ESD 5 Crawler

Operator's Instructions
 Operator's Instructions for
Diamond Core Drill

ESD 5

These instructions are intended for operators of the DBC diamond core drill ESD 5.
Instructions are given for start and stop procedures, drilling, additional instructions, maintenance, and service
schedule to be carried out by the operator. For further information concerning service measures for the drill rig,
please contact your nearest DBC 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 DBC representative in order to benefit from the
latest revision.
DBC 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 DBC about deficiencies found, particularly in matters concerning
product safety.

DBC
Contents
Introduction 4 Drilling 33
Operating safety 5 Start the power unit 33
Organizational measures 5 Positioning the core barrel 34
Operation and maintenace 6 Setting the drill string into the hole 34
Underground hazards 7 Drilling 34
Special safety device 8 Rod jointing 35
Following signs are used 8 Withdrawing the drill string 35
Supply of electric power to drills 9 Rod breaking 36
Environmental Instructions 10
General 11 Maintenance 37
Hoisting and transport 12 General 37
Hoisting the drill and power unit 12 Cleaning the hydraulic system 37
Technical specifications 13 Oil cooler 37
Characteristics 14 Hydraulic oil filters 38
Rotation unit 14 Changing hydraulic oil 39
Rod holder 14 Draining condensed water out of tank 39
Power unit 15 Periodic maintenance 40
Optional equipment and accessories 16 Lubricant recommendations 41
Mast extension 16 Daily safety check 42
Wire line hoists 17 Starting of the power unit after adjustment
Hose kits 17 or disconnecting the hoses 43
Test instruments 17 Rod holder gas spring pressure check 44
Flush pumps 17 Changing rod holder jaws and rod holder
Design features 18 guide bushings 45
Controls 19 Trouble shooting 46
Control panel functions 19
Driving/ Tracks/ Hydraulic jacks 23
Pre-start procedure 25
Lifeline 26
Positionning valve 27
Start-up Electric power unit 45 kW 28
Setting up for drilling 29
Turning the turntable 29
Turning the feed frame 29
Positionning the feed frame for upwards
Drilling 29
Surface set up 30
Underground set-up 30
Displacement of the feed frame 31
Introduction
This instruction book is part of the complete delivery of The information is divided into the following chapters
your new diamond core drill ESD 5. It offers basic
information on features and handling of the unit and Section 1: Operating safety
contains advice and measures necessary to keep the rig Section 2: General and technical
operational. It does not, though, replace thorough specification.
training of operator, helpers and service support. Section 3: Operation
It is the responsibility of the owner to make sure that Section 4 Maintenance
all personnel assigned to this ESD 5 unit, have the skill
necessary for the safe operation, service and
maintenance of the unit before carrying out any kind of
work. Personnel must have been given adequate time
to assimilate the information in this book. One copy of
the manual should be kept available for reference on
the rig at all times.
The following information is available, and relevant for
operating the ESD 5 drill rig.

ESD 5 Printed Matter

Operator’s manual
Spare parts list

Order from: DBC

Mermerciler 23.sok/No:9
Dilovası Kocaeli
Turkey
Fax: +90 262 6582055
Operating Safety
Dear operator,
Before putting your new equipment into use, we would
like to direct your attention to the safety aspects.
Drilling can be a hazard to you and to the environment.
Good order, training and well maintained equipment
are key factors to safe operation. This instruction book
is no replacement for thorough training, but will, as a
training aid and a reference book, help you maintain a
safe working environment and keep the rig in good
operational condition.
Yours faithfully;
DBC
Intended use
The diamond core drill ESD 5 is intended for
underground exploration and investigation drilling, 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 ESD 5 should be run, serviced and repaired by
personnel properly trained for their task. This
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
medicines legally prescribed, or mixture of any of them.
The manufacturer is not liable for any damage caused
by unauthorized alterations made to the unit.
1.0 Organizational measures
1.1 The diamond core drill ESD 5 shall be operated
only by personnel who have undergone theoretical
and practical training on the rig. Particular emphasis
shall be laid on safety precautions.
1.2 Keep this instruction book as well as other books
related to the equipment available on the rig at all
times.
1.3 Always use personal protective equipment, as
required by circumstances or demanded by
regulations.
1.4 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 rectified.
1.5 Warning signs must be kept easily legible at all
times. Damaged signs should be replaced
immediately.
1.6 The daily safety check, as described in this
instruction, must be carried out in addition to
maintenance measures described in the Periodic
maintenance section (Page 44).
1.7 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.
1.8 Welding repairs should only be carried out by an
authorized welder in order to meet the high
standards that apply to DBC products. Special
attention must be given to components which could
cause injury or serious damage.
1.9 After repair make sure that the rig has been
inspected and approved by the proper authorities
before being brought back to normal operation.
1.10 Never make alterations or modifications to
components of the unit, particularly to the safety
systems, which might result in hazardous
consequences. The manufacturer’s approval should
be requested for any modification done to the unit.
2.0 Operation and maintenance
2.1 In addition to this manual you should also have a
good knowledge of generally recognized safety and
accident prevention regulations. If you follow these
regulations you stand a better chance of
accomplishing your task without harm to either man
or equipment.
2.2 Prior to starting up for the first time, familiarise
yourself with the rig's features, its controls and their
functions. Refer to "Controls, Manoeuvring and
Setting up for drilling" pages for further information.
5
Operating Safety
2.3 Various safety devices are built into the system of
the rig for your personal safety. These devices must
be checked at least once at the beginning of each
shift to ensure that they are in full working order. The
equipment should not be used unless safety checks
and maintenance have been carried out according to
the schedule.
2.4 Operators and helpers should wear helmets, (with
ear protectors when called for), safety glasses, safety
shoes, gloves and suitable clothing. Loose fitting
clothing and jewellery can get caught in the moving
parts of the machinery, causing serious injury or even
death.
2.5 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. Do not drive the rig into a dust cloud. Check
the travel route if you are unsure of the safety of the
ground.
2.6 Set control levers and switches to the neutral
positions prior to starting up, otherwise the rig could
start uncontrollably. Some of the levers are spring-
loaded so that the operation will stop once released.
This is part of the safety system. Never lock these
levers into operating position using strings, sticks or
similar items.
2.7 Avoid sharp turns when tramming on inclined
ground. Take extreme care when moving on wet,
slippery ground. Secure the rig with a suitable wire
rope when operating on slopes in excess of 10° from
horizontal.
2.8 Shut the rig down when refueling. Fuels must
be handled with care, and at a safe distance from fire,
sparks or electrical systems. Smoking is not allowed
within 10 metres of the fuel ! Do not fill the tank in an
enclosed space without ensuring adequate
ventilation. Fumes are poisonous. Do not overfill the
fuel tank. If you top up the tank in the morning, the
expansion of the fuel, as the temperature increases
later in the day, may cause fuel to spill from the tank.
Tank ventilation easily clogs if the level of fuel is too
high. See the “Environmental instructions” chapter
for further information.
2.9 Never leave the rig unattended with the engine
running. Carry the ignition key with you.
2.10 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, skin and damage cloth,
insulation and metal. First aid in case of acid in the
eyes: wash with plenty of clean water and seek
medical help.
Disconnect the earth cable from the battery before
carrying out service on the electrical system.
The battery gas is explosive! Never use matches when
checking the acid level.
Be careful using tools made of iron near the battery, a
spark might set off an explosion. Read the battery
manufacturer’s manual for further information as
well as the “Environmental instructions” chapter.
2.11 Hydraulic oils are poisonous. Use eye
protection and gloves. See the “Environmental
instructions” chapter for further information.
2.12 Before any repair or service is carried out on
the rig's hydraulic or water systems, make sure the
engine is stopped and that all systems are
depressurized.
2.13 Be very careful while tracing leaks in the
pressurized systems. Hydraulic oils, water or air under
pressure can penetrate the skin and cause
complicated injuries or infection. If this happens, see
a doctor at once.
2.14 Use only authorized parts (DBC parts). Any
damage or malfunction caused by the use of
unauthorized parts is not covered by warranty.
2.15 Any warranty for work performed, only covers
DBC Products, DBC components and work performed
by authorised personnel.
6
Operating Safety
3.0 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
located and identified before drilling.
Striking such 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. Do not look into the end of a optic fibre
cable.
You are personally responsible for any injury or
material damage caused by drilling if you have not
taken proper precautionary measures. 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. These companies
must locate and mark their installations, with a
minimum of 10 meters from each side of the planned
bore path. For additional security inspect the area in
order to localize any neglected installations.
The unit should always be started from the control
panel. On a Crawler mounted rig, the operator should
ride on the rig during tramming. Any attempt to move
the rig while walking beside it could result in injury.
Check for 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 the presence of 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
may constitute a danger, expose the object along the
bore path by carefully digging by hand. 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.
Figure 1 Use only Genuine DBC parts.
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.
The level of injury depends on the current flowing
through the body. Voltage is not necessarily a measure
of the danger. Accidents have occurred in installations
with a voltage as low as 25 -30 volts. 30 % of all
electrocutions in the industry have been in connection
with 240 - 400 Volt 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 can cause painful shock and
respiratory paralysis. 0,15 A can cause ventricular
fibrillation, probable death and 0,2 A can cause severe
burns, internal bleeding and 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.Do not touch pins on signal clamps.
Expose lines by hand digging.
7
Operating Safety
Induced current is dangerous. Even if the drill string is
not in contact with a cable, electrical currents may flow
through it.
Keep a safe distance from overhead power lines.
Location: Each corner of the crawler.
5.2 Ear protectors. Ear protectors should always be
worn.

