and careful operator is the best insuranceagainst an accident.

If you require any assistance, or for Partsordering, please contact your nearest AtlasCopco sales office or contact:

At las Copco Explorat ion Products A Division of At las Copco Canada Inc. 640 McKeown AvenueNorth Bay, OntarioP1B 8H2Canada

Telephone: (1) 705 472-3320Fax: (1) 705 472-6843

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1 Introduction

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2 Safety Instructions

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Dear operator,

Before putting your new equipment into use, wewould like to direct your attention to the safetyaspects. Drilling can be hazardous to you and tothe environment. Good order, training and wellmaintained equipment are the key factors forsafe operation. This manual is no replacementfor thorough training, but will, as a training aidand a reference book, help you to maintain asafe working environment and keep the rig ingood operating condition.

Yours faithfully, Atlas Copco Exploration Products

Intended Use

The CS3001 diamond core drill is intended forSurface exploration and investigation drillingwithin the published depth ratings of the drill.

Any use going beyond this shall be considered"not intended use". The manufacturer is then notliable for damage incurred as a result.

Unintentional use shall be at the owner's risk.Proper use also includes observing the safetyinstructions and procedures in the operation,maintenance, and service manuals as describedby the manufacturer.

The CS3001 should be operated, serviced andrepaired by personnel properly trained for theirtask. These personnel must have soundknowledge about hazards in their respectiveprofession.

General safety regulations must be observed.Personnel should be aware of dangers resulting

from abuse of drugs and alcohols as well aseffects of medicines legally prescribed, ormixture of any of them.

No unauthorized alterations should be made tothe drill. The manufacturer is not liable for anydamage caused by unauthorized alterations.

2.1 Organizational Measures

2.1.1 The CS3001 core drill shall be operatedonly by personnel who have been fullytrained on the rig. Particular emphasisshall be put on the Safety Instructionsand proper maintenance of the drill.

2.1.2 Keep this instruction book available onthe rig at all times.

2.1.3 Always use personal protectiveequipment as required by circumstancesor demanded by regulations. Always

use safety harnesses when climbing theservice ladder.

2.1.4 If, during operation of the unit, anyabnormal action in the safety oroperational systems is observed, theunit should be stopped and the probleminvestigated and rectified.

2.1.5 Warning signs must be kept legible at alltimes. Damaged signs should bereplaced immediately.

2.1.6 Hydraulic and electrical systems are of acomplex nature, and can cause injury ordamage if not handled with care. Repairand service shall be carried out bypersonnel with documented experiencefor these systems.

2.1.7 Welding repairs should only be carriedout by a qualified welder in order tomeet the high standards that apply to

Atlas Copco products. Special attentionmust be given to components whichcould cause injury or serious damage.

2.1.8 After repairs, make sure that the rig hasbeen inspected and approved by theproper authorities before being broughtback to normal operation.

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2.1.9 Never make alterations or modificationsto components of the unit, or alterpressure settings, particularly to the

safety systems, which might result inhazardous consequences. Themanufacturer’s approval should berequested for any modification done tothe unit.

2.1.10 Mechanical aids should be usedwhenever it is necessary to lift morethan 25 kg (50 lbs)

2.1.11 Do not operate the drill when the windspeed exceeds 20 m/sec (45 mph).

2.1.12 Always practice good housekeeping.Keep the drill deck clear and theworking area tidy. Prevent slipperyconditions underfoot on the deck, thedriller platform, the helper’s platform (ifso equipped) and the area surroundingthe drill.

2.1.13 Do not store any flammable liquids orgas bottles near the drill. Never storeany blasting caps or explosives near thedrill.

2.1.14 Always use the deck access ladderwhen climbing onto the rig platform

2.1.15 Fall arrest and restraint equipment mustbe used whenever the vertical drop

exceeds 3 m (10 ft) or as specified bylocal safety regulations. When climbingladders (e.g. service ladder to the crownblock), it is recommended to use aguided type of fall arrest system inwhich a rope grab is attached to a bodyharness (See Figure 2.1). Fall restraintsand a guided type of fall arrest systemare available, Atlas Copco part3760009042. Follow instructionssupplied with the fall arrest and fallrestraint equipment. Do not alter ormisuse this equipment.

A body harness as shown in Figure 2.1is available from Atlas Copco as part3760008964. It should be used to climbthe service ladder to the crown block.

Fig 2.1 Fall Arrest System for Climbing Ladders

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2.2 Operation (General)

2.2.1 In addition to this manual you shouldhave a good knowledge of generallyrecognized safety and accidentprevention regulations. If you follow theregulations you stand a better chance ofaccomplishing your task without harm toeither man or equipment.

2.2.2 Prior to starting up for the first time,familiarize yourself with the rig'sfeatures, its controls and their functions.

Fig 2.3 Read the Instruction Book beforeStarting Up The drill

2.2.3 Various safety devices are built into thesystem of the rig for your personal

safety. These devices must be checkedat least once at the beginning of eachshift to ensure that they are in properworking order. The equipment shouldnot be used unless safety checks andmaintenance have been carried out.

2.2.4 The drill is equipped with a fireextinguisher when shipped from thefactory. Always ensure that the fireextinguisher is kept on the drill and is ingood working order (see section 2.10)

2.2.5 Operators and helpers should wear

helmets with ear protectors, safetyglasses, safety shoes, gloves andsuitable clothing. Loose fitting clothingand jewellery can become caught in themoving parts of the machinery, causingserious injury or even death. Usesuitable respirators in dusty conditions

2.2.6 During drilling, no unauthorizedperson(s) should be allowed near therig.

2.2.7 Set control levers and switches to theneutral positions prior to starting up,otherwise the rig could startuncontrollably. Some of the levers arespring-loaded so that the operation willstop once released. This is part of thesafety system. Never lock these leversinto operating position using strings,sticks or similar items. The drill shouldalways be started from the controlpanel.

2.2.8 Shut the rig down for refuelling. Fuels

must be handled with care, at a safedistance from fire, sparks or electricalsystems. Smoking is not allowed within10 metres of the fuel! Do not fill the tankin an enclosed space without ensuringadequate ventilation. Fumes arepoisonous. Dispose of spilled fuel inaccordance with safety andenvironmental regulations (Useabsorbents or dig out the contaminatedsoil and transport it to an approvedstorage). Do not overfill the fuel tank.

2.2.9 If you top up the fuel tank in themorning, expansion of the fuel, as thetemperature increases later in the day,may cause fuel to spill from the tank.Tank breathers clog easily if the level offuel is too high.

2.2.10 Never leave the rig unattended with theengine running. Carry the ignition keywith you.

2.2.11 Use extreme caution while handlingstarter batteries. Wear gloves andprotective glasses when servicing

batteries. The batteries contain strongacid which can seriously burn eyes, skinand damage cloth, insulation and metal.First aid in case of acid in the eyes:wash with plenty of clean water andseek medical help. Disconnect theground cable from the battery beforecarrying out service in the electricalsystem.

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The battery gas is explosive! Never usematches when checking the acid level.

Be careful using iron tools near thebattery, a spark might set off anexplosion.

2.2.12 Hydraulic oils are poisonous. Use eyeprotection and gloves. Hydraulic oils,like fuel, must be treated in compliancewith safety and environmentalregulations.

2.2.13 Before any repair or service is carriedout on the drills hydraulic or watersystems, make sure the engine is

stopped and systems aredepressurized.

2.2.14 Be very careful while tracing leaks in thepressurized systems. Hydraulic oils,water or air under pressure couldpenetrate under the skin and causecomplicated injuries or infection. If thishappens, see a doctor at once.

2.2.15 Dispose of engine oils, hydraulic oils,fuels, filters and acids in a safe manneraccording to environmental protectionregulations.

2.2.16 Avoid the use of cleaning agentscontaining solvents like carbontetrachloride. There are environmentallybetter alternatives now available on themarket

2.2.17 Use only authorized parts (Atlas Copcoparts). Any damage or malfunctioncaused by the use of unauthorized partsis not covered by warranty.

2.2.18 Any warranty, for work performed, only

covers Atlas Copco products, Atlas Copco components and workperformed by authorized personnel.

2.2.19 Establish and use a standard means ofcommunication between all drillpersonnel. Remain in eye contact witheach other where possible. TheCS3001 drill is provided with an audible

alarm (beeper) similar to a truck backupwarning device that is activated whenhydraulic functions are used during set-up and tear-down. Stand clear of jacks

and mast when this device has beenactivated.

