Operator's Instructions for

Diamond Core Drill

DIAMEC® 252 2 UK

Printed Matter No 6991 0588 01a

2
 Operator's Instructions for
Diamond Core Drill

DIAMEC® 252
These instructions are intended for operators of the Atlas Copco diamond core drill
DIAMEC® 252.
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 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 characteristics 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 1998-07

Printed Matter No 6991 0588 01a

Contents Page Contents Page

Introduction ........................................................ 4 Adjustment of speed regulation (Hydr. motor)46

Stabilizing of low rotation speed......................46
Operating safety ................................................ 5
Setting of chuck pressure .................................46
General safety advice ......................................... 6
Thread compensation and balancing of
Special safety device ....................................... 10
rotation unit ...................................................... 47
General ............................................................... 11
Adjustment of chain tension and slide
Hoisting and transport ................................... 12 shoes ...................................................................48
Changing guide sleeve in the rotation unit .... 48
Technical specifications................................. 14 Repacing wear rings, rubber sleeve and
Dimensions ....................................................... 14 jaws in the chuck................................................49
Weights ............................................................. 14 Replacing jaws and guide in the
Characteristics .................................................. 15 rod holder ......................................................... 50
Rotation unit ..................................................... 15 Adjusting pressure compensation of the
Rod holder ........................................................ 15 main- and service pump................................... 51
Capacities and torque diagram ....................... 15 Starting-up after adjustments ......................... 52
Sound noise levels ........................................... 16
Power units ....................................................... 16 Additional instructions .................................. 53
Assembly and manoeuvring instructions
Optional equipment and accessories ......... 17 for wire line hoists ............................................53
Attaching water collector ................................ 54
Design features ................................................ 21
Trouble shooting ............................................. 55
Controls .............................................................. 22
Documentations Feedback.............................61
Manoeuvring ..................................................... 25
Pre-start procedure .......................................... 25 Principle drawing for hydraulic lines ......... 62
Start-up Electric power pack ........................... 26
Start-up Diesel power pack ............................. 27 Hydraulic diagram .............................................63
Stopping Diesel power pack ........................... 27
Electrical wiring diagram (45E) ..................... 64
Setting up for drilling .................................... 28
Electrical wiring diagram (40DT) .................. 65
Stand mounting (Underground) ..................... 28
Stand mounting (Surface drilling) .................. 29
Column mounting (Underground) .................. 30
Setting up the Diamec 252 using turn table
and worm gear ................................................. 32
Displacement of the feed frame when
assembled on stand ......................................... 33
Surface set-up with Diamec 252 on skid .........34
Underground set-up with Diamec 252 on skid .
35

Drilling .................................................................36
Rod jointing .......................................................37
Withdrawing the drill string ............................ 37
Rod breaking .....................................................38

Maintenance ......................................................39
General .............................................................. 39
Periodic maintenance .......................................40
Daily safety check.............................................. 43
Lubricant recommendations ........................... 44
Hydraulic oil filters ............................................45
Changing hydraulic oil .................................... 45

4
 General safety advice

Introduction

This instruction book is part of the complete delivery of your new diamond core drill DIAMEC®252. It
offers basic information on features and handling of the unit and contains advice and measures
necessary to keep the rig operational. It does not, though, replace thorough training of operator and
helpers.

It is your responsibility to make sure that all personnel assigned to this DIAMEC®252 unit, -before
carring out any kind of work,- have the the skill necessary for the safe operation, service and
maintenance of the unit. 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 information is divided into the following chapters

Section 1: Operating safety

Section 2: General and technical specification.

Section 3: Operation

Following additional information available, relevant for operation of the DIAMEC® 252 drill rig.

Equipment Printed Matter Order from

DIAMEC® 252
Operator’s manual 6990 0588 01a Atlas Copco Craelius Printed Matter
stock
Spare parts list 6990 0589 50 Atlas Copco Craelius Printed Matter
stock

*) Address: Atlas Copco Craelius AB

Att: Surinder Kalra
S-195 82 Märsta, Sweden

Fax: +46 (8) 591 187 82

5
 Operating safety.
Dear operator,

Before taking 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 equipment well
maintained are the key factors to safe operation. This instruction book is no replacement for a
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

General safety advice.

Intended use:
The diamond core drill DIAMEC® 252 is intended for exploration and investigation drilling above or
below ground, as well for drilling grouting holes.

Any use going beyond this shall be considered "not intended use". The manufacturer is then not
liable for damage incurred as a result. Unintentional use shall be at the owner's risk. Proper use also
includes observing information in operation-, service-, and maintenance books as stipulated by the
manufacturer.

The DIAMEC® 252 should be run, serviced and repaired by personnel properly trained for their task.
These personnel must have sound knowledge about hazards in their respective profession.

General safety regulations must be observed. Personnel should be aware of dangers resulting from
abuse of drugs and alcohols as well as effects of medicenes legally prescribed, or mixture of any of
them. The manufacturer is not liable for any damage caused by unauthorized alternations made to
the unit.

Organizational measures:
1 The diamond core drill DIAMEC® 252 shall be operated only by personnel who have undergone a
theoretical and practical training on the rig. Particular emphasis shall be laid on safety precautions.

2 Keep this instruction book as well as the other books listed in chapter "Separate Instruction Books"
available on the rig at all times.

3 Always use personal protective equipment, as required by circumstances or demanded by

regulations.

4 If, during operation of the unit, any abnormal action in the safety or operational systems is
observed; the unit should be stopped and the problem be investigated and remediated.

5 Warning signs must be kept easily legible at all times. Damaged signs should be replaced
immediately.

6 The daily safety check, as described in this instruction, must inevitable be carried out as well as
the maintenance measures described in the Periodic maintenance (Page 40).

7 Hydraulic and electrical systems are of a complex nature - and can cause injury or damage if not
handled with care. Repair and service shall be carried out by personnel with documented
experience for these systems.

6
 Operating safety

8. Welding repairs should only be carried out by an authorized welder in order to meet the high
standards that apply to Atlas Copco products. Special attention must be given to components
which could cause injury or serious damage should be observed.

9. After repair make sure that the rig has been inspected and approved by the proper authorities
before being brought back to normal operation.

10. Never make alterations or modifications to components of the unit, particularly to the safety
systems, which might resulting hazardous consequences. The manufacturer should be informed
for approval of any modification done to the unit.

Operation and maintenance.

1. In addition to this manual you should also have a good knowledge of generally recognized safety
and accident prevention regulations. If you follow the regulations you stand a better chance of
accomplishing your task without harm to either man or equipment.

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 29 - 37 for
further information.

3. Various safety devices are built in to the system of the rig for your personal safety. These devices
must be checked at least once beginning of each shift to ensure that there are in full working
order. The equipment, should not be used unless safety checks and maintenance has been
carried out according to the schedule.

4. Operators and helpers should wear helmets, with ear defenders when called for, safety glasses,
safety shoes, gloves and suitable clothing. Loose fitting clothing and jewellery can become
caught in the moving parts of the machinery, causing serious injury or even death.

5. Check the surroundings. During drilling 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. Don't drive the rig into a
dust cloud. Check the travel route if you are unsure of the safety of the ground.

6. Set control levers and switches to the neutral positions prior to starting up, otherwice the rig
could start uncontrollably. Some of the levers are spring-loaded so that the operation will stop
once released. This is part of the safety system. Never lock these levers into operating position
using strings, sticks or similar. The unit should always be started from the control panel. The
operator should ride on the rig during tramming. Any attempt to move the rig while walking
beside it could result in injury.

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.

8. Shut the rig down for refuelling. Fuels must be handled with care, 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. (Do not use absorbents or
dig out 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, expansion of the fuel as the temperature increases later in
the day. may cause fuel to spill from the tank. Tank breathers clog easily if the level of fuel is to
high.

9. Never leave the rig unattended with the engine running. Carry the ignition key with you.

7
 Operating safety

10. Use extreme caution while handling starter batteries. Wear gloves and protective glasses when
servicing batteries. The batteries contain strong acid which can seriously burn eyes and skin, the
damage cloth, insulation and metal. First aid in case of acid in the eyes: wash with plenty of clean
water and seek hospital. Disconnect earth cable from battery before carrying out service in the
electrical system. The battery gas is explosive ! Never use matches when checking the acid level.
Be careful using iron tools near the battery, a spark might set off an explosion. Read battery
manufacturers manual for further information.

11. Hydraulic oils are poisonous. Use eye protection and gloves. Hydraulic oils, like fuel, must be
treated in compliance with safety- and environmental regulations.

12. Before any repair or service is carried out on the rig's hydraulic or water systems, make sure the
engine is stopped and systems are depressurized.

13. Be very careful while tracing down leaks in pressurized systems. Hydraulic oils, water or air being
under pressure could penetrate under the skin and cause complicated injuries or infection. If this
should happen, see a doctor at once.

14. Dispose of engine oils, hydraulic oils, fuels, filters and acids in a safe way according to
environmental protection regulations.

15. Avoid the use of cleaning agents containing solvents like carbon tetrachloride. There are
environmentally far better alternatives now available on the market.

16. Use only authorized parts (Atlas Copco parts). Any damage or malfunction caused by
the use of unauthorized parts is not covered by warranty or Product Liability.

17. Any warranty for work performed, only covers original company name and
components and work performed by authorized personnel.

