Atlas Copco Exploration Products

DIAMEC Diamond Core Drill

70000261 A
DIAMEC U4

DIAMEC U4 APC
Safety and Operating instructions

© 2009 Atlas Copco Craelius AB | 6991 1511 01 | 2009-09-22

2
 Operator's Instructions for
Diamond Core Drill Rig

DIAMEC U4 APC
These instructions are intended for operators of the Atlas Copco diamond core drill
DIAMEC U4 APC.
Instructions are given for start and stop procedures, drilling, additional
instructions, maintenance, and service schedule to be carried out by the operator.
For further information concerning service measures for the drill rig, please contact
your nearest Atlas Copco representative.

Read carefully the INTRODUCTION- AND OPERATING SAFETY sections before

starting to use the rig.

All rights reserved.

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

ATLAS COPCO CRAELIUS AB

MÄRSTA - SWEDEN 2007-07

Printed Matter No 6991 1511 01

3
Contents
Page Page

Introduction ........................................................ 5 Daily safety check.............................................. 40

Adjustment of speed regulation .................... 41
Operating safety ................................................ 6 Rotation unit oil level ....................................... 42
Organizational measures ................................... 6 Adjustment of chuck pressure ......................... 43
Operation and maintenace ................................ 7 Adjustment of max pressure of the main-
Underground hazards ........................................ 8 and service pumps ........................................... 44
Special safety device ........................................ 10 Starting of the power unit after adjustment
Following signs are used ................................ 10 or disconnecting the hoses.............................. 46
Environmental Instructions...............................12 Rod holder gas spring pressure check............ 47
General ............................................................... 13 Changing rod holder jaws and rod holder
guide bushings...................................................48
Hoisting and transport .................................. 14 Adjusting slide shoes on cradle .......................49
Hoisting the drill and power unit .................... 14
Flow meter (Option)......................................... 50
Technical specifications ................................. 16 General................................................................50
Characteristics .................................................. 18 Operating principle ............................................52
Feed frame ........................................................ 18 Programming .....................................................54
Rotation units .................................................... 18 Calibrating ..........................................................56
Rod holder ......................................................... 19 Flow meter display ............................................62
Power unit ........................................................ 20 Tachometer (Option) ........................................ 64
Optional equipment and accessories ......... 21 General................................................................64
Mast extension.................................................. 21 Installation environment ...................................65
Underground drilling........................................ 21 Programming .....................................................66
Wire line hoists ................................................. 21
APC System setup ........................................... 68
Hose kits ............................................................ 22
Test instruments................................................ 22 Hydraulic schematic ........................................ 70
Flush pumps...................................................... 22
Casing clamp..................................................... 22
Water swivel .......................................................22
Design features ................................................ 23
Drill module....................................................... 23
Power unit.......................................................... 23
Control panel..................................................... 23
Maneuvring ....................................................... 24
Pre-start procedure .......................................... 24
Start-up Electric power unit 45 kW ................. 25
Setting up for drilling ..................................... 26
Positioner........................................................... 26
Displacement of feed frame ............................ 27
Moving the feed frame .................................... 27
Underground set-up ......................................... 28
Underground set-up with hydraulic
bracing device ................................................... 30
Setting up the core drill using a casing
clamp.................................................................. 31
Maintenance ...................................................... 32
General............................................................... 32
Cleaning the hydraulic system ........................ 32
Oil cooler .......................................................... 32
Hydraulic oil filters .......................................... 34
Changing hydraulic oil .................................... 35
Draining condensed water out of tank ........... 35
Periodic maintenance ....................................... 36
Lubricant recommendations............................ 39

4
 Introduction
This instruction book is part of the complete The information is divided into the
delivery of your new diamond core drill DIAMEC following chapters
U4. It offers basic information on features and
Section 1: Operating safety
handling of the unit and contains advice and
measures necessary to keep the rig operational. It Section 2: General and technical
does not, though, replace thorough training of specification.
operator, helpers and service support. Section 3: Operation
It is the responsibility of the owner to make sure Section 4 Maintenance
that all personnel assigned to this DIAMEC U4 unit,
have the skill necessary for the safe operation,
service and maintenance of the unit before carring
out any kind of work. Personnel must have been
given adequate time to assimilate the information
in this book. One copy of the manual should be
kept available for reference on the rig at all times.
The following information is available, and
relevant for operating the DIAMEC U4 drill rig.

DIAMEC U4 Printed Matter No.

Operator’s manual 6991 1511 01
Spare parts list 6991 1510 50

Order from: Atlas Copco Craelius AB

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

5
Operating safety
Dear operator,
Before putting your new equipment into use, we
would like to direct your attention to the safety
aspects. Drilling can be a hazard to you and to
the environment. Good order, training and well
maintained equipment are key factors to safe
operation. This instruction book is no
replacement for thorough training, but will, as a
training aid and a reference book, help you
maintain a safe working environment and keep
PC

the rig in good operational condition.

6A
CU
ME
DIA

Yours faithfully;
Atlas Copco Craelius AB
Fig.1 Read the instruction book carefully before
starting up the drill rig.
Intended use
1.4 If, during operation of the unit, any
The diamond core drill DIAMEC U4 is intended
abnormal action in the safety or
for underground exploration and investigation
operational systems is observed; the unit
drilling, as well for drilling grouting holes. should be stopped and the problem be
Any use going beyond this shall be considered investigated and rectified.
"not intended use". The manufacturer is then not
liable for damage incurred as a result. 1.5 Warning signs must be kept easily legible
Unintentional use shall be at the owner's risk. at all times. Damaged signs should be
replaced immediately.
Proper use also includes observing information
in operation-, service-, and maintenance books 1.6 The daily safety check, as described in this
as stipulated by the manufacturer. instruction, must be carried out in addition
The DIAMEC® U4 should be run, serviced and to maintenance measures described in the
repaired by personnel properly trained for their Periodic maintenance section (Page 44).
task. This personnel must have sound knowledge
1.7 Hydraulic and electrical systems are of a
about hazards in their respective profession.
complex nature - and can cause injury or
General safety regulations must be observed. damage if not handled with care. Repair
Personnel should be aware of dangers resulting and service shall be carried out by
from abuse of drugs and alcohols as well as personnel with documented experience for
effects of medicines legally prescribed, or these systems.
mixture of any of them. The manufacturer is not
liable for any damage caused by unauthorized 1.8 Welding repairs should only be carried out
by an authorized welder in order to meet
alterations made to the unit.
the high standards that apply to Atlas
Copco products. Special attention must be
1.0 Organizational measures: given to components which could cause
injury or serious damage.
1.1 The diamond core drill DIAMEC U4
shall be operated only by personnel who 1.9 After repair make sure that the rig has
have undergone theoretical and practical been inspected and approved by the
training on the rig. Particular emphasis proper authorities before being brought
shall be laid on safety precautions. back to normal operation.

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

The battery gas is explosive! Never use

matches when checking the acid level.

Be careful using tools made of iron near

the battery, a spark might set off an
explosion. Read the battery manufacturer’s
manual for further information as well as
the “Environmental instructions” chapter.

7
Operating safety
2.11 Hydraulic oils are poisonous. Use eye
protection and gloves. See the
“Environmental instructions” chapter for
further information.

2.12 Before any repair or service is carried out

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

2.13 Be very careful while tracing leaks in the

pressurized systems. Hydraulic oils, water
or air under pressure can penetrate the
skin and cause complicated injuries or
infection. If this happens, see a doctor at GENUINE PARTS
once.