Do not spray fluids near or on electric power lines. 5.3 Risk of crush. Be aware of the risk from
Hoses on the rig (hydraulic-, air- water- etc.) can crushing.
conduct electricity if the tool strikes an electrical cable. 5.4 Diesel fill. Location: On the diesel power unit.

If you strike an electrical cable, indicated by power
failure anywhere near the job area, smoke, explosion,
arcing electricity, or if warning device alerts:
a. Do not step off grid mat. If you stand on the
ground, stay put and do not touch any equipment.
5.5 ATTENTION Before starting, oil must be filled
according to: Lubricant Recommendations
5.6 Drain water cooler. When there is a risk of
freezing, especially during storage of the unit.

b. Alert people in the area, order them to stay out

of the immediate area and not to touch any of your
equipment.
Figure 4.1
c. If the strike occurred during drilling, retract the
downhole tool. Do not attempt to break any rod
connection. Do not add or remove any drill rods.
Figure 4.2
d. Ask your supervisor to contact the utility
company in order to switch off the system.

4.0 Special safety signs

Figure 4.3

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

4.1 The “DANGER” sign warns for immediate Figure 4.4

hazards, which, when ignored, will inevitably cause
serious personal injury or death!
4.2 The “WARNING” sign warns for hazards or
unsafe practices which, when ignored, could lead to
serious personal injury or death.
4.3 The “CAUTION” sign indicates hazards or
unsafe practice, which could lead to minor personal 5.1 Lifting points 5.2 Ear Protectors
injury or damage to equipment.
4.4 The “IMPORTANT” sign is used for
recommendations such as how to run the unit
efficiently, economically and in compliance with
environmental regulations.

5.0 Following signs are used on your ESD 5

5.3 Risk of crush 5.4 Diesel fill
5.1 Lifting points. This sign is located where the
sling is recommended to be attached.

8
Operating Safety

5.6 Water cooler 5.5 Attention

6.0 Supply of electrical power to the

drill (electric drills)

Electric power is supplied to the drill by a cable that

connects the starter panel on the drill to a mine
disconnect panel mounted on the mine wall. This cable
is called the trailing cable and is connected to the mine
disconnect panel by a plug. The trailing cable and mine It is recommended that the drill operator checks that
disconnect panel are typically not supplied by DBC. the mine disconnect panel is equipped with a ground
fault/ground check system. If the mine does not supply
The trailing cable is vulnerable to mechanical damage this type of disconnect panel, such a panel can be
and should be protected by a ground fault and a obtained through DBC.
ground check system located in the mine disconnect
panel. The ground fault (GF) check system checks for an
imbalance of current in the phases in the trailing cable
(and the connected electric motor) which would
indicate a leakage to ground. The ground continuity
check system checks that the ground conductor in the
trailing cable is connected from the mine disconnect The ground fault protection system located in the mine
panel through the trailing cable to the motor starter disconnect panel (and for CE marked drills in motor
panel. The U6 motor starter panel is available with a starter panel), trips at approximately 0.3 amp which is
Zener diode that is part of the ground continuity check too high to provide personnel protection. The driller
system in the mine disconnect panel. and helper should always use suitable electrically
insulating boots when operating an electrically
powered drill.

9
Operating Safety
Dear operator,
DBC recognizes the importance of environmental
issues. As part of our commitment to a better
environment, we want to inform you, the customer,
of how you can minimize the effect on the
environment when using an DBC product. These
simple but important instructions will help to
preserve the environment.
1.0 Operation, maintenance
disposal
Dust
Rock dust can pose a health danger. Use dust binding
oil.
Chemicals
Dispose of chemicals such as drilling additives, other
additives, glycol etc. according to the manufacturer’s
instructions. Avoid the use of cleaning agents
containing solvents like carbon tetrachloride. There
are environmentally better alternatives now available
and on the market.
Follow national regulations regarding handling and
disposal of wastes.

