ESD 9

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

ESD 9

These instructions are intended for operators of the DBC diamond core drill ESD 9.
Instructions are given for start and stop procedures, drilling, additional instructions, maintenance, and service
schedule to be carried out by the operator. For further information concerning service measures for the drill rig,
please contact your nearest DBC representative.
Read carefully the INTRODUCTION- AND OPERATING SAFETY sections before starting to use the rig.

All rights reserved.

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

DBC
Contents
Introduction 5 Drilling 36
Operating safety 6 Before drilling starts 36
Organizational measures 6 Start the power unit 36
Operation and maintenace 7 Start the water pump 36
Underground hazards 8 Adjust the flow of flushing water 36
Special safety device 10 Start rotation 36
Following signs are used 10 Balancing the rod weight 35
Environmental Instructions 12 Start drill feed 37
General 13 Stop drilling 37
Hoisting and transport 14 Wireline freewheeling 38
Hoisting the drill and power unit 14 Controlled wireline lowering 38
Technical specifications 16 Controlled wireline hoisting 38
Characteristics 18 Rodrunning controls 39
Feed frame 18 Manual operation of the rod holder 39
Rotation units 18 Rodrunning in 40
Rod holder 19 Adding a drill rod and making a joint 40
Power units 20 Rodrunning out 41
Optional equipment and accessories 21 Breaking the joint 41
Mast extension 21 Water pressure dump valve 42
Underground drilling 21 Limitation of electric motor temperature 42
Wire line hoists 21 Maintenance 43
Hose kits 22 General 43
Test instruments 22 Cleaning the hydraulic system 43
Flush pumps 22 Oil cooler 43
Casing clamp 22 Hydraulic oil filters 42
Design features 23 Changing hydraulic oil 44
Drill module 23 Draining condensed water out of tank 45
Power unit 23 Periodic maintenance 46
Control panel 23 Lubricant recommendations 49
Controls 24 Daily safety check 50
Control panel functions 24 Adjustment of speed regulation 51
Maneuvring 26 Rotation unit oil level 52
Pre-start procedure 26 Replacing sleeve and jaw holder in
Start-up Electric power unit 55 kW 27 the chuck 53
Start-up Diesel power unit 110 DT 28 Changing guide bushing in the
Stopping Diesel power unit 29 rotation head 54
Setting up for drilling 30 Adjustment of chuck pressure 55
Two types of positioners available 31 Adjustment of max pressure of the mainand
Displacement of feed frame 32 service pumps 56
Moving the feed frame 32 Starting of the power unit after adjustment
Underground set-up 33 or disconnecting the hoses 58
Underground set-up with hydraulic Rod holder gas spring pressure check 59
bracing device 34 Changing rod holder jaws and rod holder
Setting up the core drill using a casing guide bushings 60
clamp 35 Adjusting slide shoes on the cradle 61
Trouble shooting 62
Hydraulic schematic 66
Introduction
This instruction book is part of the complete delivery of The information is divided into the following chapters
your new diamond core drill ESD 9. It offers basic
information on features and handling of the unit and Section 1: Operating safety
contains advice and measures necessary to keep the rig Section 2: General and technical
operational. It does not, though, replace thorough specification.
training of operator, helpers and service support. Section 3: Operation
It is the responsibility of the owner to make sure that Section 4 Maintenance
all personnel assigned to this ESD 9 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 ESD 9 drill rig.