2.14 Use only authorized parts (Atlas

Copco parts). Any damage or Fig. 2.16 Use only genuine Atlas Copco parts.
malfunction caused by the use of
unauthorized parts is not covered by
warranty.
each side of the planned bore path. For
2.15 Any warranty for work performed, additional security inspect the area in order to
only covers Atlas Copco Products, localize any neglected installations.
Atlas Copco components and work
Check for signs which might indicate buried
performed by authorised personnel.
utilities.
Look for meters for gas, oil, water etc. Manholes,
3.0 Underground hazards junction boxes and light poles indicate some
kind of underground lines. Use a metal detector
In a modern community a number of utilities are when you suspect the presence of unmarked
buried, such as electrical cables, natural gas tanks or barrels containing contaminated waste.
lines, water lines, sewer lines, pipes for industrial Changes in colour and level of the ground
chemicals, liquids or gases, storage tanks, fibre indicate previously dug threnches.
optic and standard communication lines.
Use correct safety equipment relevant to the
These installations can be hazardous and must conditions encountered.
be located and identified before drilling.
Prior to drilling near an identified installation
Striking such a utility can cause personal injury which may constitute a danger, expose the
from explosion, electrocution, fire, exposure to object along the bore path by carefully digging
hazardous materials or exposure to laser light. by hand. Monitor the progress and carefully
(Light used in fibre optic cables can cause guide the bore around the dangerous object
permanent vision damage. Do not look into the maintaining a safe distance. Electrical cables
end of a optic fibre cable. and gas lines should be shut down during
drilling. After drilling is completed, these
You are personally responsible for any injury or
installations should be tested before operation.
material damage caused by drilling if you have
not taken proper precautionary measures. You
should understand the local regulations on
excavating and trenching. Responsibility should
be defined; client, proprietor, contractor,
operator or third person. The responsible party
should call in a competent person who will
identify and eliminate the jobsite hazards. This
will include notifying all utility companies who
have underground services in the area. These
companies must locate and mark their
installations, with a minimum of 10 meters from
8
 Operating safety
Electricity does not follow the path of least c. If the strike occurred during drilling, retract
resistance. It follows all paths to some degree, the downhole tool. Do not attempt to break
to ground. The drill string is an excellent any rod connection. Do not add or remove
conductor which will conduct electric current to any drill rods.
the drill rig and anything in contact with it.
People have been injured or killed by severe d. Ask your supervisor to contact the utility
company in order to switch off the system.
shock from drilling into power cables.
The level of injury depends on the current
flowing through the body. Voltage is not
necessarily a measure of the danger. Accidents
have occurred in installations with a voltage as
low as 25 -30 volts. 30 % of all electrocutions in
the industry have been in connection with 240 -
400 Volt systems.
Small amounts of current through the body
cause dangerous shock. If the path runs through
the chest and heart, very low currents can cause
severe injury or death. (Less than 0.05 A can
cause painful shock and respiratory paralysis.
0,15 A can cause ventricular fibrillation, probable
death and 0,2 A can cause severe burns, internal
bleeding and death. The electric current flowing
through a normal household bulb is around 0,5
A !!!)
Regard the drillsite as a danger zone. Always
wear safety garments. Use electrically insulating
boots and gloves when installing anchors. Check
manufacturers recommendations for the use of
safety equipment; replace damaged items.
Anchors should never be connected to live
power lines. Do not touch pins on signal clamps.
Expose lines by hand digging.
Induced current is dangerous. Even if the drill
string is not in contact with a cable, electrical
currents may flow through it.
Keep a safe distance from overhead power lines.
Do not spray fluids near or on electric power
lines. Hoses on the rig (hydraulic-, air- water-
etc.) can conduct electricity if the tool strikes an
electrical cable.
If you strike an electrical cable, indicated by
power failure anywhere near the job area,
smoke, explosion, arcing electricity, or if warning
device alerts:
a. Do not step off grid mat. If you stand on
the ground, stay put and do not touch any
equipment.

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

out of the immediate area and not to touch
any of your equipment.

9
Operating safety
4.0 Special safety signs
On the rig and in the manuals you will come
across the following warning signs. DANGER
4.1 The “DANGER” sign warns for immediate
hazards, which, when ignored, will Fig. 4.1
inevitably cause serious personal injury or
death!

4.2 The “WARNING” sign warns for hazards or

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

4.4 The “IMPORTANT” sign is used for CAUTION

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

IMPORTANT !
Fig. 4.4
5.0 Following signs are used on
your DIAMEC U4
Description:

5.1 Lifting points. This sign is located where

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

5.2 Ear protectors. Ear protectors should

always be worn.
3716 5528 00 3716 5525 00

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

5.4 Diesel fill. Location: On the diesel power

unit.

5.5 ATTENTION Before starting, oil must be

3716 5527 00 3716 5526 00

filled according to:

Lubricant Recommendations Fig. 5.3 Fig. 5.4

5.6 Drain water cooler. When there is a risk

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

Fig. 5.5 Fig. 5.6

10
 Operating safety
6.0 Supply of electrical power to
the drill (electric drills)
Electric power is supplied to the drill by a cable
that connects the starter panel on the drill to a
mine disconnect panel mounted on the mine CAUTION!
wall. This cable is called the trailing cable and is
connected to the mine disconnect panel by a
plug. The trailing cable and mine disconnect It is recommended that the drill operator
panel are typically not supplied by Atlas Copco. checks that the mine disconnect panel is
equipped with a ground fault/ground check
The trailing cable is vulnerable to mechanical system. If the mine does not supply this type
damage and should be protected by a ground of disconnect panel, such a panel can be
fault and a ground check system located in the obtained through Atlas Copco.
mine disconnect panel. The ground fault (GF)
check system checks for an imbalance of current
in the phases in the trailing cable (and the
connected electric motor) which would indicate
a leakage to ground. The ground continuity
check system checks that the ground conductor
WARNING!
in the trailing cable is connected from the mine
disconnect panel through the trailing cable to The ground fault protection system located in
the motor starter panel. The U4 motor starter the mine disconnect panel (and for CE marked
panel is available with a Zener diode that is part drills in motor starter panel), trips at
of the ground continuity check system in the approximately 0.3 amp which is too high to
mine disconnect panel. provide personnel protection. The driller and
helper should always use suitable electrically
insulating boots when operating an electrically
powered drill.

11
Environmental Instructions
Dear operator, Chemicals
Atlas Copco Craelius AB recognizes the Dispose of chemicals such as drilling additives,
importance of environmental issues. As part of other additives, glycol etc. according to the
our commitment to a better environment, we manufacturer’s instructions. Avoid the use of
want to inform you, the customer, of how you cleaning agents containing solvents like carbon
can minimize the effect on the environment tetrachloride. There are environmentally better
when using an Atlas Copco Craelius product. alternatives now available on the market.
These simple but important instructions will help Follow national regulations regarding handling
to preserve the environment. and disposal of wastes.
Metals (steel, aluminum, etc.)
These products are recyclable and should be
1.0 Operation, maintenance and
taken care of according to national regulations.
disposal
Plastics and rubber
Oil
These products are often labeled according to
Leaks of hydraulic and lubrication oils pose an different classes. In those cases they are
environmental threat. Changing lubricating and recyclable and should be taken care of according
hydraulic oils, hydraulic hoses and hydraulic to national regulations.
filter elements also pose a threat to the
Electrical components (cables, electronics, etc)
environment.
Used components should be taken care of
Collect all oil spills and waste (e.g. oil filter according to national regulations.
elements) contaminated with oil. Dispose of
according to national regulations.
Use biologically decomposable hydraulic oils
and lubricating oils for Atlas Copco products
wherever possible. Contact your nearest Atlas
Copco office for more information.
Engine
Engine emissions are toxic and pose an
environmental threat. Always provide for fresh
air when an engine is running. Well-maintained
air filters help keep emissions at a low level.
Fuel (Petrol/Gas, Diesel)
Fuel spillage poses an environmental threat.
Collect all wastes and fuel spillage and dispose
of according to national regulations.
Grease
Lubricating grease poses a threat to the
environment. Collect all wastes and spillage and
dispose of according to national regulations.
Batteries
Batteries contain acids and heavy metals. Used
batteries can therefore pose a threat to the
environment and to your health. Avoid all
contact with acids and dispose of used batteries
according to national regulations. See also the
“Operating safety” chapter for further
information.
Dust
Rock dust can pose a health danger. Use dust
binding oil.

12
 General

Fig. 1 DIAMEC U4 APC is an all-hydraulic operated diamond core drill.

The DIAMEC U4 APC is an all-hydraulic operated The DIAMEC U4 APC uses the best technology
diamond core drill with Automatic Performance available for diamond core drills. All tube
Control APC. jointing, thread breaking, feeding, wireline hoist
sequences, are controlled from a control console
Once the APC control system has received all
which can be positioned to suit the setup.
necessary drilling parameters from the driller,
Feeding is done by a direct cylinder, thereby
the APC takes over supervision. The APC
eliminating chains in the feed system. The drill
maintains a preset penetration rate within certain
can be equipped with two different feed lengths,
limits of bit force and torque. When required by
and two different sizes of rotation units to suit
hole conditions, the APC system instantly adjusts
rod size and drilling applications.
penetration rate to suit the conditions and if
necessary, stops feeding.
Recommendations
Of course the rig can still be operated manually
To achieve the best results with regard to:
without the APC function.
- high penetration
The DIAMEC U4 APC means the latest and
- optimal core recovery
highest technology in all-hydraulic drill rigs. All
the driller has to do is load and unload the drill - and low drilling costs
rod and then step on a footpedal to instruct the it is of primary importance that drill rods, core
APC to take over the rod handling. barrels and coring bits are of the right type and
quality, matched to the rock drill and to the
The DIAMEC U4 APC consists of three main
prevailing rock conditions.
parts: the drill unit, a power pack and a control
console. Bearing in mind the core drill’s speed of rotation,
its rating and chuck diameter, the DIAMEC U4
It is suitable for a variety of drilling methods in
APC is best suited to drill holes 46 - 76 mm in
both underground and surface operations such
diameter (A - N) using both conventional as well
as core drilling, grout hole drilling, probing etc.
as wire line rods.
The drill unit can be powered by an electric
motor or diesel engine. The spindle bore diameter is 78 mm in the
N-size rotation unit and 101 mm in the optional
H-size rotation unit.