2.2.20 Obtain MSDS data sheets for the fluidsthat you use for the drill and follow theinstructions in the data sheets in case ofaccidental ingestion, skin contact orspills.

Fig. 2.4 Use Only Genuine Atlas Copco Parts

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2.3 Moving the Drill

2.3.1 Always lower the mast to thetransport position and raise the

jacks before moving the drill.Ensure that the jacks and mastslide securing pins are in place.Driving with mast out oftransport position could causerig upset.

2.3.2 Always safely stow and securethe overshot and water swivelon the deck before moving.Never move the drill with loose

items on the deck

2.3.3 Do not allow any personnel toride on the deck while the drill ismoving. Personnel must ride incab of truck only

2.3.4 Always test brakes beforedescending a ramp or steepincline.

2.3.5 For truck mounted drills, ensurethat truck’s operator’s manual issupplied and is kept in the truck.

2.3.6 Always check your surroundingsbefore moving the drill so youbecome aware of any hazards.

2.3.7 While moving the rig, nounauthorized person should beallowed near the rig. Ask asupervisor for assistance whenmoving the rig into dangerouspositions such as close to theedge of a quarry bench. Makesure the visibility is good. Don't

drive the rig into a dust cloud.

2.3.8 When the drill is mounted ontracks and is moved with theoperator at the console position,always use a spotter incommunication with theoperator to ensure that the drillis being safely moved since

visibility from the consoleposition is very limited.

2.3.9 Even with the mast down, the drillwhen mounted on a truck or tracks has

a high center of gravity. To preventsideways tipping, never move the rig ona side slope greater then 1 in 5.

2.3.10 If the drill is mounted on tracks or atruck by the customer, the customermust mount an inclinometer at thedriving position so the driver is aware ofthe slope. An inclinometer is availablefrom Atlas Copco, Part # 3760005026

2.3.11 The driver must be aware of thepossibility of soft ground or soft road

shoulders at all times since sinking ofthe wheels or tracks in soft ground canrapidly increase the sideways slope ofthe rig and lead to tipping of the rig andpersonnel injury.

2.3.12 Always ensure there is sufficientvisibility when moving the rig. Whendriving on poor roads, drive only indaylight.

2.3.13 Take extreme precautions on roughroads. Do not exceed posted speedlimits and match speeds to the roadconditions.

2.3.14 Before lowering the mast onto the frontsupport frame, ensure the mast islocated in its proper dumped position(matching alignment arrows on mastand saddle).

2.3.15 Ensure that the rig meets allowedoverall height limits.

2.3.16 Always check the clearance of overheadstructures. When sufficient clearance is

in doubt, stop and check the clearance. A common road accident with drills is acollision with an overhead structure.

2.3.17 On trips, the driver should periodicallycheck for any leaks (hydraulic oil,engine radiator, fuel tank and lines). It isrecommended that a spill kit andabsorbent be carried on the rig.

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2.3.18 For long distance shipping, or insensitive environmental areas, it isrecommended to drain the hydraulic

reservoir and fuel tank.

2.4 Set-Up of Drill

2.4.1 When inspecting the site where the drillis to be set up, ensure that there are nounderground utilities present (gas,water, electric cables) and that there areno overhead wires that can becontacted.

2.4.2 Before setting up the drill (lowering the jacks and raising the mast), ensure thatthe ground is sufficiently firm to supportthe drill. Where required use jacks padsor if necessary, timber or concrete pads.(See section 9.8.1 for details).

2.4.3 Check that the Set-up Audible Alarm isworking when any of the set-up controlsare moved (jacks, console extend, mastraise, mast slide). The purpose of thealarm is to let personnel know that amovement is taking place and allpersonnel except the operator should

stand clear.

2.4.4 When lowering the jacks, never useyour finger to check the pin holealignment (several people have lost aportion of their finger doing this!). Use avisual check only, using a secondperson if required. Always secure the

jacks with the locking pins provided.

2.4.5 When raising the mast, ensure that nohoses, winch rope or cables aresnagged. Snagging of hoses could

damage them and lead to leaks, andsnagging of winch rope or cables coulddamage them as well. Always securethe mast with the safety pins in thebackstay leg(s).

2.4.6 It is important that the bottom of themast be supported and that the supportis robust enough to take the full forceexerted on the rod when pulling with the

main winch and/or the drillhead. If thesupport moves while pulling on a stuckrod, the front of the drill could move up,depending on the angle of drilling.

2.4.7 Always secure the mast slide with thesecuring pins provided

2.4.8 If there is a possibility of thunder or anelectrical storm, a lightning conductorshould be installed on the drill.

2.4.9 Ensure parking brakes are set andwheel chocks are used to preventmovement of truck mounted drills afterthe drill has located for drilling.

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2.5 Drilling

2.5.1 Check that the emergency E-stops are

in good working order at the beginningof each shift. Also check that thedrillhead guard and perimeter guards forthe main and wireline winches are inplace.

2.5.2 All controls should be in neutral beforestarting engine. Check that neutralswitch for the rotation control lever isworking. It should not be possible tostart the engine if the rotation lever isnot in the neutral position. This is animportant safety device.

2.5.2 All main controls are live and dangerousif accidentally activated. Do not wearloose clothing. Do not stand on theconsole or place tools or equipment thatcan accidentally fall and operate thecontrols. Use approved hand protectionthat allows for positive and safe use ofall controls.

2.5.3 Use the wireline winch only for thepurpose intended, never for generalservice. The wireline winch moves toofast for any general service winching.

2.5.4 The main winch block limit switch,located at the crown block, is meant foremergency use only to prevent thewinching plug from being pulled into thecrown block. Do not use it for stoppingupward travel when winching the drillrod.

2.5.5 Always keep a minimum of 3 wraps onthe main winch drum and the mainwinch rope in a singe layer. Ensure thatthe rope end is well anchored on the

drum flange.

2.5.6 Monitor the condition of the main winchrope. At the first sign of wear or brokenstrands, the main winch rope must bereplaced.

2.5.7 Whenever possible, do not use pipewrenches to break rod joints. Break therods between the drillhead and

rodclamp or use the optional spin-outtool.

2.5.10 Always protect your hearing with bothear plugs and ear muffs (a totalattenuation rating of 15 dBA) whenworking on the rig.

2.5.11 Grease and inspect the water swivelevery shift to avoid bearing failure andseizure. Waterswivel failure can causehose whipping leading to injury or death

2.5.12 Ensure that the waterswivel is rated tomaximum load that can be applied to it.

2.5.13 Report excessive vibration to yourmanager or foreman immediately whenit occurs. Excessive vibration will causemachine damage and premature wear

2.5.14 Ensure that the operator and helper arenot exposed to continuous vibrationsince this can cause white finger andother disease

2.5.15 The audible alarm will sound on lowhydraulic oil level or high hydraulic oiltemperature (a light on the electricalpanel will show whether low level orhigh temperature caused the alarm).The engine will shut down in about 30seconds after start of the alarm (timeperiod is adjustable). This gives thedriller time to stop drilling, pull the rodsback and secure the drill hole.

2.5.16 Ground conditions can deteriorate afterheavy rainfall. Inspect jack and mastsupport areas daily.

2.5.17 Never operate the drill when the windspeeds exceed 20 m/sec (45 mph) Seesection 9.8.3 regarding guy wirerequirements

2.5.18 Do not operate the drill in lightningstorms. This could result inelectrocution.

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2.5.19 Snow/ice/freezing rain can make thework area hazardous. Take necessaryprecautions prior to working. Provide

wind protection for personnel whenoperating in cold and windy conditions.Working in cold conditions can make itdifficult to work safely.

2.5.20 Take precautions when drilling ingaseous deposits – methane gas cancause explosions and uncontrolled run-away of diesel engines. When drillinggaseous ground, use a B.O.P. (blow outpreventer), if required.

2.5.21 The operator should periodically check

for hydraulic oil, fuel and radiatorleakage. Any leaks found must berectified. It is recommended that a spillkit and absorbent be available at the drillsite.

2.5.22 It is important to practice goodhousekeeping and prevent slipperyunderfoot conditions in the workingareas.

2.5.23 Oily rags, bare conductors, spilled orleaking fuel or oil present a fire hazardand must be prevented

2.5.24 The foot clamp can crush feet or hands.Keep feet and hands away from the footclamp.

2.6 Tear-Down of Drill

2.6.1 Always put mast into transport position,

fully retract jacks, and retract theconsole before moving the rig.