ESD 9 Printed Matter

Operator’s manual
Spare parts list

Order from: DBC

Mermerciler 23.sok/No:9
Dilovası Kocaeli
Turkey
Fax: +90 262 6582055
Operating Safety
Dear operator,
Before putting your new equipment into use, we would
like to direct your attention to the safety aspects.
Drilling can be a hazard to you and to the environment.
Good order, training and well maintained equipment
are key factors to safe operation. This instruction book
is no replacement for thorough training, but will, as a
training aid and a reference book, help you maintain a
safe working environment and keep the rig in good
operational condition.
Yours faithfully;
DBC
Intended use
The diamond core drill ESD 9 is intended for
underground exploration and investigation drilling, as
well for drilling grouting holes.
Any use going beyond this shall be considered "not
intended use". The manufacturer is then not liable for
damage incurred as a result. Unintentional use shall be
at the owner's risk. Proper use also includes observing
information in operation-, service-, and maintenance
books as stipulated by the manufacturer.
The ESD 9 should be run, serviced and repaired by
personnel properly trained for their task. This
personnel must have sound knowledge about hazards
in their respective profession.
General safety regulations must be observed.
Personnel should be aware of dangers resulting from
abuse of drugs and alcohols as well as effects of
medicines legally prescribed, or mixture of any of them.
The manufacturer is not liable for any damage caused
by unauthorized alterations made to the unit.
2.0
1.0 Organizational measures
1.1 The diamond core drill ESD9 shall be operated
only by personnel who have undergone theoretical
and practical training on the rig. Particular emphasis
shall be laid on safety precautions.
1.2 Keep this instruction book as well as other books
related to the equipment available on the rig at all
times.
1.3 Always use personal protective equipment, as
required by circumstances or demanded by
regulations.
1.4 If, during operation of the unit, any abnormal
action in the safety or operational systems is
observed; the unit should be stopped and the
problem be investigated and rectified.
1.5 Warning signs must be kept easily legible at all
times. Damaged signs should be replaced
immediately.
1.6 The daily safety check, as described in this
instruction, must be carried out in addition to
maintenance measures described in the Periodic
maintenance section (Page 44).
1.7 Hydraulic and electrical systems are of a complex
nature - and can cause injury or damage if not
handled with care. Repair and service shall be carried
out by personnel with documented experience for
these systems.
1.8 Welding repairs should only be carried out by an
authorized welder in order to meet the high
standards that apply to DBC products. Special
attention must be given to components which could
cause injury or serious damage.
1.9 After repair make sure that the rig has been
inspected and approved by the proper authorities
before being brought back to normal operation.
1.10 Never make alterations or modifications to
components of the unit, particularly to the safety
systems, which might result in hazardous
consequences. The manufacturer’s approval should
be requested for any modification done to the unit.
Operation and maintenance
2.1 In addition to this manual you should also have a
good knowledge of generally recognized safety and
accident prevention regulations. If you follow these
regulations you stand a better chance of
accomplishing your task without harm to either man
or equipment.
2.2 Prior to starting up for the first time, familiarise
yourself with the rig's features, its controls and their
functions. Refer to "Controls, Manoeuvring and
Setting up for drilling" pages for further information.
Operating Safety
2.3 Various safety devices are built into the system of
the rig for your personal safety. These devices must
be checked at least once at the beginning of each
shift to ensure that they are in full working order. The
equipment should not be used unless safety checks
and maintenance have been carried out according to
the schedule.
2.4 Operators and helpers should wear helmets, (with
ear protectors when called for), safety glasses, safety
shoes, gloves and suitable clothing. Loose fitting
clothing and jewellery can get caught in the moving
parts of the machinery, causing serious injury or even
death.
2.5 Check the surroundings. During drilling and
tramming no unauthorized person should be allowed
near the rig. Ask a supervisor for assistance when
moving the rig into dangerous positions such as close
to the edge of a quarry bench. Make sure the visibility
is good. Do not drive the rig into a dust cloud. Check
the travel route if you are unsure of the safety of the
ground.
2.6 Set control levers and switches to the neutral
positions prior to starting up, otherwise the rig could
start uncontrollably. Some of the levers are spring-
loaded so that the operation will stop once released.
This is part of the safety system. Never lock these
levers into operating position using strings, sticks or
similar items.
2.7 Avoid sharp turns when tramming on inclined
ground. Take extreme care when moving on wet,
slippery ground. Secure the rig with a suitable wire
rope when operating on slopes in excess of 10° from
horizontal.
2.8 Shut the rig down when refueling. Fuels must
be handled with care, and at a safe distance from fire,
sparks or electrical systems. Smoking is not allowed
within 10 metres of the fuel ! Do not fill the tank in an
enclosed space without ensuring adequate
ventilation. Fumes are poisonous. Do not overfill the
fuel tank. If you top up the tank in the morning, the
expansion of the fuel, as the temperature increases
later in the day, may cause fuel to spill from the tank.
Tank ventilation easily clogs if the level of fuel is too
high. See the “Environmental instructions” chapter
for further information.
2.9 Never leave the rig unattended with the engine
running. Carry the ignition key with you.
2.10 Use extreme caution while handling starter
batteries. Wear gloves and protective glasses when
servicing batteries. The batteries contain strong acid,
which can seriously burn eyes, skin and damage cloth,
insulation and metal. First aid in case of acid in the
eyes: wash with plenty of clean water and seek
medical help.
Disconnect the earth cable from the battery before
carrying out service on the electrical system.
The battery gas is explosive! Never use matches when
checking the acid level.
Be careful using tools made of iron near the battery, a
spark might set off an explosion. Read the battery
manufacturer’s manual for further information as
well as the “Environmental instructions” chapter.
2.11 Hydraulic oils are poisonous. Use eye
protection and gloves. See the “Environmental
instructions” chapter for further information.
2.12 Before any repair or service is carried out on
the rig's hydraulic or water systems, make sure the
engine is stopped and that all systems are
depressurized.
2.13 Be very careful while tracing leaks in the
pressurized systems. Hydraulic oils, water or air under
pressure can penetrate the skin and cause
complicated injuries or infection. If this happens, see
a doctor at once.
2.14 Use only authorized parts (DBC parts). Any
damage or malfunction caused by the use of
unauthorized parts is not covered by warranty.
2.15 Any warranty for work performed, only covers
DBC Products, DBC components and work performed
by authorised personnel.
Operating Safety
3.0 Underground hazards
In a modern community a number of utilities are
buried, such as electrical cables, natural gas lines, water
lines, sewer lines, pipes for industrial chemicals, liquids
or gases, storage tanks, fibre optic and standard
communication lines.
These installations can be hazardous and must be
located and identified before drilling.
Striking such a utility can cause personal injury from
explosion, electrocution, fire, exposure to hazardous
materials or exposure to laser light.
(Light used in fibre optic cables can cause permanent
vision damage. Do not look into the end of a optic fibre
cable.
You are personally responsible for any injury or
material damage caused by drilling if you have not
taken proper precautionary measures. You should
understand the local regulations on excavating and
trenching. Responsibility should be defined; client,
proprietor, contractor, operator or third person. The
responsible party should call in a competent person
who will identify and eliminate the jobsite hazards. This
will include notifying all utility companies who have
underground services in the area. These companies
must locate and mark their installations, with a
minimum of 10 meters from each side of the planned
bore path. For additional security inspect the area in
order to localize any neglected installations.
The unit should always be started from the control
panel. On a Crawler mounted rig, the operator should
ride on the rig during tramming. Any attempt to move
the rig while walking beside it could result in injury.
Check for signs which might indicate buried utilities.
Look for meters for gas, oil, water etc. Manholes,
junction boxes and light poles indicate some kind of
underground lines. Use a metal detector when you
suspect the presence of unmarked tanks or barrels
containing contaminated waste. Changes in colour and
level of the ground indicate previously dug threnches.
Use correct safety equipment relevant to the
conditions encountered.
Prior to drilling near an identified installation which
may constitute a danger, expose the object along the
bore path by carefully digging by hand. Monitor the
progress and carefully guide the bore around the
dangerous object maintaining a safe distance. Electrical
cables and gas lines should be shut down during
drilling. After drilling is completed, these installations
should be tested before operation.
Figure 1 Use only Genuine DBC parts.
Electricity does not follow the path of least resistance.
It follows all paths to some degree, to ground. The drill
string is an excellent conductor which will conduct
electric current to the drill rig and anything in contact
with it. People have been injured or killed by severe
shock from drilling into power cables.
The level of injury depends on the current flowing
through the body. Voltage is not necessarily a measure
of the danger. Accidents have occurred in installations
with a voltage as low as 25 -30 volts. 30 % of all
electrocutions in the industry have been in connection
with 240 - 400 Volt systems.
Small amounts of current through the body cause
dangerous shock. If the path runs through the chest
and heart, very low currents can cause severe injury or
death. (Less than 0.05 A can cause painful shock and
respiratory paralysis. 0,15 A can cause ventricular
fibrillation, probable death and 0,2 A can cause severe
burns, internal bleeding and death. The electric current
flowing through a normal household bulb is around 0,5
A !!!)
Regard the drillsite as a danger zone. Always wear
safety garments. Use electrically insulating boots and
gloves when installing anchors. Check manufacturers
recommendations for the use of safety equipment;
replace damaged items.
Anchors should never be connected to live power
lines.Do not touch pins on signal clamps.
Expose lines by hand digging.
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.
Operating Safety
Hoses on the rig (hydraulic-, air- water- etc.) can 5.4 Diesel fill. Location: On the diesel power unit.
conduct electricity if the tool strikes an electrical cable.
5.5 ATTENTION Before starting, oil must be filled
If you strike an electrical cable, indicated by power according to: Lubricant Recommendations
failure anywhere near the job area, smoke, explosion,
arcing electricity, or if warning device alerts: 5.6 Drain water cooler. When there is a risk of
freezing, especially during storage of the unit.
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. Figure 4.1

c. If the strike occurred during drilling, retract the

downhole tool. Do not attempt to break any rod
connection. Do not add or remove any drill rods. Figure 4.2

d. Ask your supervisor to contact the utility

company in order to switch off the system.