13
Hoisting and transport
1.1 Hoisting the power units
1 Positioning a sling or similar lifting device
through the holes (See Fig.1.1).

1.2 Hoisting the drill unit

1. Position the feed frame and rotation unit
as shown in Fig. 1.2. This will obtain the
best possible point of balance and centre
of gravity.

2. Tie the skid and feed frame togther with a

section of the backstay legs.

3. Position a sling around both telescopic

tubes at each end of the feed frame. Fig. 1.1
Ensure that the feed frame clamps are
tightened on both tubes.
Note. When lifting, make sure that the
sling will not damage the hydraulic hoses,
mechanical components etc. Use spreader
bars if required.

DANGER
– The sling must be dimensioned for lifting 2
tons (Power unit) respectively 4 tons (Drill
unit) to provide a safety margin.

– Never use a damaged rope/sling.

– Always make sure that nobody is under or

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

Fig. 1.2 Hoisting the drill unit

14
 Hoisting and transport
2.1 Transportation of power unit
When transporting with fork lift or other vehicle
(Fig. 2.1) always secure the power unit to the
vehicle.

When equipped with a towing package

Max. towing speed: 5 km/h (3 mph).
At worksite, always wedge of the power unit
wheels to prevent unexpected movement.

2.2 Transportation of drill unit

1. When transporting with fork truck or other
vehicle (Fig. 2.2) always secure the drill unit Fig. 2.1
to the vehicle.

Fig. 2.2

15
Technical specifications
1.0 Drill units

Dimensions 1 800 mm
mm in

A 3 200 126.0
B 2 900 114.2
C 1 150 45.3
D 2 261 89.0
E 1 400 55.1
F 929 36.6
G 614 24.2

Weights
kg lb

900 1 980

Drill unit, 1 800 mm feed

Dimensions 850 mm
mm in

A 2 626 103.0
B 2 175 85,6
C 1 158 45.6
D 2 260 89.0
E 1 400 55.1
F 929 36.6
G 614 24.2

Weights
kg lb

830 1 826

Drill unit, 850 mm feed

16
Characteristics
1.1 Feed frame Capacities

Stroke
standard . . . . 1749 mm Drill rod size Approx. drilling
optional . . . . . . . . . . . . 852 mm depth
A Wireline 500 m 1 640 ft
(Std)
B 390 m 1 280 ft
Maximum pull . . . . . . . 52 kN N 260 m 850 ft
Maximum push . . . . . . 52 kN
Fast travel speed . . . . 1 m/sec The above capacity values only serve as a
guideline, and refer to vertical, downward
drilling in homogeneus rock.

1.2 Rotation units

1.2.1 Rotation unit 1.2.2 Rotation unit – High Torque

Rod size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A – N Axial holding force:
Spindle inner diameter . . . . . . . . . . . . . . . 78 mm Adjustable from . . . . . . . . . . . . 80 – 100 kN
Choice of rotation High torque setting
unit: . . . . . . . . . . . . . . . . . Std or High torque
Spindle speed . . . . . . . . . Adjustable from panel Speed range: . . . . . . . . . . . . . . . . 100 – 1100 rpm
Axial holding force: Max. torque: . . . . . . . . . . . . . . . . . . . . . . 2000 Nm
Adjustable from . . . . . . . . . . . . 50 – 100 kN

Standard rotation unit

Rod size: . . . . . . . . . . . . . . . . . . . . . A – N drilling
Rotation motor size. . . . . . . . . . . . . . . . . . . . 60 cc
Speed range: . . . . . . . . . . . . . . . . 500 – 1800 rpm
Max. torque: . . . . . . . . . . . . . . . . . . . . . . . 700 Nm

18
 Characteristics
1.3 Rod holder
The rod holder is hydraulically operated, and
closed by gas pressure. In case of loss of
hydraulic pressure, the rod holder closes
instantly. The gas pressure can be conveniently
monitored.
Max. rod size: . . . . . . . . . . . . . . . . . . . . . . 89 mm*
Bore (without jaws) . . . . . . . . . . . . . . . . . 102 mm
Bore (without covers) . . . . . . . . . . . . . . . 170 mm
Axial holding force: . . . . . . . . . . . . . . . . . . . 45 kN
Axial holding force (TC insert jaws). . . . . . 90 kN

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

rod guide and install optional special
covers.

Fig. 1.3 Hydraulically operated Rod holder

(shown with optional key hole wall
bracket)

19
Characteristics
1.4 Power units
Power units with variable hydraulic pumps with
energy saving load sense technique. Prepared
for auxiliary, hydraulically driven flush pump.
Complete with hydraulic tank, filters, oil cooler
and starter panel.

1.4.1 Electric
Asynchronous electric motor
Motor rating . . . . . . . . . . 45 kW at 1470 rpm

Maximum operating pressure

- main pump. . . . . . . . . . . . . . . . . . . 280 bar
- service pump . . . . . . . . . . . . . . . . 240 bar Fig.1.4.1 Electrical Power Unit 45 kW
Maximum flow
- main pump . . . . . . . . . . . . . . . 120 l/min
- service pump at 50 Hz . . . . . . 37 l/min
- service pump at 60 Hz . . . . . . 45 l/min

2 1

Fig.1.4.3 Hydraulic double pump

1. Main pump
2. Service pump

Sound noise level

Drill unit with electric power unit
Sound power emission . . . . . . . . 101,5 dB (A)
Sound pressure level at the
Operator’s position . . . . . . . . . . . . 82,5 dB (A)

20
 Optional Equipment and Accessories
1.0 Mast extension
A telescopic mast extension is mounted at the
top of the feed frame. With the standard
telescopic mast extension tubes, the total length
of the feed frame and mast extension can be
varied from 3.5 - 4.5 metres. With the optional 1
5 m mast extension tubes, the total length can 3
be increased to 7.5 m. The rod pulley and top
pulley are mounted on the extension tubes. 2

Fig.1.0 DIAMEC U4.

1. Rod pulley
2. Top pulley
3. Backstay legs*
4. Wire line hoist

* Can be used as support in the back or in

the front of the rig.

1.1 Wireline hoist, 500 m

Mounted on the positioner arm and has
adjustable lewelwind angle. Does not need to be
moved when changing drilling angle.

Data
Capacity . . . . . . . . . . . . . . . . . 4.75 mm wire rope
Pull min. . . . . . . . . . . . . . . . . . 3900 N (Full drum)
max. . . . . . . . . . . . . . . 8100 N (empty drum)

Hoisting speed
min. . . . . . . . . . . . . . . 2.1 m/s (empty drum)
max. . . . . . . . . . . . . . . . . 4.5 m/s (full drum)
Weight (without wire). . . . . . . . . . . . . . . . . . 57 kg

Fig.1.1 Wire line hoist, 3719 0016 00

21
Optional Equipment and Accessories
1.3 Hose kits
Extra long for connecting between the drill
module and the power unit. Available in
10 m length.

1.4 Test instruments

For testing and adjusting operations of the
hydraulic system.
Fig. 1.4 Test instrument kit

1.5 Turn table

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

1.6 Hydraulic bracing device

This equipment comprises two hydraulic Fig. 1.6 Hydraulic bracing device
cylinders with spikes (for assembly on the upper
part of the feed frame) and two screws with foot
pads (for attachments to the lower part of the
feed). The device is particularly suitable for use
in narrow tunnels and drifts. It allows simple
anchoring of the feed frame between the floor
and roof/wall of the gallery, drift or tunnel. The
two cylinders are operated by a control valve.