2.6.2 Before lowering the mast onto the frontsupport frame, ensure the mast islocated in its proper dumped position(matching alignment arrows on mastand saddle)

2.6.3 Be careful to avoid snagging ordamaging any hose, winch rope or cablewhen moving the mast to the travelposition.

2.6.4 Always ensure that securing pins are inplace (jacks, backstay legs, mast slide,and guards)

2.6.5 Always secure any loose items so theycannot fall off the deck.

2.6.6 Ensure that the rig meets the allowedoverall height limit.

2.6.7 When preparing for a long trip, it isrecommended that the fuel tank andhydraulic reservoir be drained. This will

prevent a major environmental problemin case of any hydraulic hose/fuel line orincident with the rig.

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2.7 Maintenance and Servicing

2.7.1 Personnel must be properly trained andhave documented experience for thetype of maintenance/service work theyare doing in order to avoid injuries andpossible damage.

2.7.2 Any maintenance should be done usingacceptable lockout procedures toensure personal safety.

2.7.3 Make sure the engine is stopped andhydraulic, air, and water circuits areproperly depressurized before being

worked on.

2.7.4 Make sure all components that canmove when hydraulic lines/componentsare disconnected (e.g. drillhead, mast,etc.) are in the lowest position orsupported by temporary means such asblocks or chains before working on thedrill.

2.7.5 When replacing components, alwayspurge air from the components prior touse to prevent uncontrolled movement.

2.7.6 Be very careful when tracing leaks in thepressurized systems. Hydraulic oils,water or air under pressure couldpenetrate under the skin and causecomplicated injuries or infection. If thishappens, see a doctor at once.

2.7.7 Do not use pressure settings differentfrom factory settings without consultingwith the factory. Mechanical failures orother dangerous situations resulting indeath or injuries could occur withsettings that are different from factory

settings.

2.7.8 Use safe lifting practices. Use powerassisted lifting wherever possible. Donot lift more than 25 kg (56 lbs) perperson or as local regulations dictate.

2.7.9 Remove suspended loads on any winchbefore commencing maintenance

2.7.10 When working on electrical circuits,the battery ground cable should bedisconnected to prevent accidental

shorting.

2.7.11 Batteries contain corrosive acid.Wear protective equipment beforedoing any maintenance on batteries.

2.7.12 Welding near computer controlledengines can cause ECU damage.Disconnect batteries and ECUharness prior to welding.

2.7.13 Use only certified welders for anywelding repairs.

2.7.14 Avoid hot areas of the rig such as theengine exhaust system whenmaintaining/servicing the rig. Allowcool-down time prior to removingheat shields and guards

2.7.15 A qualified person should inspecthigh stress locations on a yearlybasis.

2.7.16 Never use oversize fuses orbreakers. These present a firehazard.

2.7.17 Periodically check that all danger andwarning labels, as specified in theparts manual, are present andlegible. Any missing decals must bereplaced.

2.7.18 Never climb the mast using theservice ladder while the rig isrunning.

2.7.19 Procedures in section 15 must beused for setting min displacements

on replacement hydraulic motors forrotation and the main winch. Failureto do this can cause over speedingand failure of the motors and damageto the drillhead or main winch.

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2.8 Special Safety Signs

The following warning signs are used on the rig

and in the manual:

2.8.1 Fig. 2.5 warns for immediate hazards,which when ignored, can lead to seriouspersonal injury or death!

2.8.2 Fig 2.6 warns for hazards or unsafepractices which, when ignored, couldlead to serious personal injury or death

2.8.3 Fig 2.7 indicates hazards or unsafepractice, which could lead to minorpersonal injury or damage to equipment.

2.8.4 Fig.2.8 is used for recommendationssuch as how to run the unit efficiently,economically and in compliance with

environmental regulations.

Fig. 2.5

Fig. 2.6

Fig. 2.7

Fig. 2.8

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2.9 Safety Decals

The following safety decals are used:

2.9.1 Fig. 2.9 Lifting points. This sign islocated where it is recommended thatslings be attached.

2.9.2 Fig 2.10 Ear protectors. Ear protectorsshould always be worn.

2.9.3 Fig. 2.11 Risk of crush. Be aware of therisk from crushing. Fig. 2.9 Fig. 2.10

2.9.4 Fig 2.12 Diesel fill location.

2.9.5 Fig 2.13 ATTENTION: Before starting,oil must be filled according to LubricantRecommendations

2.9.6 Fig 2.14 Electrical hazardFig. 2.11 Fig. 2.12

2.9.7 Fig 2.15 Foot Crushing hazard

Check periodically that safety decals arelegible and in place. Replace as required.

See Parts Manual for safety decal locationand part numbers.

Fig. 2.13

Fig. 2.14

Fig. 2.15

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2.10 Fire Extinguisher

2.10.1 The drill rig is equipped with a portablefire extinguisher. The fire extinguisher isshipped with the drill.

This fire extinguisher is suitable for firein electrical cables, fuel and enginesand lasts for approximately one minutewhen operated continuously.

To use, remove the safety pin and presshandle. Direct the jet towards the baseof the fire.

This type of fire extinguisher puts outthe fire by eliminating access to oxygen.Embers might start the fire again. Usewater for fighting fire in wood, paper andsimilar materials.

2.10.2 If the fire extinguisher has to bereplaced, the replacement must be ratedfor both oil and electrical fires with amass rating of not less than 6 kg (13lbs) and as required by local regulations.

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3 Environmental Instructions

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Dear operator,

Atlas Copco Exploration Products recognizesthe importance of environmental issues. As partof our commitment to a better environment, wewant to inform you, the customer, of how youcan minimize the effect on the environmentwhen using an Atlas Copco product. Thesesimple but important instructions will help topreserve the environment.

OilLeaks of hydraulic and lubrication oils pose anenvironmental threat. Changing lubricating andhydraulic oils, hydraulic hoses and hydraulic

filter elements also pose a potential threat to theenvironment.Collect all oil spills and waste (e.g. oil filterelements) contaminated with oil. Dispose ofaccording to national regulations.Use biologically decomposable hydraulic oilsand lubricating oils for Atlas Copco productswherever possible. Contact your nearest AtlasCopco office for more information.

EngineEngine emissions are toxic and pose anenvironmental threat. Always provide for fresh

air when an engine is running. Well-maintainedair filters help keep emissions at a low level.

Fuel (Petrol/Gas, Diesel): Fuel spillage posesan environmental threat. Collect all wastes andfuel spillage and dispose of according to nationalregulations.

GreaseLubricating grease poses a threat to theenvironment. Collect all wastes and spillage anddispose of according to national regulations.

BatteriesBatteries contain acids and heavy metals. Usedbatteries can therefore pose a threat to theenvironment and to your health. Avoid allcontact with acids and dispose of used batteriesaccording to national regulations. See alsosection 2.2 for further information.

ChemicalsDispose of chemicals such as drilling additives,other additives, glycol etc. according to themanufacturer’s instructions and local

regulations. Avoid the use of cleaning agentscontaining chlorinated solvents. There areenvironmentally better alternatives now availableon the market. Follow national regulationsregarding handling and disposal of wastes.

Metals (steel, aluminium, etc.)These products are recyclable and should betaken care of according to national regulationsand recycled where local programs exist.

Plastics and rubber

These products are often labelled according todifferent classes. In those cases they arerecyclable and should be disposed of accordingto national regulations and recycled where localprograms exist.

Electrical components (cables, electronics,etc)Used components should be disposed ofaccording to national regulations and recycledwhere local programs exist.

Spill Kit and Absorbent Always carry a spill kit and suitable absorbentfor hydraulic oil and anti freeze.

Daily InspectionInspect fuel tank, hydraulic tank, radiator andcooler for leaks daily.

Obtain MSDS data sheets for the fluids thatyou use for the drill and follow the instructionsin the data sheets to deal with accidentalingestion, skin contact or spills.

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4.1 Ensure that mast is in the transport position

on the mast support.4.2 Locate the rotation unit above the mainwinch to obtain a good point of balance andcentre of gravity.

4.3 Lift the drill using the lifting points at the 4 jacks and spreader bars (see Fig. 4.1 & 4.2)to ensure that the forces on the jacks arevertical only.

4.4 If spreader bars are not available, use slingsat least 7m (23 ft) in length to prevent highside forces on the jacks and ensure that nohoses or mechanical components aretouched by the slings.

Fig 4.1 Spreader Bars For Hoisting the Drill

– The sling must be sized for lifting 16tons (Drill unit) to provide a safetymargin.