8

Underground hazards
In a modern community a number of utilities are
buried, such as electrical cables, natural gas
lines, water lines, sewer lines, pipes for industrial
chemicals, liquids or gases, storage tanks, fibre
optic and standard communication lines.
These installations can be hazardous and must
be ilocated and identified before drilling is
commenced.
Striking a utility can cause personal injury from
explosion, electrocution, fire, exposure to
hazardous materials or exposure to laser light.
(Light used in fibre optic cables can cause
permanent vision damage. Don't look into the
end of a fibre optic cable.)
You are personally responsible for any injury or
material damage caused by drilling if you haven't
taken proper measures of precaution. You should
understand the local regulations on excavating
and trenching. Responsibility should be defined;
client, proprietor, contractor, operator or third
person. The responsible party should call in a
competent person who will identify and eliminate
the jobsite hazards. This will include notifying all
utility companies who have underground
services in the area. The companies must locate
and mark their installations, minimum 10 meters
each side of the planned bore path. For additional
security inspect the area in order to localize any
neglected installation.
Check signs which might indicate buried utilities.
Look for meters for gas, oil, water etc. Manholes,
junction boxes and light poles indicate some kind
of underground lines. Use a metal detector when
you suspect to find unmarked tanks or barrels
containing contaminated waste. Changes in
colour and level of the ground indicate previously
dug threnches.
Use correct safety equipment relevant to the
conditions encountered.
Prior to drilling near an identified installation
which can constitute a danger, expose the object
along the bore path by careful hand digging.
Monitor the progress and carefully guide the
bore around the dangerous object maintaining a
safe distance. Electrical cables and gas lines
should be shut down during drilling. After drilling
is completed, these installations should be tested
before operation.
Electricity does not follow the path of least
resistance. It follows all paths to some degree, to
ground. The drill string is an excellent conductor
which will conduct electric current to the drill rig
and anything in contact with it. People have been
injured or killed by severe shock from drilling into
power cables.
Operating safety
The level of injury depends on the current
flowing through the body. Voltage is not
necessarily a measurement of the danger.
Accidents have occurred in installations with a
voltage as low as 25 -30 volts. 30 % of the
electrocution in the industry has been in
connection with 240 - 400 V. systems.
Small amounts of current through the body
cause dangerous shock. If the path runs through
the chest and heart, very low currents can cause
severe injury or death. (Less than 0.05 A
cancause painful chock and respiratory paralysis.
0,15 A can cause ventricular fibrillation, probable
death and 0,2 A can cause severe burns, internal
bleeding; death. The electric current flowing
through a normal household bulb is around 0,5 A
!!!)
Regard the drillsite as a danger zone. Always
wear safety garments. Use electrically insulating
boots and gloves when installing anchors. Check
manufacturers recommendations for the use of
safety equipment; replace damaged items.
Anchors should never be connected to live power
lines. Don't touch pins on signal clamps.
Expose lines by hand digging.
Induced current is dangerous. Even if the drill
string isn't in contact with a cable, electrical
currents may flow through it.
Keep a safe distance from overhead power lines.
Don't spray fluids near or on electric power line.
Hoses on the rig (hydraulic-, air- water- etc. ) can
conduct electricity if the tool strikes an electrical
cable.
If you strike an electrical line, indicated by power
failure anywhere near the job area, smoke,
explosion, arcing electricity, or if warning device
alerts;
a. Don't step off grid mat. If you stand on the
ground, stay put and don't touch any
equipment.
b. Alert people in the area, order them to stay
out of the immediate area and not
to touch any of your equipment.
c. If the strike occurred during drilling, retract
downhole tool. Don't attempt to break any
rod connection. Don't add or remove any
drill rods.
d. Ask your supervisor to contact the utility
company in order to switch off the system .
9
 Operating safety

Special safety device On the rig and in the manuals you will come
across the following warning signs.

DANGER This sign warns for immediate

hazards,which, when ignored, will
inevitably cause serious personal injury or
death!

WARNING This sign warns for hazards or unsafe

practices which, when ignored, could lead
to serious personal injury or death

CAUTION This sign indicates hazards or unsafe

practice, which could lead to minor
personal injury or damage to equipment.

IMPORTANT ! This sign is used for recommendations such as

how to run the unit efficiently, economically and
in compliance with environmental regulations.

Following signs are used on your DIAMEC 252 ®

Description and where the sign is located:

Lifting points ATTENTION

This sign is located where the sling ? Before starting, oil must be filled
is recommended to be attached. according to:
3716 5528 00

Location: Each corner of the skid, Lubricant Recommendations

and power unit.

Ear protectors Drain water cooler

-0°C
Ear protectors should always be When there is a risk of freezing,
worn. especially during storage of the
3716 5525 00

unit.

Risk of crush
Be aware of the risk from crushing.
3716 5527 00

Diesel fill
Location: On the diesel power unit.

3716 5526 00

10
 Fig. 1.
GENERAL
DIAMEC® 252 is a hydraulic, diamond core drill
ideal for exploration, investigation and grout hole
drilling above or below ground.
DIAMEC® 252 is extremely simple to operate. All
rod jointing and breaking-out cycles can be
effectively performed from the control panel All
the driller needs to do is lift the rods in and out of
position.
The DIAMEC® 252 can be set-up for drilling in all
directions, and is supplied with standard hoses
that enable the power unit to be positioned up to
4.5 metres distant from the drilling point..
The DIAMEC® 252 can be delivered with a electrical
power unit suitable for use in mines and tunnels,
or a diesel power unit mainly intended for drilling
on the surface
Recommendations
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.
DIAMEC® 252 features careful and correct
engineering for speed of rotation, capacity and
spindle bore and is designed for hole diameter
range extending from 36 - 60 mm (E - B), using
conventional drill rods as well as wire line. The
maximum bore of the spindle is 58 mm.
DIAMEC® 252 is the fundamental factor in a
complete core drilling programme. All the
equipment you are ever likely to need is available
from one and the same supplier. This not only
includes the hardware and comprehensive service,
but training and instruction of customer
personnel, also an important part of the product.
11
HOISTING- AND TRANSPORT
Hoisting the power units
1. Positioning a sling or similar lifting
device through the holes (See Fig. 2)

DANGER
– The sling must be dimensioned for
lifting 2 tons (Power units)
respectively 4 tons (Drill unit) with a
good safety margin. Fig. 2. Hoisting of the Power units 45E and 40DT

– Always make sure that nobody is

under or anywhere near a suspended
load.

Hoisting the drill unit

1. Position the feed frame and rotation unit
as shown in Fig. 3a/3b. This will obtain
the best possible point of balance and
centre of gravity.

Rotation unit on feed beam

2. Position a sling or similar as shown in
Fig. 3a.

Drill unit on stand/skid

Fig . 3a. Lifting of Diamec 252 feed and
2. Assemble one lift tool in each corner of
rotation unit
the skid as shown in Fig. 3b.

3. Position a sling or similar lifting device

through the holes in the lifting tools (4x).

4x

Fig. 3.b Lifting of Diamec 252 mounted on stand/skid.

1. Lifting tools (4 pcs, one at each corner of the skid)

12
 Hoisting and transport

Transportation of power unit

If transporingt with a fork truck or other
vehicle, always secure the power unit to
the vehicle during lifting- or towing
manoeuvres.
Max. towing speed: 5 km/h (3 mph)
At worksite, always carry out wedging of
the power unit wheels to prevent
unexpected movement. Transporting the power unit

Transporting of drill unit

1. See hoisting the drill unit page 12.

2. If transporing with a fork truck or other

vehicle, always secure the drill unit to the
vehicle, when lifting- or towing
manoeuvres.

Towing the power unit

DANGER
– The sling must be dimensioned for
lifting 2 tons (Power units) espectively
4 tons (Drill unit) with a good safety
margin.

– Never use a damaged rope/sling.

– Always make sure that nobody is

under or anywhere near, a suspended
Transporting the drill unit
load or within the swing radius of the
rope/sling.

Transporting the drill unit (mounted on skid)

Fig. 4.

13
 Dimensions and weights

TECHNICAL SPECIFICATIONS
A
Drill unit B C

Dimensions in mm (in) D

Version 850 1600 Skid

A 1940 2690 2400

(76) (106) (95)
B 1540 2290
(60) (90) F
E
C 170 170
(7) (7)
D 520 520
(20) (20)
E 420 420 800 Fig. 5. Drill unit
(16) (16) (32)
F 1160 1160 1440
(46) (46) (57)
Weight in kg (lb)
336 370 900
(725) (805) (1942)

Power units Fig.6. Drill unit on skid

Dimensions in mm (in) Fig. 7.

40 DT 45 E

A 2190 1850 H C F
(85) (73)
B 2020 1600
(78) (63) B D
C 890 820 A E
G
(35) (33)
D 800 595 Power unit 45 E
(31) (23)
E 975 975
(38) (38)
F 1110 1000
(43) (39)
H
G 3400 2700 C F
(132) (106)
H 1380 1260
(54) (50) B
A D
Weight in kg (lb) G E
810 615
(1782) (1353) Power unit 40 DT

14
CHARACTERISTICS
Feed force
Max. pull ........................................................... 33 kN
Max. push ..........................................................43 kN

Feed rate during rod running

out ............................................................. 1.0 m/s
in ...............................................................0.75 m/s

Rod handling capacity, inclusive rod,

pick-up and jointing/breaking .................. 20 m/min

Rotation unit
Spindle inner diameter: .................................58 mm

Speed range at max. output ...........550-2200 rpm

Torque. max. ..................................................570 Nm Fig. 8. Speed / Torque diagram
Chuck, max. axial holding force ................... 100 kN

Rod holder
Max. inner diameter ................................. 60.5 mm
Holding force .................................................... 12 kN

Capacities
Drill rod size Hole size Approx. drilling depth

Alu 43 46-A 650 m

Alu 53 56-B 425 m
Compolite 43 46 475 m
Compolite 53 56 360 m
Steel 42 46 400 m
Steel 50 56 225 m
AW A 325 m
BW B 275 m
AK (AQ) A 350 m
AGM A 420 m
BK (BQ) B 275 m
BGM B 330 m

15
 Characteristics

Sound noise level

Drill unit with diesel power unit

Sound power emission ..................... 100 dB (A)
Sound pressure level at the
Operator’s position .............................. 85 dB (A)

Drill unit with electric power unit

Sound power emission ..................... 100 dB (A)
Sound pressure level at the
Operator’s position .............................. 84 dB (A)

WARNING
Ear protectors must be used by the
operator and helpers when operating the Fig. 9. Power unit 45 E
rig.

Power units
Power units with variable hydraulic pumps and
separate independent hydraulic circuits for
rotation and feed thrust. Prepared for auxiliary,
hydraulically driven flush pump.
Complete with hydraulic tank, filters, oil cooler
and start box.