1.7 Flush pumps

The TRIDO® flush pumps are matched to suit the
drilling operations that may be carried out with
the DIAMEC® U4.
Fig. 1.7 TRIDO® flush pump operated with
Hydraulic powered TRIDO® 80. an hydraulic motor.

Data TRIDO® 80
max. flow 75 l/min.
max. pressure 40 bar

1.8 Casing clamp with mounting

bracket
The casing clamp mounts on the front end of the Fig. 1.8 Casing bracket
feed frame. Clamps onto casing 49 to 119 mm.
Can be used as a guide for drilling in casing

1.9 Water swivel

The WS 18/0 water swivel has been specially
designed for use with Diamec core drills.
Fig. 1.9 WS 18/0 water swivel

22
 DIAMEC U4 Design Features
10

11

12
1 13

15
14

2 Fig.1.2 Control panel

1.2 Control panel

11. Touchscreen
9
12. Adjustment knob
13. Emergency stop
14. Stand- height adjustable
8 5 15. Joystick

6 4
7

1.1 Drill module

1.3 Electrical Power Unit
1. Feed frame
16. Starter panel
2. Rotation unit
17. Hydraulic oil tank
3. Rod holder 18. Electric motor
4. Wall bracket 19. Main pump
5. Positioner 20. Service pump
17
6. Turn table
7. Skid
8. Backstay legs
9. Wireline hoist
10. Top pulley
16

19,20

18

23
Maneuvering
2
1.0 Pre-start procedure
1. Check hydraulic oil level in the oil tank. 1 4
Refill if oil level is too low Fig. 1.2.

2. If using a water type oil cooler, connect

cooling water to the hydraulic oil cooler, 3 5
see Fig. 1.1.
Fig. 1.1 Connection of cooling water for
3. Before starting motor, carry out hydraulic oil cooler
instructions given in Periodic Maintenance
pages. 1. Flush water pump
2. To water control system on Drill
module
3. Collector vessel for flush water
4. Oil cooler
5. Water supply to the drill site

IMPORTANT (Water type oil cooler)

DANGER The water hose leading to the oil cooler

should be cleaned once a week or more if
Special care and attention should be paid to neccessary and equipped with a strainer. The
damaged or worn components, which could water pressure should not exceed 10 bar.
cause structural fatique, cracks or even Always make sure that the water passing
fracture in materials or welded joints. through the oil cooler is as clean as possible.
Dirty or contaminated water will result in
rapid internal layering and blockage inside the
cooler which can cause overheating of the
hydraulic system.

Fig. 1.2. Hydraulic oil tank

1. Level indicator & Temp gauge

24
 Maneuvering
3.0 Start-up Electric power unit 45 kW 2 3 4 5 6 7 8

1. Check that the emergency stop buttons (on

the control panel and power unit are not
pressed.
2. Press the reset button (7) and turn the main
switch (11) to ( I ), the control lamp (2)
should now light up.
3. Press the S1 button (10) on the starter box.
NOTE
Make sure the second stage of the electric
motor engages automatically (can be
heard). If the motor does not start and the
control lamp lights up, this indicates that
the phase sequence is incorrect. (At first
start-up with a new electric supply
point/trailing cable. Make sure that the
electric motor turns clockwise) 1 12 11 10 9

4. Check that the emergency stop devices (on Fig. 3.0 Startbox for Electric power unit 45 kW
the control panel (1), power unit and drill
module) are working before drilling. 1. Emergency stop button
Commence by stopping the motor from
each safety stop device. 2. White control light , Power on
5. Check that there are no signs of oil leakage
from threaded joints, hose connections or 3. Red control light, Motor breaker
fittings.
4. Red control light, Wrong phase, motor trying
Stopping
1. Stop the power unit by pressing stop to turn in wrong direction
button S2 (9).
5. Red control light, Oil temperature high
2. When leaving the machine, or when
servicing, always switch-off the main circuit 6. Red control light, Oil level low
switch (11) to O position, Fig. 3.0.
7. Red control light, Emergency stop released

8. Alarm Reset button, black

When Control lamp lights come on:
Light 2 Main switch turned on 9. Remote start
Light 3 Motor breaker
Light 4 Wrong phase sequence. Change phases (call 10. S2 Motor stop button, red
for authorized electrician).
Light 6 Oil level low - light will remain on until alarm 11. S1 Motor start button, green
reset button (9) pushed.
Light 5 Oil temperature too high >70°C 12. Main switch
Light 7 Emergency stop activated - light will remain
on until alarm reset button (7) pushed.

CAUTION!
If the electric motor has been disconnected and reconnected to the starter panel, the direction
of rotation must be checked the first time the motor is started (automatic phase protection
may not prevent wrong rotation direction). If the rotation is wrong, the hydraulic pumps will
be destroyed. The connections must be changed by an authorized electrician.

25
Setting Up for Drilling
1.0 Positioner for the DIAMEC® U4:
– Working positions from - 90° to + 90°

26
 Setting Up for Drilling
1.1 Positioner, wireline hoist
The drilling angle can be changed from -90 down
to +90 up by controlling the positioning
cylinders. The wireline hoist remains in position.
The angle of the levelwind has to be adjusted to
maintain the proper alignment of the levelwind
with the pulley. This is done by pulling out the
lock pins, moving the wireline to the proper
angle and then ensuring that the lock pins are
securely seated (see Fig. 1.1).
1

Fig.1.1 Adjusting Levelwind angle

1 Lock pins

27
Setting Up for Drilling
1.5 Displacement of Feed Frame
1. Move and stop the cradle just over the
feed frame holder. Undo the two tool
screws and place the tool according to Fig.
1.5.1.

To mount the two tool screws through the

tool it can be necessary to adjust the le)
b
cradle position on the feed frame.
li a
2. Tighten the tool.
va
3. Undo the clamp screws (6 pcs) just as
t a
much needed to move the feed.
no
(
ge
DANGER a
Im
Do not undo the clamp screws too much, the
feed may come lose from its bracket and
cause personal injury.
Move the feed frame very carefully!

1.6 Moving the Feed Frame

1. Move the feed frame with the slow feed Fig. 1.5.1 Displacement of feed frame
control.

2. When the desired position of the feed

frame is obtained, tighten all clamp screws
properly. Move the tool back to its place.

28
 Setting Up for Drilling
1.7 Underground set-up
1. Anchor the skid frame to the ground or
platform by means of anchor- or expander
bolts. (See Fig. 1.7)
WARNING
2. Connect all hoses (see nr. on hoses and In order to prevent accidents, caused by
fittings). overturning the rig, strictly anchor the feed
frame / stand before starting to drill.
3. Start the power pack and check that all
hydraulic connections are tightened and
that no oil leakage appears.

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

– Before raising the feed (mast) look up to

3
check for overhead obstructions. When
overhead electrical power lines exist at, 1
2
or near a drilling site, consider all wires
to be alive and dangerous.

1
4. Move the feed frame using the positioner
Fig. 1.7 Underground set-up
control valves located in the hydraulic
valve assy. 1. Anchor bolts
2. Wall bracket for anchoring the feed to
5. Anchor the feed frame with the standard the ground
wall bracket (2, Fig. 1.7). 3. Backstay legs

6. Install backstay legs (3. Fig. 1.7) and ensure

all bolts are tight before starting to drill.

29
Setting Up for Drilling
1.8 Underground set-up with
hydraulic support jacks
1. Anchor the skid frame to the ground or
platform by means of anchor- or expander
bolts. (See Fig. 1.8)
WARNING
2. Connect all hoses (see matching nos. on In order to prevent accidents, caused by
hoses and fittings). overturning the rig, strictly anchor the feed
frame / stand before starting to drill.
3. Start the power pack and check that all
hydraulic connections are tightened and
that no oil leakage appears.

4. Move the feed frame using the positioner

control valves located in the hydraulic 2
valve assy.

This operation must be carried out

carefully to avoid damaged pipes and
piston rod.

WARNING
1
– Make sure that no loose pieces of
equipment or objects are lying on the feed.

– Before raising the feed (mast) look up to

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

Fig. 1.8 Underground set-up

5. Extend the pipes as close as possible to 1. Anchor bolts
the roof and lock with the locking pins. 2. Support jacks
6. Tighten the support jacks (2) to the roof
with the lever (Control valve in same
location as positioner valves).

30
 Setting Up for Drilling
1.9 Setting-up the core drill using
a casing clamp
1. Withdraw the telescopic tubes (3) out of 5
the feed frame and lock them in position.

2. Position the bracket (1) for the casing

clamp on the telescopic tubes and secure
with the nuts (4).
2
3. Assemble the casing clamp (2) to the
bracket with the two screws (5).