– Never use a damaged rope/sling.

– Always make sure that nobody isunder or anywhere near, a suspendedload or within the swing radius of therope/sling.

Failure to use spreader bars, or longenough slings (see section 4.4), can causedamage and permanent distortion of thedeck

Fig. 4.2 Lifting Point on Drill Jack

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.

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5 Specifications

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5 Specifications

5.1 General

CHRISTENSEN CS3001 is an all-hydraulic operated diamond core drill.

The CHRISTENSEN CS3001 is an all-hydraulicdiamond core drill for deep hole surfaceexploration drilling. The CS3001 is designed tobe mounted on a truck and can also be mountedon tracks.

The CHRISTENSEN CS3001 uses well proventechnology for diamond core drills together withsafety improvements to provide a reliable, safedrill. An optional spin-out tool avoids the use ofpipe wrenches for breaking rods

Recommendations

To achieve the best results with regard to:

• high penetration

• optimal core recovery

• low drilling costs

It is of primary importance that drill rods, corebarrels and coring bits are of the right type andquality, matched to the drill and to the prevailingrock conditions.

Bearing in mind the core drill’s speed of rotation,its depth rating and chuck diameter, theCHRISTENSEN CS3001 is best suited to drill Nto P size holes using wire line rods.

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5.2 CS3001 TechnicalSpecifications

Drill MastFeed stoke ...............................3.35 m (11 ft)Mast slide ..................................2.0 m (80 in)Rod pull ..................................... 6.1 m (20 ft)Mast style………….…..One-piece WeldmentFeed pull..........................155 kN (35,000 lbf)Feed thrust……………....62.2 kN (14,000 lbf)Drill rod centerline location.... In front of mast

Main WinchMain winch pull ................133 kN (30,000 lbf)Main winch speed:

.. 0.74 m/sec (146 fpm) @ max displacement

.. 1.17 m/sec (230 fpm) @ min displacementRope size. .............................. 19 mm (3/4 in)

DrillheadChuck axial holding capacity:…………………………….178 kN (40,000 lbf)

Actuation ......Spring apply, hydraulic releaseNumber of jaws ........................................... 5Drillhead ........Chain final drive plus 4 speed.................................................. transmissionChuck mounting .................................Bolt onFinal drive ratio ................................... 2.48:1

Drillhead spindle ID………..119 mm (4.68 in)

Wireline WinchDrum Capacity:-4.7 mm (3/16 in) wire rope.... 4,600 m (15,000 t)-6.3 mm (¼ in) wire rope......... 2,600 m (8,530 ft)

Levelwind for even spooling ...........StandardParking brake ……………………….StandardWinch position..................... Raised on stand

Control ConsoleConsole movement ....... Hydraulic in and out

Weight (less truck):

…………………………12,810 kg (28,240 lbs)……………………………will vary with options

Foot Clamp

• Hydraulically operated, self energizing foot

clamp• Easy-to-remove jaws

• Common jaws from 44.5 mm (1.75 in) to177.8 mm (7 in)

• Casing and rod jaws for all popular sizes

• 224 mm (8.8 in) foot clamp opening

• 320 mm (12.5 in) mast bottom opening

Fig. 5.1 Foot Clamp & Optional Spin-Out Tool(Shown With Foot Clamp Guard Removed)

Fig. 5.2 Control Console & Drillhead

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Diesel Engine - See Drill Manual Section II forinformation on the Diesel engine.

Diesel Fuel Reservoi r

Capacity…………………….950 L (250 gal)Filling method………………By hand pump…………….connected to main return filter

Hydraulic System

Hydraulic tank capacity ……500 litres (132 gal)

Max. operating pressure- Main pump................. 324 bar (4,700 psi)- Auxiliary pump ......... 190 bar (2,800 psi)- Secondary pump* … 207 bar (3,000 psi)

Max. flow- Main pump................. 272 l/min (72 gpm)- Auxiliary pump .......... 125 l/min (33 gpm)- Secondary pump*........ 95 l/min (25 gpm)

*Note: This is the secondary pump pressure andflow on the standard CS3001. The drill mayhave a different secondary pump if themud/water pump is different than the standardFMC W1122BCD. See the addenda sheets(section 18), parts list and hydraulic schematicfor the drill.

Options

• Spin-Out Tool for mechanized rod make-up and break-out

Depth Capacity Coring*

B Wireline ………………….. 2,360 m (7,740 ft)

N Wireline .......................... 1,830 m (6,000 ft)N Wireline – Upset Ends...... 2,120 m (6,950 ft)H Wireline ............................ 1,200 m (3,930 ft)P Wireline................................ 830 m (2,720 ft)* For vertical, straight, water filled hole

Drillhead RPM and Torque Ratings at max. &min. displacements:

-At rotation pressure of 4,300 psi-Max displacement of 80 cc-Min di splacement of 62 cc

RPM Torque Nm (ft lbf )

Gear Max Dis-placement

Min Dis-placement

Max Dis-placement

Min Dis-placement

4th 1,300 Limited

to 1,300843 (622) 653

(482)

3rd

759 980 1,449(1,069)

1,123(828)

2nd

412 532 2,671(1,970)

2,070(1,527)

1st 182 254 5,587

(4,121)4,329

(3,193)

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5.3 Dimensions

Dimensions (in mm) are subject to change. If required, consult with factory to get dimensions

certified.

Fig. 5.4 Shipping Dimensions – Elevation

Fig. 5.5 Shipping Dimensions – Plan View

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Fig. 5.6 Truck Mounted Drill in Transport Position - Elevation

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6 Design Features

Design features are described for the main drill components: mast and feed frame, rotation unit, crownblock, control console, wireline winch, main winch, hydraulic tank and optional spin-out tool.

6.1 Mast and FeedframeThe 6 m (20 ft) pull mast is a single piece weldment which is stress relieved and straightened afterwelding. The feedframe section of the mast uses a 3.3 m (11 ft) stroke, direct acting feed cylinder.The drillhead carriage is guided by rollers. This design gives maximum drillhead pulling efficiency(minimum friction).

The mast is raised by two mast lift cylinders equipped with hard-plumbed counterbalance valves. It isheld in the drilling position by two short telescopic backstay legs which are pinned in position

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6.2 Rotation UnitThe rotation unit hinges sideways to clear the hole. It consists of a variable speed bent axis hydraulicmotor for maximum efficiency, a four speed transmission, a transfer case with a heavy duty chain and

a P size hydraulic chuck. The drive chain in the transfer case can be adjusted if required. The fourspeed transmission and transfer case are pressure lubricated.

6.3 Crown BlockThe crown block is equipped with large 30 inch sheaves (grooves for 3/4” rope) running on bearings

which are remotely lubricated from drill level. A block limit switch, that prevents the hoisting plug frombeing pulled into the crown block, is standard. Use fall arrest and fall restraint equipment whenaccessing the crown block

Fall arrest and fall restraint equipment must beused whenever the vertical drop exceeds 3 m

(10 ft.). Follow instructions for the proper useand maintenance of this equipment(instructions are supplied with the equipment).

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6.4 Control Console

The control console is compact for improved visibility of the drill deck for the operator. It ishydraulically adjustable in and out to allow improved ergonomics as the drill angle changes. Therotation control has a neutral switch which prevents engine starting unless the control is in neutral.The remaining controls (main winch, wireline winch and fast travel) have neutral locks as standard toprevent accidental movements.

6.5 Wireline Winch

The high capacity wireline winch is equipped with a direct drive hydraulic motor, levelwind and parkingbrake. The winch is equipped with a load holding counterbalance valve. The parking brake is a wet typeusing case drain fluid from the motor.

It is necessary to use different drive chain kits for the levelwind drive depending on whether 4.7 mm(3/16 in) or 6.3 mm (1/4 in) wireline rope is used.4.7 mm (3/16”) cable: Drive sprocket A/C # 3760009249 (11T), chain A/C # 37600086176.3 mm (1/4” kit) cable: Drive sprocket A/C # 3760009210 (14T), chain A/C # 3760009128

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6.6 Main WinchThe main winch is designed to operate with single layer of 19 mm (3/4 inch) diameter rope. The 6 m

(20 ft) pull rods are run out.