Oil Metals (steel, aluminum, etc.)

Leaks of hydraulic and lubrication oils pose an These products are recyclable and should be taken
environmental threat. Changing lubricating and care of according to national regulations.
hydraulic oils, hydraulic hoses and hydraulic filter
elements also pose a threat to the environment. Plastics and rubber
Collect all oil spills and waste (e.g. oil filter elements) These products are often labeled according to
contaminated with oil. Dispose of according to different classes. In those cases they are recyclable
national regulations. and should be taken care of according to national
Use biologically decomposable hydraulic oils and regulations.
lubricating oils for DBC products wherever possible.
Contact your nearest DBC office for more Electrical components (cables, electronics, etc)
information. Used components should be taken care of according
to national regulations.
Engine
Engine emissions are toxic and pose an
environmental threat. Always provide for fresh air
when an engine is running. Well-maintained air filters
help keep emissions at a low level.

Fuel (Petrol/Gas, Diesel)

Fuel spillage poses an environmental threat. Collect
all wastes and fuel spillage and dispose of according
to national regulations.

Grease
Lubricating grease poses a threat to the environment.
Collect all wastes and spillage and dispose of
according to national regulations.

Batteries
Batteries contain acids and heavy metals. Used
batteries can therefore pose a threat to the
environment and to your health. Avoid all contact
with acids and dispose of used batteries according to
national regulations. See also the “Operating safety”
chapter for further information.

10
General
ESD 5 is an all-hydraulic operated diamond core drill.
The ESD 5 is an all-hydraulic diamond core drill with a
wide range of options and accessories. It consists of
three main parts: the drill unit a power pack and a
control console.
It is suitable for a variety of drilling methods in both
underground and surface operations such as core
drilling, grout hole drilling, probing etc.. The drill unit
can be powered by an electric motor or diesel engine.
When the drill rig is equipped with the electric power
unit, an optional diesel engine for tramming is
available.
The ESD 5 uses the best technology available for
diamond core drills. All tube jointing, thread
breaking, feeding, wireline hoist sequences, are
controlled from a control console which can be
positioned to suit the setup. Feeding is done by a
direct cylinder, thereby eliminating chains in the feed
system. The drill can be equipped with two different
feed lengths, and two different sizes of rotation units
to suit rod size and drilling applications.
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.
Bearing in mind the core drill’s speed of rotation, its
rating and chuck diameter, the ESD 5 is best suited to
drill holes 46 - 76 mm in diameter (A - N) using both
conventional as well as wire line rods.
The spindle bore diameter is 78 mm in the
N-size rotation unit
11
Hoisting and Transport

12
 Technical Specifications
260 cm

180cm 400 cm
200
280 cm

Feed

MAX 550 cm

Power Unit
120 cm

190 cm
13
Characteristics
1.0 Rod holder Rotation Unit

The rod holder is hydraulically operated, and closed by Rotation characteristics- High torque
Speed range 0-900 rev/min
gas pressure. In case of loss of hydraulic pressure, the Maximal torque 1 350Nm
rod holder closes instantly. The gas pressure can be Spindle inner Ø 78 mm
conveniently monitored. Chuck axial holding force 100 kN

Max. rod size: 89 mm*

Bore (without jaws) 102 mm

Bore (without covers) 170 mm

Axial holding force: 45 kN

Axial holding force (TC insert jaws) 90 kN

*Can hold 114 mm (HW Casing) if remove rod guide

and install optional special covers.

Rod Holder Unit

14
Characteristics

1.2 Power unit

Power unit with variable hydraulic pumps and
independent hydraulic circuits for rotation and feed
thrust. Prepared for auxiliary, hydraulically driven
flush pump.

Complete with hydraulic tank, filters, oil cooler and

starter panel.

1.2.1 Electric

Asynchronous electric motor

Motor rating 45 kW Power Unit

at 1450 rpm
Sound noise level
Maximum operating pressure

- main pump 300 bar

Drill unit with electric power unit
- service pump 230 bar
Sound power emission: 99 dB (A)
Maximum flow
Sound pressure level at the
- main pump 75 l/min
operator’s position: 78 dB (A)
- service pump at 50 Hz 44 l/min

A
B

Hydraulic double pump

A- Main Pump
B- Service Pump
15
Optional Equipment and Accessories
1.1 Mast Extension

A telescopic mast extension (1) is mounted at the top

of the feed frame. With the standard telescopic mast
extension tubes, the total length of the feed frame
and mast extension can be varied from 3.5 - 4.5
metres. With the optional 5 m mast extension tubes,
the total length can be increased to 7.5 m. The rod
pulley (2) and top pulley (3) are mounted on the
extension tubes.

To brace the mast, 3 meter aluminium tubes (4, Ø 49

mm) can be used.
Mast Extension

1.2 Wireline hoist, 425 m

Mounted underneath the feed frame. The hoist is

operated from the control panel.

Data
Capacity 425 m of 4.75 mm wire rope
Pull min. 3900 N (Full drum)
max. 8100 N (empty drum)
Hoisting speed
min. 2.1 m/s (empty drum)
max. 4.5 m/s (full drum)
Weight (without wire) 57 kg

Wireline hoist 425 m

16
Optional Equipment and Accessories
1.3 Hose kits
Extra long for connecting between the drill module
and the power unit. Available in 10 m length.

1.4 Test instruments

For testing and adjusting operations of the hydraulic
system.

1.5 Turn table

Test Instrument
By using the turn table, the drilling unit can be swung
360° horizontally in relation to the skid frame.

1.6 Hydraulic bracing device

This equipment comprises two hydraulic cylinders
with spikes (for assembly on the upper part of the
feed frame) and two screws with foot pads (for
attachments to the lower part of the feed). The
device is particularly suitable for use in narrow tunnels
and drifts. It allows simple anchoring of the feed
frame between the floor and roof/wall of the gallery,
drift or tunnel. The two cylinders are operated by a
control valve.

1.7 Flush pumps

The FMC flush pumps are matched to suit the drilling
operations that may be carried out with the ESD 5.
Hydraulic powered FMC pumps are available.