4
3
Fig. 1.9. Casing clamp

1.9.1 Using a casing clamp as a

guide
The clamp should be mounted with the lugs
facing towards each other.

Fig. 1.9.1. Casing clamp as guide

1.9.2 Anchoring the rig with the aid

of a casing clamp to the
casing tube cemented in the
ground
Turn the upper clamp 180° in the horizontal
plane so the lugs of the clamps will interlock.
Fig. 1.9.2. Casing clamp for anchoring to casing
tube

31
Maintenance
1.0 General
4 Use the rotation lever to circulate the
The performance and reliability of the DIAMEC® hydraulic system for about 5 minutes.
U4 is largely dependent on the amount of care If no cooling water is connected, the
and attention shown to it. Regular checks and rotation lever should be pulled backwards.
inspection of wearprone components prevent If the lever is pulled forward the rotation
breakdowns and costly downtime. direction will be clockwise and a sequence
valve will cause unwanted heat when
Dirt is a primary cause for most malfunctions in a
idling.
hydraulic system.
Therefore: 5. Disconnect the two main hoses from the
fitting and reconnect them to their correct
- Always try to keep the core drill clean and points on the hydraulic motor.
free from dirt and other pollutants. It is
much easier to detect faults or oil leakage
on clean equipment.

- Never leave any part of the hydraulic 1.2.1 Oil cooler - water type
system open or exposed to external
influence. When required, clean oil cooler by back flushing
the cooling water. The cooler cannot be
- Always attach tight-fitting plugs to disassembled
disconnected hose ends and couplings.

- Always perform oil refills into the hydraulic 1.2.2 Oil cooler - air type
oil tank by using the hand pump supplied.
(Oil should be refilled through the return When required, clean the air oil cooler by
filter) flushing dust out of the fins. Do not damage the
fins by using excessive water pressure.
- Always store fresh oil stocks in sealed
containers.

- Always use TREDO-type seals for sealing

threads. Use of Teflon tape, oakum or
similar, could damage sensitive
components in the system if fragments
dislodge and enter the system.

1.1 Cleaning the hydraulic system

Following any major intervention in the hydraulic
system, systematic and through cleaning of the
system should be performed, before drilling is
allowed to continue.
Cleaning procedure

1. Disconnect the two main hoses on the

hydraulic motor and put caps on the
fittings.

2. Reconnect the loose ends together with the

fittings included in the tool kit.

3. Start up the power unit.

32
 Maintenance

WARNING
Do not carry out any service and repair on
hydraulic equipment being under hydraulic
pressure. Stop the power unit, then operate
valves until pressure is relieved. Escaping
pressurized hydraulic oil can penetrate skin
which can cause serious inflammations. Seek
medical attention if injured. Small leaks are
practically invisible, so when searching for
them, Do not expose your face or hands but
use a piece of cardboard or wood.

33
Maintenance
1.3 Hydraulic oil filters
Oil Filter Change: every 1000 hours or when
indicators show change.

There are in total two filters on the DIAMEC® U4

drill. Both located on the tank in the power unit.
Of the filters in the power unit, one is a
breathing filter and one a return filter mounted
on the lid - inside the hydraulic tank.
The breathing filter is all in one piece, unscrew
the filter and replace with a new one. Replace
once per year and more often in dusty
conditions.
The return filter is equipped with a pressure drop
indicator. The filter contains a bowl that holds the
filter element. To change the element, unscrew
the four hexagon nuts on top of the filter and lift
the top off. Then push down the lid, turn 90
degrees counter clockwise and lift the lid out.
Inside the bowl you see the filter element. Pull it
out, rinse the bowl if necessary and replace the
element with fresh a one. Then put the lid back
on the bowl and reinstall the top back onto the
filter. Secure the top with the four nuts.

Fig 1.3 Oil filter insert

1. Cover assy
2. By-pass assy
3. Filter element
4. Filter bowl
5. O-ring
6. O-ring
7. Flat gasket
8. Clip
9. Mesh screen element
10. O-ring

34
 Maintenance
1.4 Changing the hydraulic oil.
The hydraulic oil should be changed after 2000
operating hours in normal worksite conditions, or
at least once a year.
If the quality of the oil has deteriorated for some
reason, either through extremely high
temperatures or contamination, it should be
changed as soon as possible. In such cases, the
top part of the tank should also be removed and
the entire interior of the tank cleaned thoroughly.

Oil change.
1. Drain off all the hydraulic oil by connecting
a hose to the drain valve (1) underneath
the tank. Open the valve and make sure to
collect all the oil and treat it as
environmentally dangerous waste.
2. Refill new oil (about 80 litres) using the
hand pump. As the oil is pumped into the
tank it passes through the filter so that any
impurities are filtered out. Fig. 1.3 Hydraulic oil tank
1. Drain valve
2. Sight glass
1.5 Draining condensed water out
of tank
IMPORTANT
The tank drain valve (1) is used to drain
The useful service life of the hydraulic oil can
condensed water out of the tank. Condensed
be seriously reduced at operating temperatures
water can collect at the bottom of the tank. The above +60°C.
amount of water collected depends on the
humidity levels and the number of times the drill High temperature can cause:
is shut down and the oil tank cools down. – Leaky gaskets
– Serious internal leakage in pumps and
The tank drain should be checked regularly for
valves, due to decreased viscosity and
the presence of condensed water. In conditions
lubricating properties of the oil.
of high humidity and tank cool down each shift,
condensed water may have to be drained out at
the beginning of each shift. If the power unit is
not level, try to position the drain on the low
side.

1.6 Hydraulic tank oil level

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

35
Maintenance
2.1 Periodic maintenance with Service schedule for drill and power unit 45 KW
The Service Schedule gives instructions to lubrication, inspection procedures and measures to take,
following a specific number of operating hours. Use this schedule to get the most out of your equipment
and always follow the instructions given.

6,7,13

14

12

5,5a
3
4

14
2

11
10

36
 Maintenance
2.1 Periodic maintenance with Service schedule for drill and power unit 45 KW

Ref. Check points Procedure Service interval in Notes

No. hours of operation

8 40 once/
month

1 Feed frame holder Tightening x

2 Slide shoes Adjustment x See Adjusting the slide shoes

Lubrication x More often in bad conditions

3 Chuck jaw holders Cleaning x More often in bad conditions (e.g.

up-hole drilling)

Chuck jaw inserts Cleaning x Inspect and clean if necessary

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

5 Rod guide Cleaning x See Lubr. Recommendations

Lubrication x

5a Rod jaws Cleaning x Check for wear

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

7 Hydraulic oil filters Inspection x See Hydraulic oil filters

8 Oil leakage Inspection x Continuous inspection of hydraulic

fittings, hoses and components

9 Complete drill rig Cleaning x When necessary

10 Wireline hoist with Lubrication x x Apply grease to Levelwind screw

Levelwind and one lube nipple.

11 Positioning cylinders Lubrication x Lube nipples on cylinders.

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

month

13 Oil cooler Cleaning x See Oil cooler

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

37
38
 Maintenance

2.2 Lubricant recommendations

Lubricant Check point No. Recommendation

1. Hydraulic oil 6 Use mineral-based hydraulic oil with good anti-wear, rust (oxidation)
and foam inhibiting properties, as well as effective air and water
separation abilities. The viscosity grade should correspond to the
ambient temperature and ISO 3448, as follows:

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

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

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

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

Use of flame proof or biodegradable hydraulic oil, please contact

nearest Atlas Copco representative for information.

2. Grease 2,10,11,12 Universal grease NLG12....................Operating temperature °C (°F)

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

Example of grease grades

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

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

Example of grade
15W 40 Turbo oil

4. Rotation 4 Synthetic gear oil with low foaming tendency

unit, Gear
case oil Viscosity grade 300-350 cst. at 40° degrees C
Shell Omala HD 320
Where appropriate: Oil change interval 1000 hours

39
Maintenance
3.0 Daily safety check
Before each shift commences, an extra and thorough safetey check shall be carried out to detect:

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

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

welded points.