PU 45 Electric
Asynchronous electric motor
Motor rating .................................45 kW at 1450 rpm

Max pressure
- main pump................................................... 260 bar
- service pump .............................................. 210 bar Fig. 10 . Power unit 40 DT

Max. flow 1 2
- main pump.................................................. 75 l/min
- service pump ............................................. 29 l/min

PU 40 DT
Powered by a Deutz turbo diesel, type BF4L 913
Motor rating ............................... 68 kW at 2200 rpm

Max pressure
- main pump................................................... 260 bar
- service pump .............................................. 210 bar

Max. flow
- main pump.................................................. 75 l/min
- service pump ............................................. 44 l/min

1. Service pump
Additional cooler 2. Main pump
Air oil cooler (Please contact your nearest Atlas Fig. 11. Hydraulic double pump
Copco representative).

16
OPTIONAL EQUIPMENT AND
ACCESSORIES
Column assembly (Fig. 13)
DIAMEC® 252 can also be column mounted. This is
an advantage in mine drifts where space for
setting-up the equipment may be cramped or
limited. Use of the column enables simple and
stable tensioning of the drill unit against the roof
or floor of the drift. Column-mounting is best
carried out when several holes are to be drilled at
different angles, from one and the same set-up in
a fan-shaped pattern.
Holes for expansion bolts can also be drilled with
the unit suspended on the column assembly.
The single column is made from 3” tubing and is
available in two lengths:

Working range
2 to 2.8 m (6.5 to 9.2 ft)
2.6 to 3.4 m (8.5 to 11.2 ft)

Water collector for upwards directed

drilling (Fig. 12)
The water collector, can be mounted against the
rock face in order to collect return flush water and
cuttings during upwards directed drilling. Fig. 13. Column mounted DIAMEC® 252

Fig. 12. Water collector

Turntable (Fig. 14)

By using the turntable, which mounts to the skid
frame, the drilling unit can be swung 360° 1
horizontally in relation to the skid frame.
2 3
Worm gear (Fig. 14) Fig. 14. DIAMEC® 252 mounted on a skid with
Between the feed bracket and the stand yet turn table and worm gear (Optional)
another link is available . In order to give 1. Skid
movement in a vertical plane perpendicular to the 2. Stand
first, a worm gear can be mounted. The worm 3. Turn table
gear is operated by a handle. 4. Worm gear

17
 Optional equipment and accessories

Hinge set
Both rotation unit and rod holder can be mounted 2
on a hinge set to allow free passage of rods and
tubes larger than the inner diameter of the rod 1
holder or rotation unit. If either the rod holder or
rotation unit is hinge mounted the other should
also be hinge mounted in order to make up for the
increased height. The rotation unit hinge can, if
required, be replaced by a spacer.

Part numbers
1. Hinge set / rod holder .................3715 0973-92.
Hinge set / rotation unit ...............3715 0983-90
Spacer / Rotation unit ..................3715 0975-00
Fig. 15. Hinge set
1. For rod holder
2. For rotation unit

Casing clamp (Fig. 16a and 16b)

To facilitate anchoring of the feed beam to the
casing tube, a casing clamp can be used. This can
either be mounted on the rod holder stand (See
Fig. 16a), or if the core drill is supplemented with
the rod holder conversion kit, on the hinged
bracket See Fig. 16b).

Clamps are available for the following size

casings:
54 mm, 64 mm, 74 mm, AW Fig.16.b Mounting the clamp on the rod holder
and BW. hinge attachment

Fig.16.a Mounting the clamp on the rod holder

frame

Heavy duty rod holder (Fig. 17)

DIAMEC® 252 can be equipped with a larger and
more robust rod holder, if drilling is to be carried
out using heavier drill rods in deep holes.

Axial hold-back force ........................................22 kN

Max jaw size ................................................... 98 mm
Fig. 17. Heavy duty rod holder

18
 Optional equipment and accessories

Dimensionally-dependent
components
The following components (Fig. 18) must be A
1
selected in consideration of the type and diameter
of the drill rods, core barrels and casing tubes in B
2
use (See spare parts list). Complete diametric sets
are available for 33, 43, 53 mm, EW, A and B sizes.

3
C
4
D
E
5
6
F
G
7

H
8

Wire line hoist, Fig. 18. Dimensionally-dependent components

version 300/425 m (Fig. 19) 1. Guide socket 5. Support ring
2. Chuck jaws 6 Sleeve
Designed to be mounted underneath the feed 3. Guide socket 7. Washer
frame. Hoist extension, top pulley and hoses (not 4. Rod holder 8. Casing clamp
wire rope) are included. The hoist is operated from jaws
the control panel.

Data
Capacity ........................... 300 m of 6 mm wire rope
...........................................425 m of 5 mm wire rope

Pull
min. ........................................ 3400 N (full drum)
max. ...................................5800 N (empty drum)

Hoisting speed
min. ....................................3.0 m/s (empty drum)
max. ........................................5.0 m/s (full drum)

Weight (Without wire)........................................57 kg

Fig. 19. Wire line hoist kit

Needle valve (Fig. 20)

To increase the system pressure and stabilize the
speed of rotation when drilling at low speed,
i.e.when either overburden or DTH drilling. 1

Chuck / rod holder functions become more reliable

with a higher system pressure. The needle valve
(1, throttle) is mounted on the control panel and
restricts the flow of return oil from the rotation
motor (see Fig.20) Fig. 20. Needle valve

19
 Optional equipment and accessories

Hose sets
Depending on the space available, it may prove
more practical to position the power unit further
away from the drilling unit than the standard
hoses permit. Two separate hose sets are
consequently available for this purpose. One 10
metre hose set and another 25 metre set. An
extension nipple kit is also available which enables
connection of the standard hoses to the extension
sets. Fig. 21. Test instrument

Test instrument
For testing and adjusting operations of the
hydraulic
system.

Extra cooler (Fig. 22)

To increase cooling effiency, an extra cooler can
be mounted. The cooler should be mounted if
drilling is being carried out in abnormally high
ambient temperatures, or if the temperature of
cooling water s higher than + 30°C for instance. Fig. 22. Extra cooler

Flush pumps (Fig. 23 and 24)

The TRIDO® flush pumps are matched to suit all
forms of drilling operations that may be carried
out using the DIAMEC® 252.

The Trido 80/140 pumps can either be supplied by Fig. 23. Trido 45 flush pump operated with the
an electric- or diesel motor, or equipped for drill rigs own hydraulic system via the
hydraulic operations from the power pack. Trido control panel
45 can be supplied either by an electric motor or
by a hydraulic motor powered from the core drill
hydraulic system.

Type TRIDO®45 TRIDO®80 TRIDO®140

Max. flow 45 l/min. 70 l/min. 135 l/min *

Max pressure 45 bar 40 bar 35 bar

Values from hydraulic driven flush pumps

*) (Reduced pressure when hydraulic driven)

Water swivel
The WS 18/0 water swivel has been specially
designed for use with Diamec core drills.
Fig. 24. Trido 80 flush pump operated with an
electric motor

20
DESIGN FEATURES

Drill rig
1. Water swivel
4
2. Rotation unit
3. Drill rod 1
4. Emergency stop wire
5. Feed frame
6. Stay 5
7. Rock attachment
8. Rod holder

Electric power pack

9. Start box 2 6
10. Tow bar
11. Hydraulic oil tank
12. Hydraulic oil filter
13. Water cooler
14. Hydraulic double pump
15. Electric motor
3
Control panel
16. Control panel
17. Stand
18. Fire extinghuisher
19. Emergency stop button 8

7
19

9 11 12
16

10

18
17

13

15 14

Fig. 25. Design features, drill rig, power unit and control panel

21
CONTROLS
17a 17b 17c 1 2 3

16
15

4
13
14

8
7

1. System pressure gauge

0 - 400 bar

9
11
2. Feed pressure gauge
0 - 65 kN

12

3. Water flush pressure gauge

0 - 60 bar

4. Chuck pressure gauge

0 - 400 bar

5. Selector valve for rod running / 13. Control knob for rotation speed
drilling regulation
6. Feed control lever
7. Rotation control lever 14. Control knob for chuck
pressure
8. Wire line control lever
15. Feed force knob
9. Control lever - flush pump
11. Counter pressure valve, for 16. Main pump pressure relief
balancing the rotation unit when valve
drilling upwards directed holes and
proper opening of the rod holder 17. Lever detent adjustment
when rod handling (running) a Wireline hoist
12. Counter pressure valve, for b Spindle rotation
balancing the rotation unit when c Feeding
drilling downwards directed holes
and proper opening of the rod
holder when rod handling (running)
Fig. 26.

22
 Controls

5 Selector valve for rod running

( F ) Rod running
IN

(D) D O ( 0 ) Rod
Drilling holder
open

(B) Rod running

OUT

6. Feed control lever 8. Control lever for Wire line hoist

( F ) Forward feeding ( L ) Lowering
F L
(Lever towards the control (Lever towards the control
panel) panel)

( N Neutral N ( N ) Neutral N

( R ) Reverse feeding
(Lever from the control R ( H ) Hoisting H
panel) (Lever From the control
panel)

9 Control valve for flush water

7 Rotation control lever pump
( R ) Right-hand rotation
R
(Lever towards the control Closed
panel)

( N ) Neutral N

Fully open
( L ) Left-hand rotation
(Lever from the control L
panel)
23
 Controls

11. Counter pressure valve for feed 15. Control valve for feed force
cylinder when drilling upwards regulation

Clockwise turning Anti- Clockwise

Increased back pressure clockwise turning
turning
Higher feed force
Lower feed
Anti-clockwise turning force
Reduced back pressure

12. Counter pressure valve for feed 16. Main pump relief valve
cylinder when drilling
downwards

Not to be adjusted
Clockwise turning Set at factory
Increased back pressure

Anti-clockwise turning
Reduced back pressure

13. Control valve for rotation speed

regulation
Anti- Clockwise
clockwise turning
turning
Increased rpm
Decreased rpm

14. Control valve for chuck pressure

regulation

Anti- Clockwise
clockwise turning
turning
Higher pressure
Lower
pressure

24
MANOEUVRING
Pre-start procedure
DANGER
Special care and attentions should be
paid to damaged or worn components,
General which could cause structural fatique
1. Connect all hoses between the control cracks or even fracture in materials or
panel, drill rig and power unit (see page 60) welded joints.
and tighten all nipples properly.
2
2. Check hydraulic oil level in the oil tank. Refill
if oil level is too low (See level indicator Fig.
28) 1 4
3. Connect cooling water to the hydraulic oil
cooler. (See Fig.27).
3 5

Fig. 27. Connection of cooling water for

DANGER 1.
hydraulic oil cooler
Flush water pump
2. Water swivel
Set control levers and switches to 3. Collector vessel for cooling water
neutral position prior to start, otherwise 4. Oil ccoler
the rig functions might start moving 5. Water supply to the drill site
instantly and uncontrolled.