4.0 Special safety signs Figure 4.3

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

5.0 Following signs are used on your ESD 9 5.3 Risk of crush 5.4 Diesel fill

5.1 Lifting points. This sign is located where the

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

5.2 Ear protectors. Ear protectors should always be

worn.
5.6 Water cooler 5.5 Attention
5.3 Risk of crush. Be aware of the risk from
crushing.
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 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 panel are typically not supplied by DBC.
The trailing cable is vulnerable to mechanical damage
and should be protected by a ground fault and a
ground check system located in the mine disconnect
panel. The ground fault (GF) check system checks for an
imbalance of current in the phases in the trailing cable
(and the connected electric motor) which would
indicate a leakage to ground. The ground continuity
check system checks that the ground conductor in the
trailing cable is connected from the mine disconnect
panel through the trailing cable to the motor starter
panel. The U6 motor starter panel is available with a
Zener diode that is part of the ground continuity check
system in the mine disconnect panel.
It is recommended that the drill operator checks that
the mine disconnect panel is equipped with a ground
fault/ground check system. If the mine does not supply
this type of disconnect panel, such a panel can be
obtained through DBC.
The ground fault protection system located in the mine
disconnect panel (and for CE marked drills in motor
starter panel), trips at approximately 0.3 amp which is
too high to provide personnel protection. The driller
and helper should always use suitable electrically
insulating boots when operating an electrically
powered drill.
Environmental Instructions
Dear operator,
DBC recognizes the importance of environmental
issues. As part of our commitment to a better
environment, we want to inform you, the customer,
of how you can minimize the effect on the
environment when using an DBC Craelius product.
These simple but important instructions will help to
preserve the environment.
1.0 Operation, maintenance
disposal
Oil
Leaks of hydraulic and lubrication oils pose an
environmental threat. Changing lubricating and
hydraulic oils, hydraulic hoses and hydraulic filter
elements also pose a threat to the environment.
Collect all oil spills and waste (e.g. oil filter elements)
contaminated with oil. Dispose of according to
national regulations.
Use biologically decomposable hydraulic oils and
lubricating oils for DBC products wherever possible.
Contact your nearest DBC office for more
information.
Chemicals
Dispose of chemicals such as drilling additives, other
additives, glycol etc. according to the manufacturer’s
instructions. Avoid the use of cleaning agents
containing solvents like carbon tetrachloride. There
are environmentally better alternatives now available
on the market.
Follow national regulations regarding handling and
disposal of wastes.
and
Metals (steel, aluminum, etc.)
These products are recyclable and should be taken
care of according to national regulations.
Plastics and rubber
These products are often labeled according to
different classes. In those cases they are recyclable
and should be taken care of according to national
regulations.
Electrical components (cables, electronics, etc)
Used components should be taken care of according
to national regulations.

Engine
Engine emissions are toxic and pose an
environmental threat. Always provide for fresh air
when an engine is running. Well-maintained air filters
help keep emissions at a low level.

Fuel (Petrol/Gas, Diesel)

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

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

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

Dust
Rock dust can pose a health danger. Use dust binding
oil.
General
Figure 2: ESD 9 is an all-hydraulic operated diamond core drill.
The ESD 9 is an all-hydraulic diamond core drill with a
wide range of options and accessories. It consists of
three main parts: the drill unit a power pack and a
control console.
It is suitable for a variety of drilling methods in both
underground and surface operations such as core
drilling, grout hole drilling, probing etc.. The drill unit
can be powered by an electric motor or diesel engine.
When the drill rig is equipped with the electric power
unit, an optional diesel engine for tramming is
available.
The ESD 9 uses the best technology available for
diamond core drills. All tube jointing, thread
breaking, feeding, wireline hoist sequences, are
controlled from a control console which can be
positioned to suit the setup. Feeding is done by a
direct cylinder, thereby eliminating chains in the feed
system. The drill can be equipped with two different
feed lengths, and two different sizes of rotation units
to suit rod size and drilling applications.
Recommendations
To achieve the best results with regard to:
- high penetration
- optimal core recovery
- and low drilling costs
it is of primary importance that drill rods, core barrels
and coring bits are of the right type and quality,
matched to the rock drill and to the prevailing rock
conditions.
Bearing in mind the core drill’s speed of rotation, its
rating and chuck diameter, the ESD 9 is best suited to
drill holes 46 - 96 mm in diameter (A - H) using both
conventional as well as wire line rods.
The spindle bore diameter is 78 mm in the
N-size rotation unit and 101 mm in the optional H-
size rotation unit.
Hoisting and Transport
1.1 Hoisting the power units 2.1 Transportation of power unit

1 Positioning a sling or similar lifting device When transporting with fork lift or other vehicle
through the holes. 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.
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 2.2 Transportation of drill unit
point of balance and centre of gravity.
When transporting with fork truck or other vehicle
2. Tie the skid and feed frame togther with a
always secure the drill unit to the vehicle.
section of the backstay legs.

3. Position a sling around both telescopic

tubes at each end of the feed frame. Ensure that the
feed frame clamps are tightened on both tubes.

• 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.
 Technical Specifications
260 cm

180cm 400 cm
200
280 cm

Feed

MAX 550 cm

Power Unit
120 cm

190 cm
Characteristics
1.0 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.
Figure 3 Speed / Torque diagram (H-Size)

Rod Holder Unit

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

Complete with hydraulic tank, filters, oil cooler and

starter panel.

1.2.1 Electric

Asynchronous electric motor

Motor rating 90 kW
at 1450 rpm
Figure 5 Power Unit
Maximum operating pressure
Sound noise level
- main pump 300 bar

- service pump 230 bar

Drill unit with electric power unit
Maximum flow
Sound power emission : 99 dB (A)
- main pump 200 l/min
Sound pressure level at the
- service pump at 50 Hz 65 l/min*
Operator’s position: 78 dB (A)
- service pump at 60 Hz 65 l/min*

* limited by set screw

A
B

Figure 4 Hydraulic double pump

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

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

of the feed frame. With the standard telescopic mast
extension tubes, the total length of the feed frame
and mast extension can be varied from 3.5 - 4.5
metres. With the optional

5 m mast extension tubes, the total length can be

increased to 7.5 m. The rod pulley (2) and top pulley
(3) are mounted on the extension tubes.

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

mm) can be used. Figure 6 Mast Extension

1.2 Wireline hoist, 425 m

Mounted on the positioner underneath the feed

frame. The hoist is operated from the control panel.

Data
Capacity 425 m of 4.75 mm wire rope
Pull min. 3900 N (Full drum)
max. 8100 N (empty drum)
Hoisting speed
min. 2.1 m/s (empty drum)
max. 4.5 m/s (full drum)
Weight (without wire) 57 kg
Figure 7 Wireline hoist 425 m

1.3 Wireline hoist, 1000 m

Mounted on the positioner arm and has adjustable

lewelwind angle. Does not need to be moved when
changing drilling angle.

Data
Capacity 1000 m of 4.75 mm wire rope
Pull min. 4000 N (full drum)
max. 10000 N (empty drum)
Hoisting speed
min. 1.7 m/s (empty drum)
max. 4.2 m/s (full drum)
Weight (without wire) 96 kg Figure 8 Wireline hoist 1000 m
Optional Equipment and Accessories
1.3 Hose kits
Extra long for connecting between the drill module
and the power unit. Available in 10 m length.

1.4 Test instruments

For testing and adjusting operations of the hydraulic
system.

1.5 Turn table

Figure 9 Test Instrument
By using the turn table, the drilling unit can be swung
360° horizontally in relation to the skid frame.

1.6 Hydraulic bracing device

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

1.7 Flush pumps

The FMC flush pumps are matched to suit the drilling
operations that may be carried out with the ESD 9.
Hydraulic powered FMC pumps are available.

