Ajustes Hidraulicos

UDR 200D
COMMISSIONING PROCEDURE
Revision 2
Table of contents
1 VISUAL INSPECTION AND OTHER NOTES............................................................................4
2 COMPONENT CLEANING........................................................................................................ 4
3 GREASE THE ITEMS LISTED BELOW....................................................................................4
4 OIL FILTER CHART...................................................................................................................5
5 DIESEL ENGINE PREPARATIONS...........................................................................................5
6 MISCELLANEOUS HYDRAULIC CHECKPOINTS....................................................................5

6.1Oil cooler.............................................................................................................................. 5
6.2Main winch............................................................................................................................ 5
6.3Wire line winch motor........................................................................................................... 6
6.4Rotation head motor............................................................................................................. 6
6.5Traverse cylinder..................................................................................................................6
6.6Mast raise cylinders..............................................................................................................6
6.7Mast dump cylinder..............................................................................................................6
6.8Control cabinet..................................................................................................................... 6
6.9Pressure flow control manifold item 46................................................................................7
6.10 jack leg / Mast raise / Mast dump......................................................................................7
6.11 Water pump system........................................................................................................... 7
6.12 Main control valve.............................................................................................................. 7
6.13 Hand pump........................................................................................................................ 7
6.14 track drive controls............................................................................................................. 8
6.15 trackdrive........................................................................................................................... 8
7 MISCELLANEOUS MECHANICAL CHECKPOINTS.................................................................8
8 PRIME THE HYDRAULIC PUMPS............................................................................................8
9 LUBRICATING OIL CHART.....................................................................................................14
10 SHORT CIRCUIT THE MAIN SUPPLY HOSES OF THE FOLLOWING MOTORS.................14
11 CONTROL ADJUSTMENT IN PREPARATION FOR FLUSHING............................................14
12 FIRST EVER DIESEL START-UP...........................................................................................15
13 FLUSHING.............................................................................................................................. 16
13.1 Flushing Table.................................................................................................................. 16
13.2 Flushing Circuit Pressure Checks....................................................................................16
14 RECONNECT HOSES, PRIME HYDRAULIC MOTORS AND HYDRAULIC OIL TANK LEVEL
17
15 OPERATION CONTROL CHECK...........................................................................................17

16 SET UP PROCEDURE FOR CONTROLS OF PUMPS 6A-6B-6C..........................................18
16.1 FIRST STAGE MAIN PUMP 6A.......................................................................................18
UDR AUSTRALIA 200D COMMISSINING PROCEDURE REVISION 2 10/2001 1
16.1.1 Flow regulator setting...............................................................................................18
16.1.2 main control pressure relief valve setting.................................................................18
16.1.3 pressure regulator setting.........................................................................................19
16.2 SECOND STAGE PUMP 6B............................................................................................21
16.2.1 Flow Regulator Adjustment Procedure.....................................................................21
16.2.2 Pressure Relief Valve Item 4 Adjustment Procedure................................................21
16.2.3 Pressure Regulator Adjustment Procedure..............................................................22
16.3 THIRD STAGE PUMP 6C................................................................................................24
16.3.1 Flow Regulator Adjustment Procedure.....................................................................24
16.3.2 Pressure Relief Valve Item 44 Adjustment Procedure..............................................24
16.3.3 Pressure Regulator Adjustment Procedure..............................................................24
17 PRESSURE REDUCING VALVE ITEM 45..............................................................................25
18 PILOT SYSTEM PRESSURE VALVE ITEM 35.......................................................................25
19 JACK LEGS /MAST RAISE / MAST DUMP............................................................................25

19.1 Front and Rear Jack legs Cylinders.................................................................................25
19.2 Mast Raise Cylinders.......................................................................................................25
19.3 Mast Dump Cylinder........................................................................................................ 26
20 ROD CLAMP........................................................................................................................... 27
21 HEAD TRAVERSE MICRO FEED, HOLD BACK, PULL DOWN, MICRO FEED SPEED
CONTROL..................................................................................................................................... 28
21.1 Traverse System Operational Checks.............................................................................28
21.2 Head Traverse Holdings Valve.........................................................................................28
21.3 Main Control Valve Port Pressure Relief Valve Settings..................................................28
21.4 Pull Down Pressure Control Valve...................................................................................29
21.5 Micro Feed System.......................................................................................................... 29
21.6 Balance the rotation head as follows...............................................................................30
21.7 Hose Burst Valve Item 64................................................................................................30
21.8 Power Float Set Up Procedure........................................................................................30
21.9 Control Valve Stroke Limit Adjustment.............................................................................31
21.10Traverse Speed Checks.................................................................................................31
22 ROTATION.............................................................................................................................. 32
22.1 Motor control location......................................................................................................32
22.2 Rotation Head Speed Control Item 55.............................................................................33
22.3 Rotation Chuck Operation...............................................................................................33
22.4 Rotation Head Pivots.......................................................................................................33
22.5 Rotation Head Operational Checks.................................................................................33
22.5.1 Minimum Rotation Head Speed check.....................................................................33
22.5.2 Maximum Rotation Head Speed Setting..................................................................34
22.5.3 Motor Control End Regulator Setting........................................................................34
22.5.4 Rotation Reverse Speed Interlock Valve Check Procedure.....................................34
22.5.5 Rod Spin Guard........................................................................................................35
22.5.6 Rotation Forward Pressure Check...........................................................................35
22.5.7 Main Filter Back pressure Checks............................................................................35
22.5.8 Speed Control Test...................................................................................................36
22.5.9 Control Valve Stroke Limit Adjustment......................................................................36
22.6 Rotation Head to Rod Clamp Alignment..........................................................................36
22.7 Rotation Head Make Up Torque Control..........................................................................36
22.8 Rotation/ Float Operational Check..................................................................................37
23 MAIN WINCH WITH HD TYPE MOTOR.................................................................................38

23.1 Brake Release Test.......................................................................................................... 40
23.2 Main Winch Operational Checks.....................................................................................40
23.2.1 Brake Release and Engagement Test......................................................................40
23.2.2 Counter Balance Open and Close Test....................................................................40
23.2.3 Main Winch HD Regulator Setting............................................................................40
23.2.4 Main Winch Maximum Speed Setting.......................................................................41
23.2.4.1 Control Valve Stroke Limit Adjustment..................................................................41
23.2.5 Main Winch Counter Balance Valve Setting.............................................................41
23.2.6 Main Winch Pressure Cut-Off Setting.......................................................................41
23.2.7 Main Winch Main Control Valve Port Relief Valve Pressure Setting.........................42
23.2.8 Main Winch No load Pressure Check.......................................................................42
23.2.9 Main Winch Pull Test................................................................................................42
23.2.10 Main Winch Float System.........................................................................................43
23.2.10.1 Counter Balance Valve Item 80.........................................................................43
23.2.10.2 Operational Checks...........................................................................................43
23.2.11 Test the Winch with a Test weight.............................................................................44
24 WIRELINE WINCH................................................................................................................. 45
24.1 Wire Line Winch Operational Check...............................................................................45
24.2 Double Counter Balance Valve Item 84...........................................................................45
24.3 Maximum Speed Check and Adjustment.........................................................................45
24.4 Wire Line Winch Maximum Pull Pressure Relief Setting.................................................46
24.5 Wire Line Winch Rope....................................................................................................46
25 WATER PUMP........................................................................................................................ 47
26 TRACK DRIVE CONTROLS...................................................................................................49

26.1 Main control valve port relief setting................................................................................49
26.2 Operational check............................................................................................................ 49
26.2.1 Direction of operation...............................................................................................49
26.2.2 Straight ahead reverse operation..........................................................................49
26.2.3 General operation.....................................................................................................49
27 DIESEL LOAD TEST.............................................................................................................. 50
28 COMMISSIONING CHECK POINTS CHECK THE FOLLOWING...........................................51
29 SERIAL NUMBERS OF EQUIPMENT....................................................................................53
30 SIGNATURE FORM................................................................................................................ 54

1 VISUAL INSPECTION AND OTHER NOTES
Obtain a copy of the production order from the sales department and verify that the rig is
built to the production order.
Obtain copies of the following drawings for the particular rig and use them as a reference
source;
Hydraulic Circuit DR/NO 8040 Latest revision
Water Circuit DR/NO Latest revision
Fuel System Assembly DR/NO Latest revision
Electrical Circuit DR/NO Latest revision
The item numbers on the hydraulic circuit drawing will be used as reference numbers
through out this procedure.
Refer to the UDR 200D operators manual when necessary
ALL POINTS in this commissioning procedure MUST BE initialled and dated by
commissioning personnel.
Please initial and date each line in the left- hand margin.
The following abbreviations will appear throughout this procedure.
A.P.R. = Acceptable Pressure Range in bar /psi.
A.T.R. = Acceptable Temperature Range in C.
A.M.R. = Acceptable Measurement Range in mm / inch.
A.R.R. = Acceptable Revolution Range in rpm.
Use these letters for reference to what is an acceptable range to work in.
While commissioning this rig, the hydraulic oil temp should be between 50C to 60C for
most of the procedure. Please note the hydraulic oil flow to the cooler has a thermal valve
fitted in the system, that will keep the oil temperature stable.
The finished procedure must be sighted and signed by sales department and the
production manager following a visual and operational inspection with any points noted by
the sales inspection checked and corrected by production.
2 COMPONENT CLEANING
Remove the hydraulic oil tank lid and check that the hydraulic tank has been cleaned out.
Thoroughly inspect for perfect cleanliness.
3 GREASE THE ITEMS LISTED BELOW
Description No. of Grease
Nipples
Rotation Head - air & water swivel 1
- top seal cover slinger 1
- chuck thrust bearing 1
- chuck rod jaw bowl 1
Rod Clamp - clamp rod jaw lever 4
bearings
- sliding faces
Water pump - push rods 3 if fitted
Main winch - drum bearing pack with grease
Wire line winch - drum bearing pack with grease

4 OIL FILTER CHART
ITEM ELEMENT MAKE & PARTNO

Hydraulic Tank Main Filter Hydac RFBN660 F10 A1.1
Hydraulic Tank Breather Hydac 0160 MG 010 P
Rotation Head Lube System Vickers 5203174
Rotation Head Breather As supplied by JKS Boyles
High Pressure Filters Elements Hydac 0330 D 10 BN/HC
5 DIESEL ENGINE PREPARATIONS

Get reference drawings for the particular rig for following items
main drive assembly
cooler, radiator assembly
fuel tank assembly
fuel system assembly
Check the oil level
Check all coolant system piping and hoses are tight and correctly positioned.
Check the water level and anti-corrosion / antifreeze additive
Check the battery electrolyte level
Check the air filter assembly, that the primary and safety filter elements are fitted.
Check the fan belt is tight
Spin-on type oil filter fitted and accessible
Spin-on type fuel filter fitted and accessible
Racor primary fuel / water separator filter element is fitted.
Fuel line ball valve open if fitted.
Diesel fuel in tank
Fuel lines in and out correctly fitted
Check valve fitted in fuel suction line
Diesel throttle cable correctly fitted and functional
Oil pressure gauge and hose correctly fitted and functional
Temperature gauge and capillary line correctly fitted
Electrical system correctly connected and functional
Emergency stop switch correctly connected and functional
Check the exhaust system is correctly fitted and functional.
6 MISCELLANEOUS HYDRAULIC CHECKPOINTS
6.1 OIL COOLER

Check the oil cooler by pass check valve Item 10 is pipe in correctly and has a 3 bar /
43.5 psi cracking pressure
Check the oil cooler, thermal valve item 8 is correctly piped in.
6.2 MAIN WINCH
Check all cartridges fitted to the main winch block part no WU8816, do not have any
damaged or missing O rings or back up rings.
Check the cartridges are fitted into the correct cavities in the main winch manifold block,
part no WU8816.
Check the HD control end pressure of the main winch motor item 70 has been preset
to 15 bar / 217.5 psi.