4. Before engine start, carry out instructions IMPORTANT

given in Periodic Maintenance page 40 to The hose leading to the oil cooler should
43 preferably be equipped with a strainer. The
water pressure should not exceed 10 bar.
Starting-up the electric power unit in Always make sure that the water passing
temperatures below +5° C through the oil cooler is as clean as possible.
In low ambient temperatures (below +5° C), the oil Dirty or contaminated water will result in rapid
flow from the main pump should be reduced to at internal layering and blockage inside cooling
least 50%. pipes, with eventual overheating of the
hydraulic system.
Procedure
1. Reduce the oil flow by turning the needle
1 2 3 4
valve (1, Fig. 28) clockwise.
2. Start-up the power unit and let it run for
about two minutes and then switch-off.
Repeat the procedure several times
succession.

3. After continuous operation lasting about

ten minutes, reset the oil flow to full
capacity turning the valve (1)
anticlockwise.
If the pressure drop indicators (1, Fig. 30)
on the hydraulic oil filters stick out, this
could be due to the oil being too cold or
excessively viscous. As soon as the
hydraulic system has warmed up, repress
the indicators. If these continue to
Fig. 28. Hydraulic oil tank
activate and stick out, then the filter
cartridges need replacing immediately. 1. Needle valve
(See section “Replacing filter 2. Level indicator
cartridges in the hydraulic oil filters” 3. Temp gauge
page 45). 4. Arrow indicating right rotation direction

25
 Manoeuvring

Start-up
Electrical power pack (Fig. 29)
1. Turn the main switch (10, Fig. 29) to (I)
The control lamp (1) should now light up.
NOTE, Check that all control lamps are
working by pushing the control button (6). C°

All lamps 1 to 5 should now be lit up.

To facilitate start of the electric motor, open 1 2 3 4 5

the ball valve (2, Fig. 30) to circulate
hydraulic oil from the service pump during
I O
1

=O

the start procedure.

=1

2. Check that the emergency stops are not 10 7 8 6

pressed (4 and 19 Fig.25, and 9 Fig 29 and
31)

3. Press the ON button (7).

Note: Make sure the second stage of the 9
electric motor engages automatically (can Fig. 29. Startbox for Electric power unit
be heard). 1. Control Lamp, Power on
If the motor doesn’t start and the control 2. Control Lamp, Phases (Rotation direction)
lamp (2) will lights up, this indicates that the 3. Control Lamp, Motorprotection
phases are incorrect (Incorrect direction of 4. Control Lamp, Hydraulic oil lever
rotation). 5. Control Lamp, Hydraulic oil temperature
6. Button for lamp control
4. Check that the direction of rotation is correct
7. ON
The control lamp (2) will lit up if wrong
8. OFF
rotation direction.
9. Emergency stop
5. Check that the emergency stop devices (On 10. Main switch
control panel, power pack and drill rig) are
working before drilling. commence by Note, The Control box cannot be opened if
stopping the engine from each safety stop the Main switch (10) is in position I.
device.

6. Check that there are no signs of oil leakage

from threaded joints, hose connections or
nipples.

Stopping (Fig. 29)

1 Check that every lever on the control panel 1
is in neutral position.

2. Press the OFF button (8).

3. When leaving the machine, or when

servicing, always switch-off the main circuit
switch (10) to O position.
When Control lamp lights up:
Lamp. 1. Power to the control box 2
Lamp. 2. Incorrect rotation of direction, Change phases
(Call for authorized electrician)
Lamp. 3. Safety protection for electrical motor released
(Call for authorized electrician)
Lamp. 4. Low hydraulic oil level (Fill oil, see page 41/44)
Lamp. 5. Too high a hydraulic oil temperature (See
Trouble shooting)
Fig. 30. Hydraulic oil filters
Lamp. 6. Any of above control lamps are out of function 1. Pressure drop indicators
(Check all for function) 2. Ball valve

26
 Manoeuvring

Start-up 1 2 3 4 9

Diesel power pack

Before starting the diesel engine, certain checks
and measures must be carried out to prevent
accidents, unnecessary stoppages or breakdown.

See Maintenance schedule for power unit,

7
page 41 and 42

8
Start
1. Check that the emergency stop buttons are
in out position.

2. Turn the main switch (14) 1/4 turn.

3. Turn the ignition key (10) to START

6
position.
Note that all lamps are lit-up. When the 5
engine starts, all lamps will expire.
10
4. Check that the emergency stop devices (On
control panel, power pack and drill rig) are 11
working before drilling commences, by
stopping the engine from each safety stop
device. 12 13
15
5. Adjust the rpm.with lever (15)

NB. Always start-up at low r/min.

14

IMPORTANT

When starting up in cold weather,

(below + 5°C), the speed of Fig. 31. Startbox for diesel power unit.
rotation (diesel engine) should not Pos. 1 to 8 )= Indication lamps for:
exceed 1000 rpm until the engine 1. Charging
has been warmed up to about 2. Oil pressure (Engine)
+10°C. 3. Cylinder temperature
4. Cooling fan (Engine)
Stopping the diesel engine 5. Emergency stop failure
6. Cooling fan (Hydraulic oil)
Allow the engine to idle for a few minutes before 7. Hydraulic oil level
switching it off. This particularly applies when the 8. Hydraulic oil temperature
rig has been operating for lengthy periods. 9. Emergency stop button (RED)
10. Ignition key
11. Hour counter
IMPORTANT 12. 24 V. connection for external
lights etc.
The diesel engine should 13. Remote control connection (Start
only be shut down directly and stop functions)
from its operating rpm in 14. Main switch
the cases of emergency. 15. Rpm control

27
SETTING UP FOR DRILLING
DIAMEC® 252 operates at rotation speeds between
550-2200 rpm, within a feed force range of 0-43
kN. These high feed force and rotation speed
ranges in turn demand a securely anchored and
stable feed frame. It is therefore wise to remember
that vibration reduces the life span of:
• Chuck jaws
• Rubber sleeve for the hydraulic chuck
• Slide shoes
• Guide sockets
• Drill rods and drill bits
Consequently, follow the given instructions for
setting up and securely anchoring the feed frame.
WARNING
• Always anchor the rig in a proper way
before drilling commences.
• Make sure that no loose pieces of
equipment or objects are lying on the
feed.
• Before raising the feed look up to
check for overhead obstructions. When
overhead electrical power lines exist at,
or near a drilling site, consider all wires to
be live and dangerous.

• Always make sure no unauthorized

persons are within the working area of
the drill rig in use.
Stand mounting (Underground, Fig. 32)
In Fig. 32. the DIAMEC® 252 is set-up with
standard equipment, i.e. anchored to the rock face
with the aid of a expansion bolt and positioned in
correct drilling direction to the ground by the
support legs.

Procedure (Fig. 32 and 33)

1. Decide the location of the drill hole.

3
2. Measure the position for the expansion
bolt, i.e. 105 mm from the centre
of the rod holder chuck and the
centre for the expansion bolt.

3. Drill a 35 to 42 mm hole about 1 metre 2

deep for the expansion bolt.

4. Insert the bolt in the hole and fix in 1

position using a resin or cement
grout, allowing about 10
cm of the bolt end to protrude
from the rock face.
1
5. Now attach the expander bolt to the
fulcrum ball.

6. Tighten the frame securely to the

expander bolt and align the drill
unit in the intended drilling direction Fig. 32. Stand mounting
by adjusting the stand support 1. Support legs
legs. 2. Expander bolt
3. Adjustment screw
7. Tension the drill unit securely in place by
tightening the adjustment screws (3).

8. Connect the hydraulic hoses (see

Drawing for hydraulic lines, page 60).

28
 Setting-up for drilling

3
4

Fig. 33. Stand mounting (Under ground)

1. Drill rod
2. Adjustment screw
3. Expansion bolt
4. Fulcrum ball

Stand mounting (Surface drilling, Fig.

34))
Standard equipped Drill unit.

To facilitate anchoring of the feed frame to a

casing rod a casing clamp is to be used. This can
either be attached to the rod holder stand (Fig. 35),
1
or if the core drill is supplemented with a
conversion kit for the rod holder, attached to the
hinged bracket (Fig. 36).

Procedure
1. Dismantle and remove the flushing hose
and ejector, as well as the fulcrum ball and
flange.

2. Assemble a casing clamp to the rod holder

2
stand (Fig. 35)

3. Tighten the clamp around the casing rod.

3 4
Fig. 34. Positioning and stabilizing the rig before
drilling.
1. Support legs
2. Adjustment screw
3. Casing rod
4. Casing clamp

29
 Setting-up for drilling

2 1 1
2

3 3
4

Fig. 35. Anchoring the feed frame to a casing Fig. 36. Assembling the casing clamp to a
rod. 1. Rod holder hinged bracket.
2. Screw 1. Hinged bracket
3. Casing clamp 2. Screw
4. Casing rod 3. Casing clamp

Column mounting (Fig. 37)

When column mounted, drilling can be carried
out in almost any angle.

Procedure (Fig. 37 and 38)

1. Align the column (1) and tension it in 360°

position between the roof and the floor
of the drift.

2. Attach the machine holder (2) to the

column, and the frame support (3) to the
feed frame using the frame clamp (8).