The main winch is equipped with a top pressure roller for improved rope management. The pressureroller is equipped with 2 limit switches. One limit switch signals that three or fewer wraps are left onthe drum (there should always be a minimum of 3 wraps on the drum). The other limit switch signalsthat the pressure roller is higher than for a single layer of rope). This informs the operator that therope is crossing which can kink and/or damage the rope. Both limit switches sound the audible alarmand a winch indicator light lights up in the control console to let the operator know that one of themain winch limit switches is triggering the audible alarm.

The winch is equipped with a continuously variable, bent axis, piston motor. This allows the mainwinch speed to be increased by up to 58% when the rod string load is reduced as the rod string ispulled out of the hole. The winch motor displacement control should be adjusted so the main winchhydraulic pressure is maintained at 297 bar (4,300 psi) as long is there sufficient load on the hoist.

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6.7 Hydraulic Tank

The hydraulic tank is equipped with a combination sight glass/thermometer and a combination low oillevel/high oil temperature switch.

If the oil level drops below the level of the sight glass or the temperature increases to over 80°C (176° F), the audible alarm will sound and the oil level or oil temperature indicator light in the electricalpanel will light up. An adjustable timer will then shut the engine down in about 30 seconds (time isadjustable). This will prevent hydraulic system damage and give the operator time to safeguard thedrill hole (e.g. pull back the rods, stop rotation and flush the cuttings out) before the engine stops.

The indicator light (for the fault which triggered the alarm) will stay lit to tell the operator which faultoccurred. The indicator light can then be cancelled with the reset button (see section 13.1)

The tank is pressurized with 0.55 bar (8 psi) air from the engine mounted compressor for high altitudeoperation. Two breathers mounted on the tank filter incoming air and limit max tank gauge pressureto 0.68 bar (10 psig).

The main return filter is mounted in the top of the tank.

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6.8 Mechanical Guards

Mechanical guards are supplied for the following locations:-Perimeter guards (4 pieces) restrict access to the engine (turbo side), main winch and wireline winch-Hinged drill rod guard at the bottom of the mast-Guard over foot clamp actuator arms

6.9 Optional Spin-Out Tool An optional spin-out tool is available to make and break the rod joints when tripping into and out ofthe hole without using the chuck or a pipe wrench. See Section 16 for details

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7 Controls

7.1 Main Control Panel (Pilot Operated)

Figure 7.1 CS3001 Main Contro l Panel

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7 Controls

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7.1 CS3001 Main Control Panel - Pilot Operated (cont’d )(Numbers refer to Balloon Numbers in Fig. 7.1)

The following acronyms are used in this section:

CCW or ccw means counterclockwiseCW or cw means clockwise

1. Light Switches- Control console and decklighting.

2. Pull Down Pressure – Controls pressure onpulldown side of feed cylinder. CWrotation increases pull down pressure.

3. Feed Rate – Controls feed rate. CCW

rotation increases feed rate.

4. Slow Feed Direction – When the lever islowered, the drill head will feed into thehole. When the lever is raised, the drill

head will raise.

5. Head Opener Cylinder – Swings drillheadopenhydraulically

6. HydraulicChuck

Control – Opens the hydraulic chuck when thelever is lowered. When the lever isreturned to the central position, the chuckis closed and grips the drill rod.

7. Emergency Stop Button – Drains the mainpump load sense line to tank, thusstopping functions powered by mainpump. Also shuts engine down. Pull out toreset.

8. Main Winch Control – Controls the directionand speed of the main winch.

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9. Fast Travel Control – Controls the fast travel

speed and direction of the drillhead.

10. Wireline Winch Control – Controls thespeed and direction of the wireline winch

11. Rotation Control – Controls the speed anddirection of the rotation motor. This controlmust be returned to neutral before theengine can be started

12. Mud/Water Pump Speed Control –Controls the speed of the mud/water

pump.

13. Water Pressure Release – Allows water

pressure in the drill string to be released.

14. Main Winch Motor Control – Controls themain winch motor displacement. Turningthe knob counter cw decreases motordisplacement (torque) and thereforeincreases speed.

15. Engine Speed Control – For Tier I Dieselengine only. For Tier II and III engines, theengine speed control is in the EngineControl panel See Manual Section II –Diesel Power Unit, for details

Do not use wireline hoist for generalservice since speed is too high.

16. Winch Brake Release – Move up to applybrake and down to release brake on main

winch.

17. Foot clamp – Opens and closes thehydraulic foot clamp.

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18. Thread Compensation – Middle position is

for normal drilling. Put in upper position tocompensate for drillhead weight on thethreads for both make (drillhead movesup) and break (drillhead moves down)operations. Put in lower position to floatdrillhead. The adjusting knob behind thedirectional valve adjusts the force used tocompensate for the drillhead weight formake and break.

19. Mud Mixer Speed – Controls flow to themud mixer.

20. Mud/Water Pump Hi/Lo Speed – Setsmud/water pump motor to hi or low speed.

21. Make /Drill Pressure – Selects max

rotation pressure as pump compensator(drill setting) or a preset pressure for rod

joint make-up (adjustable at the back ofthe console to suit rod size).

22. Hydraulic Tank Pressure Gauge –Indicates hydraulic tank charge pressure.Do not operate the drill when pressure isbelow 0.3 bat (4 psi).

23. Auxiliary Pump Pressure Gauge –Indicates the system pressure in theauxiliary pump circuit.

24. Water Pressure Gauge – This gauge is

connected to the mud/water pump outletand indicates the mud/water pressure.

25. Main Pump Load Sense Pressure – Givessystem pressure in the main pumpfunction currently being used (main winch,fast travel, wireline or rotation).

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26. Engine Control Panel (not shown) -Contains key switch, throttle control,tachometer, and other engine monitoringgauges.

27. Audible Alarm (not shown) - Providesaudible warning for low oil level & high oiltemperature, main winch ropemanagement (see section 6.6), operationof secondary console controls (hyd jackmovements, mast raising etc.).

28. Rotation Motor Displacement Control –Controls the rotation motor displacement,and is continuously variable during drilling.Turning the knob cw decreases motor

displacement and therefore increasesmotor speed. For given rod torque, therotation pressure will be increased.Turning the knob ccw increases the motordisplacement and therefore decreasesmotor speed. For a given rod torque, therotation pressure will be decreased.

29. Spindle Tachometer – Provides the chuckrpm.

30. Flow meter – Provides mud/water pumpflow by measuring mud/water pump rpm.

31. Pulldown Pressure Gauge – Shows

pressure on the pulldown side of the feedcylinder. A calibrated decal ring istranslates the pressure to feed cylinderpulldown force (in pounds).

32. Holdback Pressure Gauge – Showspressure on the holdback side of the feedcylinder. A movable calibrated decal ringcan be used to indicate the net bit force.

33. Circuit Breaker – Provides protection ofmain electrical control panel.

34. Spin-Out Tool (Optional) – Allows user tomake or break rods

35. Spin-Out Tool Torque Adjustment –Raises or lowers Spin-Out Tool (UDRSafe-T-Spin) make-up torque.

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36. Pressure Gauge – Shows make-uppressure applied to the Spin-Out Tool

37. Rod Lifter – Lifts the rod to lineup with thechuck centerline.

38. Test Button for Audible Alarm (not shown) –Used to test audible alarm

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7.1 Engine Control Panel

The drill can be equipped with a number of different engines depending on customer requirements.Information on the engine control panel is contained in Section II of the Drill Manual

7.2 Secondary Control Panel

1 8 7 6 5 4 3 2

Fig. 7.2 CS3001 Secondary Control Panel

6. Mast Raise – Raises and lowers mast1. Selector valve – Directs hydraulic oil to eithermain control panel or secondary control panel(prevents inadvertent movement of set-upcontrol while drilling)

7. Mast Slide – Slides mast so mast bottom can

be supported on ground.

2, 3, 4, 5 Hydraulic Jacks – Controls jacks.Locking pins must also be used.

8. Console Extend – Extends/retracts console

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8 Diesel Engine Start-Up

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Always fol low the Safety Instruc tions in Section 2.

Before starting the diesel engine, certain checks and measures must be carried out to prevent accidents,unnecessary stops or breakdown. Some of these measures must be carried out regularly as a part of theCS3001 Maintenance Schedule - see Table 11.1.

The following start-up information applies to all diesel engines – however the pictures are for theCummins QSC 8.3 litre engine and will be only representative for the other engines. Specific Informationon the engine installed on the drill is included in Section II of the Drill Manual – Diesel Power Unit

8.1 Pre-StartCheck that all controls are in neutral position. Check that none of the emergency stop buttons are

depressed. E-stop buttons are located on the main control panel, secondary control panel, on right side ofdrill and on the helper’s platform (if drill equipped with optional rod rack)

8.1.1 Check the oil level in the diesel engine

• fill when necessary

8.1.2 Check coolant level

• fill when necessary

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8.1.3 Check the engine air intake filter.