Data
max. flow 140 l/min

max. pressure 70 bar

Flush Pump

17
ESD 5 Design Features
8 7 6
5

1 2
3

1- Power Unit
2-Wireline Hoist
3-Control Panel
4- Turn Table
5- Rod Holder
6-Rotation Unit
7- Feed
8-Top Pulley

18
Controls

2
1

3
10
0
9
15
16

14 17

13

11,12

19
Controls
1 System pressure
gauge 0 - 400 bar 12 Counter pressure
valve, for balancing
the rotation unit
2 Feed pressure gauge when drilling
0 - 65 kN downwards directed
holes and proper
opening of the rod
holder when rod
handling (running)
3 Water flush pressure
gauge 0 - 60 bar
13 Control knob for
4 Chuck pressure rotation speed
gauge 0 - 400 bar regulation

14 Control knob for

5 Selector valve for chuck pressure
rod running /
drilling 15 Feed force knob
6 Feed control lever
7 Rotation control
lever
8 Wire line control 16 Main pump pressure
lever relief valve
9 Control lever - flush 17 Lever detent
pump adjustment

a Wireline hoist

b Spindle rotation
10 Emergency Stop
c Feeding

11 Counter pressure
valve, forbalancing
the rotation unit
when drilling
upwards directed
holes and proper
opening of the rod
holder when rod
handling (running)

20
Controls

21
Controls

22
Controls
CONTROLS (Driving/Tracks/Hydraulic Jacks)

TIP-OVER HAZARD WHEN TRAMMING.

- Can cause severe bodily injury or porperty damage.

- Keep feed in tramming position (fold down).

- Do not exceed slopes of 25° forward/rearward or 20° sideways.

- Always make sure no unauthorized persons are within the tramming area of the crawler

WARNING
- Always stabilize / anchor the rig in a proper way before drilling comence to avoid
overturning.

- Make sure that no loose pieces of equipment or objects are lying on the feed.

- Before raising the feed (mast) look up to check for overhead obstructions. When
overhead electrical power lines exist at, or near a drilling site, consider all wires to be alive
and dangerous.

- Always make sure no unauthorized persons are within the working area of the drill rig in
use.

23
Controls

24
Controls
1.0 Pre-start procedure
1. Check hydraulic oil level in the oil tank. Refill if oil level is too low.

2. If using a water type oil cooler, connect cooling water to the hydraulic oil cooler, see Fig. A

3. Before starting motor, carry out instructions given in Periodic Maintenance pages.

DANGER
Special care and attention should be paid to damaged or worn components, which could cause structural fatique,
cracks or even fracture in materials or welded joints.

Starting-up the electric power unit in temperatures below +5° C

In low ambient temperatures (below +5° C), the oil flow from the main pump should be reduced to at least 50%.

Procedure

1. Reduce the oil flow by turning the ball valve clockwise.

2. Start-up the power unit and let it run for about two minutes and then switch-off. Repeat the procedure several
times in 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 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
activate and stick out, then the filter cartridges need replacing immediately. (See section "Replacing filter cartridges
in the hydraulic oil filters")

Figure A Connection of cooling water for hydraulic oil cooler

25
Controls
Important (Water type oil cooler)

The water hose leading to the oil cooler should be cleaned once a week or more if neccessary and equipped with a
strainer. The water pressure should not exceed 10 bar.

Always make sure that the water passing through the oil cooler is as clean as possible. Dirty or contaminated water
will result in rapid internal layering and blockage inside the cooler which can cause overheating of the hydraulic
system.

Lifeline- emergency stop cable

Lifeline cable
Life Line reset button
The machine stops when pulled
It is necessary to reset when lifeline
cable is pulled and red led on the
electric panel is ON

26
Controls
Positioning valves 1

1. Mast lift

2. Mast dump

3. Hydraulic worm gear

4. Hydraulic bracing cylinder ( optional)

27
Controls

1. Pressure filter, main pump

2. Pressure filter, service pump

3. Ball valve to throttle flow from the main pump

4. By pass valve for easy start-up/activation of positioning valves.

In order to facilitate starting of the power unit and not to overload the electric system (motor), this
by-pass valve is used on the pressure line of the service pump. When starting up the power unit this
valve should be in open position (for round pumping) and to be closed completely after few seconds
in order to operate the service pump.

28
Setting Up for Drilling
SETTING UP FOR DRILLING 2. Turn the feed frame 180° with the aid of the worm
gear. Now you are able to drill 90° from the horizontal
ESD 5 can be set-up for drilling in almost every plane upwards.
drilling angle when equipped with worm gear and turn
table.

Turning the turn table as shown in Fig. A. A

With turn table the feed/stand can be turned 360°.

1. Place the feed frame with the rotation unit as shown

in Fig. A. Undo the clamps on the turn table just as
much to be able for turning.

2. When desired position, tighten the clamps.

Turning the feed frame in the vertical plane (Fig. B)

B
1. With the aid of the worm gear and a ratched handle
it is possible to turn the feed frame as shown in Fig. B.
To facilitate turning, position the rotation unit on the
feed to obtain the best point of balance.

WARNING

* Always anchor the rig in a proper way before

drilling commencing. When drilling as shown in
Fig. A, its very important to anchor the rig to avoid
overturning.
C
* Make sure that no loose pieces of equipment or
objects are lying on the feed.

* Before raising the feed (mast) look up to check for

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

* Always make sure no unauthorized persons are

within the working area of the drill rig in use.

Positioning the feed frame/stand for drilling up-

wards directed holes (Fig. B)

To be able to drill upwards the feed frame and stand

must be turned as shown in Fig. B, only the stand has
been turned 180°.

1. Turn the turn table 180° and tighten the clamps.

29
Setting Up for Drilling
Surface set-up
1. Anchor the skid frame to the ground or a platform
by means of anchor- or expander bolts
* Before raising the feed (mast) look up to check for
overhead obstructions. When overhead electrical
power lines exist at, or near a drilling site, consider
all wires to be alive and dangerous.

2. Connect all hoses (see matching nos. on hoses and

fittings).

3. Start the power unit and check that all hydraulic

connections are tightened and that no leakage appears.

4. Raise the feed frame/mast with control lever to

desired angle.

5. Anchor the support legs to the skid.

6. Check and tighten all connections and stays.

WARNING

In order to prevent accidents, caused

by overturning the rig, strictly anchor the feed Underground set-up
frame / stand before starting to drill.
1. Anchor bolts
Underground set-up 2. Wall bracket to anchor the feed to the ground
3. Backstay legs
1. Anchor the skid frame to the ground or platform by
means of anchor- or expander bolts.

2. Connect all hoses (see matching nos. on hoses and

fittings).

3. Start the power pack and check that all hydraulic

connections are tightened and that no oil leakage
appears.

4. Raise the feed frame to desired angle with lever.

WARNING

In order to prevent accidents, caused

by overturning the rig, strictly anchor the feed
frame / stand before starting to drill.

WARNING

* Make sure that no loose pieces of equipment or

objects are lying on the feed.