3. Adjust the position of the feed frame so

it becomes evenly balanced (Fig. 38).

4. Suspend the lifting block (4) in the stop

ring (5) and then attache the sling to the
feed frame.

5. Position the feed frame at a suitable

height and align it in the direction of
drilling.

6. Tighten the screws on the machine

Fig. 37. Column mounting for 360° drilling
holder (2) and frame support (3).

7. Insert a 36 mm guide sleeve in the rod
holder and prepare the drill unit for
drilling with the short lenght 36 mm core
barrel and drill bit. (Included with the
column assembly for insertion of
expansion bolts).
8. Drill the hole carefully with low feed
force for the expansion bolt. (Two
expansion bolts, 1 and 2 m respectively,
are included with the column assembly).
9. Insert and secure the expansion bolt in
the drill hole (See stand mounting Fig.
33, page 29).
30
Raising or lowering the feed frame on the
column, See Fig. 38.
1. Check that the feed is securely slung with
ropes and safely suspended in the lifting
block (4).
2. Loosen the machine holder screw (6) and
either raise or lower the frame to desired
height with the aid of the locking block.
3. Tighten the machine holder screw before
disengaging the lifting block and
removing the rope slings.
 Setting-up for drilling

Fig. 38. Raising or lowering the feed frame on

the column.
1. Column
2. Machine holder
3. Frame support 1
4. Lifting block
5. Stop ring
6. Screw, machine holder
7. Screw, frame support 8
8. Frame clamp
9. Sling

3
DANGER
Always make sure that nobody is under 6 2 7
or anywhere near a suspended load.

31
 Setting-up for drilling

Setting-up the DIAMEC® 252 using

turn table and worm gear (Optional)
As an optionl, DIAMEC® 252 can be set-up for
drilling in almost every drilling angle when
equipped with worm gear and turn table.

Clamps Clamps
Turning the turn table as shown in (Fig. 39).
With turn table the feed/stand can be turned 360°.

1. Place the feed frame with the rotation

unit as shown in Fig. 39. Slacken the
clamps on the turn table enough to allow 360°
for turning.
Fig. 39. The Turn table can be turned 360°
2. When desired position is reached, tighten
the clamps.
180°
3. Position the feed frame for the desired
drilling angle with the aid of the mast
raising cylinder (See Fig. 46 page 44).

Turning the feed frame in the vertical plane

(Fig. 40)
1. With the aid of the worm gear and a
ratched handle it is possible to turn the
feed frame as shown in Fig. 40. To
facilitate turning, position the rotation unit
on the feed to obtain the best point of
balance. Fig. 40. Turning the feed frame in the
vertical plane
Positioning the feed frame/stand for drilling
up-wards directed holes (Fig. 42)
To be able to drill upwards the feed frame and
stand must be turned as shown in Fig. 42. In Fig.
41, only the stand has been turned 180°.

1. Turn the turn table 180° (See Fig. 41) and

tighten the clamps.

2. Turn the feed frame 180° (See Fig. 42)

with the aid of the worm gear. Now you
are able to drill 90° from the horizontal 90°
plane upwards.

3. Position the feed frame for the desired

drilling angle with the aid of the mast Fig. 41. Feed frame and stand turned 180°
raising cylinder (See Fig. 46 page 44).

90°

DANGER
In order to prevent accidents, caused by
overturning the rig, strictly anchor the
feed frame/stand before starting to drill.

Fig. 42. Position for upwards- directed drilling

32
Setting-up for drilling

Displacement of the feed frame

when assembled on stand.
1. Loosen the clamps (3, 4 pcs) by undoing the
clamp screws (2). 1

DANGER 3

Do not undo the clamp screws (2) too

much, the feed may come lose from its
bracket and cause personal injury.

MOVE THE FEED FRAME VERY

CAREFULLY!

2. Move the feed frame to desired position . Fig. 43. Moving the feed frame.
1. Feed frame
3. Tighten the clamp screws (2). 2. Clamp screw
3. Clamp

33
 Setting-up for drilling

Surface set-up with DIAMEC® 252

on skid
Anchoring with casing clamp
1. Anchor the skid and feed frame to the
ground by means of expander bolts and a
casing clamp (2, Fig. 44), or if no casing is
used, with an expander bolt to the fulcrum
ball,
see Fig. 45.
3
2. Connect all hoses (see matching nos. on
hoses and fittings page 60).

3. Start the power pack and check that all 2

hydraulic connections are tightened and that 1
no oil leakage appears.
Fig. 44. Anchoring the feed frame to a casing rod.
4. Raise the feed frame to desired angle with 1. Casing
lever (Fig 46). 2. Casing clamp
3. Expander bolt (4 pcs)

WARNING
In order to prevent accidents, caused
by overturning the rig, strictly anchor
the feed frame/stand before starting to
drill.

2
1
Fig. 45. Anchoring the feed frame to an expander
bolt.
1. Expander bolt
2. Fulcrum ball on the rod holder flange

WARNING
• 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 live and dangerous.

Fig. 46. Control lever for raising the feed frame

34
 Setting-up for drilling

Underground set-up with DIAMEC®

252 on skid.
1. Anchor the skid frame to the ground or
platform by means of anchor- or expander
bolts. (See Fig. 47)
WARNING
2. Connect all hoses (see matching nos. on
hoses and fittings page 60). In order to prevent accidents, caused
by overturning the rig, strictly anchor
3. Start the power pack and check that all the feed frame/stand before starting to
hydraulic connections are tightened and that drill.
no oil leakage appears.

4. Raise the feed frame to desired angle with

lever (Fig 46).

3 3

2
1

Fig. 47. Anchoring the feed frame to the drift floor with expander bolts.
1. Expander bolt
2. Fulcrum ball on the rod holder flange
3. Expander bolt (4 pcs)

35
DRILLING
DIAMEC® 252 is equipped with effective
mechanized rod running sequences. (the chuck L R F F
and rod holder perform synchronized alternate
movements). N N N D O

B
Positioning the core barrel (Page 23, H L R
and Fig. 48)
8 7 6 5
1. Move the selector valve (5) to the
position O. The rod holder should now be
Fig. 48. Controls positioned for positioning a
open.
core barrel.
2. Insert the core barrel and a drill rod
through the chuck and rod holder.

3. When the entire core barrel has passed

through the rod holder, move the selector
valve (5) to position F.The rod holder is
now in the automatic position for rod
running in.
L R F D

Setting the drill string into the hole.

N N N D O
(Fig. 49)
B
Run the drill string forward by moving H L R
the control lever (6) to position F.
8 7 6 5

Fig. 49. Positioned levers for rod running IN.

Drilling (Page 23, and Fig. 50)
1. Move the selector valve (5) to position D.

L R F
F

DANGER N N N D O

B
Make sure the water swivel is properly
H L R
tightened to the drill rod. 8 7 6 5
Fig. 50. Positioned levers for DRILLING.
2. Check that flushing water is flowing out
from the drill bit.

3. Open the feed valve (15, page 22) anti- IMPORTANT

clockwise for minimum feed force. With synchronized movements of the rotation
unit and rod holder correct handling of the
4. Move the rotation lever (7) forward to control levers is vital.
position R.

5. Move the feed lever (6) to position F.

If vibrations occur during drilling, either change
6. Adjust the feed force using the feed
rpm or the free length of the drill rod
control knob (15, page 22).
The feed force can now be read on the
feed pressure gauge (2).
36
 Drilling

Rod jointing (Page 23, and Fig. 51)

1. The open end of the rod should be just
outside the rear end of the rotation unit,
and the rotation unit should be in the
extreme forward position towards the rod
holder.

2. Move the selector valve (5) to position F.

3. Thread a new rod into position.

NB, Thread on the first few turns by
hand.

4. Move the feed lever (6) towards position

R. The rotation unit will now move
backwards without the drill string, as this
is held in place by the rod holder.

5. Move the feed lever (6) back to neutral, N R F

L F
position, as soon as the chuck has passed
the rod joint.
N N N D O
6. Move the rotation lever (7) to position R,
B
so that the rod threads and tightens in H L R
position. Then move lever (7) back to N,
(neutral position). 8 7 6 5
Fig. 51. Rod jointing sequence

Withdrawing the drill string (Page 23, L R F

F
and Fig. 52)
1. Move the selector valve (5) to position B. N N N D O

B
2. Move the feed lever (6) to position F. The
rotation unit will now move forward
H L R
towards the forward end position, 8 7 6 5
without gripping the rod.
Fig. 52. Controls positioned for withdrawal of
3. Move the feed lever (6) to position R. The the drill string
chuck will grip the rod and the rod holder
will open. The rotation unit will now pull
the drill string backwards.

4. NB, Before the core barrel passes

through the rod holder, this should be
opened manually with selector valve (5),
and the core barrel lifted out of position
by hand to prevent unnecessary
clamping damage to the core barrel and
tools.

37
 Drilling

Rod breaking (Page 23, and Fig. 53)

1. Position the rotation unit so that the rod
joint aligns between the chuck and rod
holder.

NB, The rotation unit must not be moved

too close to the rear end of the feed
frame. It must have enough space to
move backwards during the breaking-out
sequence.

2. Move the selector valve (5) to position B.

3. Move the rotation lever (7) quickly to

position L. This movement must be
carried out extremely quickly if the
automatic chuck delay mechanism is to
function as intended. What happens is
this: The chuck rotates 3/4 of a full turn L R F
before the jaws grip and unthread the rod F
joint. This kinetic energy is needed due to
rod joints sometimes proving difficult to N N N D O

breakout. B
H L R
4. Return the rotation lever (7) to neutral
position N. 8 7 6 5

5. Move the feed lever (6) to position F. The Fig. 53. Rod breaking sequence
rotation unit will now move forwards
towards the forward end of the feed
frame. The rod can now be picked up and
removed from the core drill.

IMPORTANT: IMPORTANT

Never try to remove the drill rod until the Always make sure the counter pressure valve
rotation unit has passed over the open rod joint has been correctly adjusted and set before rod
and stopped. breaking starts.
(Adjusting counter pressure valve see page 47)

If this valve is set too high or too low, 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. This particularly applies when drilling
upwards-directed holes.