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

weakness or fracture

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

weakness or fracture

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

From the safety aspects therefore, the

following check points are particularly
important (see illustration below)

1. Feed frame / feed frame holder 7

2. Positioner and positioner cylinders

3. Skid 6
4. Positioner attachment

5. Turntable

6. Rotation unit, cradle & slides

7. Rod holder

8. Mast top, top pulley

1
9. Wireline hoist, wire rope
8
10. Feed frame clamps, backstay
legs

Fig. 3.0 2

10
3 4
5

40
 Maintenance
4.0 Adjustment of speed regulation 2

The speed of the rotation motor is proportional

to the RPM pilot pressure. Regulation is active in
a 15 bar region and “start of regulation”
pressure can be adjusted from 5 to 25 bar. In the
U4 a “start of regulation” pressure of 10 bars is
1
used.
Under the threshold pressure, the motor is at
maximum displacement and gives maximum
torque. The spindle speed obtained in this mode
vary with the size of the rotation unit and size of
motor used. Also shown are the maximum
spindle speed that must be set on the motor.
Fig. 4.0 Adjustment of speed regulation
1 “Start of regulation adjustment screw
Rotation Motor U4 spindle RPM Maximum 2 Minimum displacement adjustment
unit Size - cc at max motor spindle RPM screw
displacement RPM

Std 60 500 (85 l) 1800

High 80 180 (85 l) 1100

Torque

4.1 Adjustment procedure with

replacement motors

CAUTION
When replacing the motor in the field, the right
procedure must be used to ensure that the
rotation motor is not damaged by over-speeding

1. Check that the maximum rotation flow is

according to the table above with a flow
meter.

2. Place a test RPM gauge at test port “Drill”

on the console block or at port X5 where
hose enters the rotation motor. Screw in Control panel
the RPM control knob on the control panel
until the pressure on the test gauge reads 5. Turn the RPM control knob on the control
10 bars. panel clockwise until the spindle reaches
max. rpm. Slowly screw out the minimum
3. Start rotation with maximum flow. The displacement adjusting screw until the
spindle RPM should be as in the table for spindle rpm reaches the maximum value
max motor displacement. for the motor. Lock the adjustment screw.
4. Check that the RPM increases when
If the drill is not equipped with the optional RPM
increasing the pilot pressure with the RPM
gauge on the panel, use a hand held tachometer
control.
on the spindle.
If there are any questions about this procedure,
phone the Atlas Copco service department.

41
Maintenance
4.2 Rotation Unit oil Level
The rotation unit holds 0,5 liters of synthetic oil
see Lubricant specifications.
The oil level can be accurately checked in the
positions shown:
The two oil level indicators (55) on the gear
housing. They will be used for checking the oil
level, and needs to be 50 % full. 55a will be used
for vertical drilling and 55b for horisontal
drilling.
The magnetic plugs with their belonging washer
(23). 75a is used for horisontal drilling and 75b
for vertical drilling.

It is important to have the correct oil quantity

when drilling at 90 degrees down and 90
degrees up. In these positions 0,5 liters is
needed to maintain lubrication of the gears.
When drilling between 45 degrees up and 45
degrees down, the oil level is correct as long as fig 4.2.0
oil can be seen in one of the two sight glasses.
The oil can be drained at 90 degrees down.
When refilled to the top plug (a, see Fig. 4.2.1),
the gearcase contains 0,5 liters of oil.
Important: Do not overfill the gearcase as this
will cause overheating.

40 Plug alt. Pressure Sensor

41 Filter Plug
42 Plug alt Induction Sensor
52 Locking Screw
55 Oil Level Indicator
75 Magnetic plug
a Oil In, Ch
b Oil Out, Dr

fig 4.2.1

42
 Maintenance
7.0 Adjustment of chuck pressure
1V5
1. The higher the chuck pressure, the higher
the chuck holding capacity. For maximum
service life of the rotation unit seals, it is
recommended that the chuck pressure be
set only as high as necessary.
G Chuck
– For definition drilling, set the chuck
pressure at 100 bars.

– For exploration drilling (> 200 m BQ),

set the chuck pressure at 120 bars.

NOTE

When delivered the chuck pressure is set

to 110 Bar
5H
2. Attach a test gauge to the chuck pressure
test port (G Chuck). Turn the chuck pressure
adjustment screw (5F) clockwise to
increase chuck pressure, counterclockwise
to reduce chuck pressure. Tighten the lock 5F
screw after making the adjustment.

Fig. 7.0 Adjustment of chuck pressure

5F. Chuck pressure test port
5H. Chuck pressure adjustment screw

7.1 Adjustment procedure

1. Connect a 250 bar test gauge to the test
port marked “G Chuck” on the logic block
(1V5) in the column of the control panel
and start the motor.

2. Close the chuck by putting the rodrunning

mode selection lever (8) on the control
panel into “rodrunning out” position. Then
run the head to back end of the feedframe
with the fast feed lever. Keep the lever held
in the stalling position while the chuck
pressure is checked with the test gauge.

3. If the pressure needs to be adjusted,

loosen the lock nut on the pressure
reducing valve (2, Fig. 7.0) and adjust the
valve until the desired pressure is reached.
Retighten lock nut.

43
Maintenance
8.0 Adjusting maximum pressure of the main- and servicepumps

8.1 Main pump

Maximum pressure: 280 bar
Stand-by pressure: 22 bar

8.1.1 Maximum pressure adjustment

1. Start the motor.

2. Apply maximum pump pressure to the

feed cylinder, move the fast feed lever
backwards and hold it there until you can
read the maximum pump pressure on the
system pressure gauge on the control
panel.

3. If necessary, adjust the maximum pump

pressure by turning the max. working
pressure screw (1, Fig. 8.1) on the main
pump regulator, closest to the pump
housing. Use a 6 mm allen key. One turn
equals approx. 50 bar, clockwise turning
increases the pressure. Unscrew the
locking nut before adjustment, tighten
when desired max. pressure is obtained
(280 bar).
Control panel

8.1.2 Stand-by pressure adjustment

1. Start motor. The pump stand-by pressure
can now be read on the system pressure
gauge.
2. If necessary, adjust the stand-by pressure
by turning the stand-by pressure screw.
Stand-by pressure adjustment screw is
located on the main pump regulator,
further out from the pump housing (One 1
turn is approx. 17 bars).
2
Use a 6 mm allen key, clockwise turning
increases the pressure. Unscrew the
locking nut before adjustment and tighten
it when desired stand-by pressure is
obtained (22 bar).
3. After pressure adjustment, stop the motor.
Fig. 8.1 Adjusting the main pump

1. Adjustment screw, max. working

pressure
2. Adjustment screw, stand-by pressure

44
 Maintenance
8.2 Service pump
Maximum pressure: 200 bar
Stand-by pressure: 22 bar
8.2.1 Maximum pressure adjustment
1. Screw stand-by pressure adjustment to
the bottom after removing cap and lock 1
nut. Count the revolving needed.
2
Plug outgoing pressure hose from the
service pump. Connect a 250-400 bar
gauge to the pressure hose.

2. Start motor, adjust the maximum pressure

screw so that the gauge reads 200 bar.
Fig. 8.2 Adjusting max. pressure of the
service pump
8.2.2 Stand-by pressure adjustment
1. Adjustment screw, max. working
1. Stop motor, unscrew the standby pressure
adjustment pressure screw to the same 2. Adjustment screw, stand-by pressure
position as before testing
(the remembered revolvings). Adjust to 22
bar stand-by pressure.

45
Maintenance
9.0 Starting up the power unit
after adjustment or
disconnecting the hoses
1. Jog the motor shortly to check that the
direction of the rotation is correct
(clockwise from the fan end of the motor).
WARNING
2. Start up the power unit with no load but Rotating the pumps in the wrong direction will
with full flow. Eg. with the rotation motor destroy the pumps.
engaged but no rods in the chuck. Let the
pumps work in this condition for 2
minutes.

Counterclockwise will give less energy

consumption and less cooling is needed.

3. Bleed off the load sense hoses at the

bulkhead fitting on the power unit.

4. Stroke the feed cylinder 5-6 times, to get

air out of the cylinder.

5. Bleed off the rotation speed pilot hose at

the rotation motor with the rotation motor
spinning at 1000 rpm.

6. Check oil level in sight glass on tank and

top off the tank with fresh hydraulic oil if
necessary.