Check the pressure cut off of main winch motor item 70 has been preset to 200 bar /
2900 psi.
Check the holding valve item 71 has been preset to 220 bar / 3190 psi.
Check that both orifice check valves item 72, for the following;
Correctly piped in
Have 0.6mm 0.0236 inch orifice drilled in them.
Are free of any debris eg sealing compounds, hose dust.
Check the holding valve [winch float] item 80 has been preset to 250 bar / 3625 psi.
Check pilot open check valve item 81 has been correctly piped in.
Check the external hosing is correct by the hydraulic circuit drawing.
6.3 WIRE LINE WINCH MOTOR
Check the holding valves item 77, have been preset to 210 bar / 3045 psi.
6.4 ROTATION HEAD MOTOR
Check the HD control end pressure setting of the motor item 78 has been preset to 25
bar / 362.5 psi.
Check the pressure cut off setting has been set above 275bar/ 3987.5 psi.
The pressure cut off is not used in this particular rotation head set up.
6.5 TRAVERSE CYLINDER
Check the holding valve item 63 has been preset to 260 bar / 3770 psi.
Check the orifice plate has been removed from the hose burst valve, which is fitted to
the traverse cylinder.
6.6 MAST RAISE CYLINDERS
Check the mast raise cylinder holding valves item 63 for the following
Have been preset to 230 bar / 3335 psi
Correctly piped in
6.7 MAST DUMP CYLINDER
Check the mast dump cylinder holding valves item 63 for the following
Have been preset to 230 bar / 3335 psi
Correctly piped in
6.8 CONTROL CABINET
Check the cartridges items 45 & 35, which are fitted to the three station (chuck / clamp /
float) manifold block item 23, do not have any damaged or missing O rings or back up
rings.
Check the cartridges fitted to the feed control manifold block item 38, do not have any
damaged or missing O rings or back up rings.
Check the correct cartridges are fitted into the correct cavities of the manifold block item
38.
Check the pilot control valves item 25 & 26 have the correct pilot control curves (curve
06) fitted to them.
Check the rotation pilot control lever has the modified lockable control lever WU9388
has been correctly fitted to it.
Check the pull down minimum back pressure check valve item 29 is a 5 bar / 72,5 psi
cracking pressure check valve and that the cartridge is in the correct location.
Check that check valve item 43 WU8059 has a 0.6mm orifice in it and that the cartridge
is in the correct location.
Check the following directional control valve have detents fitted to them
Micro-feed
Float
Check the winch float 3-way ball valve item 27 has been correctly in.
Check the drill make ball valve is correctly piped in.
6.9 PRESSURE FLOW CONTROL MANIFOLD ITEM 46
Check the primary pressure relief valve item 44 has been preset to 210 bar / 3045 psi.
Check the pressure reducing cartridge for the chuck / float / rotation speed control item
45 has been preset to 100 bar / 1450psi.
Check the pressure relief valve item 35 has been preset to 35-40bar / 507.5-580psi.
Check the flow control orifice item 47 for the mud mixer is the correct size (1.3 mm id x 4
mm long) (0.51 id x 0.157 long) and is fitted into the port P8 of the pressure flow
control manifold item 46.
Check the flow control orifice item 47 for the jack leg / mast raise / mast dump and
micro-feed control valves is the correct size (1.3 mm id x 4mm long) (0.51 id x 0.157
long) and is piped into the port P7 of the pressure flow control manifold item 46.
Check the flow control orifice for the pilot pressure system, is the correct size (1.2mm id
x 4mm long) (0.47 id x 0.157 long). The orifice is fitted inside the port marked ORF of
the flow control manifold item 46
Check the flow control orifice item 49 for the rotation speed control is the correct size
(0.9mm id x 4mm long) (0.35 id x 0.157 long) and is fitted into port P9 of the pressure
flow control manifold item 46.
6.10 JACK LEG / MAST RAISE / MAST DUMP
Check the primary pressure relief valve of item 59 has been preset to 230 bar / 3335
psi.
Check the mast lower port pressure relief valve cartridge has been preset to 170 bar /
2465 psi.
Check the mast dump port pressure relief valve cartridge [port A], has been preset to
70 bar / 1015 psi. This port supplies pressure to lower the mast on the dump slides.
Check the mast dump port pressure relief valve cartridge [port B], has been preset to
100 bar / 1450 psi. This port supplies pressure to raise the mast on the dump slides.
6.11 WATER PUMP SYSTEM
Check the primary pressure relief valve item 4 has been preset to 200 bar / 2900psi.
Check the water pump ON-OFF 3-way ball valve item 27 has been correctly in.
Check the water pump fine and coarse speed control items 33 & 36 have been correctly
piped in.
6.12 MAIN CONTROL VALVE
Check the spike protection pressure relief valve, in the inlet section of the main control
valve item 24, has been preset to 275 bar / 3988 psi.
Check the B port pressure relief valve of the main winch valve section has been preset
to 235 bar / 3407 psi.
Check the B port pressure relief valve of the wire line winch valve section has been
preset to 235 bar / 3988 psi.
Check the A & B port pressure relief valves of the traverse valve section has been
preset to 210 bar / 3045psi.

6.13 HAND PUMP
Check the hand pump outlet check valve Item 38 is correctly piped in.

6.14 TRACK DRIVE CONTROLS
Check the front /rear track selector valve item 27.3 is correctly hosed up.
Check the rig /track selector valve item28 is correctly hosed up.
Check the shuttle valves items 64 are correctly hosed up.
Check the port relief valves of the main control valve item 24 have been preset to 235
bar / 3407 psi.
6.15 TRACKDRIVE
Check the track drive final drives are full to the correct level with the correct grade
lubricating oil.
Check the track drive motor cases are filled with clean hydraulic oil.
Check the tracks are correctly adjusted.
7 MISCELLANEOUS MECHANICAL CHECKPOINTS
Check the main winch drum to gearbox drive shaft shoulder clearance is a minimum 1mm /
0.4.
Check the main winch drum bearing has been correctly fitted.
Check the wire line winch drum to motor drive shaft shoulder has a minimum clearance of
1mm / 0.4.
Check the wire line winch drum bearing has been correctly fitted and the lock nut torqued up
to the recommended torque.
Check the mast raise cylinder pins are fitted and secured.
Check the mast pivot pins are correctly fitted and secured.
Check the mast dump cylinder pins are fitted and secured.
Check the mast dump cylinder barrel U bolt is secured.
Check all bolts and nuts have been torqued up to the recommended torque.
Check the mast sections fit together easily.
Check the main and wire line winch rope sheave assembly has been assembled correctly.
8 PRIME THE HYDRAULIC PUMPS
Open the upper drain port of No.6A-6B-6C of pump assembly. Fill the cases of each pump with
clean hydraulic oil. Ensure that all air has been expelled from each pump case.

MAIN WINCH MANIFOLD BLOCK PART NO WU 8816
The above manifold is comprised of the following items. Refer to the hydraulic circuit for
further details.
71 PD24464U VALVE COUNTER BALANCE WINCH OVER RUN CONTROL
73 5-203-341 VALVE SHUTTLE CART.
80 PD24464KT VALVE COUNTER BALANCE WINCH FLOAT SYSTEM
81 PD24464AH VALVE CHECK PILOT OPEN WINCH FLOAT SYSTEM
82 PD24464KV VALVE BODY(MANIFLOD BLOCK)

PRESSURE FLOW CONTROL MANIFOLD PART NO WU 8817
further details.
35 PD24464BB VALVE RELIEF CART. PILOT PRESSURE SYSTEM
44 PD24464GX VALVE RELIEF CART. PRIMARY PRESURE RELIEF
(FOR PRESSURE FLOW BLOCK)
45 5-203-232 VALVE PRESSURE REDUCING CART.
CHUCK/CLAMP/FLOAT AND ROTATION SPEED SYSTEMS
46 PD24464KW VALVE BODY (MANIFOLD BLOCK)

PRESSURE FLOW CONTROL MANIFOLD PART NO WU 8817
1. Pressure test point for the pilot pressure valve item 35. Item 35 controls the primary pilot
pressure.
2. Pressure test point for pressure reducing valve item 45. Item 45 controls the pressure
for the operation of the chuck / clamp / power float controls.
3. Pressure test point for primary pressure relief valve item 44 and pump 6C. Item 44 is the
safety pressure relief valve for pump 6C. If the pressure regulator of pump 6C fails this
valve will activate.
4. Pressure test point for the micro-feed and jack leg / mast raise / mast dump control
valves.
5. Pressure test point for the rotation head speed control valve item 37

FEED CONTROL MANIFOLD PART NO WU8823
further details. Items 18 and 19 not shown on the above view.
18 PD22870UM VALVE DIRECTIONAL MAST RAISE (not fitted)
19 PD22870UQ VALVE DIRECTIONAL MICRO-FEED
29 PD24464KY VALVE CHECK PULLDOWN MINIMUM BACK PRESSURE
37 PD22870QY VALVE RELIEF CART. ROTATION SPEED CONTROL
38 WU8283 MANIFLOD BLOCK
39 PD22870AA VALVE RELIEF CART. HOLD BACK AND PULL DOWN
40 5-203-694 VALVE CHECK
41 PD24464JK VALVE NEEDLE CART. MICRO FEED SPEED CONTROL
43 WU8059 VALVE CHECK WITH ORIFICE
44 PD24464GX VALVE RELIEF CART. ROTATION MAKE TORQUE CONTROL

2-STATION CETOP 3 MANIFOLD PART NO WU8824
further details. Items 19 and 21 not shown on the above view.
19 PD22870UQ VALVE DIRECTIONAL FLOAT OPERATION
21 PD22870VT VALVE DIRECTIONAL CLAMPS / CHUCK
23 PD24464LA VALVE BODY 3 STATION CETOP 3
35 5-203-232 VALVE PRESSURE RELIEF (FLOAT SYSTEM BACK RESSURE)
45 PD24464BB VALVE PRESSURE REDUCING

9 LUBRICATING OIL CHART
OBSERVE CORRECT LEVELS
ITEM OIL TYPE QTY OIL LEVEL

LTRS
DIESEL AS RECOMMENDED BY THE DIPSTICK

ENGINE SUPPLIER TO SUIT THE
AIR TEMPERATURE WHEN
OPERATING
ROT. HEAD * CASTROL ALPHA SP220 5 LEVEL GAUGE
MAIN WINCH ALPHA SP 220 OR 3 LEVEL PLUG - MUST BE