• Clean or replace cartridge. Remove coarse particles daily at X

X

8.1.4 Check oil level in hydraulic oil tank.

• Use only hand pump to add hydraulic oil when required

Temperature and Level gauge Hand Pump for filling

8.1.5 Check fuel level.

• Top up before beginning of each shift.

Filler Cap Level Indicator for Fuel Tank.

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8.1.6 Activate Battery Disconnect switch Q1. Press in and turn in clockwise direction.

Q1

8.1.7 Starting instructions vary between the different engines. See 2. Engine Control Panel Starting

Instructions, which can be found in Manual Section II – Diesel Power Unit .

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8.2 Engine Start

8.2.1. After starting the engine, check that none of the indicator lamps is lit when the engine is running.If any lamp remains on, switch off the engine, investigate and remedy

8.2.2 Check the oil temperature on the combined temperature and level indicator mounted on the oiltank. If the temperature is below +20°C, let the engine run a few minutes until this value isreached before activating any control levers.

8.2.3 Check that the tank pressure is 0.55 bar (8 psi) to prevent pump cavitation at high altitude.

Hydraulic pumps will cavitate at highaltitude if boost pressure fails.

8.3 Display Parameters

When starting up in cold weather, (below+ 5°C ), run engine at 1000 rpm until the enginetemperature is about +10°C.

8.3 Engine Shut-Down Allow the engine to idle for a few minutes before switching it off. This particularly applies when the rig hasbeen operating for lengthy periods.

The diesel engine should only be shutdown directly from its operating rpm inthe case of emergency.

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9 Drill Set-up

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9 Dri ll Set-Up

Always fo llow the Safety Ins truc tions included in Section 2 and speci fically those insection 2.3 for Moving The Drill and section 2.4 for Setting Up The Drill

It is the responsibility of the owners,operators or drivers, to ensure that thisvehicle meets all and any highwayregulations for road passage used by

this vehicle. Liability as a result of failureto comply with road/transport regulationsis the responsibility of the Owner and not

Atlas Copco or its employees.

9.1 Start -Up

Before engine start, ensure that the checks to be done each shift in Table 11.1 – CS3001 MaintenanceSchedule, have been completed and that all controls are in the neutral position.

With all checks made and systems warmed up, move throttle to high engine speed to begin operation.The engine and all systems are designed to operate at 2100 rpm.

Check Hydraulic tank pressure. Pressure should be 0.55 bar (8 psi).

Do not operate this drill if this pressure is

below 0.3 bar (4 psi).

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9.2 Secondary Controls

The secondary controls operate the four jacks, mast raise, mast slide and console retraction.The selector valve at the left side of the secondary control console directs hydraulic oil toeither the secondary controls or the main control console. This feature prevents accidentalmovement of the secondary controls when operating the main control console.

Establish and use a standard means of communication between all drill personnel. Remainin eye contact with each other where possible. The CS3001 drill is provided with an audiblealarm (beeper similar to a truck backup warning device) that is activated when secondarycontrols are operated. Stand clear of jacks, mast and main console when the audible alarmsounds when operating the secondary controls.

Selector Valve A/C # 3760009862

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9.3 Levelling the Dril l

Ensure that drill is levelled on stableground and pins are in place. Followguidelines in section 9.6.1 & 9.6.2

– Precautions Required for GroundConditions

Level the drill using the 4 levelling jacks located

at each corner of the machine. Controls forthese jacks are located in the secondary controlpanel, at the left rear corner of the drill deck. Pinall 4 legs with the safety pins provided - safetypin A/C # 3760010587

Check hole alignment visually only. Do notcheck for hole alignment using a finger(fingers have been lost doing this!).

Inspect footings every shift. Watch forchanging conditions due to weather /environment.

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9.4 Operator’s Platform

Attach operator platform with four ½”-13 NC x 5”

long grade 8 bolts and nuts. Torque to 107 ft/lbs.(145Nm). Platform can be adjusted up or down tosuit drillers needs.

9.5 Mast SlideSlide mast down using the mast slide lever locatedin the secondary control panel section 9.2. Whenmast is in desired position, pin mast to mastsaddle with two pins – A/C # 3760010588.Mast must always rest on the ground, usingblocking if required. (Picture shownhas 2 bolts to secure mast to saddle forshipping reasons. Pins are shipped with drillfor customer.)

Do not operate the drill without themast lock pins in place

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9.6 Ground Support & WindConditions

Stability Precautions

The CS3001 with the 20 foot pull mast in the raised position is stable under most operating andenvironmental conditions. This section describes some environmental and abnormal operatingconditions which can cause sudden motion or upset of the drill and what the operator can do tosafeguard against this and reduce the risk of personal injury or property damage. The environmentalconditions considered are ground conditions and wind. Earthquakes and hurricanes can also causesudden motion or upset of the drill but these are not considered here.

9.6.1 Precautions Required For Ground Condit ions – Jacks

Before setting up the drill, check the ground conditions. If the ground is soft enough, it can yield underthe jack and cause misalignment of the drill or in extreme cases tilting and upset of the drill. Also the

ground should not be sloped more than 1 in 10 in any direction.

Where the ground is not hard enough to support the standard jack foot, jack pads, shown in Fig 9.1, ora stronger support such as a timber or concrete pad must be used. The fabricated jack pads in Fig 9.1are available from Atlas Coco as part 3760012873. Also fabrication drawings for this part are availableupon request.

Figure 9.1 Jack Pad 3760012873

As a general guide, the cut-off ground soi l strength between using the standard jacks and 0.5 m (2 ft)diameter jacks pads is a sub grade modulus reaction of 80,000 kN/m3, and the cut-off soil strengthbetween the jack pads and a timber/concrete platform is 48,000 kN/m

3. The soil bearing ratings shown

here are based on a standard 76 cm (30 in) disc test. A civil engineer or geologist can do a soil test toobtain the ground rating. Suitable soils are typically as follows:

Standard jacks: hard, rocky ground, gravel, gravel clay, well graded sand

Jacks with 0.5 m (2 ft) pads: uniformly or poorly graded sand, sandy clayConcrete/timber platforms: compressible silts, clays and organics

If expert advice is not available, a simple test of the soil strength can be done with a 13 cm(5 in) diameter, 5 cm (2 in) thick test disc:

• with a truck mounted drill, place the test disc under the front or rear jacks

• with drills not mounted on trucks, raise the mast to the vertical position and place the test discsunder the rear jacks.

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Check after 6 hours:

• if there is no significant sinking of the test disc, standard jack pads should be sufficient

• if disc has sunk 1.3 cm (½ in) or less, the use of jack pads is recommended

• if the disc has sunk more than 1.3 cm (½ in), a wooden or concrete platform is required.

The mast should always be lowered so that it is supported on the ground, using blocking i f required.This will prevent the deck from lifting at the front during angle drilling if the operator pulls with both thewinch and drillhead. This is an abnormal operating condition, but could be done by an operator trying tofree a stuck drill rod. The closer the drilling angle is to 45 degrees, the more important a solid supportof the end of the mast becomes.

The operator must also be aware that ground conditions can change in the case of prolonged rainfall orimproper drainage of drilling fluid return. Support of the jacks and the mast base should be checkedeach shift.

9.6.2 Precautions Required For Ground Conditions – Mast Support

When setting up the drill, the dumped mast must always be supported on the ground by setting on afirm support and blocking as required. If the ground becomes soft enough from rain or drilling fluids toyield under the dumped mast so the mast is no longer fully supported on the ground, shear forces canbe generated in the bolted connection between the deck and the jack leg.

If pulling with maximum forces (drillhead and main winch) on drilling angles between 20 and 45degrees off vertical, and under conditions where the ground can yield under the mast base, then twooptional diagonal braces (2 x kit part # 3760012851) should be installed between the jack and the deckThis will prevent excessive shear forces in the bolted connection and possible mechanical damage. Fig9.2 shows the diagonal brace installed. For a truck mounted drill, the outer rear tires must be removedto install the diagonal brace.

Fig. 9.2 Diagonal Brace Kit Installed on Truck Mounted Drill

Diagonal Jack Braces may berequired if can lose firm groundsupport under the mast base whileangle drilling – See sect. 9.6.2

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9.6.3 Precautions Required For Windy Condi tions

Wind can exert very high forces on the drill, even upsetting the drill if the wind velocities are high enough.