46
 Maintenance
10.0 Rod Holder Gas Spring
Pressure Check
The U4 rodholder grips the rod using gas
pressure in the gas spring cartridge. The gas
spring cartridge is charged to 70 bar pressure
with nitrogen gas and is designed for long
service life (tested to more than one million
cycles). It uses two main piston seals, one active
and one backup.
The gas pressure can be checked by slowly
increasing the pressure with the rotation lever in
clockwise rotation (press the lever forward) read
the system pressure when the rod holder
balances midway open.
The area difference in gas spring gives 70 bar
Nitrogen equals 104 ± 5 bar hydraulic pressure.
To eliminate that the measurement is false, check
the hydraulic pressure when the rod holder
slowly opens and slowly closes and calculate the
averidge drifting pressure. Rod holder
It is recommended that the gas pressure be
checked once per month, when rods start to slip
in the rod holder, or before drilling an uphole. If
the rod starts to slip in the rodholder, the cause Table 10 “Drifting“ pressure when
can be worn jaws or too low a gas pressure. This checking rodholder gas pressure
test allows a quick and convenient check of the
gas pressure. Rods*

“Drifting” pressure with

gas spring fully charged 104
“Drifting” pressure when
gas spring requires service 94
*) in the rod holder

NOTE:
“Please observe that gas pressure is depending
on ambient air temperature, the pressure given
in the table “10” is at 20 degrees Celcius.
10 degrees colder temperature equals 4% lower
gas and hydraulic pressure.”

DANGER
Operating the rig on an up hole with drifting
pressures less than 80 bar may lead to rod
slippage and personal injury

47
Maintenance

Fig. 11.0-11.2 Rod holder jaws and guide bushing

1 Bolt
2 Rod holder insert
3 Jaw
4 Back cover
5 Bearing
6 Socket holder
7 Retainer
11.0 Changing Rod Holder Jaws
8 Guide bushing
And Rod Holder Guide
Bushings 9 Circlip

11.1 Changing Jaws 11.2 Rod Holder Guide Bushing

Remove two bolts (1) holding the rod holder The diameter of the bushing (8) must be chosen
insert (2) in the rod holder housing. Pull out the to suit the drilling equipment to be used (See
insert so the jaws (3) are clear of the housing, spare parts list).
taking care not to damage or stretch the
The bushing replaced by prying it out of the
hydraulic hose. The jaws can now be pulled out
bearing. The new bushing is knocked into the
and replaced.
bearing (snap fit).
For N size bushings, the bearing (5) is centered
Important: The jaws have a flange on one side. directly in the back cover (4) .
Ensure that the jaws are put in so that the flange
keeps the jaws from falling out of the jaw
holders and down the drill hole when the rod
holder insert is pulled out.

48
 Maintenance
13.0 Adjusting slide shoes on cradle
1. Move the rotation unit to its rear position.

2. Loosen the lock nuts and take up clearance

by screwing in the pins.
Turn only until the slide pads are in
contact with wear liner, do not tighten too
much.

3. Back off both pins on one side only by 1/4

turn - creating 0.5 mm total side to side
clearance (pin thread has 2 mm pitch).

4. Grip the drill rod in chuck with rod end

close to the rod holder. Rotate the chuck
for possible throw. Adjust front pins to
make rod lines up with the rod holder
(Keeping total clearance of 0.5 mm).

5. Loosen the chuck and move the rotation

unit to its front position and regrip the rod.
Adjust the pins to line up the rod with the
rod holder.

6. Check that total side to side adjustment is

0.5 mm.

7. Tighten the lock nuts.

8. Grease well using the recommended

grease. If slide pads wipe off all grease, Fig. 13.0 Adjusting slide shoes on cradle
side to side clearance is too small. 1 Lock nut
2 Pin

49
Flow meter Optional equipment

Fig.1 Flow meter S030, 8032

1. Design 3. Functionalities

The flow rate controller 8032 is made up of an The device has three operating modes :
electronic module SE32 and a fitting S030 with
integrated paddle-wheel. It may switch a
solenoid valve, activate an alarm or establish a Normal Mode
control loop. Display of the measured flow rate and the
The switching point can be adjusted by means of switching thresholds programmed.
the three keys located under the display. The From the Normal mode, you can access the
adjustment can optionally be carried out by Calibration and Simulation modes.
means of a 4-20 mA loop via an external
controller.
The electrical connection is carried out via an Calibration Mode
EN175301-803 connector and/or an M12 multipin Access to the programming of all the parameters
connector. (unit, K-factor, calibration through the „Teach-in“
feature, output, filtre, bargraph and, if available

2. Measuring principle in your controller version extension board

parameters). From the Calibration Mode, you
The controller 8032 detects the rotation of the can go back to the Normal Mode.
paddle-wheel S030. The latter produces pulses
whose frequency is proportional to the flow rate
(f = K.Q, where f is the frequency in Hz, K the K Simulation Mode
factor specific to each fitting in pulses/l and Q the Entering a theoretical flow rate value to test the
flow rate in l/s). configuration programmed in the Calibration
Mode. Depending on your controller 8032
version, you may also calibrate the extension
board. From the Simulation Mode, you can go
back to the Normal Mode.

50
Optional equipment Flow meter

Fig.2 Flow meter display 8032

Fig.3 Display, placed in the control panel

(102)

51
Flow meter Optional equipment

3.1 Operating principle

The paddle-wheel is set in rotation by the fluid. The rotation frequency f of the paddle-wheel is
proportional to the flow rate.

Fig.5 Operating principle

52
 Optional equipment Flow meter

To the electrical cabinet To flow meter.

Fig. 6 Connect the display according to the electrical wiring diagram. (Connecting principle)
53
Flow meter Optional equipment

Programming, Flow rate Controller 8032

To display the measured value

and the configuration (8
characters: To indicate the status of
4 numeric and 4 alphanumeric the switching output
charact.) (red LED)

Modifies the displayed value To validate a function;

(0…9) ; To validate the entered
data.
To go to the previous function.
To select the character;
To go to the next
function.

4. Programming keys

4.1 Default Configuration

At the first powering up, the configuration of the controller 8032 is as follows:

Flow rate unit: l/s

K factor 1
Output: hysteresis, inverted
OLO: 0
OHI: 0
DEL: 0s
Filtre: 2
BGLO: 0
BGHI: 0
Extension board: no

54
 Optional equipment Flow meter
4.2 Programming Flow rate Controller 8032

1 Normal mode

Display of the measured flow rate.

Unit of the measured flow rate.

To go back to the
previous function.

To display the high threshold

value (O HI).

To go to the next function.

To display the low threshold

value (O LO).

1 Normal mode

2 Calibration mode

3 Simulation mode

Error messages
Displayed Signification What to do
message
ERR 0 Calibration data is lost. Press the ENTER key to go back to the Normal
Reading error: the process is mode. The device has returned to its default
stopped. configuration: the device must be calibrated again.
If the message appears frequently, contact Atlas
Copco.
ERR 1 Calibration data cannot be saved. Press the ENTER key to go back to the Normal
Write error: the process is mode. The device displays the configured data; BUT
stopped. this data has not been saved: the device must be
calibrated again.
If the message appears frequently, contact Atlas
Copco.
ERR 2 The calibration parameters Press the UP and DOWN keys under the display to
cannot be accessed. scroll through the menus.
Menu reading error:the process If the message appears frequently, contact Atlas
goes on operating. Copco.
55
Flow meter Optional equipment

2 Calibration mode

Settings for flow meter S030 with display 8032.

4.2.1 Calibration mode

1. Press the keys simultaneously

2. UNIT will be displayed

3. Press ENTER

4. Choose “l/min” by up/down

arrows and end with ENTER

5. K-factor is displayed.
(K is the multiplication coefficient
between the rotational
frequency of the paddlewheel
S030 and the fluid to
be measured).

6. Press ENTER

56
 Optional equipment
Flow meter
2 Calibration mode

7. Choose “NO/TEAC” by up/down

arrows and end with ENTER

8. 66.48 KFAC will be displayed.

Use the up/down arrows to
change the value.

Set the new value to 57.00

end with ENTER

9. The K-factor is now set and the

display shows “OUT”

10. Press down/back arrow

11. The display will show “FILT”

12. Press ENTER

57
Flow meter Optional equipment

2 Calibration mode

13. Choose “6/FILT” by up/down

arrows and end with ENTER

14. The display shows “BRGR”

15. Press down/back arrow

16. The display shows “EXT”

17. Press ENTER

58
 Optional equipment
Flow meter
2 Calibration mode

18. Choose “YES/EXT” by up/down

arrows and end with ENTER

19. “IN” will be displayed.

20. Press ENTER

21. “NO/OK” will be displayed

22. Choose “NO/OK” by up/down

arrows and end with ENTER

23. “OUT” will be displayed

59
Flow meter Optional equipment

2 Calibration mode

24. Choose “0.0/4mA” by up/down

arrows and end with ENTER

25. Choose “140.0/20mA” by

up/down arrows and end with
ENTER

26. “END” will be displayed

27. Press ENTER

28. “00.00/l/min” will be displayed,

the calibration is finnished.