GEAR BOX EQUIVALENT HALF FULL
WATER PUMP SAE 40 2.5 LEVEL PLUG
HYDR. TANK HYDRAULIC OILTO SUIT CLIMATE 200 TO UPPER LEVEL MARK
CONDITIONS. ON SIGHT GLASS
NOTE: Check the Rotation Head oil cooler lines are full with lubricating oil.
10 SHORT CIRCUIT THE MAIN SUPPLY HOSES OF THE FOLLOWING MOTORS
Main Winch Motor
Rotation Head Motor
Water Pump Motor
Wire line winch motor
Mud mixer motor if fitted or short circuit quick release couplings.
Track drive motors if fitted
NOTE:
Close the motor ports with plugs, caps during flushing to prevent dirt and water entering.
11 CONTROL ADJUSTMENT IN PREPARATION FOR FLUSHING
Fully open the mud mixer speed control valve item 58
Fully open the water pump fine and coarse control valves items 33 & 36.
Water pump ON-OFF 3-way ball valve in the ON position.
Drill / Make control item 31 in the DRILL position.
Micro feed control lever in the neutral position.
Chuck / clamp control lever in the neutral position.
Float control lever in the OFF position.
The override pin must be fitted to the rod spin guard valve at the mast base.
Fit a 100 bar / 1450-psi pressure gauge to the pressure test point item 14 on the pressure
relief valve item 4.
Fit a 100 bar / 1450-psi pressure gauge to the pressure test point item 14 on the pressure
flow control manifold to check pump 6C pressure.
Adjust by two full turns out the pressure cut off adjustment of pumps 6A-6B-6C
Connect the X port of the rotation head motor to the case drain port via a 0.50 mm
0.019orifice
Connect the X port of the main winch motor to the case drain port via a 0.50 mm
0.019orifice
Fully increase the rotation speed control item 55.
Remove the brake release hose from the main winch gearbox and connect the line via a
0.5mm 0.019orifice to the drain hose of the main winch motor.
Put the main winch float control item 27 into the float position.
Fit a 100 bar /1450 psi gauge to the pressure measuring point teed into the P5 port of
the pressure flow control manifold, to check the pilot pressure for the pilot oil controllers
item no 25 & 26.
While commissioning this rig, the hydraulic oil temp should be between 50C to 60C for
most of the procedure. Please note the hydraulic oil flow to the cooler has a thermal valve
fitted in the system, which will keep the oil temperature stable.
12 FIRST EVER DIESEL START-UP
Ring the engine supplier to commission diesel
Immediately after first kick over let the diesel idle at 800 to 850 rpm and check the
following:
Diesel water temperature settles below 85C
Diesel fan is sucking air through radiator
Diesel oil pressure minimum 1.03 bar/15psi idling
Check that Rexroth pumps work properly, correct rotation
Engine supplier representative to commission diesel
Ensure the correct operation of diesel emergency shut down system.
High water temperature.
Low oil pressure
Entire diesel installation is satisfactory
Set the maximum no load speed of diesel at 2400 rpm.

13 FLUSHING
Note
During flushing no pressure to exceed 60 bar in any circuit.
Oil temperature in tank not to exceed 70C
All flushing to be carried out at 2200 rpm A.R.R. 2200-2220
13.1 FLUSHING TABLE.
Time in Minutes. Total flushing time 1hour 30 minutes
0-15 15-30 30-45 45-60 60-75 75-90 90-105 105-120
ROTATION ROTATION MAIN MAIN WIRE LINE WIRE LINE RIGHT & RIGHT &
HEAD HEAD WINCH WINCH WINCH WINCH LEFT LEFT
FORWARD REVERSE RAISE LOWER RAISE LOWER TRACK TRACK
FORWARD REVERSE
PUMP 3B WATER PUMP
Note
Do not operate the mast raise / micro-feed / chuck / clamp / traverse levers
13.2 FLUSHING CIRCUIT PRESSURE CHECKS
FUNCTION PUMP DIESEL PRESS PRESS BAR PRESS BAR OIL TEMP
RPM CHECK AT C
ITEM ACTUAL EXPECTED
Rotation forward 6A 2200 24 30-35

Rotation reverse 6A 2200 24 30-35
Main winch raise 6A 2200 24 25-30
Main winch lower 6A 2200 24 25-30
Wire line winch raise 6A 2200 24 30-35
Wire line winch lower 6A 2200 24 30-35
Right & left track 6A 2200 24 30-35
forward
Right & left track 6A 2200 24 30-35
reverse
Water Pump 6B 2200 Pump 3B 25-30
Mud Mixer 6C 2200 Pump 3C 95-100
Pilot pressure 6C 2200 P port of pilot 50-55
control
NOTE: During flushing check the following:

diesel water temperature
diesel oil pressure
main filter back pressure - max. 2 bar
No pressure to exceed 60 bar
Note and report any anomalies

After 90 mins of operation note main filter back pressure and oil temp (item 25 at
panel).
OIL TEMPERATURE C ATR 60 - 65C

ACTUAL PRESS BAR APR 0.- 0.2 BAR
14 RECONNECT HOSES, PRIME HYDRAULIC MOTORS AND HYDRAULIC OIL

TANK LEVEL
Reconnect the brake release hose to the main winch gearbox.
Reconnect the X port hose to the main winch motor.
Reconnect the X port hose to the rotation head motor.
Reconnect the pressure hoses to the following motors.
Main winch motor
Rotation head motor
Water pump motor
Mud mixer motor if fitted
Track drive motors. Refer to track control section
Prime the motor cases with clean hydraulic oil if applicable.
Check the hydraulic oil tank level, top up if required.
15 OPERATION CONTROL CHECK
Check the following controls for correct operation versus nametags.
Rapid Traverse Up - Down
Main Winch Up Down
UP = Clockwise rotation from right-hand side of rig facing
hydraulic oil tank
Wire Line Winch Up Down
UP = Counter clockwise rotation from right-hand side of rig
facing hydraulic oil tank
Rotation Head Forward Reverse
Note
Refer to rotation section re lube oil and chuck operation
before rotating head
Water Pump Clockwise rotation. Look inside crank case with oil fill cap
removed.
Note
Each of the above controls will be commissioned in depth under their own
respective section.
Check the above at 900 - 1,000 diesel rpm.
No mechanical fouling.
No hoses being nipped or pulled.
No hydraulic oil leaks.
Check hose reel for any mechanical fouling.

16 SET UP PROCEDURE FOR CONTROLS OF PUMPS 6A-6B-6C
DFR Control (Pressure & Flow Regulation - Load Sensing)
16.1 FIRST STAGE MAIN PUMP 6A
16.1.1 FLOW REGULATOR SETTING

1. Refer to the drawing on the following page to locate the pump control positions.
2. Check the pilot levers for the main drill functions (main winch, wire line winch,
rotation, traverse) are in the neutral position.
3. Fit a 40 bar gauge to the pressure test point on the G port of the main control
valve inlet.
4. Remove the flow regulator cap nut. Loosen the flow regulator locknut.
5. Start the engine and operate at 1200-1300 rpm.
6. Using an allen key, adjust the flow regulator setting screw until the pressure
gauge at the G port indicates 18-18.5 bar.
Actual flow regulator setting BAR A.P.R 18-18.5 BAR
PSI A.P.R. 261-268 PSI

7. Tighten the flow regulator locknut and replace the cap nut.
8. Recheck the flow regulator pressure setting.
9. Remove the pressure gauge from the test point.
16.1.2 MAIN CONTROL PRESSURE RELIEF VALVE SETTING
1. Reduce the pressure setting of the main control pressure relief valve by one full
turn.
2. Remove the pressure hoses from the rotation head motor and plug the hoses,
cap the fittings to stop any dirt ingress.
3. Remove the pressure regulator cap nut.
4. Loosen the pressure regulator locknut.
6. Engage the rotation control lever fully.
7. Using an allen key, slowly turn the pressure regulator setting screw (maximum
system pressure) clockwise.
Turning the setting screw clockwise increases the pressure.
Turning the setting screw counter-clockwise reduces the pressure.
One turn of the setting screw corresponds to 50 bar /725psi pressure in
the range 20 to 250 bar / 290 to 3625psi.
Observe the pressure reading at main pump pressure gauge.
8. Adjust the pressure regulator screw until the main control pressure relief valve
responds. Adjust the pressure regulator screw in one complete turn.
9. Set the pressure relief valve to 275 bar / 3977 psi for pump 6A. Check the
pressure setting at main pump pressure gauge with the diesel at 1800-1850 rpm
Actual pressure regulator setting BAR A.P.R 275-280 BAR
PSI A.P.R. 3977-4060 PSI
Actual diesel rpm RPM A.R.R 1800-1850 RPM

16.1.3 PRESSURE REGULATOR SETTING
1. Remove the pressure hoses from the rotation head motor and plug the hoses,
cap the fittings to stop any dirt ingress.
2. Remove the pressure regulator cap nut.
3. Loosen the pressure regulator locknut.
5. Engage the rotation control lever fully.
One turn of the setting screw corresponds to 50 bar /725psi pressure in
the range 20 to 250 bar / 290 to 3625psi.
Observe the pressure reading at main pump pressure gauge.
7. Set the pressure regulator to 260 bar / 3770 psi for pump 6A. Check the
pressure setting at main pump pressure gauge with the diesel at 1800-1850 rpm
NOTE
The spike protection pressure relief valve, of the main control valve item
No. 24, may open and vent to tank, if the pressure regulator is set above
260 bar / 3770 psi. If this happens, check the spike protection opens at
275 bar / 3988 psi by adjusting the pressure regulator in very small
increments.
PSI A.P.R. 3741-3770 PSI
8. Tighten the locknut and fit the cap nut.

FIGURE OF PUMP 6A

16.2 SECOND STAGE PUMP 6B
16.2.1 FLOW REGULATOR ADJUSTMENT PROCEDURE

1. Refer to the picture on page 21 for the location of the regulator setting screws.
2. Remove the pressure hose from the water pump motor. Cap the fitting and plug
the hose end with steel plugs.
3. Remove the flow regulator cap nut and loosen the lock nut.
Note
When the cap nuts are loosened, a slight oil weep will occur.
4. Fit a 50 bar pressure gauge to the test coupling of pressure relief valve, which is
connected to the pump 6B pressure port.
5. At the control panel set the water pump hydraulic controls as follows:
Water Pump on-off: OFF
Water Pump fine control: CLOSED ( fully counter clockwise)
Water Pump coarse control: CLOSED (lever up)
6. Start the engine and set the diesel rpm to 1800 to1850 rpm.
7. Operate the water pump on-off control to the ON position.
8. Adjust the flow regulator adjustment screw until the pressure gauge reads 14-15
bar.
Actual flow regulator setting BAR A.P.R 14-15 BAR
9. Check the setting by operating the water pump on-off control OFF-ON several
times.
Note
The flow regulator cannot be set correctly, if pressure relief valve or the
water pump on / off ball valve is faulty.
10. Tighten the flow regulator lock nut and replace the cap nut.
11. Operate the water pump on-off control to the OFF position. Stop the engine.
16.2.2 PRESSURE RELIEF VALVE ITEM 4 ADJUSTMENT PROCEDURE
1. Refer to the picture on page 21 for the location of the pump regulator setting
screws.
2. Fit a 250 bar pressure gauge to the test coupling of pressure relief valve, which
is connected to the pump pressure port of pump 6B.
3. Remove the pressure hose from the water pump motor. Cap the fitting and plug
the hose end with steel plugs.
Water Pump fine control: CLOSED (fully counter clockwise)
Water Pump coarse control: OPEN (lever up)
5. Loosen the lock nut on the pressure relief valve cartridge.
6. Remove the pressure regulator cap nut and loosen the lock nut.
Note
Operate the water pump on-off control to ON.