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.

38
MAINTENANCE
General
The performance and reliability of the DIAMEC ® Following major intervention in the hydraulic
252 is largely dependent on the amount of care
and attention shown to it. Regular checks and
inspection of wear-prone components prevent
breakdowns and costly downtime.
Dirt is 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.
- 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
oiltank by first pumping through filters.
- 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.
Water oil cooler
Clogged cooling water elements in the oil cooler
Symptom: Poor water circulation through the
cooler.
Procedure:
1. Open the cooler by removing the gables.
2. Clean the interior of the elements (Use
compressed air or high pressure water
when cleaning).
3. Replace gaskets of the gables.
Air oil cooler
Clean the exterior with compressed air- or water.
Cleaning the hydraulic system
system,
systematic and through cleansing of the system
should be performed, before drilling is allowed to
continue.
Cleaning procedure
1. Disconnect the two main hoses (1, Fig.
54) on the hydraulic motor and put caps
on the nipples.
2. Reconnect the loose ends to the nipple
included in the tool kit.
3. Start up the power unit.
4 Set the mode selector (5, page 22, 23) at
position drilling.
5. Move the rotation control lever (7, page
22, 23) to position R and circulate the
hydraulic system for about five minutes.
6. Disconnect the two main hoses from the
nipple and reconnect them to their
correct points on the hydraulic motor.
fig. 54. Hydraulic hose connections on the
hydraulic motor
WARNING
Do not carry out any service and repair
on hydraulic equipment being under
hydraulic pressure.
Stop engine, 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,
don’t expose your face or hands but use
a piece of cardboard or wood.
39
 Maintenance

Periodic maintenance
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.

3
1

11 17
1
14

12
1

14
18

15 17 7

16

Fig 55.

40
 Maintenance

Service schedule for drill unit and power unit 45 E

Ref. Check points Procedure Service interval in Notes

No. hours of operation

8 40

1 Feed attachment Tightening x Look for cracks etc.

2 Sprocket bearings Lubrication x 4 lube nipples

3 Feed chain Tensioning x See Adjusting chain tensioning

4 Slide shoes Adjustment x See Adjusting the slide shoes

Lubrication x

5 Chuck jaws Cleaning x Use oil for external lubrication of

Lubrication x springs and wear surfaces

6 Rod holder Cleaning x

Lubrication x 2 lube nipples

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

8 Hydraulic oil filters Inspection x See Hydraulic oil filters

9 Oil leakage Inspection x Continuous inspection of hydraulic

nipples, hoses and components

10 Complete drill rig Cleaning x When necessary

11 Worm gear Lubrication x 4 lube nipples

12 Turn table Lubrication x 1 lube nipple

13 Wire line hoist Lubrication x 2 lube nipples

14. Feed raising cylinder Lubrication x 2 lube nipples

15 Electrical motor Lubrication 2 lube nipples, 30 g grease every 6

month

16 Water cooler Cleaning x See page 39

17 Emergency devices Test of function x (On control panel, power unit and
rig)

18 Adjustment screw Lubrication x

41
 Maintenance

Service schedule for power unit 40 DT

1 1

Fig. 56.

Ref. Check points Procedure Service interval in hours of Notes

No. operation

8 40 200 1000

1 Engine oil Level check x See Service manual for Engine

Change x

2 Battery Level check x

Cables x

3 Air filter Cleaning x

4 V-belt Tensioning x

5 Oil filter Change x

6 Fuel filter Change x

7 Cylinder flanges Cleaning x

42
 Maintenance

Daily safety check

Before each shift commences, an extra and thorough safety check shall be carried out intended to detect:

— emergency stop failure (On panel, rig and power unit)

— cracks or fractures in materials or at 1, 2, 3, 4, 5, 7, 8, 9, 10, 11, 13

welded points.
— damage, which could cause structural 1, 2, 3, 4, 5, 7, 8, 9, 10, 11, 13
weakness or fracture

— wear, with the risk of same consequences 2, 3, 4, 6, 7, 10, 11, 12, 13

— loose junctions, loose threaded unions 1, 2, 3, 4, 5, 7, 8, 9, 10, 11, 12, 13, 14

12

From the safety aspects therefore, the

3 15 following check points are particularly
important (see illustration below)

1. Feed frame / feed attachment

11
2. Chain
3. Sprockets
2 4. Stand
5. Skid
10 6. Turn table
7. Worm gear
8. Rotation unit /cradle.
9. Rod holder
10. Water swivel
11. Wire line hoist / wire rope
7
12. Mast top
13. Anchor bolts
8 14
4
14. Raise cylinder

1 15. Emergency stop wire

Fig. 57.
9
6 5 13

43
 Maintenance

Lubricant recommendations

Lubricant Check point No. Recommendation

See page 40 to 42

1. Hydraulic oil 7 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 vegetable hydraulic oil, please contact

nearest Atlas Copco representative for information.

2. Grease 2, 6, 11, 12, 13, Universal grease NLG12....................Operating temperature °C (°F)

14, 15 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. Air tool oil Use mineral-based air-tool oils

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

-20 to +15 (-4 to + 59) ISO VG 32-46
+15 to +35 (59 to 95) ISO VG 46-100

44
 Maintenance

Hydraulic oil filters

The filter is equipped with a pressure drop
indicator. When this activates, a red pin sticks out
about 5 mm which in turn indicates the cartridge
should be renewed. 5
1
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 2
malfunction of hydraulic components as the
result. 3
When the oil temperature is low, the indicator
will activate through the pressure drop caused
by the high viscosity of the oil.

Replacing the filter cartridge 4

1. Clean the exterior of the filter housing Fig. 58. Hydraulic oil filter
thoroughly.
1. Filter housing
2. Remove the cartridge container from the 2. Filter cartridge
filter housing. Use a open-end spanner 3. Filter container
on the hexagon underneath the 4. Hexagon for disassemble of the filter
container. container
5. Pressure indicator (red pin)
3. Remove the oil filter cartridge.

4. Clean the cartridge container and filter IMPORTANT

housing thoroughly.
5. Inspect all the seals to make sure they
are undamaged and in good condition.
Replace if necessary.
6. Insert the new cartridge inside the
container and reassemble the various
parts of the filter housing.
7. Press in the pressure drop indicator.
The useful service life of the hydraulic oil can be
seriously reduced at operating temperatures
above +60°C.
High temperature can cause:
– Leaky gaskets
– Serious internal leakage in pumps and
valves, due to decreased viscosity and
lubricating properties of the oil.

Changing the hydraulic oil. Oil change.

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.
1. Drain off all the hydraulic oil by undoing
one of the plugs underneath the tank.
2. Refill new oil (about 70 litres) using the
hand pump. As the oil is pumped into
the tank it passes through the filter so
that any impurities are strained off.
NB. Check the pressure indicator (5) when
refilling oil.

45
 Maintenance

Adjustment of speed regulation

(Hydraulic motor)
The speed of the hydraulic motor is proportional
to the pilot pressure. Regulation is active in a 10
bar region and should be adjusted to act between
15 to 25 bar. The pressure compensation is not
affected by this adjustment.

Adjustment procedure (Fig. 49)

1. Mount a low pressure gauge, 0-60 bar (5)
to the pilot line with a T-nipple (6).

2. Run rotation unit and turn the control

valve (13) for rotation speed (on the
control panel, Fig. 26) until the pilot
pressure is 15 bar.

3. Reed the rotation speed on a tachometer. Fig. 49. Hydraulic motor

The rotation speed should be at 1. Speed regulation adjustment
minimum 550 rpm. 2. Max. speed setting
3. Pressure compensator
4. Adjust if necessary with the adjustment 4. Pilot line
screw (1) on the hydraulic motor. 5. Pressure gauge
6. T-nipple
5. Continue turning of the speed regulating
valve until max rpm is obtained. Read the
pilot pressure on the gauge (5). The
pressure should be ² 25 bar.

6. If the max. rotation speed do not

correspond to the rig specification,
adjust by means of the screw (2) for max.
speed setting.

Stabilizing of low rotation

speed
Turn the control knob anti-clockwise (See Fig. 60)
until the rotation speed has stabilized. Also check
Fig. 60. Valve for stabilizing low rotation speed
that the rod holder opens correctly.

NB: Throttle the oil flow just enough to

stabilize the rpm (I.e. about 100 bar 14. Control valve for chuck pressure
system pressure). Too much throttle regulation
can cause overheating of the
hydraulic system.
Anti- Clockwise
clockwise turning
turning
Setting of chuck pressure (Fig. Higher pressure
Lower
61 pressure
For normal applications chuck pressure should be
set at 100 bar.
Fig. 61 Setting og chuck pressure

46
 Maintenance

Thread compensation and 7

balancing of rotation unit when
drilling downwardly directed
holes.
The valve is used to set the counter pressure so
that the threads of the drill rods are not damaged
during the breaking operation. The valve is also 11
used to balance the weight of the rotation unit
12
when drilling downwardly directed holes.

Clockwise turning - Increased pressure

Anticlockwise turning - Decreased
pressure 7 Rotation control lever
Setting of correct counter pressure (Fig. 61)
(R) Right-hand rotation
1. Position the feed frame to desired angle R
(Lever towards the control
2. Turn the setting screw (12) anti-clockwise panel)
to stop position.
(N) Neutral N
3. Place the control valve (7) for rotation in
position L (lefthand rotation). When the
chuck rotates anticlockwise, turn the
adjustment screw clockwise until rotation (L) Left-hand rotation L
unit starts to move - i.e. moves away (Lever from the control
from the rod holder. The valve is now panel)
correctly set for the rod breaking
11. Counter pressure valve for feed
operation and balancing of the rotation
cylinder when drilling upwards
unit. directed holes

Clockwise turning
Counter pressure valve for rod Increased back pressure

holder function and balancing

of rotation unit when drilling Anti-clockwise turning
upwardly directed holes. Reduced back pressure
The counter pressure valve (Setting screw 11) is
preset to 30 bar pressure upon delivery. This
value must be maintained if the rod holder
function is to perform correctly. This back
pressure is also sufficient for balancing the self- 12. Counter pressure valve for feed
weight of the rotation unit when drilling upwards- cylinder when drilling
directed holes downwards

IMPORTANT Clockwise turning

Increased back pressure
If the setting of the counter pressure valve is too
low, it will affect the rod holder function so that
the jaws lie against the drill rod.
Anti-clockwise turning
Reduced back pressure

Fig. 62. Counter pressure valves

47
 Maintenance

Adjusting chain tension (Fig. 63)

Chain tension should be checked after every 8
hours of operation.