60
 Optional equipment
Flow meter
2 Calibration mode Complete programming sequence for S030 and 8032

61
Flow meter Optional equipment

Programming of flow meter display

1. Turn the main switch (1) on

the power unit to “ON”
postition.

Programming mode: general

When you set the values for the

the display it always toggles
between the name of setting and
the value.

If the value is right press the two

buttons simultaneously (2) when
the name of setting is visible. 2
If the value is wrong change the
value to the right one by
pressing the gray button when
the value is visible until the right
value appers.

Thereafter press the two buttons

simultaneously to confirm (3).
3
This will take you to the next
name of setting/value.

62
 Optional equipment
Flow meter
The programming loop of the display:

Program start 1. RANGE 2. MAX 3. MIN 4. DP 5. LO

Program end 9. ENDPRO 8. HIDIS 7. HIGH 6. LODIS

Here follows the different settings:

" Range
Will toggle between Range and its value. The value should be 4-20 mA.
If the value is different change by pressing the gray button according to the general
instructions above.

" MAX
Will toggle between MAX and its value. The value should be NO.
If the value is different change by pressing the gray button according to the general
instructions above.

" MIN
Will toggle between MIN and its value. The value should be NO.
If the value is different change by pressing the gray button according to the general
instructions above.

" Dp
Will toggle between Dp and its value. The value should be 0.00.
If the value is different change by pressing the gray button according to the general
instructions above.

" Lo
Will toggle between Lo and its value. The value should be 2.860.
If the value is different change by pressing the gray button according to the general
instructions above.

" Lodis
Will toggle between Lodis and its value. The value should be -10.00.
If the value is different change by pressing the gray button according to the general
instructions above.

" High
Will toggle between High and its value. The value should be 20.00.
If the value is different change by pressing the gray button according to the general
instructions above.

" Hidis
Will toggle between Hidis and its value. The value should be 140.00.
If the value is different change by pressing the gray button according to the general
instructions above.

" Endpro
Will toggle between Endpro and its value. The value should be Yes if you want to exit the
programming loop.
If the value is different change by pressing the gray button according to the general
instructions above.

63
Tachometer Optional equipment

General Specifications

The DITAK 9 is a self-powered rate indicator 1. DISPLAY: 5-Digit LCD, 0.46" (11.68 mm)
designed to operate in medium/high speed high digits.
applications. It is ideal for use with magnetic
pick-ups or other bi-polar sensors operating at a 2. POWER SOURCE:
minimum of 30 Hz*. The unit features Internal 3.0 V lithium
selectable timebase, rate multiplier, and decimal battery provides over 7 years of
points via two front panel pushbuttons. It has a continuous service (battery life is
5-digit LCD Display with 0.46" high digits that dependent upon usage).
are available in positive image reflective (black
digits, reflective background) or negative image 3. BACKLIGHT POWER REQUIREMENTS:
transmissive red or yellow/green (illuminated 9 to 28 VDC @ 35 mA.
digits, dark background). Backlight version units Above 26 VDC, derate operating
require power from an external 9 to 28 temperature to 50°C.
VDC supply. Must use the MLPS or a Class 2
or SELV rated power supply.
The unit is constructed of a lightweight, high
impact plastic case with a clear viewing window. 4. SIGNAL INPUT:
The sealed front panel meets NEMA 4X/IP65 0 to 10 KHz from a magnetic or
specifications for wash-down and/or dusty bi-polar output (with a
environments, when properly installed. A Ditak 9 50% duty cycle). Min. input
unit can be mounted in the same panel cut-out sensitivity is 0.9 V. Max. input =
as the earlier Ditak 7 units. 28 V.

The optional Micro Line/Sensor Power Supply 5. TIMEBASE:

(MLPS0000) is designed to attach to the rear of Adjustable in 1 sec increments
an installed backlight version Ditak 9. The via front panel. Timebase
optional supply can be powered from either a ranges from 1 second to 7
115 or 230 VAC source, and can provide power seconds; 0.05% accuracy.
for the backlighting of a unit and a sensor. The
maximum current draw for the sensor is 45 mA. 6. ENVIRONMENTAL CONDITIONS:
Operating Temperature: 0 to 75°C
(Above 50°C derate backlight
operating voltage to 26 VDC
max.)
Storage Temperature: -30 to 80°C
Operating and Storage Humidity:
85% max. relative humidity
(noncondensing) from 0°C to
75°C.
Altitude: Up to 2000 meters

64
 Optional equipment Tachometer
INSTALLATION ENVIRONMENT

The unit should be installed in a

location that does not exceed the
maximum operating temperature
and provides good air circulation.
Placing the unit near devices that
generate excessive heat should be
avoided.

The bezel should be cleaned only

with a soft cloth and neutral soap
product.

Do NOT use solvents. Continuous

exposure to direct sunlight may
accelerate the aging process of the
bezel.

65
Tachometer Optional equipment

PROGRAMMING 2. DECIMAL POINT SELECTION

The selection of the decimal point
From the factory, the Ditak 9 is programmed position for the display (DDP) is
with a fixed 1 second timebase to read directly accomplished by repeatedly pressing
in HZ or RPM with a 60 tooth gear To enter the SEL. This selection will always default to
programming mode, place a jumper between 0.0000 when advancing to it from the
the Push Button Enable (P. B. En.) Terminal and Rate Multiplier selection. By pressing
the Common Terminal. Once the jumper is PAR, the shown decimal point selection
connected the programming buttons is entered and the Time base selection
are now activated. The Programming Mode is shown.
consists of three selections; Rate Multiplier,
Decimal Point, and Timebase. There is a fourth 3. TIMEBASE SELECTION
display which is the main display or run mode. The Ditak 9 has a Time Base selection
Once programming is complete, the unit must range from 1 second to 7 seconds. See
be returned to the main display before exiting Programming Calculations to determine
the programming mode to obtain normal the calculated Rounded Time Base
operation. (RTB) value. The value is changed by
pressing SEL. The value is entered by
Settings for Diamec: pressing PAR and the Main Display/Run
Mode is shown.
Rate multiplier: Decimal point: Timebase:
4. MAIN DISPLAY/RUN MODE
0.8 0 1 This display follows the Timebase
Selection. The unit must be in this mode
to exit the Programming Mode and have
1. RATE MULTIPLIER the unit display properly. The push
The Ditak 9 has a Rate Multiplier (RM) button enable jumper can be removed
selection range from 0.0001 to after the Ditak 9 is returned to the main
1.9999. See Programming Calculations to display.
determine the calculated value. After
entering the programming mode, the
least significant digit will be flashing. To
increment this digit, press the SEL
button. After the value 9, the digit will
start over at 0. To move to the next digit
press PAR and then that digit can be
changed by pressing SEL. When
reaching the most significant digit,
pressing PAR will advance the meter to
the Decimal Point selection.
66
 Optional equipment
Tachometer
5. TO CALIBRATE:

A) Place a jumper between the P.B. EN. terminal and the

COMMON terminal at the back of the rpm indicator.

B) Press PAR.

Enter the RM value. The least significant digit will flash.

Use SEL to increment to correct digit 0,8 .

C) Press PAR
Enter Decimal Point Selection. You will see 0.0000

Press SEL unti you read 0

Press PAR to enter the Time Base Selection.

D) You should see 1.

Press SEL until you read 1
( On Diamec it should be 1).

E) Press PAR to enter the Run mode.

F) Check the setting by comparing with a portable RPM

meter, when running the drill.

If the reading deviates from the true value, adjust the RM

value up or down as under B).

G) Remove the jumper.

67
APC System setup

See 6991 1516 01 AIB APC Control System for following parts

1. Control system
2. Setting up for drilling
3. Drilling
4. Maintenance
Starting up the power unit after adjustment or disconnecting the hoses
Adjustment of chuck pressure
Adjustment of maximum service pump pressure
Adjustment of maximum main pump pressure
Adjustment of rotation speed regulation
Checking the pressure of the gas in the rod holder
5. Hardware
6. Trouble shooting

68
APC System setup

69
 © Copyright 2009, Atlas Copco Craelius AB Märsta, Sweden. Any unauthorized use or copying of the contents or any part thereof is prohibited. This applies in
particular to trademarks, model denominations, part numbers and drawings. Illustrations and photos in this document may show equipment with optional extras.
6991 1511 01 Märsta, Sweden, 22 September 2009 Specifications and equipment subjects to change without notice. Consult your Atlas Copco Customer Center for specific information.

www.atlascopco.com