8. Set the pressure relief as follows.
Slowly adjust the pump pressure regulator setting screw IN until the pressure
relief valve responds.
At this point you will hear the diesel engine noise change due to the hydraulic
pump producing oil and allowing that oil flow to vent over the pressure relief
valve.
Adjust the pressure regulator screw in a further half a turn.
Adjust the pressure relief valve setting screw until the 200 bar is indicated on the
pressure gauge.
Check the setting by operating the water pump on-off control OFF-ON several
times.
Actual pressure relief valve setting BAR A.P.R 198-200 BAR
PSI A.P.R. 2871-2900 PSI
9. Tighten the lock nut of the pressure relief valve cartridge.

10. Refer to the pressure regulator setting procedure and carry it out.
12. Refit the pressure hose onto the water pump motor if no further adjustment is
required.
16.2.3 PRESSURE REGULATOR ADJUSTMENT PROCEDURE
1. Refer to the picture on page 21 for the location of the regulator setting screws.
2. Refer to the hydraulic circuit for this rig. A copy of the circuit is normally located at
the end of this manual.
3. Fit a 250 bar pressure gauge to the test coupling of pressure relief valve item 4,
which is connected to the pump 6B pressure port.
4. Remove the pressure hose from the water pump motor. Cap the fitting on the motor
and plug the hose end with steel plugs
Water Pump fine control: CLOSED (fully counter clockwise)
Water Pump coarse control: OPEN (lever down)
6. Remove the pressure regulator cap nut and loosen the lock nut.
Note
8. Using an allen key, set the pump pressure regulator setting (maximum system
pressure) by turning the setting screw as follows.
Observe the pressure reading on the gauge on the test coupling.
Operate the water pump on-off control to the ON position.
Adjusting the pressure regulator setting screw clockwise increases the pressure.
Adjusting the pressure regulator setting screw counter-clockwise reduces the
pressure.
One turn of the setting screw corresponds to 50-bar pressure in the range 20 to
250 bar.
Adjust the pressure setting to 180 bar.
PSI A.P.R. 2581-2610 PSI


Note
Do not exceed the pressure relief valve setting, note that pump pressure
regulator setting is generally 15-20 bar lower than relief valve setting.
The pressure regulator cannot be set correctly, if the pressure relief valve
or the water pump on / off ball valve is faulty.
7. Check the setting by operating the water pump on-off control OFF-ON several
times.
8. Tighten the lock nut and replace the cap nut.
10. Refit the pressure hose onto the water pump motor if no further adjustment is
required.
FIGURE OF PUMP 6B

16.3 THIRD STAGE PUMP 6C
16.3.1 FLOW REGULATOR ADJUSTMENT PROCEDURE

Refer to the figure for pump 6B for the location of the pump control locations.
1. Fit the 250 bar / 3625 psi pressure gauge to the pressure test coupling item 14
for item 44 primary pressure relief valve in the pressure flow control manifold
item 46. Refer to page 9 for location of test point.
2. Reduce the rotation the rotation speed control item 55 fully.
3. Close (fully decrease) the mud mixer speed control item 48
4. Remove the flow regulator cap nut and loosen the locknut.
NOTE
When the cap and lock nuts are loosened, a slight oil weep will occur.
5. Using an allen key, turn the flow regulator setting screw clockwise all the way in,
then back out the screw by 1/2 turn tighten the locknut. Fit and tighten the cap
nut.
16.3.2 PRESSURE RELIEF VALVE ITEM 44 ADJUSTMENT PROCEDURE
1. Remove the pressure regulator cap nut and loosen the locknut
NOTE
When the cap and lock nuts are loosened, a slight oil weep will occur.
2. Reduce the pressure setting of item 44 by one full turn.
3. Start the diesel engine and operate at 1800-1850 rpm.
One turn of the setting screw corresponds to 50 bar / 725 psi pressure in
the range 20 to 250 bar / 290 to 3625 psi.
Observe the pressure reading at the 250 bar / 3625 psi pressure gauge.
3. Adjust the pressure regulator until item 44 opens, adjust the pressure regulator
screw in a further complete turn.
4. Adjust the pressure relief valve item 44 to 210 bar / 3045 psi.
Actual pressure relief valve setting BAR A.P.R 210-215 BAR
PSI A.P.R. 3045-3117 PSI
5. Tighten the locknut of item 44.

16.3.3 PRESSURE REGULATOR ADJUSTMENT PROCEDURE
system pressure) counter clockwise.
One turn of the setting screw corresponds to 50 bar / 725 psi pressure in
the range 20 to 250 bar / 290 to 3625 psi.
Observe the pressure reading at the 250 bar / 3625 psi pressure gauge.
2. Set the pressure regulator to 200 bar / 2900 psi for pump 6C.
NOTE The pressure relief valve item No.44 may open and vent to tank,
if the pressure regulator is set above 200 bar / 2900 psi.
If this happens set the pressure relief valve to open at 210 bar / 3045 psi
by adjusting the pressure regulator.

PSI A.P.R. 2870-2900 PSI
Actual diesel rpm RPM A.R.R 1800-1820

RPM
3. Tighten the locknut and replace the cap nut of the pressure regulator
adjustment screw.
17 PRESSURE REDUCING VALVE ITEM 45
1. Fit a 150 bar / 2175-psi pressure gauge to the pressure test coupling fitted to the
pressure flow control manifold item 46. Refer to page 9 for location of test point for
item 45.
2. Adjust the pressure-reducing valve until 100 bar is indicated on the gauge. Diesel
engine rpm 800-850 rpm.
ACTUAL PRESSURE BAR A.P.R. 100-102 BAR

PSI A.P.R. 1450-1480 PSI
18 PILOT SYSTEM PRESSURE VALVE ITEM 35

1. Connect a 100 bar / 1450 psi gauge to the pressure test coupling item 14 which is
fitted into the port ORF of the pressure flow control manifold item 46. Refer to page
9 for location of test point for item 35.
2. Check the pressure setting at the gauge, it should read 40 bar / 580 psi.
3. Adjust valve 35 until 40 bar is indicated on the gauge if necessary. Diesel engine
rpm 800-850 rpm.
19 JACK LEGS /MAST RAISE / MAST DUMP
19.1 FRONT AND REAR JACK LEGS CYLINDERS

Raise and lower to ground level only each jack leg cylinder several times, do not
raise the rig, check as follows:
Correct operation versus name tag drawing.
Any mechanical fouling
Any hydraulic oil leaks.
Jack the rig up clear of ground, level the rig both front and rear and side to side.
Check for any drift in cylinders, there must not be any drift in 15 minutes. Check
during the day.
19.2 MAST RAISE CYLINDERS
Check all 4 screws holding the 2 upper mast raise cylinder pivot pins shear plates
are tight and the pivot pins have been greased.
Check the lower mast raise cylinders pivot pins have been properly secured and that
the pivots have been greased.
Check fittings of the double holding valves connected to the mast raise cylinders are
tight.
Check the holding valve cartridges fitted to the valves are tight.

Set the mast up as follows.
Rotation head in the drill position and at the top of the mast.
All sections of the mast bolted together.
Mast crown assembly fitted.
Rod slide fitted
Basket fitted
Operate the mast raise control lever and slowly raise the mast with the diesel at 850
rpm.
Note the raising pressure at Item 14 at the inlet of valve 59, whilst raising the mast
up to 1 metre above the mast cradle.
ACTUAL PRESSURE BAR APR 200- 210 BAR
Twice raise the mast to 60 then lower, the third time raise mast fully check as
follows:
Correct operation versus name tag drawing
Any hoses being nipped or pulled
Check that the mast goes OVER-CENTRE smoothly.
Let mast go into vertical position under its own weight, do not apply pressure
LOWER the mast from vertical position with diesel idling and note pressure
required to initially move it.
ACTUAL PRESSURE BAR APR
Check at Item 14 at the inlet of valve 59
Lower the mast fully, check the mast alignment to the nylon wear pads on the tray.
Raise the mast to vertical position.
19.3 MAST DUMP CYLINDER
Lower mast to 45, operate the mast dump control lever several times. Check as follows:
Any hoses being nipped or pulled particularly the hoses on the left-hand side of the
mast leading to and from the tray.
Check and record pressure to raise and lower mast (on dump slide). Check at item 14 at
the inlet of valve 59.
ACTUAL RAISE PRESSURE BAR APR 48-50 BAR
ACTUAL LOWER PRESSURE BAR APR 8-10 BAR
Raise the mast to highest position on mast dump slides. Close item 19. Raise the mast to
the vertical position. Check the mast dump for any drift over 60 minutes.
ACTUAL DRIFT MM AMR 0-5 MM ATR 0-60 MINS

20 ROD CLAMP
Connect the C1 and C2 ports of the double counter balance valve item 42 together with
a hose. Tee a 200bar pressure gauge into the hose.
Remove the lock nuts from the pressure adjustments of the valve.
Start the engine and operate between 850-857 rpm.
Operate the rod clamp control lever in both directions and adjust the pressure controls
until 70 bar is indicated on the pressure gauge for both directions of operation.
Fit an N size rod jaw set to the rod clamp. Operate the control lever and check the
following.
No hydraulic oil leaks.
No hoses nipped or pulled.
Fit a short length of N size rod to the rod clamp Check for correct operation of the rod
clamp versus nametag on the control panel.
Note
The alignment of the rod clamp with the rotation head will be covered in the rotation
section.