The following guidelines should be followed in regards to wind conditions:-The maximum wind speed for safe operation is 20 m/sec (45 mph). Do not operate the drill if wind speedexceeds 20 m/sec (This is a requirement of EN 791, the European Safety Standard for DrillingEquipment). -If there is a possibility of wind speeds greater 36 m/sec (80 mph), the mast should be lowered.

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10 Drilling

Always fo llow the Safety Ins truc tions included in Section 2 and speci fically those in

section 2.5 for Drilling

To achieve the best results with regard to:

• high penetration

• optimal core recovery

• less deviation

• low drilling costs,

It is of primary importance that drill rods, core barrels, reaming shells and coring bits are of the right typeand quality, matched to the drill and to the prevailing rock conditions. Core barrels should have the righttype of stabilization.

Based on the core drill’s speed of rotation and chuck diameter, the CHRISTENSEN CS3001 is bestsuited to drill holes in diameter N to P (76 mm-123 mm).

Familiarize yourself with the location andoperating principals of all emergencystops. Assign responsibilities foroperation of the E-stops to the driller andhelper as applicable and complete

training on usage.

Always protect your hearing with bothear plugs and ear muffs with a totalrating of 15 dBA when working on thisdrill.

Report excessive vibration to yourmanager or foreman immediately when itoccurs.

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10.1 Before Drilling Starts

Make sure that the supply of water is adequate.

Ensure that the suction hose to the mud/waterpump in good condition, strainer clean and notclogged.

10.2 Start the Power Unit

a. Activate master disconnect switch (Q1)in Fig 10.1

b. Start the engine as described inSection II of Drill Manual - Diesel EngineUnit

10.3 Start the Mud/Water Pump

10.3.1 Water flow control knob.Controls oil flow to mud/water pump motor andtherefore water flow. CCW rotation increasespump speed, CW rotation decreases pumpspeed (Fig 10.2, pos 2.)

10.3.2 Hi/Lo mud/water pump control knob.Controls speed of mud/water pump motorbetween Lo speed position (used for drilling withlower flow, higher pressure) and Hi speedposition (used for washing the hole with higher

flow, lower pressure). (Fig. 10.3, pos 1)Turn knob cw for Hi speed position.Turn knob ccw for Lo speed.

Q1

S1

Fig. 10.1 Q1 Master Disconnect switch

Keep all guards in place and in goodworking condition.

2

• •

Fig. 10.2 Start Mud/Water Pump

1

Fig. 10.3 Select Hi or Lo Mud/Water Pump

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10.4 Adjust the Flow ofMud/Water

a. Set the Hi/Lo knob in the Lo speedposition for drilling

b. Start the mud/water pump with thecontrol knob (Fig 10.4, pos 1) at thefront on the panel.

c. Read the water flow rate on the flowmeter (Fig 10.4, pos 2) on the controlpanel.

d. Read the water pressure on the gauge(Fig 10.4 pos 3) in the control panel.

10.5 Start Rotation

Before starting rotation, select gear on therotation gear box that gives you the right rpmrange for the ITH equipment.

a. Position the drill string with the corebarrel and the drill bit about 50 cm (20in) above the bottom of the drill hole.

b. Open the foot clampc. Start the drill rotation with rotation lever.d. Adjust the rotation speed to the desired

RPM on the display.(Fig 10.5, pos 1)

The rotation speed must be adjusted loweras the hole deepens and the drilling torqueincreases so the maximum rotation pressureremains at 297 bars (4300 psi). (Fig 10.5,pos 2)

3 2

1Fig 10.4 Adjusting Mud/Water Flow

2 1

Fig 10.5 Start Rotation

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10.6 Start Dri ll Feed

a. Before the drilling operation can be

started, the rod weight must becompensated for so the actual bit forcecan be read.

b. Adjust rpm and mud/water flow, with thefine feed directional valve (Fig 10.6, pos4) in the neutral position. The pulldownpressure can be read on the gauge (Fig10.6, pos 31) and should be zero. Thepulldown force can be read on thecalibrated decal located around thegauge.

c. Turn the feed rate valve knob (Fig 10.6,pos 3) clockwise (zero feed rate

position). The holdback pressure can beread on the gauge (Fig 10.6, pos 32).

d. Adjust the calibrated ring for reading thebit force (located around the holdbackgauge) to zero at the point of theholdback gauge needle.

e. When the rod weight has beenbalanced, the drill feed can be activatedwith lever (Fig 10.6, pos 4) without anydanger that the drill string will plunge tothe bottom of the drill hole and damagethe drill bit.

f. Increase the fine feed rate knob slowlyccw until the drill bit reaches thebottom of the hole and the bit forcereaches the desired value for thechosen drill bit and formation. Thepulldown pressure may have to beincreased, depending on the current rodstring weight.

g. Do not apply more bit weight than isrecommended for the drill bit.

h. Continue drilling to the end of the feedstroke, fill the inner tube, or until you getcore blockage.

10.7 Stop Drilling

a. Stop the drill feed by moving the finefeed lever (Fig 10.6, pos 5) to theneutral position.

b. Stop the rotation by moving the drillrotation lever (Fig.10.6, pos 11) toneutral

c. It is recommended to flush the drill holefor some minutes after stopping drillingto avoid problems with cuttings andsludge especially at the end of the workshift.

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Figure 10.6 Main Console Controls

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10.8 Controlled WirelineLowering

a. To spool out rope from the wirelinedrum, push the lever slowly forward(away from you). The drum will start torotate.

1b. To increase the speed, push the leverfurther forward.

c. Always stop the winch smoothly. If thelever is dropped, the spring force willmove it back to neutral.

10.9 Controlled Wireline

Winchinga. To spool in rope onto the wireline drum,

pull the lever slowly backwards (towardsyou). The drum will start to rotate.

b. To increase the speed, pull the leverfurther backward.

c. Always stop the winch smoothly. If thewinch comes to a sudden stop it cancause a jump. This in turn can cause thecore lifter to loosen its grip on the core

and lose the core.

d. When the lever is dropped, the springforce will move it back to neutral, whereit will stop automatically.

10.10 Thread Compensation

a. Thread compensation balances theweight of the rotation unit and drill rodbeing unscrewed and prevents theweight of these components from

loading the threads when the joint isbeing unscrewed. The amount of threadcompensation should be adjusted whenstarting with a new drill rod size or alarge change in drilling angle.

b. When making the joint, the feed cylinderis disengaged through the slow feedlines. It is recommended that the helper

turns the rod in at least one full turnbefore the rest of the joint is made withthe rotation unit.

c. Turn the thread compensationadjustment screw (Fig. 10.7, pos 1) cwto increase the thread compensationforce or ccw to decrease the threadcompensation force. Tighten the lockscrew after making the adjustment.

Fig. 10.7 Adjusting Thread Compensation

Always make sure the thread compensationhas been correctly adjusted and set beforerod breaking starts. If this drillhead weightcompensation is set too low, the threads willwear prematurely and leak.

When rod threads leak, it is difficult to judgehow much flushing water is reaching the drillbit.

It is also necessary to occasionally checkthe condition and diameter of the rods beingused. Worn rods can slip in the jaws.

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10.11 Adding a Drill Rod

Note: If the drill is equipped with the optional

Spin-Out Tool, see section 17.1 for

instructions on how to use this tool.

a. Move the thread compensation control(Fig 10.6, pos 18) into “joint making”position. Rod ends can screw togetherwithout damage to the threads (feedcylinder is disengaged through the slowfeed lines).

b. Ensure the preset makeup torquepressure is set to the desired value forthe drill rod being used (select pressurefrom Tables 10.1 & 10.2). Move themake/drill pressure control (Fig. 10.6,pos 21) to “joint making” position.

c. Screw out the rotation motordisplacement control (Fig.10.6, pos 28)so motor is at max displacement.

d. When adding a drill rod, ensure that thethreads are properly engaged, by

spinning the rod in one full turn by hand,before making the remainder of the jointwith the machine.

e. To make the joint, close the chuck andstart the rotation head to rotateclockwise.