Data
max. flow 140 l/min

max. pressure 70 bar

Figure 10 Flush Pump

ESD 9 Design Features
8 7 6
5

1 2
3

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

7 5 6 3

1 4 2

8 9 10 11 12
22

13
14 15 16 17
19
18

20
21
Controls
1. System pressure gauge for main hydraulic pump circuit (bar)

2. Feed force pressure on rodstring (kN kilo Newtons)

3. Holdback pressure on rodstring (kN kiloNewtons)

4. Waterpressure at flushpump outlet (bar)

5. Flowmeter for flush pump water flow -liters per minute.

6. RPM meter for rotation head.(Option)

7. Service pump pressure gauge -bar. Also usedto check gas pressure in rod handler gasspring.

8. Control lever for wire line free wheeling.

9. Control lever selection for rodrunning modewith 3 positions:

– rodrunning in (forward)

– drilling (center position)

– rodrunning out (backwards)

10. Control lever for rotation on/off when drilling.

11. Control lever for drill feed direction -back,neutral or forward.

12A. Control lever for manual opening of rodholder.

12B. Locking device to keep rod holder lever in ”rodholder closed” position.

13. Control knob for system pressure limiter formain pump circuit.

14. Control knob for flush water pump in highspeed non drilling mode.

15. Control knob for speed regulation for rotationhead.

16. Control knob for hold back pressure ondrillstring.

17. Control knob or feed force pressure ondrillstring.

18. Joystick control for wire line winch inand out. Prevent unintended movement.

19. Joystick for rodrunning

– forward / backwards movement for controlling fast travel, chuck and rod holder

– sideways movement for controlling rotation unit for making and breaking the joint

20. Control lever for flush pump in drillingmode.

21. Water pressure dump valve for relievingflush water pressure in the drill string

22. Emergency stop button for trippingmotor.

Maneuvering
1.0 Pre-start procedure
1. Check hydraulic oil level in the oil tank. 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, see Fig. 1.1.
3. Before starting motor, carry out instructions given in
Periodic Maintenance pages.
DANGER
Special care and attention should be paid to damaged
or worn components, which could cause structural
fatique, cracks or even fracture in materials or welded
joints.
Figure 11 Connection of cooling water for hydraulic oil cooler
Important (Water type oil cooler)
The water hose leading to the oil cooler should be
cleaned once a week or more if neccessary and
equipped with a strainer. The water pressure should
not exceed 10 bar.
Always make sure that the water passing through the
oil cooler is as clean as possible. Dirty or contaminated
water will result in rapid internal layering and blockage
inside the cooler which can cause overheating of the
hydraulic system.
Controls
CONTROLS (Driving / Tracks / Hydraulic Jacks)
Controls
( Raising the Feed Frame / Hydraulic bracing device )
Setting Up for Drilling
Displacement of Feed
eed Frame

2 1
1- Undo the hex secrews
2- Move the feed frame with mast dump cylinder
- forward
- backward
Setting Up for Drilling

0 - 90°
0 - 90°

0 - 180°

0 - 180°
Maneuvering

3 4 5 6 7

13
8 9 10 11 12

Figure 12 Startbox for Electric Power

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

Start-up Electric power unit 90 kW
1.Check that the emergency stop buttons (on the
control panel and power unit are not pressed.
2.Press the reset button and turn the main switch to ,
the control lamp should now light up.
3.Press the start button on the box.
NOTE, Make sure the second stage of the electric
motor engages automatically (can be heard). If the
motor does not start and the control lamp lights up,
this indicates that the phase sequence is incorrect.
working before drilling. Commence by stopping the
motor from each safety stop device.
5.Check that there are no signs of oil leakage from
threaded joints, hose connections or fittings.
Stopping
1.Stop the power unit by pressing stop button.
2. When leaving the machine, or when servicing,
always switch-off the main main switch to O position,
Fig. 12

4.Check that the emergency stop devices (on the

control panel, power unit and drill module) are
Operation
Start of the Diesel Engine

Before starting the diesel engine, certain checks and

measures must be carried out to prevent accidents,
unnecessary stops or breakdown.
Some of these measures must be carried out regularly
as a part of the preventive maintenance schedule.

Pre-Start
Check that all controls are in neutral position. Check
that the emergency stop buttons (on the control panel
and power unit are not depressed.

1. Check the oil level in the diesel engine and fill when
necessary.

2. Oil viscosity and quality according to engine

manufacturer manual.

3.Check cooler fluid level

4. Check the engine air intake filter. Clean or replace

cartridge.

5. Check oil level in hydraulic oil tank. Add when

required.
Drilling

+45° Drilling -45°

45° Drilling

Horizontal Drilling

+90° Drilling -90࿲° Drilling

Drilling
1.0 Before drilling starts
Make sure that the supply of water is adequate.

If there is not enough water, an overheating problem

can occur when using the power unit.

1.1 Start the power unit

Turn the main switch (15) to (I) position and press the
start button (10) at the starter box on the power unit .

1.2 Start water pump

1. Choose high speed mode (14 ) for pumping in the
overshot or filling the rod string.

2. Choose low speed mode (20 ) for drilling.

If the high speed mode is used when drilling, then the

rotation motor performance will be reduced since
some oil flow will go to the water pump instead of to
the rotation motor.

1.3 Adjust the flow of the flushing water

1. Start the water pump with the control lever (20) at
the front on the panel. 3. Start the drill rotation with rotation lever (10).

2. Adjust the water flow to the desired value by 4. Adjust the rotation speed to the desired value by
moving the lever. turning the RPM control (15 ). The RPM can be read
on the RPM meter (6, optional) on the control panel.
3. Read the water flow rate on the flow meter (5,
optional) on the control panel. The rotation speed must be adjusted as the hole
deepens so the maximum rotation pressure remains
4. Read the water pressure on the gauge (4) in the
at 240 bars -See also section 5.0 Limitation of electric
control panel.
motor temperature.
1.4 Start rotation
1. Position the drill string with the corebarrel and the
drill bit about 50 cm above the bottom of the drill
hole.

2. It is possible to reduce the maximum torque on the

rotation motor with the system pressure limiter (13).
This could be necessary in a bad formation or if it is
difficult to sharpen the drill bit.
Drilling
1.5 Balancing the rod weight
1. Before the drilling operation can be started, the
rod weight must be compensated for so the actual
feed force can be read.

2. Turn the feed force knob completely out (17) by

turning it counter-clockwise. The feed force can be
read on the gauge (2) on the control panel.

3. Turn the holdback knob (16 ) some turns clockwise.

The holdback force can be read on the gauge (3) in the
control panel.

4. Start the drill feed with the drill feed lever (11).

5. Regulate the holdback knob (16) so that the cradle

is stationary -not moving up or down. Now the rod
weight is balanced.

6. When the feed is holding the load, the drill feed

can be activated without any danger the drill string
rushing to the bottom of the drill hole and damaging
the drill bit.

1.6 Start the drill feed

1. Increase the feed force slowly using knob (17) until
the drill string reaches bottom of the hole or the face.

2. Continue to increase the feed force in order to

reach desired penetration rate for chosen drill bit and
formation.

3. Continue drilling to the end of the feed stroke, fill

the inner tube, or until you get coreblockage

1.7 Stop drilling

1. Stop the drill feed by moving the drill feed lever
(11) to the neutral position.

2. Stop the rotation by moving the drill rotation lever

(10) to neutral.