21 HEAD TRAVERSE MICRO FEED, HOLD BACK, PULL DOWN, MICRO FEED
SPEED CONTROL
21.1 TRAVERSE SYSTEM OPERATIONAL CHECKS

With the diesel engine at 800-850 rpm. Operate the traverse lever UP and DOWN
several times and check the following
Correct operation versus the name tag drawing
No mechanical fouling
No hoses connected to the rotation head and traverse cylinder being nipped or pulled
Carry out the above test again but with the micro feed lever.
21.2 HEAD TRAVERSE HOLDINGS VALVE
Set the head traverse holding valve as follows:
Fully increase the pull down pressure control.
Slowly engage the head traverse lever DOWN with the diesel engine at 900 RPM, so
that the rotation head just creeps down the mast.
Adjust the counter balance valve item 63 until 30 bar A.P.R. 29-30 bar / 435psi A.P.R.
420-435 psi reads on the pull down pressure gauge item 51.
21.3 MAIN CONTROL VALVE PORT PRESSURE RELIEF VALVE SETTINGS

Operate the traverse lever DOWN and traverse the rotation head to the bottom of the
mast.
With the diesel at 1800 rpm. Operate the traverse lever DOWN and adjust the A port
relief valve of the main control valve until 210 bar A.P.R 210-212 BAR / 3045 psi A.P.R.
3045-3074 PSI reads on the main pump pressure gauge.
Operate the traverse lever UP and traverse the rotation head to the top of the mast.
With the diesel at 1800 rpm. Operate the traverse lever UP and adjust the B port relief
valve of the main control valve until 210 bar A.P.R 210-212 BAR / 3045 PSI A.P.R. 3045
3074 PSI reads on the main pump pressure gauge.
ACTUAL A PORT PRESSURE BAR A.P.R. 210-212 BAR
PSI A.P.R. 3045-3074 PSI
ACTUAL B PORT PRESSURE BAR A.P.R. 210-212 BAR
PSI A.P.R. 3045-3074 PSI

21.4 PULL DOWN PRESSURE CONTROL VALVE
Fully decrease the pull down pressure control item 39 at the control panel. Rotation head
fully down the mast, diesel at 2200 rpm. Micro feed control lever engaged DOWN, micro
feed speed control item 41 fully increased. Hold back pressure control Item 39 fully
decreased.
Slowly increase the pull down pressure control item 39, observe the pull down gauge
readings follows smoothly.
Pull down pressure control fully increased. Note the pressure at the pull down gauge item
51 at the panel.
PSI A.P.R. 2827-2900 PSI

Engage the head traverse lever DOWN, as well as the micro feed. Note the pressure
reading on the pull down gauge item 51 at the panel.
ACTUAL PRESSURE BAR A.P.R 210-215 BAR
PSI A.P.R. 3045-3117 PSI
21.5 MICRO FEED SYSTEM

Engage the micro feed lever DOWN, diesel 2200 rpm, pull down pressure control item 39
fully decreased, hold back pressure control item 39 fully decreased, micro feed speed
control item 41 fully increased.
Slowly increase the pull down pressure control. Note on the pull down pressure gauge, the
pressure to just lower the head.
ACTUAL OIL TEMPERATURE C ATR 55-60C
Slowly increase the hold back-pressure control and balance, stop the head movement
with the hold back. Note the pressure at the pull down pressure gauge and hydraulic oil
temp.
ACTUAL PRESSURE BAR A.P.R 6-7 BAR

ACTUAL OIL TEMPERATURE C ATR 55-60C
As head moves down the mast, play with various hold back; pull down and diesel rpm
settings, the head movement must be smooth.
Increase the pull down control to maximum, stop the head movement with hold back
control.

21.6 BALANCE THE ROTATION HEAD AS FOLLOWS
Fully decrease the pull down pressure control item 39.
Fully decrease the hold back pressure control item 39.
Micro feed speed control item 41 fully increased.
Engage the micro feed control lever DOWN and balance the mass of head with the
holdback control.
Use the head traverse to move the head fully down, leave the micro feed engaged
DOWN and set the pull down pressure to 100 bar / 1450 psi.
Leave all controls as set.
Move the head to the top of the mast with the HEAD TRAVERSE.
Let the head come down with the micro feed.
Adjust the micro feed speed control item 41 and set head speed at 50.8mm / 2 per
minute. Head movement must be smooth.
Stop the head with micro feed speed control (fully decreased), check for zero drift in one
minute.
ACTUAL DRIFT MM A.M.R. 0-5 MM
INCH A.M.R. 0-0.196
21.7 HOSE BURST VALVE ITEM 64

The valve cannot be tested safely under work-shop conditions.
The valve could be tested at a hydraulic repair shop where a flow in excess of 80 lpm
could be put through the valve.
21.8 POWER FLOAT SET UP PROCEDURE
Fully decrease the pressure setting of the float control valve item 35, which is at the
control panel.
Fully decrease the pressure setting of the float system back pressure relief valve item 45,
which is fitted to the 3 station valve manifold item 23.
With the diesel at 1500 rpm A.R.R 1500-1550. Operate the traverse lever and bring the
head to the bottom of the mast.
Engage the float lever to the FLOAT position.
Adjust the float control until 20 bar A.P.R 19.5-20 bar / 290-psi A.P.R.283-290 psi reads on
the pull down pressure gauge item 51.
Operate the traverse lever and position the rotation head about the centre of the mast.
Adjust the float system back pressure relief valve item 45 until the rotation head just stops
moving.
Check the setting by decreasing and increasing the pressure setting of the float control
valve item 35
Decreasing the pressure setting below 20 bar / 290 psi should stop movement of the
rotation head.
Increasing the pressure setting above 20 bar / 290 psi will allow the rotation head to
move down the mast.

21.9 CONTROL VALVE STROKE LIMIT ADJUSTMENT
Adjust the B port stroke limit adjustment until it contacts the spool. Back the
adjustment out 2 full turns. Traverse the head to the bottom of the mast. Mark a line on
the mast 1.5 metres from the top of the carriage. Engage the traverse control UP
completely with the diesel engine at 2175-2200 rpm. Check the time to traverse the
head 1.5metres UP the mast. It should be 3 seconds A.T.M 3-3.5 seconds. Re adjust
the B port stroke limiter until the correct time is achieved. Tighten the lock nut on the
stroke limit adjustment.
Adjust the A port stroke limit adjustment until it contacts the spool. Back the
adjustment out 2 full turns. Traverse the head to the top of the mast. Mark a line on the
mast 1.5 metres from the bottom of the carriage. Engage the traverse control DOWN
completely with the diesel engine at 2175-2200 rpm. Check the time to traverse the
head 1.5metres DOWN the mast. It should be 3 seconds A.T.M 3-3.5 seconds. Re
adjust the A port stroke limiter until the correct time is achieved. Tighten the lock nut on
the stroke limit adjustment.
21.10TRAVERSE SPEED CHECKS
Balance head as pervious stated. Operate the rig with diesel rpm at 2200. Fill in table.
ACTUAL MEASUREMENTS
MICRO HEAD Time Pull Down Main Oil

FEED TRAVERSE Mins Secs Gauge pump Temp
Pressure
Gauge
Down -
Up -
- Down
- Up
REFER TO NEXT TABLE FOR A.P.R., A.T.R.

USE TWO MEN TO TAKE MEASUREMENTS
TRAVERSE SPEED CHECKS COMPARISON CHART
MICRO HEAD Mins Secs Pull Main Pump Oil Temp

FEED TRAVERSE Down Pressure
Down - 1 00 60 / 20 / 25 45 - 60C
1 05 65
Up - 1 40 0/5 20 / 25 45 - 60C
1 45
- Down 4 60 / 65 / 75 45 - 60C
5 70
- Up 4 0/6 90 / 95 45 - 60C
5

22 ROTATION
22.1 MOTOR CONTROL LOCATION

Refer to figure below to identify the various motor controls.
Adjust the height of the maximum speed adjustment screw to 15mm above the maximum
speed screw lock nut.
Refer to stamped rotation head serial number. Check with the rotation head assembly
section if head has been tested. If not, get a photocopy of test procedure for the rotation
head assembly and test the rotation head.
Check the rotation head is filled with lube oil to the correct level and the lube oil system
has been primed with oil.
Fit a external filter to the inlet of the lube oil sight glass at the rotation head.
Fit the override pin to the rod spin guard valve at the base of the mast.
Rotation Head Motor
1. Optional secondary pressure

cut off control. Not used in this
application
2. X port on motor control
block
3. Control regulator screw
4. Maximum speed screw
5. Optional primary pressure cut
off control. Not used in this
application.
6. Optional case drain port. not
used in this application
7. Minimum speed screw on the
opposite side of motor.
8. Case drain port item T on
hydraulic circuit drawing on
the opposite side of motor.

22.2 ROTATION HEAD SPEED CONTROL ITEM 55
Tee a 50 bar / 725 psi pressure gauge in between the hose and fitting at P9 port of the
pressure flow control manifold item 46.
Slowly increase and decrease the pressure setting of rotation speed control and observe
the pressure gauge reading.
The gauge reading should follow the change in movement of the rotation speed control
and be smooth in operation.
Fully increase the rotation speed control and note the maximum reading.
Fully decrease the rotation speed control item 55.

22.3 ROTATION CHUCK OPERATION
Fit a N size rod jaw set to the rotation head chuck.
Operate the control lever and check the following.
No hoses being nipped or pulled.
Fit a short length of N size rod to the rotation head and the chuck. Check for correct
operation of the chuck versus the nametag on the control panel.
Leave the short length of N size rod in the chuck for further commissioning of the
rotation head.
22.4 ROTATION HEAD PIVOTS
Release the rotation head eye bolts and check the rotation head swings freely on the pivot
pin.
Swing the rotation head into the drill position and tighten the eye bolts.
22.5 ROTATION HEAD OPERATIONAL CHECKS
With the diesel engine at 850-875 rpm. Operate the rotation head control lever
FORWARD and REVERSE and check the following.
22.5.1 MINIMUM ROTATION HEAD SPEED CHECK
Disconnect and plug the X port hose from the rotation head motor
Rotation head in high gear (3 :1)
Engage the rotation pilot lever into the FORWARD position
Diesel engine at 2200 rpm A.R.R 2195 2200
ACTUAL ROTATION RPM A.R.R 473-475
Refit the hose to the X port of the rotation head motor.

22.5.2 MAXIMUM ROTATION HEAD SPEED SETTING
Set the maximum rotation speed at 1500 rpm with the following conditions
Diesel at 2200 rpm ARR2195-2200
Rotation speed control fully increased
Rotation pilot lever engaged FORWARD.
Check you can feel the rotation motor piston barrel resting firmly against the
maximum speed adjustment screw as the screw is adjusted.
Check the rotation head rpm with a hand held tachometer.
ACTUAL ROTATION MAXIMUM RPM ARR 1500- 1505 RPM
22.5.3 MOTOR CONTROL END REGULATOR SETTING

Tee a 50 bar / 725 psi pressure gauge in between the hose and fitting at P9 port of
the pressure flow control manifold item 46.
Run diesel at 1500 rpm. A.R.R. 1490 - 1500.
Engage the rotation pilot lever FORWARD.
Adjust the rotation speed control item 37 until the pressure gauge reads 25 bar, A.P.R.
25 - 25.5 bar / 362 psi A.P.R. 362-369 psi.
Undo the locknut of maximum speed adjustment screw, FEEL the screw. At the same
time adjust the control regulator screw until you feel the motor piston barrel just
moving away from the maximum speed adjustment screw. Lock the control regulator
screw and check setting as follows:
Rotation speed control pressure = 26 bar A.P.R. 26-26.5 bar.
= 377 psi A.P.R. 377-384 psi
The motor piston barrel must be firmly against the maximum speed adjustment
screw. The adjustment screw will be hard to turn.
Rotation speed control pressure = 24.5 bar A.P.R. 24-24.5bar.
= 355 psi A.P.R. 348-355 psi.
The motor piston barrel has moved away from the maximum speed screw. The
adjustment screw will be easy to turn.
Recheck the above by decreasing and increasing the pressure setting of the rotation
speed control item 37.
ACTUAL CONTROL REGULATOR SETTING BAR A.P.R. 25 - 25.5 BAR
Recheck the maximum rotation speed as previously stated, reset if required.