10.12 Removing a Dril l Rod

a. Move the thread compensation control (Fig

10.6, pos 18) into “joint breaking” position.Rod ends can screw apart without damageto the threads (drillhead weight iscompensated for)

b. Move the make/drill pressure control(Fig. 10.6, pos 21) to “drill” position.Screw out rotation motor displacementcontrol (Fig.10.6, pos 28) so motor is atmax displacement. Shift thetransmission to a suitable gear to breakthe joint.

c. To break the joint with the rod holderclosed, start the rotation unit to rotateccw.

d. Do not unscrew the joint fully. Leave atleast one turn of the thread engaged.When the rod is lifted out, the last threadis screwed out by hand.

Use caution when making or breaking rod joints and handling the rods.

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10.13 Water Pressure DumpValve

Dump valve (Fig. 10.6, pos 13) relieves thewater pressure in the drill string. Push the leverdown to open the valve.

10.14 Operating Main Winch

(See section 6.6 for a description of the mainwinch features)

a. To spool in rope onto the main winchdrum, pull the lever slowly backwards(towards you). The drum will start torotate.

b. To increase the speed, pull the leverfully backward (main valve passes maxflow). If winching pressure is less than297 bar (4300 psi), increase winchspeed by decreasing winch motordisplacement by turning in winch speedcontrol (Fig.10.6, pos 14). Periodicallyadjust this control to maintain winchingpressure at 297 bar (4300 psi).

c. Always start and stop the winchsmoothly.

d. Always leave at least 3 wraps on thewinch drum and keep the rope in asingle layer. The audible alarm willsound if there is less than 3 wraps onthe drum or the rope climbs on a secondlayer.

e. Use a hoisting plug that is heavyenough to pull the rope down the rod

slide when lowering

Use the main winch for raising, loweringand handling drill rods only. Do not use forgeneral service or pulling off line except

when handling drill rods.

The block limit switch is a safety device toprevent the winching plug from beingpulled into the crown block. Do not use it to

stop upward movement of the winchingplug

Monitor the condition of the main winchrope. At the first sign of wear, such as

broken strands, replace the winch rope.

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10.15 Rod Handling

There are 3 ways of handling rods when tripping rods into and out of the drill hole:

i. Using the drillhead to break/make the rod joint

ii. Using the optional Spin-Out Tool to break/make the rod joint

iii. Using the a pipe wrench above the drillhead to break the rod joint (This procedure is not recommended and is not permitted in some jurisdictions)

10.15.1 Rod Handling Using Drillhead – Tripp ing Out

Drillhead is in first gear and thread compensation control (Fig. 10.6 pos 18) is in thread compensationup position.

a. Attach main winch hoisting plug and plug extension to rod string (rod joint is locatedbetween drillhead and foot clamp). Remove any slack in the main winch rope until slackis removed and rope is slightly tensioned.

b. Open foot clamp and raise drill string until rod joint to be broken is located between chuckand rod clamp.

c. Close foot clamp and then chuck

d. Break rod joint using drillhead (drillhead is in first gear and thread compensation isengaged)

e. When joint has separated, take up the rope slack, lift drill rod through drillhead and run

out to horizontal position or stack in optional rod rack.

f. Move drillhead back to starting position and lower/guide hoisting plug extension throughchuck and repeat.

10.15.2 Rod Handl ing Using Drill head – Tripping In

Make/drill Control (Fig 10.6 pos 21) is in make setting, make up torque is adjusted to suit drill rod andtransmission gear (see Table 10.1), thread compensation control (Fig. 10.6, pos 18) is in floatposition.

a. Locate chuck in lowest position and rod joint above chuck

b. Lift rod into place with hoisting plug, connect joint and hand tighten with pipe wrench. Use

the drill rod alignment device to align the rods and prevent cross threading when startingthe joint

c. Lower rod joint between chuck and clamp, close chuck and clamp

d. Pre-torque rod joint using drillhead (ref Table 10.1). Note that rotation motordisplacement control (Fig. 10.6, pos 28) must be turned fully ccw

e. Open chuck, tension rope, open foot clamp and lower rod(s), leaving next rod joint abovethe chuck.

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f. Close foot clamp and repeat

Rod size

Gear Gear

Ratio

BT NT HT PT

RecommendedMake Up Torque

1,016 Nm750 ft lbf

1,360 Nm1,000 ft lbf

1,490 Nm1,100 ft lbf

2,030 Nm1,500 ft lbf

1 6.63 54 bar780 psi

72 bar1,040 psi

79 bar1,150 psi

108 bar1,560 psi

2 3.17 113 bar1,640 psi

150 bar2,180 psi

165 bar2,400 psi

226 bar3,270 psi

3 1.72 208 bar3,010 psi

RecommendedMake UP PressureIn Various Gears

4 1

Table 10.1 CS3001 Recommended Make-Up Torque And Corresponding Rotation Pressure BasedOn:

-Rotation motor set at max displacement of 80 cc – rotation speed controlturned fully counter clockwise-Total mechanical efficiency o f 90% for dr illhead-No allowance for inertial effects

Spindle Torque – Ft LBF4th gear 3rdh gear 2nd gear 1st gear

RotationPressure

PSI Min Disp Max Displ Min Disp Max Displ Min Disp Max Displ Min Disp Max Displ

4300 482 622 828 1,069 1,527 1,970 3,193 4,121

4000 448 578 995 770 1,420 1,833 2,970 3,834

3800 426 549 732 945 1,349 1,741 2,821 3,642

3600 403 520 693 895 1,278 1,650 2,673 3,4503400 381 491 655 845 1,207 1,558 2,524 3,258

3200 358 463 616 796 1,136 1,466 2,376 3,067

3000 336 434 578 746 1,065 1,375 2,227 2,875

2800 314 405 539 696 994 1,283 2,079 2,683

2600 291 376 501 646 923 1,191 1,930 2,492

2400 269 347 462 597 852 1,100 1,782 2,300

2200 246 318 424 547 781 1,008 1,633 2,108

2000 224 289 385 497 710 916 1,485 1,917

1800 202 260 347 448 639 825 1,336 1,725

1600 179 231 308 398 568 733 1,188 1,533

1400 157 202 270 348 497 642 1,039 1,342

1200 134 173 231 298 426 550 891 1,150

1000 112 145 193 249 355 458 742 958

800 90 116 154 199 284 367 594 767

600 67 87 116 149 213 275 445 575

400 45 58 77 99 142 183 297 383

Table 10.2 CS3001 Spindle Torque (ft lbf) For Range Of Rotation Pressures (ps i) Based On:-Rotation motor d isplacement at:

-minimum at 62 cc, displacement cont rol screwed in

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-maximum at 80 cc, displacement control screwed out-Total mechanical efficiency o f 90% for dr illhead-No allowance for inertial effects

10.15.3 Rod Handl ing Using Optional Spin-Out Tool

See Section 17.1 for instructions in using this tool. The drillhead is moved aside and not used whentripping drill rods with this tool.

10.16 Drill Rod Break-In Procedure

It is recommended that rod joints of exploration drilling rods be pre-torque to the recommended values.

Wireline drill rods are typically manufactured using conical threads, and in such a manner to allow for astand-off between box and pin when hand tightened. Because these threads are intended to be in a stateof tension while in use, closing the standoff and further pre-loading of the joint through adequatemechanical pre-torque accomplishes this.

A properly made up and lubricated tool joint reduces the likelihood of galling and wear through movementbetween mating surfaces. A properly made-up joint also reduces the likelihood of service failure fromfatigue due to cyclic bending, (tension/compression/tension).

ACEP Platinum Series wireline drill rods are surface treated on the pin thread to provide a low frictionsurface that absorbs lubricant and promotes a smooth break in and conditioning of the new rod joint,particularly during the critical first make-ups and break-outs. Proper break-in practices promote longservice life and joint integrity.

Particular attention to proper joint make-up should be exercised where one or more conditions couldcontribute to a joint running loose. Hole depth, deviation, dry holes, spin-outs from rapid deceleration,

and vibration as examples.

The recommended pre-torque values for Platinum wireline drill rods are given in Table 10.1. For moreinformation, please contact your nearest ACEP representative.

Pi e wrenches and breakout tools can cause serious in uries. Take extreme recautions.

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11 Maintenance And Servicing

11.1 General

Always fo llow the Safety Ins truc tions included in Section 2 and speci fically those insection 2.7 for Maintenance and Servic ing

The performance and reliability of the Christensen CS3001 is largely dependent on the amount of careand attention shown to it. Regular checks and inspection of wear prone components prevent breakdownsand costly downtime.

Dirt is the primary cause for most malfunctions in a hydraulic system.

Therefore:

• Always try and keep the drill clean and free from dirt and other pollutants. It is much easier todetect faults or oil leakage on clean

cs 3001

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