3. It is recommended to flush the drill hole for some

minutes after stopping drilling to avoid problems with
cuttings and sludge in the core barrel if wireline
equipment is used.
Drilling
Wireline Operation

2.0 Wireline freewheeling

1. For lowering the overshot or pumping in the
overshot it is possible to freewheel the wireline drum.

2. Move the free wheel control lever (8) from the

neutral position to disengage the winch drum.

3. In the disengaged position, the winch drum will

freewheel and spool out the wireline cable with the
weight of the overshot or by the water pressure when
pumping in the overshot.

2.1 Controlled wireline lowering

1. To spool out cable from the wireline drum with the
hydraulic motor, push the joystick (18) slowly forward
(away from you). The drum will start to rotate. The
joystick must be lifted before it can be moved.

2. To increase the speed, push the lever (18) further

forward.

3. When the lever is dropped, the spring force will

move it back to neutral, where it locks automatically.
This prevents accidental activation of the hoist.

2.2 Controlled wireline hoisting

1. To spool in cable rope from the wireline drum with
the hydraulic motor, lift the wireline joystick (18) and
move it slowly backwards (towards you). The drum
will start to rotate.

2. To increase the speed, pull the lever (18) further

backward.

3. When the lever is dropped, the spring force will

move it back to neutral, where it locks automatically.
The locking device prevents accidental activation of
the hoist.

4. The maximum pull of the hoist can be reduced with

the system pressure limiting control (13). To decrease
the hoist pull,turn the control counter- clockwise. To
increase the hoist pull, turn the control clockwise.
Drilling
Rodrunning

3.0 Rodrunning controls

1. Chuck and clamp sequencing during rod handling is
automatic. This means that the chuck, rod holder and
fast travel are controlled with joystick (19). The
operator must select the rodrunning IN or rodrunning
OUT mode with the mode selector (9).

2. Thread compensation balances the weight of the

rotation unit and drill rod being unscrewed and
prevents the weight of these components from
loading the threads when the joint is being unscrewed
for both downhole and uphole drilling. The amount of
Figure 13
thread compensation should be adjusted when 1
starting with new drill rod size or large change in
2
drilling angle. 1.Thread compensation adjustment screw

When making the joint, the feed cylinder is put into a 2.Selector lever for downhole or uphole drilling.
floating condition with both sides of the cylinder
connected. It is recommended that the helper turns
the rod in at least one full turn before the rest of the
joint is made with the rotation unit.

3. Turn the thread compensation adjustment screw

(1) fig 3.0 clockwise to increase the thread
compensation force or counterclockwise to decrease
the thread compensation force.

Tighten the lock screw after making the adjustment.

4. When changing from downhole to uphole drilling,

the direction of the thread compensation force must
be reversed. This is done by changing the selector
valve (2) fig 13
Drilling
3.2 Rodrunning in
1.Move the rodrunning selector lever (9) to
rodrunning in position.

2.The chuck will grip and the rodholder open

automatically when the rodrunning joystick (19) is
moved forward.

3.Move the joystick further and the rotation unit will

move forward with the drill rod gripped.

4.If the joystick is dropped, it goes back to neutral,

the rod holder closes and the chuck opens
automatically.

5.Now re-chuck by pulling the joystick backwards. The

rotation unit moves backwards with the chuck open
and the drill rod held by the rod holder.

6.Run the rotation unit to the end of the feedframe

and stop.

Note: slow down and stop the fast travel before

hitting the end of the feed stroke at either end of the
feed frame.
7.Now move the joystick forward. The chuck will close
automatically and the rod will be gripped. The rod
holder will open and the drill rod moves into the drill
hole.
by hand, before making the remainder of the joint
with the machine.
2.To make the joint, move the rodrunning joystick
(19) to the right. The chuck will close and the rotation
head start to rotate clockwise. At the same time the
feed cylinder disengages so the rod ends can screw
together without damage to the threads.

When rodrunning in, it is recommended that the

system pressure be reduced to the lowest pressure
required to move the rods into the hole. This is to
prevent damage to the in-hole equipment and the drill
if the rods suddenly encounter a blockage while being
moved into the hole at full speed and with maximum
system pressure available.
3.3 Adding a drill rod and making the
joint
1.When adding a drill rod, ensure that the threads are
properly engaged, by spinning the rod in one full turn
It is important to limit the applied torque when
making the rod joint or the joints may be difficult to
break:
–Set the system pressure to 150 bars when rod
running in. This limits the stall torque of the rotation
motor.
–Rotate the chuck slowly when making the joint, with
a maximum of about 250 to 300 rpm. A high rotation
speed will cause a high inertia torque loading of the
joint when the joint bottoms out.
Drilling
3.4 Rodrunning out
1. Move the rodrunning selector lever (9) to
rodrunning out.

2. The chuck will grip and the rod holder open

automatically when the rodrunning joystick (19) is
moved back.

3. Move the joystick further and the rotation unit will

move back with the rod gripped.

4. If the joystick is dropped, it goes to neutral, the rod

holder closes and the chuck opens automatically.

5. Now re-chuck by moving the joystick forwards. The

rotation unit moves forward with the chuck open and
the drill rod held by the rod holder.

6. Run to the end of the feed frame and stop.

Note: Slow down and stop the fast travel before

hitting the end of the stroke at either end of the feed
frame.

7. Now move the joystick back. The automatic

sequencing will close the chuck and grip the rod. The
rod holder will open and the drill rod pulled out of the
hole.

3.5 Breaking the joint

1. To break the joint, the rodrunning joystick (19) is
moved to the left.
2. When the joystick is moved fast to left, the rotation
unit will start to rotate counter- clockwise.
After a short delay the chuck will grip the drill rod
and then break the joint with a dynamic effect. Thread
compensation is automatically engaged to prevent
damaging the threads.
When drilling upholes, it is important to leave at least
one thread engaged so the rod to be removed
remains suspended in the joint when rotation stops.
The helper should not approach the rod until the
chuck has stopped rotation and is moved above the
joint.

3. Do not unscrew the joint fully. Leave at least one

turn of the thread engaged. When the rod is lifted out,
the last thread is screwed out by hand.
Drilling
4.0 Water pressure dump valve
Valve (21) relieves the water pressure in the drill
string. Push the lever down to open the valve. In
uphole drilling, the valve can be used to control the
lowering speed of the overshot and inner tube by
varying the valve opening.

5.0 Limitation of electric motor

temperature
The electric motor is protected from overload, and the
resulting motor temperature increase, by two
thermistors which monitor the temperature of the
windings. The first thermistor activates a warning light
at 130 C. The second thermistor will shut down the
motor when the windings reach 155° C. This allows
the maximum power of the motor to be used and
takes account of the ambient temperature and motor
cooling conditions.

It is recommended that the driller monitor the

warning light in two operating modes:

– starting to pull the rods from maximum rated depth

at maximum speed

– drilling at system pressures higher than an average

pressure of 240 bars.

If the warning light come on under these conditions,

the rod pulling speed should be reduced or the
rotation rpm reduced, thus lowering the system
pressure.
Maintenance
1.0 General
The performance and reliability of the DIAMEC® U6 is
largely dependent on the amount of care and
attention shown to it. Regular checks and inspection
of wearprone components prevent breakdowns and
costly downtime.
4. Use the rotation control to set the drill location
lever (10) in drilling position to circulate the hydraulic
system for about 5 minutes.
5. Disconnect the two main hoses from the fitting and
reconnect them to their correct points on the
hydraulic motor.