22.5.4 ROTATION REVERSE SPEED INTERLOCK VALVE CHECK PROCEDURE
Engage the rotation control lever into REVERSE and note the rotation speed with the
diesel at 1500 rpm with the rotation speed control fully decreased.
Adjust the rotation head speed control to fully increased. Note the rotation rpm. There
should not be any increase in rotation speed between fully decreased and fully
increased.

22.5.5 ROD SPIN GUARD
With the override pin removed from the rod spin guard valve at the base of the mast
and the rod spin guard OPEN.
Set the rotation head rpm as follows:
Rotation torque control fully increased. Rotation head in high gear.
Diesel at 2000 rpm ARR 1900- 2000 RPM.
Rotation control lever fully engaged.
Adjust item 83 until the rotation head is doing 100-105.
Check the setting by disengaging and engaging the rotation control lever
several times
ACTUAL ROTATION RPM A.R.R 100-105 RPM
Check the rod spin guard fits and operates correctly. Refer to Drawing No.8249
ensure the rod spin guard conforms to these drawings. Check the operation of the
guard as follows.
No mechanical fouling when the head is traversed UP or DOWN the mast.
When the guard is open the maximum rotation speed is 100 with the diesel at
2200 rpm.
When the guard is closed the maximum rotation speed is 1500 with the diesel at
2200 rpm.
22.5.6 ROTATION FORWARD PRESSURE CHECK
With diesel at 2200 rpm fill in table.
Gear Head M
(rpm) a
i
Main Pump Press. A.P.R bar Oil Temp C A.T.R C
Psi
High 1500 80/ 85 55/65
1160-1232
22.5.7 MAIN FILTER BACK PRESSURE CHECKS
Run machine as follows:
Diesel at 2200 rpm
Rotation at top speed forward
Run for 5 minutes, fill in table.
MAIN FILTER BACK HYDRAULIC

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

22.5.8 SPEED CONTROL TEST
Fit a piece of NQ drill rod to the chuck before rotating the head.
Rotation speed control fully decreased
Engage the rotation pilot lever into FORWARD.
Diesel rpm 2200 rpm A.R.R.2180-2200.
Slowly increase the rotation speed control.
Check the following:
Check for a smooth raising and lowering of rotation rpm is possible
Check that rpm stays stable at any rotation speed control pressure setting.
NOTE
The dimension of maximum speed adjustment screw from the top of adjustment nut.
The length will vary depending on the motor / rotation head combination
ACTUAL LENGTH MM
INCH
22.5.9 CONTROL VALVE STROKE LIMIT ADJUSTMENT

Engage the rotation control REVERSE completely with the diesel engine at 700-800
rpm. Adjust the B port stroke limit adjustment until it contacts the spool. Back the
adjustment out a turn. Tighten the lock nut.
Engage the rotation control FORWARD completely with the diesel engine at 700-800
rpm. Adjust the A port stroke limit adjustment until it contacts the spool. Back the
22.6 ROTATION HEAD TO ROD CLAMP ALIGNMENT
Fit an N size rod jaw set to the rotation head chuck and rod clamp.
Fit the rod guide bushes to the rotation head.
Fit a short length of N size rod to the rotation head chuck and to the rod clamp. The rod
should be straight and long enough to protrude out of the rotation head and chuck by 200
mm / 8. The same should apply to the rod clamp.
Align the two pieces of rod to within 0.4mm / 0.015 over 600mm / 24 both front to back
an side to side of the rod.
This should be achieved by packing under the rod clamp base with shim material.
When the rod clamp base bolts has been torqued up and the rods have been reinspected
for alignment.
22.7 ROTATION HEAD MAKE UP TORQUE CONTROL
Operate the DRILL-MAKE control lever item 31, to the ON position.
Fully decrease the ROTATION MAKE TORQUE pressure control item 44.
Fully increase the rotation head speed control item 37.
Operate the chuck and clamp control levers to the RELEASE position.
Fit a N size drill rod to the chuck and rod clamp.
Operate the chuck and clamp control levers to the HOLD position.
Check the rotation head is in high gear.
Slowly engage the rotation head lever into FORWARD position.
Slowly increase the pressure setting of the rotation make torque control item 44. Observe
the pressure reading on the main pump pressure gauge item 50. Check the pressure
increases gradually with the movement of the rotation make torque control item 44.

Fully increase the rotation make torque pressure control, and note the maximum pressure
reading.
MAXIMUM PRESSURE BAR A.P.R. 205-210 BAR
PSI A.P.R. 2972-3045 PSI

Fully decrease the rotation make torque pressure control release the control lever to
neutral.
Operate the chuck and clamp control levers to the RELEASE position.
Remove the drill rod and fit a short length of N size rod to the chuck. Operate the chuck
control lever to the HOLD position.
22.8 ROTATION/ FLOAT OPERATIONAL CHECK

Operate the rod clamp lever into the RELEASE position and fit a short length of N size
rod to the rod clamp with the box end (female thread) about 200 mm / 8 above the rod
clamp. Operate the rod clamp lever into the HOLD position.
Operate the traverse lever and traverse the rotation head until the bottom of the chuck is
about 600mm / 24 above the rod clamp.
Operate the chuck control lever into the RELEASE position and fit a N size rod through
the rotation head spindle and screw the rod into the rod clamped in the rod clamp. Do the
threads up by hand.
Operate the chuck lever into the HOLD position.
Engage the drill / make, control lever item 31 into the ON position.
Decrease fully the rotation make torque pressure control item 44
Engage the float control lever into the FLOAT position and at the same time engage the
rotation control lever FORWARD.
The rotation head should rotate and the head travel down at the same time. If necessary
adjust the rotation make torque control item 44 until the rod thread shoulders butt up
together. Release the rotation lever and operate the float lever to the OFF position.
Operate the chuck control lever into the RELEASE position.
Break the drill rod apart with a 915mm 36 stillson wrench, but do not screw the rod joint
apart.
Operate the chuck control lever into the HOLD position.
Repeat the last five steps, several times and check the operation of the float / rotation
system.

23 MAIN WINCH WITH HD TYPE MOTOR
Refer to figure below to identify the various motor controls. Check the main winch brake
and gearbox is filled with lubricating oils.
Adjust the height of the minimum speed screw to 15 mm above the minimum speed screw
locknut.
Refer to figure below and undo the lock nut of the secondary pressure cut off adjustment
screw item 3. Adjust the screw fully in, do up the lock nut.
Refer to figure below to identify the various cartridges of the main winch manifold block.
MAIN WINCH MOTOR
View of a motor with control

locations similar to the main winch
motor.
1. Secondary pressure cut off
adjustment screw, not used in
this application
2. X Port Of Motor
3. Control regulator adjustment
screw
4. Maximum speed screw
5. Primary pressure cut off
adjustment screw, used in this
application.
6. Case drain leakage port.
7. Minimum speed screw on the
opposite side of motor.
8. Second case drain port item
on hydraulic circuit drawing on
the opposite side of motor.

MAIN WINCH MANIFOLD BLOCK PART NO WU 8816
further details.
71 PD24464U VALVE COUNTER BALANCE WINCH OVER RUN
CONTROL
73 5-203-341 VALVE SHUTTLE CART.
80 PD24464KT VALVE COUNTER BALANCE WINCH FLOAT SYSTEM
81 PD24464AH VALVE CHECK PILOT OPEN WINCH FLOAT SYSTEM
82 PD24464KV VALVE BODY(MANIFLOD BLOCK)

23.1 BRAKE RELEASE TEST
Operate the drill-make control lever item 31, into the MAKE position.
Fully decrease the rotation make torque control item 44.
Tee a 100 bar / 1450 psi pressure gauge between item 72 and the brake release pressure
port on the main winch gear box.
With diesel at 850-875 rpm, check by engaging the main winch control lever UP and
DOWN very slowly, that a pressure of 20-24 bar / 290-348 psi reads on the gauge,
before the drum turns in either direction. Adjust the rotation make torque control as
necessary to carry out the above test.
Operate the drill-make control lever item 31 into the DRILL position.
23.2 MAIN WINCH OPERATIONAL CHECKS
With the diesel engine at 850-875 rpm. Operate the main winch control lever UP and
DOWN and check the following.
23.2.1 BRAKE RELEASE AND ENGAGEMENT TEST
Connect a 250 bar / 3625 psi pressure gauge to the brake release pressure port hose.
With the diesel at 1500 rpm, operate the main winch UP-DOWN several times.
Note the time taken for brake to release and the drum to rotate and the time taken
from when the control lever is released to neutral and the pressure to reduce to below
5 bar / 72 psi and the brake to engage. There should be a slightly longer time delay for
the brake to engage than to release. This is done to check that item 72 is correctly
piped in.
23.2.2 COUNTER BALANCE OPEN AND CLOSE TEST
Tee a 250 bar / 3625 psi pressure gauge to the hose leading to the pilot port of the
counter balance valve item 71.
With the diesel at 1500 rpm, operate the main winch UP-DOWN several times.
Note the time taken for the pressure gauge reading to increase and the drum to rotate
and the time taken from when the control lever is released to neutral and the pressure
gauge reading to reduce to below 5 bar / 72 psi and the drum to stop rotating. There
should be a slightly longer time delay for the drum to stop rotating than to start
rotating. This is done to check that item 72 is correctly piped in.
23.2.3 MAIN WINCH HD REGULATOR SETTING
Tee a 100 bar / 1450 psi pressure gauge into the hose leading to the main winch
motor X port Check that 30-35 bar / 435-508 psi pilot pressure reads on the pressure
gauge.
With diesel at 1500-1550 rpm, operate the main winch control lever DOWN
Undo the maximum speed screw lock nut. The maximum speed screw must be hard to
turn (motor piston barrel must be pushing against the speed screw as it is screwed in
or out )
If the motor barrel is not against the screw, adjust the HD control regulator screw
OUT slowly until the motor piston barrel is firmly against the speed screw.
Check the above by operating the main winch lever UP-DOWN several times.

23.2.4 MAIN WINCH MAXIMUM SPEED SETTING
With diesel at 2200 rpm ARR 2195 2200, main winch control UP. Adjust the main
winch motor, maximum speed screw to give a drum speed of 169 rpm.
ACTUAL DRUM RPM A.R.R. 168 - 170 RPM
23.2.4.1 Control Valve Stroke Limit Adjustment

Engage the main winch control UP completely with the diesel engine at 850-875 rpm.
Adjust the B port stroke limit adjustment until it contacts the spool. Back the
Engage the main winch control DOWN completely with the diesel engine at 850-875
rpm. Adjust the A port stroke limit adjustment until it contacts the spool. Back the
23.2.5 MAIN WINCH COUNTER BALANCE VALVE SETTING
Increase the pressure setting of counter balance valve item 80 by two full turns.
Remove the hose from the X port of the main winch motor.
With diesel at 850 rpm, operate the main winch control UP. Note the pressure
required to operate the winch on the main pressure gauge.
Operate the main winch control DOWN. Note the pressure required to operate the
winch on the main pressure gauge.
Adjust the counter balance valve item 71 until there is difference between the up and
down reading of 73 bar
Check with diesel at 2200 rpm that the main pump pressure does not exceed 150 bar /
2175 psi when operated DOWN.
Reconnect the hose to the X port of the main winch motor.
Decrease the pressure setting of counter balance valve item 80 by two full turns.
23.2.6 MAIN WINCH PRESSURE CUT-OFF SETTING
Stop the diesel, remove the brake release pressure port hose and plug the hose.
Undo the lock nut of the main winch motor maximum speed screw.
With the diesel at 1500rpm. Engage the main winch DOWN feel the maximum speed
screw.
Adjust the rotation make torque control item 44 until 200 bar is indicated on the main
pressure gauge.
Adjust the main winch motor pressure cut off as follows:
Main Pump Pressure 200 bar / 2900 psi A.P.R 198-203 bar / 2870-2944 psi
The motor piston barrel must be firmly against the maximum speed screw.
The motor piston barrel has moved away from the maximum speed screw.
Check the above several times and at various diesel rpm by decreasing and
increasing the pressure setting of the rotation make torque control item 44.
Release the main winch lever.
Reconnect the brake release pressure port hose.
Operate the drill-make control lever item 31, into the Drill position.