30
Setting Up for Drilling
Displacement of Feed Frame

2 1
1- Unscrew the hex bolts

2- Move the feed frame with mast dump cylinder

- forward

- backward

3. When the desired position of the feed frame is obtained, tighten all clamps and set screws properly.

DANGER
Do not undo the clamp screws too much, the
feed may come lose from its bracket and
cause personal injury.

MOVE THE FEED FRAME

VERY CAREFULLY!

31
Setting Up for Drilling
Drilling
downwards

0 - 90°
0 +90°

Drilling upwards

Hydraulic
wormgear
0 - 180°

0 +180°

32
Drilling

3 4 5 6 7

13
8 9 10 11 12

Startbox for Electric Power

1. Emergency stop 4.Phase sequence 8.Motor Start 12.Alarm Reset
button correct 9.Main Switch Off 13.Main Switch
2. Main Switch On 5.Oil temperature high 10.Low Oil Level
3. Motor Stop 6.Motor overloaded 11.Lifeline Stop
7.General Alarm

Start-up Electric power unit 45 kW
1.Check that the emergency stop buttons (on the
control panel and power unit are not pressed.
2.Press the reset button and turn the main switch to ,
the control lamp should now light up.
3.Press the start button on the box.
NOTE, Make sure the second stage of the electric
motor engages automatically (can be heard). If the
motor does not start and the control lamp lights up,
this indicates that the phase sequence is incorrect.
4.Check that the emergency stop devices (on the
control panel, power unit and drill module) are
working before drilling. Commence by stopping the
motor from each safety stop device.
5.Check that there are no signs of oil leakage from
threaded joints, hose connections or fittings.
Stopping
1.Stop the power unit by pressing stop button.
2. When leaving the machine, or when servicing,
always switch-off the main main switch to O position.

33
Drilling
DRILLING

ESD 5 is equipped with effective mechanized rod

running sequences, the chuck and rod holder perform
synchronized alternate movements.

Positioning the core barrel (Fig. A)

1. Move the selector valve (5) to the position O. The Fig. A.Control positioned for positioning a core barrel
rod holder should now be open.

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.

Setting the drill string into the hole.

(Fig. B) Fig. B. Positioned levers for ROD RUNNING IN

Run the drill string forward by moving the control 6. Adjust the feed force using the feed control knob
lever (6) to position F. (15).

Drilling (Fig. C) The feed force can now be read on the feed pressure
gauge (2).
1. Move the selector valve (5) to position D.

DANGER

Make sure the water swivel is properly tightened to

the drill rod.

2. Check that flushing water is flowing out from the

drill bit.
Fig. C. Positioned levers for DRILLING.
3. Open the feed valve anticlockwise for minimum
feed force.
IMPORTANT
4. Move the rotation lever (7) forward to position R.
With synchronized movements of the rotation unit and
rod holder correct handling of the control levers is
5. Move the feed lever (6) to position F.
vital.

34
Drilling

Rod jointing (Fig. D)

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 position,

as soon as the chuck has passed the rod joint.

6. Move the rotation lever (7) to position R, so that the Fig. D Rod jointing sequence
rod threads and tightens in position. Then move lever
(7) back to N, (neutral position).

Withdrawing the drill string (Fig. E)

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

2. Move the feed lever (6) to position F. The rotation

unit will now move forward towards the forward end
position, without gripping the rod.

3. Move the feed lever (6) to position R. The chuck

will grip the rod and the rod holder will open. The
rotation unit will now pull the drill string backwards.
Fig. E Controls positioned for withdrawal of the drill
4. NB, Before the core barrel passes through the rod string
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.

35
Drilling

Rod breaking (Fig. F)

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 before the
jaws grip and unthread the rod joint. This kinetic
energy is needed due to rod joints sometimes proving
difficult to breakout.

4. Return the rotation lever (7) to neutral position N. Fig. F. Rod breaking sequence

5. Move the feed lever (6) to position F. The 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:
Always make sure the counter pressure valve has been
Never try to remove the drill rod until the rotation unit correctly adjusted and set before rod breaking starts.
has passed over the open rod joint and stopped.

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.

36
Maintenance
1.0 General
The performance and reliability of the ESD 5 is largely
dependent on the amount of care and attention
shown to it. Regular checks and inspection of
wearprone components prevent breakdowns and
costly downtime.
4. Use the rotation control to set the drill location
lever (10) in drilling position to circulate the hydraulic
system for about 5 minutes.
5. Disconnect the two main hoses from the fitting and
reconnect them to their correct points on the
hydraulic motor.

Dirt is a primary cause for most malfunctions in a 1.2.1 Oil cooler - water type
hydraulic system.
When required, clean oil cooler by back flushing the
Therefore:
- Always try and keep the core drill clean and free cooling water. The cooler cannot be disassembled if it
is the standard fin type.
from dirt and other pollutants. It is much easier to
detect faults or oil leakage on clean equipment.
1.2.2 Oil cooler - air type
- Never leave any part of the hydraulic system open
When required, clean the air oil cooler by flushing
or exposed to external influence.
dust out of the fins. Do not damage the fins by using
- Always attach tight-fitting plugs to disconnected excessive water pressure.
hose ends and couplings.

- Always perform oil refills into the hydraulic oil tank

by using the hand pump supplied.

- Always store fresh oil stocks in sealed containers.

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

Cleaning procedure

1. Disconnect the two main hoses on the hydraulic

motor and put caps on the fittings.

2. Reconnect the loose ends to the fittings included in

the tool kit.

3. Start up the power unit.

37
Maintenance
1.3 Hydraulic oil filters All filters in contact with oil on ESD 5 drill have filter
elements that are lifted from a bowl. The advantage of
There are in total three filters on the ESD 5 drill. Two this is that there is no leakage when replacing the
pressure filters on the power unit and one return filter filter elements. Even if the clogging indicators have
on the hydraulic tank. not called for a cartridge change, the cartridges should
be changed once every year.
Power unit
Of the two on the power unit, one is a breathing filter
mounted on top of the tank, and one a return filter
mounted from the lid - inside the hydraulic tank.

The breathing filter is all in one piece, unscrew the

filter and replace with a new one. Replace once per
year and more often in dusty conditions.
The return filter is equipped with an electrical clogging
indicator. The filter contains a bowl that holds two
filter elements. To change those elements, unscrew
the four hexagon nuts on top of the filter and lift the
bowl straight out. Once you have the bowl in your
hand, push down the lid, turn 90 degrees counter
clockwise and lift the lid out. Inside the bowl you see
two filter elements stacked on each other. Pull them
out, rinse the bowl if necessary and replace the
elements with fresh ones. Then put the lid back on the
bowl and reinstall the the bowl.
If the oil temperature is normal (+50 to +60°C) and the
indicator (5) reactives a couple of times, the filter
cartridge has to be replaced at once. Otherwise there
is a high risk of the oil bypassing the filter and dirt
contained in the oil being transported further into the
hydraulic system with the ultimate breakdown or
serious malfunction of hydraulic components as the
result.
When the oil temperature is low, the indicator will
activate through the pressure drop caused by the
high viscosity of the oil. Reset the indicator, if it pops
out again or not possible to reset. Change filters.