Procedure:

1. Run the cradle to its rear end position.

2. If chain tension is correct, you should be

able to lift the chain at its central position
about 5 mm.

3. Adjust chain tension by undoing the lock 3

nut (1) and then turning the tension nut
(2) until the chain is correctly taut.

Measuring feed chain wear (Fig. 64)

Chain stretch in excess of nominal length is
measured as follows:

1. Position the drilling feed vertically so that

the upper part of the chain takes the
weight of the rotation unit.
1 2
2. Measure length (M. Fig. 63)
corresponding to a set number of links.
Fig. 63. Adjusting chain tension
The number of links should be at least
12. 1. Lock nut
Length of one link is 25.4 mm. 2. Tension nut
3. Set screw for slide shoe
3. As a rule the chain is too worn for use
and must be replaced when the
percentage stretch reaches 2.0%. Normal 12 Links (One link length = 25.4 mm)
percentage stretch is 0.7 to 1.0%.

Adjusting slide shoes (Fig. 63 )

The slide shoes of the cradle should be checked Fig. 64. Measuring feed chain wear
after every 8 hours of operation.

1. Eliminate any play between the slide

2
shoes and rails by tightening the three set
screws (3)

2. Check alignment of chuck and rod holder

after adjustment.

Changing the guide sleeves in 1

the rotation unit (Fig. 65)
The diameter of the guide sleeve (1) must be
chosen in consideration of the drilling equipment
to be used.

1. Undo the screw (2) and remove the

guide sleeve (1).

2. Mount a new guide sleeve and tighten Fig. 65. Changing guide sleeve in the rotation
the screw (2). unit
1. Guide sleeve
2. Screw

48
 Maintenance
Replacing wear rings, rubber sleeve and jaws in the chuck

11 10 7
9 88 7 6 5 4 3 2 1

0.1 - 0.2 mm

Fig. 66. Replacing rubber sleeve, wear rings and chuck jaws.

Procedure:
11. Reassemble the outer cover (2).
1. Undo the eight screws (1) and remove
the outer cover (2) together with the O- NB, Make sure the guide pins (3) fit perfectly
ring (4) and guide pin (3). in position in the recessed grooves in the
jaws.
2. Remove the springs (5), jaws (6), wear The tightening torque for the screws
rings (7) and rubber sleeve (8) at the (1) is 10 kpm.
same time.
12. Insert a drill rod through the jaws and
3. Remove wear washer (10) and O-ring carefully pressurize the chuck for the first
(11). time following reassembly.
4. Press out the jaws and springs from the
rubber sleeve and then remove the wear
rings.

5. Clean all parts thoroughly, including the

inside of the chuck housing. At the same
time, inspect all parts and replace any
found damaged or excessively worn.
6. Lubricate all the parts including the
inside of the chuck housing with a thin
coating of oil. (Check that the screws in
the bottom of the chuck housing are
securely tightened)
IMPORTANT
If breakdown of the rubber sleeve occurs, the
axial play of the jaws must be checked. Ideal
play should be between 0.1 to 0.2 mm.
Play over this tolerance will cause excessive
wear on the internal parts.

7. Reassemble the O-ring (11) and wear Check the cover (2), jaws (6) and wear plate (10)
washer (10) in the bottom of the chuck for damage or excessive worn. Replace if
housing. necessary

8. Reassemble the jaws and springs by

pressing them into the rubber sleeve.

9. Reassemble the wear rings (7) in the

rubber sleeve.

10. Position the rubber sleeve with jaws in

the chuck housing.

49
 Maintenance

Replacing the jaws and rod

guide in the rod holder
5
IMPORTANT
Keep all rod holder parts clean and well
1
oiled to prevent corrosion from water and
dirt pollusion.
2
The jaws and rod guide must be chosen in 3
consideration of the diameter of the drill rod in
use. 4
9
Replacing jaws (Fig. 67) 10

The rod holder is equipped with standard jaws for 8

43 mm drill rods. Jaws for other rod diameters are
available upon request. (see spare parts list) 5 62
1. Remove the springs (1) by unhooking 71
them from the frame.

2. Remove the screws (2) that hold the

lower ends of the springs in position

3. Withdraw the hydraulic gripper (3)

4. Withdraw the jaws (7) from the jaw

retainers (6) and replace with new. Fig. 67 Rod holder
1. Spring
5. Reassemble the hydraulic gripper and 2. Screw
springs. 3. Adjustment screw
4. Lock nut
Adjusting the rod holder jaws 5. Hydraulic gripper
6. Jaw retainer
1. Undo the lock nut (4) and adjust the play 7. Jaws
by means of the adjustment screw (3). 8. Screw (2 pcs)
(Turning clockwise will increase the 9. Guide sleeve
clerarance). 10. Bearing housing
2. Tighten the lock nut (4) when adjustment
has been completed.

When the rod holder is fully open, the core barrel

should run smoothly and easily through the jaws,
with minimum play between the core barrel and
the jaws.

Replacing rod holder guide (Fig. 68)

1. Undo the two screws (5) and remove the
guide sleeve (1) with the bearing housing
(4).

2. Remove the circlip (3) and bearing (2)

from the guide sleeve (1). Check the Fig. 68. Replacing rod holder guide
bearing for wear. If worn replace.
1. Guide sleeve
3. Reassemble in reverse order. 2. Bearing
3. Circlip
4. Bearing housing

50
 Maintenance

Adjusting pressure
compensation of the main- and
service pump 5

Main pump (System pressure 260 bar) 2 4

1. Undo the lock nut (5)
3
1
2. Adjust the system pressure (screw 4)
using a 6 mm allen key.

3. Lock the adjustment screw (4) with the

lock nut (5) when correct pressure has
been set. Fig. 69. Adjusting pressure compensation
1. Pressure comp. valve, service pump
2. Adjustment screw, service pump
3. Pressure comp. valve, main pump
Service pump (System pressure 210 4. Adjustment screw, main pump
bar) 5. Lock nut
Adjust the system pressure (Screw 2).

Clockwise turning - Increased pressure

Anticlockwise turning - Decreased
pressure

Limiting the oil flow from the

main pump at drive motor
speed above 1500 rpm (Fig. 70)
1
When mounting a new hydraulic pump, type A
Vickers on power pack 45E (with 60 Hz electric 2
motor), or on 40 DT (with Deutz diesel engine), a 3
restriction washer must be installed in the main
circuit in order to obtain correct oil flow from the
C
main pump.
B
The restriction washer (3716 1467-90) is included
with the new pump upon delivery. See following
mounting instructions:

1. Dismantle the nipple (1) and needle valve

(3).

2. Position the restriction washer (2) with its

flat side facing upwards, at point A in the
needle valve (3).

3. Reconnect the nipple (1) to the needle

valve and tighten all connections.
Fig. 70 Limiting the oil from the main pump
4. Top-up the hydraulic system with fresh oil 1. Nipple
if necessary. 2. Restriction washer
3. Needle valve
B. Cover, service pump
IMPORTANT C. Cover, main pump
Vent the hydraulic pump by undoing the covers
B and C. Tighten the covers when oil overflows.

51
 Maintenance

Starting-up the power pack

after adjustment
1. Top-up the hydraulic system with fresh
oil if necessary. 1
2. Vent the hydraulic pump by undoing
A 2
covers (B & C, Fig. 71). 3
3. Retighten the covers again when oil
overflows. C
B
4. Start-up the power pack and check that
the direction of rotation is correct. (See
Fig. 28, page 25)

5. Run the power pack for about 90 seconds

and then switch off.

6. Allow the power pack to remain

inoperative for about 5 minutes before
resuming continuous operation.

Fig. 71. Starting-up the power pack after

adjustment
IMPORTANT A. Cover, service pump
B. Cover, main pump
Repairs to the hydraulic system should
only be carried out by engineers or
mechanics experienced and familiar with
the drill rig

52
ADDITIONAL INSTRUCTIONS
Assembly- and manoeuvring
instructions for wire line hoist.
First mount the mast top and pulley on the feed
frame/mast (See Fig. 71)
A
The wire line hoist is to be attached beneath the
feed frame via clamps (See Fig. 71).
B
The hoist is operated from the control panel.
(See Fig. 74)

For connection of hydraulic hoses, see Fig. 73,

connections A and B, and the Principle drawing Fig. 73 Connections for wire line hoist on the
for Hydraulic system page 62. control panel.

DANGER
– The Wire line hoist is only permitted to
be used for lifting- or lowering
equipment in the drill hole. 8
– Never use a damaged wire.

– Always make sure that nobody is

under or anywhere near a suspended
load or within the swing radius of the
rope.

8. Control lever for Wire line hoist

(L) Lowering
L
(Lever towards the control
panel)

(N) Neutral N

(H) Hoisting
(Lever From the control H
panel)
1 2 4
Fig. 74 Control panel.
3 8. Lever for wire line hoist

Fig. 72 DIAMEC® 252 equipped with wire line

hoist
1. Pulley
2. Mast top
3. Wire line hoist
4. Clamp

53
 Additional instructions

6 7
Attaching the water collector
(Opt.)
1. Attach the ejector (3) to the rod holder
with the aid of two clamps (4).

2 Mount the bellow (1) on the ejector (3)

and tighten with a hose clamp (2).

3. Assemble the hose (5) on the ejector for 1

the return flushing water.