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

- Always perform oil refills into the hydraulic oil tank

by using the hand pump supplied.

- Always store fresh oil stocks in sealed containers.

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

Cleaning procedure

1. Disconnect the two main hoses on the hydraulic

motor and put caps on the fittings.

2. Reconnect the loose ends to the fittings included in

the tool kit.

3. Start up the power unit.

Maintenance
1.3 Hydraulic oil filters
There are in total four filters on the ESD 9 drill. Two on
the power unit and two in the valve assembly.
filter elements. Even if the clogging indicators have
not called for a cartridge change, the cartridges should
be changed once every year.

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

The pressure filters on the drill rig are placed under

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

Make sure that the KZx25 element is placed in the

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

All filters in contact with oil on ESD 9 drill have filter

elements that are lifted from a bowl. The advantage of
this is that there is no leakage when replacing the
Maintenance
1.4 Changing the hydraulic oil.
The hydraulic oil should be changed after 2000
operating hours in normal worksite conditions, or at
least once a year.

If the quality of the oil has deteriorated for some

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

Oil change.

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

valve (1) underneath the tank.

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

pump. As the oil is pumped into the tank it passes The useful service life of the hydraulic oil can be
through the filter so that any impurities are strained seriously reduced at operating temperatures above
out. +60°C.
High temperature can cause:
– Leaky gaskets
– Serious internal leakage in pumps and
1.5 Draining condensed water out of tank
valves, due to decreased viscosity and
The tank drain valve (1) is used to drain condensed lubricating properties of the oil.
water out of the tank. Condensed water can collect at
the bottom of the tank. The amount of water
collected depends on the humidity levels and the
number of times the drill is shut down and the oil tank
cools down.

The tank drain should be checked regularly for the

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

1.6 Hydraulic tank oil level

The oil level in the tank should be kept in the sight
glass at all times. There is a low oil level guard which
will trip the motor when the oil level is about 50 mm
below the lowest sight glass level. This will prevent
damage to the hydraulic pumps.
Maintenance
2.1 Periodic maintenance with Service schedule for drill and power unit 90 KW
Ref. Check points Procedure Service interval in . Notes
No. hours of operation
8 40 once/month

1 Feed frame holder Tightening X

Adjustment X See Adjusting the slide shoes
2 Slide shoes
Lubrication X More often in bad conditions
More often in bad
3 Chuck jaw holders Cleaning conditions(e.g. up-hole
drilling)
Chuck jaw inserts Cleaning X Inspect and clean if necessary
Rotation unit and gear Check level and
4 X See Rotation unit
case temperature
Cleaning X
5 Rod guide See Lubr. Recommendations
Lubrication X
5a Rod jaws Cleaning X Check for wear
Level check X Fill oil when necessary (clean
6 Hydraulic oil tank
Oil temperature X the tank once a year
7 Hydraulic oil filters Inspection X See Hydraulic oil filters
Continuous inspection of
8 Oil leakage Inspection X hydraulic fittings, hoses and
components
9 Complete drill rig Cleaning X When necessary
Wireline hoist with Apply grease to Levelwind
10 LubricatioN X
Levelwind screw and one lube nipple.
11 Positioning cylinders lubrication X Lube nipples on cylinders.
2 lube nipples, 30 g grease
12 Electrical motor Lubrication
every 6 month
13 Oil cooler Cleaning X See Oil cooler
On control panel, power unit
14 Emergency devices Test of function X
and rig
Maintenance
2.2 Lubricant recommendations
Lubricant Check point No. Recommendation
1. Hydraulic oil 6 Use mineral-based hydraulic oil with good anti-wear, rust (oxidation) and
foam inhibiting properties, as well as effective air and water separation
abilities. The viscosity grade should correspond to the ambient
temperature and ISO 3448, as follows:

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

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

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

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

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

Example of grease grades

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

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

Where appropriate: Oil change interval 1000 hours

Maintenance

3.0 Daily safety check

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

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

— cracks or fractures in materials or at

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

— damage, which could cause sructural

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

— wear, which could cause structural

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

— loose junctions, loose threaded

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

1. Feed frame / feed frame holder

2. Positioner and positioner cylinders 6. Rotation unit, cradle & slides
3. Crawler 7. Rod holder
4. Feed Rotation 8. Mast top, top pulley
5. Turntable 9. Wireline hoist, wire rope
10. Feed frame clamps, backstay legs
Maintenance
4.0 Adjustment of speed regulation
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 U6 a “start of
regulation” pressure of 19 bars is used.
If the drill is not equipped with the optional RPM
gauge on the panel, use a hand held tachometer on
the spindle.
If there are any questions about this procedure,
phone the DBC service department.

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.

Rotation Motor U6 spindle RPM Maximum

unit Size - cc at max motor spindle RPM
displacement RPM

H-Size 110 500 (160 l) 1400

2 1
1- Start of regulation adjustment screw

2- Minimum displacement adjustment screw

4.1 Adjustment procedure with
replacement motors

1. Check that the maximum rotation flow is according

to the table above with a flow meter.

2. Place a test pressure gauge at test port “Drill” on

the console block or at port X5 where hose 15 enters
the rotation motor. Screw in the RPM control knob on
the control panel until the pressure on the test gauge
reads 19 bars.

3. Start rotation with maximum flow. The spindle RPM

should be as in the table for max motor displacement.

4. Slowly screw out the “start of regulation”

adjustment until the spindle speed starts to increase.
Lock the adjustment screw.

5. Turn the RPM control knob (15) on the control

panel fully clockwise until the spindle reaches max.
rpm. Slowly screw out the minimum displacement
adjusting screw until the spindle rpm reaches the
maximum value for the motor. Lock the adjustment
screw. 4.2 Rotation Unit Oil Level
Maintenance
The rotation unit holds 0.8 liters of synthetic oil (see
Lubricant specifications.

The oil level can be accurately checked in the three

positions shown, 90 degrees down, 45 degrees down,
and 45 degrees up.

It is important to have the correct oil quantity when

drilling at 90 degrees down and 90 degrees up. In
these positions 0,6 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 oil can be seen
in one of the two sight glasses. 1
The oil can be drained at 90 degrees down. When
refilled to the top plug (1, see Fig. 5.0), the gearcase 2
contains 0,6 liters of oil.

Important: Do not overfill the gearcase as this will

cause overheating.