The pressure filters on the drill rig are placed under

the cover for hydraulics. The pressure filter is
equipped with an optical clogging indicator (5).
Whenever the pressure filter is clogged, the clogging
indicator will pop out and call for a cartridge change.
No automatic breakdown will stop the rig, therefore
the indicators must be checked once every week. To
change cartridges (2), (always change elements in
both filters at the same time) unscrew the lid (4) by
turning the hexagon knob counter clockwise with a
wrench. Lift the element (2) from the filter container
(3), clean the filter housing (1) if necessary and
replace the elements with fresh ones.

Make sure that the KZx25 element is placed in the

main filter (coarse hoses, (4F1) and the KZ25 is placed
in the service filter (5F1)).

38
Maintenance
1.4 Changing the hydraulic oil.
The hydraulic oil should be changed after 2000
operating hours in normal worksite conditions, or at
least once a year.

If the quality of the oil has deteriorated for some

reason, either through extremely high temperatures
or contamination for example, then it should be
changed as soon as possible. In such cases, the top
part of the tank should also be removed and the
entire interior of the tank cleaned thoroughly.

Oil change.

1. Drain off all the hydraulic oil by opening the drain

valve underneath the tank.

2. Refill new oil (about 120 litres) using the hand

pump. As the oil is pumped into the tank it passes
through the filter so that any impurities are strained
out.
1.5 Draining condensed water out of tank
The tank drain valve (1) is used to drain condensed
water out of the tank. Condensed water can collect at
the bottom of the tank. The amount of water
collected depends on the humidity levels and the
number of times the drill is shut down and the oil tank
cools down.
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.
Environmentally friendly oils can produce static
electric. This type of oils must be used with special oil
filters. For more information please contact DBC .

The tank drain should be checked regularly for the

presence of condensed water. In conditions of high
humidity and tank cool down each shift, condensed
water may have to be drained out at the beginning of
each shift. If the power unit is not level, try and
position the drain on the low side.

1.6 Hydraulic tank oil level

The oil level in the tank should be kept in the sight
glass at all times. There is a low oil level guard which
will trip the motor when the oil level is about 50 mm
below the lowest sight glass level. This will prevent
damage to the hydraulic pumps.
39
Maintenance

2.1 Periodic maintenance with Service schedule for drill and power unit 45 KW
Ref. Check points Procedure Service interval in . Notes
No. hours of operation
8 40 once/month

1 Feed frame holder Tightening X

Adjustment X See Adjusting the slide shoes
2 Slide shoes
Lubrication X More often in bad conditions
More often in bad
3 Chuck jaw holders Cleaning conditions(e.g. up-hole
drilling)
Chuck jaw inserts Cleaning X Inspect and clean if necessary
Rotation unit and gear Check level and
4 X See Rotation unit
case temperature
Cleaning X
5 Rod guide See Lubr. Recommendations
Lubrication X
5a Rod jaws Cleaning X Check for wear
Level check X Fill oil when necessary (clean
6 Hydraulic oil tank
Oil temperature X the tank once a year
7 Hydraulic oil filters Inspection X See Hydraulic oil filters
Continuous inspection of
8 Oil leakage Inspection X hydraulic fittings, hoses and
components
9 Complete drill rig Cleaning X When necessary
Wireline hoist with Apply grease to Levelwind
10 Lubrication X
Levelwind screw and one lube nipple.
11 Positioning cylinders lubrication X Lube nipples on cylinders.
2 lube nipples, 30 g grease
12 Electrical motor Lubrication
every 6 month
13 Oil cooler Cleaning X See Oil cooler
On control panel, power unit
14 Emergency devices Test of function X
and rig

40
Maintenance
2.2 Lubricant recommendations
Lubricant Check point No. Recommendation
1. Hydraulic oil 6 Use mineral-based hydraulic oil with good anti-wear, rust (oxidation) and
foam inhibiting properties, as well as effective air and water separation
abilities. The viscosity grade should correspond to the ambient
temperature and ISO 3448, as follows:

Ambient temp. °C (°F) Viscosity grade Viscosity index +25 to +40 (77 to
104) ISO VG 68 Min. 150
0 to +25 (32 to 77) ISO VG 46 Min. 150
-30 to 0 (-22 to +32) ISO VG 32 Min. 150

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

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

Use of flame proof or biodegradable hydraulic oil, please contact nearest

DBC representative for information.
2.Grease 2,10,11,12 Universal grease NLG12 Operating temperature °C (°F)
lithium/molybdenum Max. 100 (212)
additive
Synthetic sodium or Max. 140 (284)
calcium grease

Example of grease grades

Shell Retinax AM
Esso MP Grease
BP Energrease LS-EP 2
3.Engine oil Use engine oil according to diesel engine Instruction Manual

Example of grade
15W 40 Turbo oil
4.Rotation Unit, Synthetic gear oil with low foaming tendency
Gear Case Oil Viscosity grade 65-70 cst. at 40° degrees C
Mobile Mobile SHC 626
Statoil Mereta 68
Shell Omala HD 68
Petro Canada Syn Gear TOS 75W-90

Where appropriate: Oil change interval 1000 hours

41
Maintenance
3.0 Daily safety check
Before each shift commences, an extra and thorough safetey check shall be carried out to detect:

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

— cracks or fractures in materials or at

1, 2, 3, 4, 5, 6, 7, 8, 9
welded points.

— damage, which could cause sructural

1, 2, 3, 4, 5, 6, 7, 8, 9
weakness or fracture

— wear, which could cause structural

5, 6, 8, 9, 10
weakness or fracture

— loose junctions, loose threaded

1, 2, 3, 4, 5, 6, 7, 8, 9, 10
unions

1. Feed frame / feed frame holder

2. Mast raise cylinder 6. Rotation unit, cradle & slides
3. Crawler 7. Rod holder
4. Feed Rotation 8. Mast top, top pulley
5. Turntable 9. Wireline hoist, wire rope
10. Feed frame clamps, backstay legs

42
Maintenance
9.0 Starting up the power unit after
adjustment or disconnecting the hoses

1. Jog the motor shortly to check that the direction of

the rotation is correct (clockwise from the fan end of
the motor).
2. Start up the power unit with no load but with full
flow. Eg. with the rotation motor engaged but no rods
in the chuck. Let the pumps work in this condition for
2 minutes.
3. Bleed off the load sense hose at the bulkhead
fitting on the power unit.
4. Stroke the feed cylinder 5-6 times, to get air out of
the cylinder.
5. Bleed off the rotation speed pilot hose at the
rotation motor with the rotation motor spinning at
1000 rpm.
6. Check oil level in sight glass on tank and top off the
tank with fresh hydraulic oil if necessary.