4
3
2 7
1

Fig. 75. Adjusting the water collector against the

rock face.
1. Bellow
2. Hose clamp for the Bellow
3. Ejector
4. Clamp (2 pcs)
5. Hose and clamp for return flushing water
6. Adjustment screw
7. Rod holder

54
TROUBLE-SHOOTING CHART

Type of fault Cause Pinpointing the fault Remedy

1. Chuck does not A. Oil is cold and thus too
open enough viscid
B. Wrong oil used
(Too thick)
C. Drainage filter clogged
D. Springs beetween
chuck jaws worn out
or broken
E. Dirt between the jaws
F. Dirt between the wear
plates and jaws, e.g.
rubber from the chuck
inserts
A. Warm-up the core drill
B. Change to a thinner oil see
Lubricant recommendation
C. Check if indicator has C. Change the filter cartridge
avctivated
D. Dismantle and inspect D. Replace with new springs
the springs
E. Dismantle and inspect E. Clean the jaws thoroughly
jaws
F. Dismantle and inspect F. Clean all parts thoroughly
all parts thoroughly

2. Chuck inserts A. Internal parts in the A. Dismantle and inspect A. Replace worn parts
break frequently chuck excessively worn
B. Too much axial play B. Measure the clearance B. If the clearance is more
than 0.2 mm,
between the outer replace worn parts
cover and the jaws
using a feeler gauge

3. Chuck fails to grip A. Chuck jaws to worn A. Dismantle and inspect A. Replace the chuck jaws
the rod or slips the chuck jaws
on it
B. Incorrect dimension jaws B. Dismantle and inspect B. Replace with the correct
are being used dimension
C. Drill rod worn C. Measure the drill rod C. Replace the drill rod
D. Too much grease on the D. Clean the drill rod from all
drill rod grease
E. Low system pressure at E. Read the system E. Example:
low rpm pressure At system pressure below
80-100 bar:
1. Increase rpm
2. Install a needle valve
on the hydraulic
motor return line
(rotation left)
F1. Pressure reduction valve F1. Read the pressure on F1. Increase the pressure
3743 0083-05 for the the chuck pressure
chuck set too low gauge
F2. Defective O-rings in F2. Renew the O-rings
in the pressure reduction
valve
Oil is cold and thus viscid

55
 Trouble shooting

Type of fault Cause Pinpointing the fault Remedy

4. Rod holder fails to A. Rod running lever in A. Move the selector valve 5,
grip rod, or slips drilling position page 23 to
during rod breaking Rod running OUT during
and rod jointing rod breaking, and to
Rod running IN during rod
jointing

B. Fractured cup springs B. Dismantle the springs B. Mount new spring sets
and inspect them
C. Rod holder jaws worn C. Replace the jaws
D. Wrong diameter of jaws D. Replace with correct jaw
are being used size
E. Drill rod worn E Measure the drill rod E. Replace the drill rod
F. Too much grease on F. Clean the rod from all
the rods excess grease

5. Uneven grip inter- A. Malfunction of the chuck A. See points 2 and 3 A. See points 2 and 3
change cycles or rod holder
beetween the chuck
and the rod holder
during rod running
B. Counter pressure valves B. Adjust the valve settings,
set too low see page 47

6. Rotation unit does A. Counter pressure valve A. Adjust the valve,

not remain still, but set too low see page 47
sinks down while
in neutral on the
control panel

7. Poor, uneven or A. Malfunction of the feed A. Dismantle the valve A. Clean the valve. Replace
no feed force force valve (15, page 22) (15) and inspect O-rings. any worn parts or possibly
during drilling Also see whether the replace the entire valve
operation valve spindle moves
easily

B. Faulty gaskets in the B. Run the cradle to its
feed cylinder
B. Remove the feed cylinder
forward end position. and renew the gaskets
Undo hose s from the
feed cyl. Continue
to press towards the
end position. If the piston
seals in the feed cyl. are
faulty, or oil will spurt out
through the open cyl.
connections when the
cradle stands and press
against the end pos.

56
 Trouble shooting

Type of fault Cause Pinpointing the fault Remedy

7. D. Malfunction of the D. Check the condition of the

service pump service pump with regard
to pressure and flow.
Use a test box.
E. Counter pressure valve E. Adjust the valve setting
set too high value (Page 47)

8. Feeding un- A. Faulty O-rings (See A. Dismantle the feed A. replace worn or faulty
parts
controllable during spare parts list) valve and inspect the
drilling O-rings

9. Rod running too A. Faulty gaskets in the A. See point 7b A. See point 7b
slow feed cylinders
B. Counter pressure valve B. Adjust pressure (Page 47)
C. Scored bearings in the C. Replace shafts and
chain rollers bearings
D. Setting on feed force D. Increase feed force by
valve (15, page 22) too clockwise turning
low

10. Cradle does not A. Feed force valve (15, A. Turn the valve clockwise
move when feed page 22) completely
lever (6, page 22) unthreaded
is moved to feed-in
position
B. Setting on the counter B. See point 9b
pressure valve (See
page 47) too high

11. Poor breaking-out A. Core drill dislodged from A. Insert some rods in the A. Realign the core drill so
that
force its position drill hole and stop when the centre of the chuck and
the end of the rearmost the drill rod are aligned
rod is high up on the correctly
frame. Now run the
cradle just far enough
back to allow the chuck
to slip-off the drill rod.
If the rod does not point
through the centre of the
chuck, the core drill has
been dislodged from the
drill centre.
B. Threads on the drill rod B. Unthread several joints B. Clean all the rod threads
by hand. Check that this and file off any burrs and
does not prove too hard grease the threads
to do. afterwards

57
 Trouble shooting

Type of fault Cause Pinpointing the fault Remedy

11. C. Malfunction in the chuck C. Insert a drill rod so that C. Wait a few seconds before
delay valve there is no joint the breaking-out cycle, so
beetween the chuck that the chuck jaws have
and the rod holder. time to open. Then quickly
During the breaking-out jerk the rotation control.
cycle, the chuck should Check that the main valve
rotate 180 degrees runs easily.
before it grips the rod
D. Chuck pressure too D. See point 3 F D. See point 3 F
low
E. Faulty check valve E. Poor rotation and E. Dismantle plug 3716 4682
gripping ability in the and inspect the valve cone
chuck and spring

12. Chuck fails to A. Dirt clogging nozzle on A. Dismantle the valve and A. Clean or replace the nozzle
grip the rod during chuck delay valve then unthread the nozzle
breaking-out cycle 3715 6441 (See spare from the valve
parts list)

13. System pressure A. Malfunctioning hydraulic A. Run the rotation unit A. Check the condition of the
too low pump towards its end position main pump with regard to
and read the pressure pressure and flow, using
shown on the system a test box.
gauge (1,Page 22).
The value should be
260 bar
B. Pressure relief valve B. If a“ hissing” noise can B. Check the condition of the
on the control panel be heard from the control panel, and the
set too low control panel, then this setting of the valve using a
indicates the valve test box
setting is to low

C. Malfunction of the C. Insert a drill rod through C. Replace the hydraulic

hydraulic motor the chuck and rod motor
holder. Move the control
lever for rod running IN
5, page 23). Perform a
rod jointing cycle. If the
motor is in good
condition, the system
pressure gauge (1,
Page. 22) should show
260 bar. Now breakout
the rod. If the pressure
does not reach 260 bar
as when the rod joint,
there is probably a fault
with the check valve in
the control panel.

14. Oil temperature A. Cooling water too hot A. Temperature of cooling A. Mount an extra oil cooler
becomes too high water should not exceed if no other solution exists
during drilling +30°C
operations
B. Too low flow of cooling B. Increase the water flow
water

58
 Trouble shooting

Type of fault Cause Pinpointing the fault Remedy

14. C. Clogged oil cooler C. Feel the water that C. Dismantle the short gables
has passed through of the cooler and clean the
the oil cooler is cold interior

D. Pressure relief valve D. Check as explained D. Adjust and reset the valve
on the control panel is in point 13b
set too low
E. Worn distributor and E. Measure the amount of
shaft in the rotation leakage through the
unit distributor
F. Wrong type of oil in the F. Change the oil. See
hydraulic system Lubricant
recommendations

15. Performance of A. Incorrectly set pressure A. Rpm should reduce A. Adjust the pressure comp.
the core drill compensation on the to about 1/3 rd at a setting on the motor
seems weak or hydraulic motor system pressure of
underpowered between 220 to 230 bar
during drilling
B. See point 13a B. See point 13a
See point 13b See point 13b
See point 13c See point 13c

16. Rod threads A. Incorrectly set counter A. Adjust to the correct

setting
“screech” when pressure valve page 47
breaking-out
B. Threads not greased B. Grease the threads

Trouble shooting, Electrical system for power unit 45E

If any of below listed faults accure, always investigate the reason for the fault before you reset the
component.
1. Motor do not start A. No power t the unit
(Or stops during
operation)
B. Wrong phase order
C. Electric motor is
overloaded
D. Low hydraulic oil
level
E. High hydraulic oil temp
F. Emergency stop tripped F.
A. Control lamp A. Check power supply
”power on”.
does not lit up
B. Control lamp phases B. Switch connector
is lit up for two phases (By
an authorized elecrician
C. Control lamp ”Motor C. Reset overload relay
overload is lit up (By an autorized
electrician)
D. Control lamp D. Fill hydraulic oil
”Hydraulic oil level” is
lit up
E. Control lamp ”Hydraulic E.
temp” is lit up
F. Reset Emergency stop

2. Circuit breaker A. A. A. Reset with reset button

F18 or F66
tripped out by
overload in the
control circuit for
the star delta
starter
59
 Trouble shooting

Type of fault Cause Pinpointing the fault Remedy

3. Circuit breaker F6 Reset the breaker

tripped out by
overload in the
ground fault circuit
4. Ground fault relay Reset with reset button
tripped out
5. Main circuit breaker Reset the breaker
Q7 tripped out by
under-voltage

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Documentations Feedback

Dear Operator.

If you find any deficiency in this manual (a procedure insufficiently or not described, a safety risk not
referred to etc. please make a copy of this page, fill it in and send it to:

Atlas Copco Craelius AB

Att: Jerzy Lederman
S-195 82 Märsta
SWEDEN

Printed Matter No: 6990 0588 01a

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