1- Refilling and oil level check at 90° drilling down

2- Oil drain at 90°

2
1- Oil level check at 45° drilling up

2- Oil level check at 45° drilling down

Maintenance

6 42 21
23 29 24 7 20 8 54

5.0 Replacing sleeve and jawholder in 60

6 Wear plate 24 O-ring
the chuck
7 Inner cover 29 Inserts
1. Undo the eight bolts (54), and remove the outer 8 Outer cover 42 O-ring
cover (8) together. 20 Guide pins 54 Bolts
2. Remove the jaw inserts (29). 21 Sleeve 60 Screws
3. Undo the four screws (60), and remove the inner 23 Springs
cover (7) together with the O-ring (42).
4. Remove jawholder (24) ,springs (23), sleeve (21) at
the same time.
5. Remove wear plate (6) and O-ring (42) To replace/change the jaw insert
6. Press the jawholders (24) and springs(23) out of 1. Undo the eight bolts (54), and remove the outer
the sleeve (21). cover (8) together.
7. Clean all parts thoroughly, including the inside of
the chuck housing. At the same time, inspect all parts 2. Remove the jaw inserts (29).
and replace any found damaged or eccessively worn.
8. Lubricate all parts,including the inside of the chuck 3. Push the new/replaced jaw insert (29) back into
housing with a thin coating of oil. Check that the bolts the jaw holder.
at the bottom of the chuck housing are securely
tightened. 4. Re-assemble the outer cover (8) in place. NOTE!
9. Re-assemble the O-ring (42) and the wear plate (6) Make sure the guide pins (20) fit perfectly in the
in the bottom of the chuck housing. recessed grooves in the jaw holder. The tightening
10. Re-assemble the jaw holders (24) and the springs torque for the bolts (54) is 100Nm.
(23) in the sleeve (21).
11. Position the rubber sleeeve with jaw holders in
the chuck housing.
12. Re-assemble the inner cover (7) with o-ring (42)
13.Push the jaw inserts (29) back into the jaw holder.
14. Re-assemble the outer cover (8) in place. NOTE!
Make sure the guide pins (20) fits perfectly in the
recessed grooves in the jaw holder. The tightening
torque for the bolts (54) is 100Nm.
Maintenance

34 18 45 68 19 52
5.1 Changing guide bushing in the
rotation head
18 Locking ring 45 O-ring
19 Cover 52 Screws
The diameter of the guide sleeve (68) must be chosen 34 V-seal 68 Bushing
to suit the drilling equipment to be used (see spare
part list).

1. Undo the screws (52) and remove the cover (19)

2. Insert /replace the guide bushing (68).
3. Check the condition of the v-seal (34) , if worn
replace it.
4. The locking ring (18) is held in place in the groove
on the shaft by the o-ring (45)
5. Reassamble the cover (19), check that the screw
holes in the cover line up with the holes in the locking
ring(18) and tighten the screws (52)
Maintenance
6.0 Adjustment of chuck pressure
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.

– For definition drilling, set the chuck pressure at

100 bars.
– For exploration drilling (> 200 m BQ), set the
chuck pressure at 120 bars. 1
2. Attach a test gauge to the chuck pressure test port
(1). Turn the chuck pressure adjustment screw (2)
2
clockwise to increase chuck pressure,
counterclockwise to reduce chuck pressure. Tighten Adjustment of chuck pressure
the lock screw after making the adjustment. 1. Chuck pressure test port
2. Chuck pressure adjustment screw

6.1 Adjustment procedure

1. Connect a 250 bar test gauge to the test port (1)
marked “Chuck” on the logic block in the valve
assembly and start the motor.

2. Close the chuck by having an assistant put the

rodrunning mode selection lever (9) on the control
panel into “rodrunning out” position. Then run the
head to back end of the feedframe with joystick (19).
Keep the joystick held in the hoisting 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.
Maintenance
7.0 Adjusting maximum pressure of the
main- and servicepumps
8.1 Main pump
Maximum pressure: 315 bar
Stand-by pressure: 25 bar

7.1.1 Maximum pressure adjustment

1. Start the motor. Locate a rod in the chuck and rod
holder, with no rod joint between chuck and rod
holder.
2. Apply maximum pump pressure to the rotation
motor by having an assistant put the rodrunning
mode selection lever (9) on the control panel into
“rodrunning out” Move the rodrunning joystick (19) to
the left and hold it there. Read the maximum pump
pressure on the system pressure gauge (1) on the
control panel.
3. If necessary, adjust the maximum pump pressure
by turning the max. working pressure screw (1, Fig.
14) 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 (315
bar).

7.1.2 Stand-by pressure adjustment

1. Disconnect load sense line from pump and plug.
Put loose cap on the main pump load sense port so no
pressure can build up in this port.
2. Start motor. Run the cradle to the end of the feed
frame and hold it there. The pump stand-by pressure
can now be read on the system pressure gauge.
3. If necessary, adjust the stand-by pressure by
turning the stand-by pressure screw (2, Fig. 14).
Stand-by pressure adjustment screw is located on the Figure 14
main pump regulator, further out from the pump
housing. Use a 6 mm allen key. Clockwise turning
increases the pressure. Unscrew the locking nut 1. Adjustment screw, max. working pressure
before adjustment and tighten it when desired stand- 2. Adjustment screw, stand-by pressure
by pressure is obtained (25 bar).
4. After pressure adjustment, stop the motor and
reconnect the load sense line.
Maintenance
7.2 Service pump
Service pressure is 240 bar in normal operation, 300
bar for drilling uphole to maximum capacity.
1. The pressure is shown on the service pump
pressure gauge (7) on the control panel. There is also
a test port “Serv. P” on the console block which can be
used to check the pressure reading on the service
pump pressure gauge.
2. If necessary adjust the service pressure by turning
the maximum working pressure screw. Maximum
pressure adjustment screw (1, Fig. 8.2) is located on
the service 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
and tighten it when the desired service pressure is
obtained (normally 240 bar).
3. The service pump should work as a constant
Fig. 15 Adjusting max. pressure of of the service
pressure pump. Screw in the stand-by pressure
pump
adjustment screw (2) as far as possible (clockwise
1. Adjustment screw, max. working pressure
turning). Stand-by pressure adjustment screw is
2. Adjustment screw, stand-by pressure
located on the service pump regulator, further out
from the pump housing. Use a 6 mm allen key.
Unscrew the locking nut before adjustment and
tighten it when the adjusting screw is fully screwed in.
Maintenance
9.0 Starting up the power unit after
adjustment or disconnecting the hoses

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

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

Rotating the pumps in the wrong direction will destroy

the pumps.
Maintenance
10.0 Rod Holder Gas Spring Pressure
Check

The ESD 9 rodholder grips the rod using gas pressure

in the gas spring cartridge. The gas spring cartridge is
charged to 110 bar pressure with nitrogen gas and is
designed for long service life (tested to more than one
million cycles). It uses two main piston seals, one
active and one backup.
The gas pressure can be checked by measuring the
force the gas exerts on the hydraulic fluid as the fluid
bleeds down over an orifice when the rodholder is
closed using the manual rodholder control.
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 can be worn jaws or
too low a gas pressure. This test allows a quick and
convenient check of the gas pressure.