Rotating the pumps in the wrong direction will destroy

the pumps.

43
Maintenance
10.0 Rod Holder Gas Spring Pressure 5. If the “drop-off” pressure is 30 bar or less, the rod
spring unit should be replaced or serviced in
Check
accordance with the service instructions in the service
manual.
The ESD 5 rod holder grips the rod using gas pressure 6. Phone the DBC service department if you have any
in the gas spring cartridge. The gas spring cartridge is questions.
charged to 40 bar pressure with nitrogen gas and is
designed for long service life (tested to more than one
million cycles). It uses two main piston seals, one
active and one backup.
The gas pressure can be checked by measuring the
force the gas exerts on the hydraulic fluid as the fluid No Rods* Rods*
bleeds down over an orifice when the rod holder is “Drop-off” pressure with 30 40
closed using the manual rod holder control. gas spring fully charged
It is recommended that the gas pressure be checked
once per month, when rods start to slip in the rod “Drop –off” pressure when 25 35
holder, or before drilling an uphole. If the rod starts to gas spring requires service
slip in the rod holder, the cause can be worn jaws or *) in the rod holder
too low a gas pressure. This test allows a quick and
convenient check of the gas pressure.

10.1 Testing procedure

1. Bring the machine to operating temperature.
2. Open the rod holder manually . This can be done
with or without rods in the rodholder
3. Close the rod holder and observe the service pump
pressure gauge (7). The pressure decreases slowly as
the gas spring forces the oil over an orifice to tank.
When the jaws grip the rod (rods in rod holder) or the
gas spring is fully closed (no rod in rodholder), the
pressure will suddenly drop more quickly. The
pressure when this sudden drop occurs is called the
“drop-off” pressure and should be compared to the
values in the Table 10.1 to the right:
4. Repeat the procedure a few times to get a
consistent reading.

44
Maintenance

4
5 2
6 3 1
8 7
9
Rod holder jaws and guide bushing

1 Bolt 6 Socket holder

2 Rod holder insert 7 Retainer
3 Jaw 8 Guide bushing
4 Back cover 9 Circlip
5 Bearing

10.0 Changing Rod Holder Jaws And Rod Holder Guide Bushings
10.1 Changing Jaws
Remove two bolts (1) holding the rod holder insert (2) in the rod holder housing. Pull out the insert so the jaws (3)
are clear of the housing, taking care not to damage or stretch the hydraulic hose. The jaws can now be pulled out and
replaced.

Important: The jaws have a flange on one side. Ensure that the jaws are put in so that the flange keeps the jaws from
falling out of the jaw holders and down the drill hole when the rod holder insert is pulled out.

10.2 Rod Holder Guide Bushing

The diameter of the bushing (8) must be chosen to suit the drilling equipment to be used (See spare parts list).
The bushing replaced by prying it out of the bearing. The new bushing is knocked into the bearing (snap fit).
There are two sizes of bearings – one for A and B size bushings, the other for N and H size bushings.
For A and B size reainer, the bearing (5) is held and centered in the back cover (4) by socket holder (6).
For N and H size bushings, the bearing (5) is centered directly in the back cover (4) .

45
Trouble Shooting Chart
Type of fault Cause Pinpointing the fault Remedy
1. Chuck does not open A. Jaw is too small A. Check size A. Install correct jaw size
enough B. Oil is cold and too B. Warm up the core drill
viscous C. Change to lighter oil
C. Wrong oil used (Too see Lubricant recom.
thick)
D. Springs between D. Dismantle and inspect D. Replace the springs
chuck jaws worn or the springs
broken
E. Dirt between the jaws E. Dismantle and inspect E. Clean the jaws
F. Dirt between the wear jaws thoroughly
plates and jaws, i.e. F. Dismantle and inspect F. Clean all parts
rubber from the chuck all parts thoroughly Thoroughly
inserts
G. Drainage filter clogged G. Check if indicator has G. Change the filter
activated cartridge
2. Chuck inserts break A. Internal parts in the A. Dismantle and inspect A. Replace worn parts
frequently chuck excessively
worn
B. Too much axial play B. Measure the B. If the clearance is more
C. Cradle too loose clearance between than 0,2 mm, replace
the outer cover and all worn parts
the jaws using a C. Readjust slides
feeler gauge

3. Chuck fails to grip the A. Chuck jaw holders or A. Dismantle and inspect A. Replace the chuck jaw
rod or slips on it chuck jaw inserts too chuck jaw holders and holders or jaw inserts
worn jaw inserts B. Replace with correct
B. Incorrect dimension B. Dismantle and inspect dimension
jaws are being used. C.Replace the drill rod
C. Drill rod worn C. Measure the drill rod
D. Too much grease on D. Clean the drill rod from
the rod all grease
E. Too low chuck E. Measure the chuck E. Increase chuck
pressure pressure (100 Bar) pressure
F. Malfunction of the F. Connect a pressure F. Check condition of the
service pump gauge to a test point service pump with
regard to pressure and
flow. Use a test box.
G. Jaw drive pins broken G. Inspect drive pins G. Replace drive pins
H. Low system pressure at H. Read the system H. At system pressure
low rpm pressure below 80-100 bar;
1. Increase rpm
2. Install a needle valve
on the hydraulic motor
return line