23.2.7 MAIN WINCH MAIN CONTROL VALVE PORT RELIEF VALVE PRESSURE SETTING
With the diesel at 1800 rpm A.R.R 1800-1850 RPM, engage the main winch control
lever UP and adjust the B port pressure relief valve to 235 bar / 3407 psi A.P.R. 235
236 bar / 3407-3422 psi.
Check the pressure setting by engaging and disengaging the main winch control lever.
23.2.8 MAIN WINCH NO LOAD PRESSURE CHECK
Operate the main winch control UP-DOWN, with no rope fitted and with the diesel
at 2200 rpm A.R.R 2195-2205. Fill in the table.
MAIN WINCH SYSTEM HYDR OIL TEMP C

PRESSURE
ACTUAL A.P.R. ATR 55-65C
UP 80-85 bar ACTUAL

1160-1233 psi
DOWN 140-145 bar ACTUAL

2030-2102 psi
23.2.9 MAIN WINCH PULL TEST
Locate the main winch motor minimum speed screw. Remove the lock nut of the
screw, adjust the screw in until it is 5mm inside the body of the motor.
Undo the lock nut of the main winch motor maximum speed screw.
With the diesel at 1500rpm. Engage the main winch DOWN feel the maximum speed
screw.
Adjust the rotation make torque control item 44 until 200 bar is indicated on the main
pressure gauge.
Adjust the rotation make torque control item 44 as follows:
The motor piston barrel must be firmly against the maximum speed screw.
The motor piston barrel has moved away from the maximum speed screw and is
firmly against the minimum speed screw.
Check the above several times and at various diesel rpm by decreasing and
increasing the pressure setting of the rotation make torque control item 44.
Release the main winch lever.
Operate the drill-make control lever item 31, into the Drill position.
Refit the minimum speed screw lock nut.

23.2.10 MAIN WINCH FLOAT SYSTEM
23.2.10.1 Counter Balance Valve Item 80

Disconnect the hose to the P1 port of the main winch manifold block. Plug the hose
with a steel plug.
Disconnect the hose to the P3 port of the main winch manifold block. Plug the hose
with a steel plug.
Connect a hose from the P3 port of the main winch manifold block and tee it into the
B port of the main winch motor.
Remove the hose from the X port of the main winch motor.
Operate the chuck control lever into the HOLD position.
With diesel at 700 rpm, operate the main winch control UP. Note the pressure
required to operate the winch on the main pressure gauge.
Operate the main winch control DOWN. Note the pressure required to operate the
winch on the main pressure gauge.
Adjust the counter balance valve item 80 until there is difference between the up and
down readings of 25 bar.
Reconnect the hose to the X port of the main winch motor.
Reconnect the hose back onto the P3 port of the main winch manifold block.
Disconnect and remove the hose between the P3 port and the B port.
Reconnect the hose to the P1 port of the main winch manifold block.
23.2.10.2 Operational Checks
Tee a 100 bar 1450-psi pressure gauge into the brake release pressure port of the
main winch gearbox.
Do not operate the main winch control lever during this test.
Operate the main winch float control item 27 to the ON position with the diesel at
850-rpm A.R.R. 850-875.
You should have a 35-40 bar / 507-580 psi reading on the pressure gauge at the
brake port.
Check the pressure drains out of the brake cavity and pressure gauge by operating
the winch float control to the OFF position.
Carry out the above operations several times to check the gauge reading builds to 35-
40 bar / 507-580 psi when the winch float control is ON and drains when OFF and
with the diesel engine at various rpm.
Operate the main winch float control item 27 to the ON position,
Connect a large adjustable wrench to one of the lugs that supports the ring around the
winch drum. You should be able to turn the winch drum slowly up down.
Operate the main winch float control item 27 to the OFF position, you should not be
able to turn the winch drum slowly up down.
Operate the winch float control to the ON position. Operate the chuck control lever
item 21 to the RELEASE position, the pressure reading on the gauge at the brake
port should drain.
winch drum. Try to turn the winch drum, you should not be able to turn the winch drum
slowly up down.
Operate the chuck control lever to the HOLD position and check the pressure
reading at the gauge at the brake port. It should build to 35-40 bar / 507-580 psi.
winch drum. Try to turn the winch drum, you should be able to turn the winch drum
slowly up down.
Carry out the above operations several times to check the gauge readings builds to
35-40 bar / 507-580 bar when the chuck control lever is in the HOLD position and

drains when the lever is in the RELEASE position and with the diesel engine at
various rpm.

23.2.11 TEST THE WINCH WITH A TEST WEIGHT
Fit the main winch rope to the drum.
Reeve the main winch rope through the sheave block at the top of the mast.
With a test 200 Kg / 440 lbs weight suspended from the main winch rope and at any
possible diesel rpm and main winch control lever position, check for:
Any surging as the weight is raised or lowered
Any excessive response delay
Excessive runout when the control lever is released to the neutral position.
Brake holding, cut diesel, check if weight drifts, beware that if weight drifts that
it will free fall.

24 WIRELINE WINCH
24.1 WIRE LINE WINCH OPERATIONAL CHECK

With the diesel engine at 850-900 rpm, engage the wire line winch control lever UP and
DOWN slowly, and check the following.
Correct operation versus the nametag.
The drum runs reasonable true and does not have any excessive run out.
24.2 DOUBLE COUNTER BALANCE VALVE ITEM 84
The wire line winch counter balance valve cartridges Item 77 should have been preset to
210 bar / 3045 psi. With a pilot ratio of 3:1, if set correctly 70 bar / 1015 psi, is required to
move the wire line winch drum slowly UP or DOWN.
With the diesel rpm at 800rpm A.R.R 800-850 rpm, engage the wire line winch lever UP
and DOWN slowly until the drum just rotates. Adjust the counter balance valves item 77
until 70 bar / 1015 psi A.P.R. 68-72 bar / 986-1044 psi reads on the main pump pressure
gauge.
Hydraulic oil temperature 60C ATR 55 -65C
ACTUAL PRESSURE UP BAR A.P.R.68-72 BAR

A.P.R. 986-1044 PSI
PSI
ACTUAL PRESSURE DOWN BAR A.P.R.68-72 BAR
A.P.R. 986-1044 PSI
PSI
24.3 MAXIMUM SPEED CHECK AND ADJUSTMENT

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

TEMP PRESSURE PRESSURE RPM RPM
BAR A.P.R. A.R.R.
PRESSURE 100-105 BAR 274-276
UP 1450-1522 PSI
PRESSURE 100-105 BAR 274-276
DOWN 1045-1522 PSI
Check that when engaging the wire line winch control lever at any diesel rpm or lever
position combination that no surging continues more than 5 seconds.
Check that when engaging the wire line winch control lever at any diesel rpm that there is
a steady increase or decrease in drum rpm especially at the start of control.

24.4 WIRE LINE WINCH MAXIMUM PULL PRESSURE RELIEF SETTING
Remove the hose from the V1 port of the counter balance valve assembly item 76. Cap
the fitting and plug the hose.
With the diesel at 1800 rpm A.R.R. 1800-1850, engage the wire line winch lever UP.
Adjust the B port pressure relief valve of the wire line spool of the main control valve to
235 bar / 3407 psi A.P.R. 230-235 bar / 3335-3407 psi. Check the pressure reading on the
main pump pressure gauge.
ACTUAL B PORT PRV PRESSURE BAR A.P.R. 230-235 BAR
PSI A.P.R. 3335-3407 PSI
Reconnect the hose to the V1 port.

24.5 WIRE LINE WINCH ROPE
Fit the wire line winch rope using the rope pre tension device.

25 WATER PUMP
Connect an air-tight suction line to the water pump suction port, and submerge it into a
205 litre drum filled with water.
Fit a modified drill rod (water swivel one end and a high pressure ball valve attached to the
other end of the rod) to the Rotation Head.
Set the water pressure relief valve at water pump to the minimum setting.
Fit a 200 bar / 2900 psi pressure gauge to the pressure test coupling item 14 on pressure
relief valve item 4.
Run a suitable sized hose from modified drill rod to the water drum.
Water Valve - ON position
Vent Valve - OFF position
Water pressure gauge connected to water manifold.
With diesel at 2200 rpm, water ON-OFF control valve item 27 in the OFF position,
water pump coarse flow control item 36 fully increased, ball valve connected to the drill
rod fully open.
NOTE
During this test the water pressure relief valve setting will have to be
increased.
Check as follows:
Start and stop the water pump with water pump ON-OFF control valve at the control
panel.
Control the rpm of water pump from maximum to minimum with the water pump fine
and coarse flow controls at the control panel.
Check for any excessive vibrations at the water pump, which could indicate a
misalignment between the water pump and the motor drive shaft.
Check for leaks in the water piping, water pump and valves.
With water pump at max. speed note the following:
PRESSURE AT VALVE 4 BAR A.P.R.[ ]-[ ] BAR
PSI A.P.R. PSI
WATER PUMP MOTOR RPM

A.R.R. [ ] [ ]
RPM
WATER PRESSURE PSI A.P.R. 0-10 PSI
With the water pump controls set as described above, slowly close the ball valve on
starter rod until 60 bar / 870 psi shows on the water pressure gauge. Check as
follows:
Adjust the water pressure relief valve as required.
Water pressure gauge follows the opening and closing of the ball valve.
Adjust the water pump speed control from maximum to minimum and back to
maximum.
Any excessive vibrations.
Leak in the water piping, water pump and valves.
Fill in the table below

NOTE
Hydraulic circuit pressure at Item 14 valve 4.
During this test the water pressure relief valve setting will have to be increased.
PRESSURE AT VALVE 4 BAR A.P.R. [ ]-[ ] BAR
PSI A.P.R. PSI
WATER PUMP MOTOR RPM A.R.R. [ ]-[ ]

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

26 TRACK DRIVE CONTROLS
26.1 MAIN CONTROL VALVE PORT RELIEF SETTING

Check the drill make control lever is in the DRILL position.
Plug each of the four track drive motor hoses with steel plugs.
Select track drive from the rear [drill control panel].
With the diesel at 2175-2200, operate the following controls and adjust the port relief
valve for that particular operation.
Left track FORWARD, port relief valve setting 235 bar A.P.R 230-235bar
Left track REVERSE, port relief valve setting 235 bar A.P.R 230-235bar
Right track FORWARD, port relief valve setting 235 bar A.P.R 230-235bar
Right track REVERSE, port relief valve setting 235 bar A.P.R 230-235bar
Remove the steel plugs and connect each of the hoses to there respective motor ports.
26.2 OPERATIONAL CHECK
Check the track drive final drives are full to the correct level with the correct grade
lubricating oil.
Check the track drive motor cases are filled with clean hydraulic oil.
Check the tracks are correctly adjusted.
26.2.1 DIRECTION OF OPERATION
Check the direction of operation of track drive controls as follows
Jack the rig up so that the tracks do not touch the ground.
Left Track Drive Forward Reverse from both track drive locations
Right Track Drive Forward Reverse from both track drive locations
Lower the tracks back onto the ground
26.2.2 STRAIGHT AHEAD REVERSE OPERATION
Select operation from the front [track drive cabin]
Take the rig outside onto the dirt area at the rear of the workshop.
Arrange to have the rig parallel to the fence. Measure the distance from the fence to
the rig.
Operate both of the track drive control levers FORWARD with the diesel at 2175-
2200.
Drive the rig at least 10 metres FORWARD without moving the control levers.
Measure the distance from the fence to the rig. It should be within 500mm of the
previous distance.
If this rig drives more to one side the stroke limit adjustments of the track drive valves
will have to adjusted so that the rig drives FORWARD in a straight line.
Carry out the same as above but with the rig in reverse.
26.2.3 GENERAL OPERATION
Operate the rig at various diesel rpms and control lever positions. Check for ease of
operation.
Check for oil leaks from the track drive motors and final drives.