10.1 Testing procedure

1. Bring the machine to operating temperature. No Rods* Rods*
2. Open the rod holder manually (lever 12 on the “Drop-off” pressure with 120 140
control panel). This can be done with or without rods gas spring fully charged
in the rodholder
3. Close the rodholder and observe the service pump “Drop –off” pressure when 100 110
pressure gauge (7). The pressure decreases slowly as gas spring requires service
the gas spring forces the oil over an orifice to tank. *) in the rod holder
When the jaws grip the rod (rods in rod holder) or the
gas spring is fully closed (no rod in rodholder), the
pressure will suddenly drop more quickly. The
pressure when this sudden drop occurs is called the
“drop-off” pressure and should be compared to the
values in the Table 10.1 to the right:
4. Repeat the procedure a few times to get a
consistent reading.
5. If the “drop-off” pressure is 110 bar or less, the
rod spring unit should be replaced or serviced in
accordance with the service instructions in the service
manual.
6. Phone the DBC service department if you have any
questions.
Maintenance

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

1 Bolt 6 Socket holder

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

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

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

10.2 Rod Holder Guide Bushing

The diameter of the bushing (8) must be chosen to suit the drilling equipment to be used (See spare parts list).
The bushing replaced by prying it out of the bearing. The new bushing is knocked into the bearing (snap fit).
There are two sizes of bearings – one for A and B size bushings, the other for N and H size bushings.
For A and B size reainer, the bearing (5) is held and centered in the back cover (4) by socket holder (6).
For N and H size bushings, the bearing (5) is centered directly in the back cover (4) .
Trouble Shooting Chart
Type of fault Cause Pinpointing the fault Remedy
1 Chuck does not open A Jaw is too small A Check size A Install correct jaw size
enough B Oil is cold and too D Dismantle and inspect B Warm up the core drill
viscous the springs C Change to lighter oil
C Wrong oil used (Too E Dismantle and inspect see Lubricant recom.
thick) jaws D Replace the springs
D Springs between F Dismantle and inspect E Clean the jaws
chuck jaws worn or all parts thoroughly thoroughly
broken F Clean all parts
E Dirt between the jaws thoroughly
F Dirt between the wear
plates and jaws, i.e.
rubber from the chuck
inserts

2 Chuck inserts break A Internal parts in the A. Dismantle and inspect A Replace worn parts
frequently chuck excessively B Measure the B If the clearance is more
worn clearance between than 0,2 mm, replace
B Too much axial play the outer cover and all worn parts
C Cradle too loose the jaws using a C Readjust slides
feeler gauge

3 Chuck fails to grip the A Chuck jaw holders or A Dismantle and inspect A. Replace the chuck jaw
rod or slips on it chuck jaw inserts too chuck jaw holders and holders or jaw inserts
worn jaw inserts B Replace with correct
B Incorrect dimension B Dismantle and inspect dimension
jaws are being used. C Measure the drill rod C Replace the drill rod
C Drill rod worn E Measure the chuck D Clean the drill rod from
D Too much grease on pressure (100 Bar) all grease
the rod F Connect a pressure E Increase chuck
E Too low chuck gauge to a test point pressure
pressure G Inspect drive pins F Check condition of the
F Malfunction of the service pump with
service pump regard to pressure and
G Jaw drive pins broken flow. Use a test box.
G Replace drive pins

4 Rods not centered in A Drive pins broken A. Inspect drive pins A Replace drive pins
chuck or excess
vibration

5 Rod holder fails to A Gas spring pressure A. Check gas spring A Replace gas spring or
grip rod or slips too low pressure increase gas pressure
during braking and by recharging
rod jointing See gas pressure

6 Uneven grip A Malfunction of the A See points 2, 3 and 5 A See points 2, 3 and 5
interchange chuck or rod holder
cycles
between the chuck
and the rod holder
during rod runing
Trouble Shooting Chart
7 Poor, uneven or no A Malfunction of the A Clean the valve.
feed force during feed force valve Replace any worn parts
drilling operation B Faulty seals in the B Run the cradle to its or possibly replace the
feed cylinders forward end position. entire valve
C Malfunction of the Undo hoses from the B Remove the feed
service pump feed cylinder. cylinders and renew
D Slide shoes too tight Continue to press the seals
toward the end C Check the condition of
position. If the piston the service pump with
seals in the feed cyl. regard to pressure and
are faulty, oil will flow. Use a test box.
spurt out through the D Readjust slide shoes
open cyl. connections
when the cradle
stands and press
against the end
position
C Check for clearance

8 Feeding jerky during A Malfunction of the B Check for clearance A Bleed the feed and
drilling feed force valve hold back valves
B Slide shoes too tight B Readjust slide shoes

9 rodrunning too slow A Faulty seals in the A See point 7B A See point 7B
feed cylinder B Check for clearance B Readjust slide shoes
B Slide shoes too tight

10 Poor breaking-out A Core drill dislodged A Insert some rods in A Realign the core drill
force from its position the drill hole and stop so that the centre of
when the end of the the chuck and drill rod
rearmost rod is high are aligned correctly.
up on the frame.

10 Poor breaking-out A Now run the cradle

force just far enough back
to allow the chuck to
slip-off the drill rod.
If the rod does not
point through the
centre of the chuck,
the core drill has been
dislodged from the
drill centre.
B Threads on the drill B Unthread several B Clean all rod threads
rod joints by hand. Check and file off any burrs
that this is not too and grease the threads
hard to do. afterwards.
C Chuck pressure too C See point 3E C See point 3E
low
Trouble Shooting Chart
11 System pressure too A Malfunctioning main A Run the rotation unit A Check the condition of
low hydraulic pump against its end the main pump with
position and read the regard to pressure and
system pressure. The flow, using a test box
value should be 315
bar

12 Oil temperature A Cooling water too hot A Temperature of A Mount an extra cooler
becomes too high B Too low flow of cooling water should if no other solution
during drilling cooling water not exceed +30°C exists
operations C Clogged oil cooler C Feel the water that B Increase the water flow
D Wrong type of oil in has passed through C Backflush the cooler or
the hydraulic system the oil cooler is cold replace it
D Change the oil. See
Lubricant
Recommendations
13 Performance of the A Worn rotation motor A Check rotation motor A Replace rotation motor
core drill seems weak B See point 11a case drain leakage if case drain leakage
or underpowered excessive
during drilling B See point 11A

14 Rod threads A Incorrectly set thread A Adjust to correct

”screech” when compensation setting
breaking-out B Threads not greased B Grease the threads

15 Slow reaction of A Air in load sense A Bleed load sense line

rotation, fast travel of system
wireline

16 Hydraulic water A Water pump motor A Check RPM of motor A Replace motor not
pump faulty and hydraulic flow to producing RPM
does not produce B Worn distributor in motor using test box according to oil flow
enough flow rotation unit B Check leakage B Replace distributor
through distributor seals if leakage is in
seals 8-10 lpm range
Trouble Shooting Chart
1.0 Electrical system for electrical power unit
Type of fault Cause Pinpointing the fault Remedy
1 Motor does not start A No power to the unit A Control lamp ”Power A Check power supply
(or stops during B Wrong phase order On” does not lit up B Switch connector for
operatio) C Electric motor is B Control lamp for two phases (By an
overloaded phases is lit up authorized Electrician
D Low hydraulic oil C Control lamp for only)
level ”Motor overload” is C Reset overload relay
E High hydraulic oil lit up (By an authorized
temp D Control lamp Electrician only)
F Emergency stop Hydraulic oil level is D Fill hydraulic oil
tripped lit up E See point 12
E Control lamp F Reset Emergency stop
Hydraulic temp is lit
up

2 Circuit breake tripped A Reset with reset button

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

3 Circuit breaker tripped A Reset the breaker

out by overload in the
ground fault circuit

4 Ground fault relay A Reset with reset button

tripped out

5 Main circuit breaker A Reset the breaker

tripped out by
undervoltage