46
Trouble Shooting Chart
4. Rods not centered in A. Drive pins broken
chuck or excess
vibration
5. Rod holder fails to A. Gas spring pressure
grip rod or slips too low
during braking and B. Rod holder jaw holders or
rod jointing jaw inserts too worn
C. Incorrect dimension
jaws are being used.
D. Drill rod worn
E. Too much grease on
the rod
6. Uneven grip A. Malfunction of the A. See points 2, 3 and 5
interchange cycles chuck or rod holder
between the chuck B. Counter pressure valves
and the rod holder set too low
during rod runing
7. Poor, uneven or no A. Malfunction of the
feed force during feed force valve
drilling operation
B. Faulty seals in the
feed cylinders
C. Malfunction of the
service pump
D. Slide shoes too tight
E. Counter pressure valve
set too high value
A. Inspect drive pins A. Replace drive pins
A. Check gas spring A. Replace gas spring or
pressure increase gas pressure
B. Dismantle and inspect by recharging
chuck jaw holders and See gas pressure
jaw inserts B. Replace the chuck jaw
C. Dismantle and inspect holders or jaw inserts
D. Measure the drill rod C. Replace with correct
dimension
D.Replace the drill rod
A. See points 2, 3 and 5
B. Adjust the valve settings
A.Dismantle the valve and A. Clean the valve.
inspect O-rings. Also see Replace any worn parts
whether the valve spindle or possibly replace the
moves easily entire valve
B. Run the cradle to its B. Remove the feed
forward end position. cylinder and renew
Undo hoses from the the seals
feed cylinder.
Continue to press
toward the end
position. If the piston
seals in the feed cyl.
are faulty, oil will
spurt out through the
open cyl. connections
when the cradle
stands and press
against the end
position
C. Check for clearance C. Check the condition of
the service pump with
regard to pressure and
flow. Use a test box.
D. Readjust slide shoes
E. Adjust the valve setting
47
Trouble Shooting Chart
8. Feeding jerky during A. Malfunction of the
drilling feed force valve
B. Slide shoes too tight
9. Rod running too slow A. Faulty seals in the
feed cylinder
B. Slide shoes too tight
10 Poor breaking-out A. Core drill dislodged
force from its position
B. Threads on the drill
rod
C. Chuck pressure too
low
D. Malfunction in the chuck
delay valve.
E. Faulty check valve
12. Chuck fails to grip A. Dirt clogging nozzle on
the rod during breaking- chuck delay valve
out cycle. 63611071
13. Cradle does not A. Feed force valve
move when feed lever is completely unthreaded
moved to feed-in B. Setting of the counter
position. pressure valve too high
B. Check for clearance
A. See point 7B
B. Check for clearance
A. Insert some rods in
the drill hole and stop
when the end of the
rearmost rod is high
up on the 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. Unthread several
joints by hand. Check
that this is not too
hard to do.
C. See point 3E
D. Insert a drill rod so that
there is no joint between
the chuck and rod holder.
During the breaking-out
cycle the chuck should
rotate 180 ° before it grips
the rod.
E. Poor rotation and
gripping ability in the
chuck.
A. Dismantle the valve and
then unthread the nozzle
from the valve.
A. Bleed the feed and
hold back valves
B. Readjust slide shoes
A. See point 7B
B. Readjust slide shoes
A. Realign the core drill
so that the centre of
the chuck and drill rod
are aligned correctly.
B. Clean all rod threads
and file off any burrs
and grease the threads
afterwards.
C. See point 3E
D. Wait a few seconds
before the breaking-out
cycle, so that the chuck
jaws have time to open.
Then quickly jerk the
rotation control. Check
that the main valve runs
easily.
E. Dismantle plug 3716
4682 and inspect the valve
cone and spring.
A. Clean or replace the
nozzle
A.Turn the valve clockwise
B. Adjust pressure
48
Trouble Shooting Chart
14. System pressure too A. Malfunctioning main
low hydraulic pump
B. Pressure relief valve on
the control panel set too
low
C. Malfunction of the
hydraulic motor
15. Oil temperature A. Cooling water too hot
becomes too high B. Too low flow of
during drilling cooling water
operations
C. Clogged oil cooler
D. Wrong type of oil in
the hydraulic system
E. Pressure relief valve on
the control panel is set too
low
F. Worn distributor and
shaft in the rotation unit
16. Performance of the A Worn rotation motor
core drill seems weak
or underpowered
during drilling B. See points 14A, 14B, 14C
C.Incorrectly set pressure
compensation on the
hydraulic motor
A. Run the rotation unit
against its end
position and read the
system pressure. The
value should be 260
bar
B. If a “hissing” noise can
be heard from the control
panel, then this indicates
the valve setting is too low
C. Insert a drill through the
chuck and rod holder.
Move the control lever for
rod running IN. Perform a
rod jointing cycle. If the
motor is in good condition,
the system pressure gauge
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
A. Temperature of
cooling water should
not exceed +30°C
C. Feel the water that
has passed through
the oil cooler is cold
E. Check as explained in
point 14 B
A Check rotation motor
case drain leakage
C. Rpm should reduce to
about 1/3rd at a system
pressure of 220-230 bar.
A Check the condition of
the main pump with
regard to pressure and
flow, using a test box.
B. Check the condition of
the control panel and the
setting of the valve using a
test box.
C. Replace the hydraulic
motor.
A.Mount an extra cooler
if no other solution
exists
B. Increase the water flow
C. Backflush the cooler or
replace it
D. Change the oil. See
Lubricant
Recommendations
E. Adjust and reset the
valve
F. Measure the amount of
leakage through the
distributor.
A. Replace rotation motor
if case drain leakage
excessive
B. See points 14A, 14B,
14C
C. Adjust the pressure
compensation setting of
the the motor
49
Trouble Shooting Chart
17. Rod threads A. Incorrectly set counter A. Adjust to correct
”screech” when pressure valve for thread setting
breaking-out compensation
B. Threads not greased B. Grease the threads

18. Hydraulic water A. Water pump motor A. Check RPM of motor A. Replace motor not
pump faulty and hydraulic flow to producing RPM
does not produce motor using test box according to oil flow
enough flow B. Worn distributor in B. Check leakage B. Replace distributor
rotation unit through distributor if leakage is in 6-8 lpm
range

50
Trouble Shooting Chart
1.0 Electrical system for electrical power unit 45 kW
Type of fault Cause Pinpointing the fault Remedy
1. Motor does not start A. No power to the unit A. Control lamp ”Power A. Check power supply
(or stops during B. Wrong phase order On” does not lit up B. Switch connector for
operatio) B. Control lamp for two phases (By an
phases is lit up authorized Electrician
C. Electric motor is C. Control lamp for only)
overloaded ”Motor overload” is C. Reset overload relay
lit up (By an authorized
D. Low hydraulic oil D. Control lamp Electrician only)
level Hydraulic oil level is D. Fill hydraulic oil
lit up
E. High hydraulic oil E. Control lamp E. See point 14
temp Hydraulic temp is lit
F. Emergency stop up F. Reset Emergency stop
tripped

2. Circuit breake tripped A. Reset with reset button

out by overload Check what caused the
circuit in the control problem before
circuit for the Star resetting the breaker
Delta starter

3. Circuit breaker tripped A. Reset the breaker

out by overload in the
ground fault circuit

4. Ground fault relay A. Reset with reset button

tripped out

5. Main circuit breaker A. Reset the breaker

tripped out by
undervoltage

51