27 DIESEL LOAD TEST
RIG TYPE 200D
DIESEL TYPE JOHN DEERE 4045H
IDLING SPEED 850
MAX. NO LOAD SPEED 2375
FULL LOAD SPEED 2200 A.R.R.

2195-2205
FULL LOAD POWER ( CONTINUOUS)

AT 2200 RPM 92 KW 123 HP
CHECK FULL LOAD SPEED AS FOLLOWS
Mud Mixer Circuit

Connect together the mud mixer motor supply and tank return hoses.
Fully increase the mud mixer speed control item 48.
Water Pump Circuit

Connect an air-tight suction line to the water pump suction port, and submerge it into a 205
litre drum filled with water.
Attach a suitable return hose to the vent port of the water pressure relief valve.
Fully decrease the water pressure relief valve setting.
Close the water drain and water valve.
Fit a 250 bar / 3625 psi pressure gauge to pressure test coupling Item 14 at water pump
pressure relief valve item 4.
Fully increase the water pump speed control item33
Traverse system
Traverse the rotation head to the top of the mast.
Rotation speed control
Fully decrease the rotation speed control item 37.
Start Diesel and Run at Full Speed
Engage the water pump ON-OFF valve item 27 to the ON position.
Adjust the water pressure relief valve until the pressure gauge at pressure test coupling at
item 4 reads 160 bar 2320 psi A.P.R.160-165 bar / 2320-2392 psi
Engage the traverse lever UP.
The engine should hold the load generated by the traverse system, water pump system, mud
mixer system, pilot pressure system and rotation speed control. The engine should pull down to
2200 rpm and not continue to drop.
ACTUAL PRESSURE PRV ITEM 4 bar A.P.R. 160-165 bar

psi 2320-2392 psi
ACTUAL MAIN PUMP PRESSURE GAUGEbar A.P.R. 210-215 bar
psi 3045-3117 psi
With the system set up as above the calculated power requirements is 93.26 kW
124.9hp.

28 COMMISSIONING CHECK POINTS CHECK THE FOLLOWING
Before the rig is handed over to the sales department, check the following list for any items that
may have not covered or forgotten during the commissioning procedure.
Grease points
Refer to section 3 and regrease all grease points
Lubricating oils
Refer to section 5 and recheck all oil levels and top up if required.
Rod Clamp
Operation - Oil leaks - Check tightness of all bolts, nuts Clamp pivot pins are correctly
secured
Drillers Platform
Pivot pins have split pins fitted - Folds up and down easily - Transport strap is fitted - Platform
is 90 degrees to the tray
Wire line winch
Operation - Oil leaks - Check tightness of all bolts, nuts - Rope is fitted and secured to the
drum - Wire line sheaves rotate freely - Wire line sheave frame correctly fitted, check all bolts
and nuts are tight.
Water pump
Operation - Oil leaks - Check tightness of all bolts, nuts - Water relief valve has been reset to
the minimum setting - Suction fitting has been plugged
Diesel engine
Check water level Check radiator inhibitor / antifreeze been put into the cooling system - If a
water conditioning filter is fitted is it turned on - Water leaks - Oil leaks - Alternator and fan
drive belts - Correct operation of the throttle cable - Check tightness of all bolts, nuts -
Emergency shut down operates correctly - Battery acid level is correct Lube Oil levels
correct - Tachometer is correctly adjusted - All electrical connections have been sprayed with
sealant.
Pump group
Operation - Oil leaks - Check tightness of all bolts, nuts - All adjustment are securely tighten
and correctly adjusted Tamper proof covers fitted where applicable.
Rotation head
Lube Oil levels correct - All adjustment are securely tighten and correctly adjusted Tamper
proof covers fitted where applicable - Rod spin guard has been fitted and operate correctly
Lube Oil levels correct .
Control cabinet
Operation of all functions versus name tag drawing - Oil leaks - Check tightness of all bolts,
nuts - All adjustment are securely tighten and correctly adjusted - All control levers are tight -
Check gland nut tension on all needle valves - All pressure gauges are straight - All electrical
connections have been sprayed with sealant -
Main winch
Operation - Oil leaks - Check tightness of all bolts, nuts - Rope is fitted and secured to the
drum Tamper proof covers fitted where applicable - Lube Oil levels correct in gearbox -
Winch rope clamps are tight Winch rope guard fitted.
Mast raise cylinders
Operation - Oil leaks - Check tightness of all bolts, nuts - Cylinder pivot pins are correctly
secured and have been greased.
Mast dump cylinder
secured and have been greased.

Traverse cylinder
secured - Lock nuts fitted where applicable and tight - No misalignment of components.
Hydraulic oil tank
Correct oil level - Oil leaks - Check tightness of all bolts, nuts and hose ends - Bleed and
check operation of the hand pump.
Mast platform (basket) assembly
Refer to MPL and drawing number 8311 for the particular reg and check all of the components
listed on the MPL are available and have been trail fitted to the rig
Platform stay rod assemblies and mast stay rods
Refer to the RBR for the rig and check the get the necessary drawings and MPl for the stay
rods. Check all of the components listed on the MPLs are available and have been trail fitted
to the rig.
General points
Match drill all name tags - Check all standard accessories fit are painted and in the standard
accessories box - Safety and warning stickers have been fitted - Check the rig has the latest
up date modifications fitted - Check the hoses to from the rotation head and traverse cylinder
travel in a neat group when the rotation head is moved UP-DOWN the mast regardless of
mast angle Fire extinguishers brackets fitted.

29 SERIAL NUMBERS OF EQUIPMENT
CLIENT: RIG
NO.:
ITEM DESCRIPTION SERIAL NO. ADJUST

NO. MENT
SCREW
MIN MAX
1 Rig Engine Type
2 Rig Engine No
3 Pump Drive Gear Box
4 Hydraulic Pump No 3A
5 Hydraulic Pump No 3B
6 Hydraulic Pump No 3C
7 Rotation Head
8 Rotation Head Motor
9 Main Winch Gearbox
10 Main Winch Motor
11 Wire Line Winch Motor
12 Water Pump
13 Water Pump Motor
14 Rig Hydraulic Oil Cooler
15 Rotation Oil Cooler
16 Water / Air Manifold
17 Mud Mixer Motor

30 SIGNATURE FORM
30.1 All points in this procedure have been commissioned as per procedure and have been
initialled and dated.
Commissioning Personnel
Name _____________________ Date _______________
Name _____________________ Date _______________
30.2 A visual and operational inspection by sales has been done and any points noted by sales
corrected by production.
Sales Department Personnel
Name _____________________ Date _______________
Name _____________________ Date _______________
30.3 Production Manager has sighted finished procedure and sales correction list.
Production Manager
Name _____________________ Date _______________
30.4 Finished procedure must be filed with Rig Build Record.

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UDR 200D

3 GREASE THE ITEMS LISTED BELOW....................................................................................4

4 OIL FILTER CHART...................................................................................................................5

5 DIESEL ENGINE PREPARATIONS...........................................................................................5

6 MISCELLANEOUS HYDRAULIC CHECKPOINTS....................................................................5

7 MISCELLANEOUS MECHANICAL CHECKPOINTS.................................................................8

8 PRIME THE HYDRAULIC PUMPS............................................................................................8

9 LUBRICATING OIL CHART.....................................................................................................14

10 SHORT CIRCUIT THE MAIN SUPPLY HOSES OF THE FOLLOWING MOTORS.................14

11 CONTROL ADJUSTMENT IN PREPARATION FOR FLUSHING............................................14

12 FIRST EVER DIESEL START-UP...........................................................................................15

15 OPERATION CONTROL CHECK...........................................................................................17

17 PRESSURE REDUCING VALVE ITEM 45..............................................................................25

18 PILOT SYSTEM PRESSURE VALVE ITEM 35.......................................................................25

19 JACK LEGS /MAST RAISE / MAST DUMP............................................................................25

23 MAIN WINCH WITH HD TYPE MOTOR.................................................................................38

26 TRACK DRIVE CONTROLS...................................................................................................49

27 DIESEL LOAD TEST.............................................................................................................. 50

28 COMMISSIONING CHECK POINTS CHECK THE FOLLOWING...........................................51

29 SERIAL NUMBERS OF EQUIPMENT....................................................................................53

UDR AUSTRALIA 200D COMMISSINING PROCEDURE REVISION 2 10/2001 3

UDR AUSTRALIA 200D COMMISSINING PROCEDURE REVISION 2 10/2001 4

ITEM ELEMENT MAKE & PARTNO

5 DIESEL ENGINE PREPARATIONS

6.1 OIL COOLER

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ITEM OIL TYPE QTY OIL LEVEL

DIESEL AS RECOMMENDED BY THE DIPSTICK

ROT. HEAD * CASTROL ALPHA SP220 5 LEVEL GAUGE

MAIN WINCH ALPHA SP 220 OR 3 LEVEL PLUG - MUST BE

WATER PUMP SAE 40 2.5 LEVEL PLUG

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0-15 15-30 30-45 45-60 60-75 75-90 90-105 105-120

Rotation forward 6A 2200 24 30-35

NOTE: During flushing check the following:

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OIL TEMPERATURE C ATR 60 - 65C

14 RECONNECT HOSES, PRIME HYDRAULIC MOTORS AND HYDRAULIC OIL

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16.1.1 FLOW REGULATOR SETTING

PSI A.P.R. 261-268 PSI

Actual pressure regulator setting BAR A.P.R 275-280 BAR

PSI A.P.R. 3977-4060 PSI

Actual diesel rpm RPM A.R.R 1800-1850 RPM

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

PSI A.P.R. 3741-3770 PSI

Actual diesel rpm RPM A.R.R 1800-1850 RPM

8. Tighten the locknut and fit the cap nut.

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