AC Explorac 220 RC specification

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Explorac - Reverse circulation

drilling

Safety and Operating instructions

Explorac 220 RC

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Introduction

These instructions are intended for operators of the Atlas Copco equipment. The aim of the instructions is to provide you with knowledge of how to use the equipment in an efficient and safe way. These instructions also give you advice and tell you how to perform regular maintenance on the equipment. It does not replace thorough training of operator, it is a complement. For further information concerning service measures, please contact your nearest Atlas Copco representative.

Always read these instructions carefully and make sure that you understand all of them before starting for the first time.

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.

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02 Safety Instructions Ed.1

Safety instructions

To reduce risk of serious injury or death to yourself or others, read these safety instructions before operating the machine. Post these safety instructions at work locations, provide copies to employees, and make sure that everyone reads the safety instructions before operating or servicing the machine. Comply with all safety regulations.

All possible hazards cannot be covered here, but we highlight some of the most important. For additional safety information consult:

Other documents and information packed with this machine.

Appropriate standards as refered to in the EC Declaration of Conformity, if provided.

Safety signal words

The safety signal words Danger, Warning and Caution have the following meanings:

DANGER Indicates a hazardous situation

which, if not avoided, will result in death or serious injury.

WARNING Indicates a hazardous situation

which, if not avoided, could result in death or serious injury.

CAUTION Indicates a hazardous situation

which, if not avoided, could result in minor or moderate injury.

Personal precautions and

qualifications

Only qualified and trained persons may operate or maintain the equipment. Always use your common sense and good judgement.

Hoisting and transport

Hoisting and transport of the equipment may only be undertaken by persons who:

are authorized to operate a crane or fork-lift truck in conformity with the applicable national directives, are aware of all the relevant national safety

instructions and accident prevention instructions and have read and understood the safety and

hoisting and transport chapters of this manual.

Storage, repair, maintenance and

disposal

Storage, repair, maintenance and disposal of the equipment may only be undertaken by persons who: are aware of all the relevant national safety

instructions and accident prevention instructions and have read and understood the Safety and

operating instructions.

Operation

Operation of the equipment may only be undertaken by qualified drill rig operators. Operators are qualified if they:

have undergone theoretical and practical training on the equipment in conformity with the national directives,

are aware of all the relevant national safety instructions and accident prevention instructions and have read and understood the Safety and

operating instructions.

Personal protective equipment

WARNING Entanglement hazard

Loose fitting clothing and jewelry can get caught in the moving parts of the machinery and cause serious injury or death.

►Do not wear jewelry and loose fitting clothes.

Always use approved protective equipment. Operators and all other persons in the working area must wear protective equipment, including at a minimum: Protective helmet

Hearing protection in accordance with occupational health and safety regulation

Impact resistant eye protection with side protection Respiratory protection when appropriate

Protective gloves Proper protective boots

Drugs, alcohol or medication

WARNING Drugs, alcohol or medication

Drugs, alcohol or medication may impair your

judgment and powers of concentration. Poor reactions and incorrect assessments can lead to severe

accidents or death.

►Never use the machine when you are tired or under the influence of drugs, alcohol or medication.

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►Prevent other people from using the machine if they are under the influence of drugs, alcohol or medication.

Safety area

WARNING Falling objects can cause serious injury or death

During operation, falling objects from great heights can cause bodily injury and extensive damage.

►Close off the working area.

►Before starting always make sure no unauthorized persons are within the working area of the drill rig in use.

►Immediately stop operation when persons are present in the danger area.

►

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

other objects are lying on the feed.

Hoisting and transport

WARNING Heavy equipment can cause serious injury

►Use a sling dimensioned for the load it is to carry. ►Use only straps that are whole and intended for the

load in question.

►Never use a damaged rope/sling.

►Fasten straps in lifting eyes when present. ►Always lift at the centre of gravity.

►Always make sure that nobody is under or anywhere near a suspended load or within the swing radius of the rope/sling.

►Observe great care when strapping and lifting heavy objects.

WARNING Unexpected movement can cause serious injury

If the rig is left unattended or disconnected from the transport unit an unexpected movement of the drill unit can cause serious injury or death

►Lock the articulated steering before hoisting

►Make sure that the hydraulic jacks are grounded or wedge the wheels of the carrier

NOTICE Sling can damage components

►When lifting, make sure that the sling will not damage the hydraulic hoses, mechanical components etc.

►Use a spreader bar to lift the drill unit.

Operation, precautions

WARNING Hydraulic oil at high pressure

Thin jets of hydraulic oil under high pressure can penetrate the skin and cause permanent damage. ►Immediately consult a doctor if hydraulic oil has

penetrated the skin.

►Never use your fingers to check for hydraulic fluid leaks.

►Keep your face away from any possible leaks.

WARNING Dust hazard

When drilling with compressed air, the rock cuttings are carried out of the bore in the form of small cuttings, and dust, which can cause serious injury.

Some dusts, fumes or other airborne material created during use of the machine may contain chemicals known to the state of California to cause cancer and birth defects or other reproductive harm. Some examples of such chemicals are:

Crystalline silica, cement and other masonry products.

Arsenic and chromium from chemically-treated rubber.

Lead from lead-based paints.

►To reduce your exposure to these chemicals, work in a well ventilated area and work with approved safety equipment, such as dust masks that are specially designed to filter out microscopic particles. ►Use a dust collector, or spray water with a water/

foam pump.

WARNING Heavy equipment can cause serious injury

►Make sure that the drill is anchored to withstand the set forces.

►Make sure that the rig is stable before starting to drill.

WARNING Unexpected movement can cause serious injury

If control levers and switches are not set to neutral position, start of the machine can lead to unexpected movements and can therefore cause injury.

►Set control levers and switches to the neutral positions prior to starting up.

WARNING Noise hazard

High sound levels may cause permanent hearing loss. ►Use hearing protection in accordance with

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WARNING Compressed air

When drilIing with compressed air, the rock cuttings are carried out of the bore in the form of small cuttings, and harmful dust. In order to reduce the injurious effect.

►Wear a breathing mask, use a dust collector, or spray water with a waterlfoam pump, use hearing protection in accordance with occupational health and safety regulations

WARNING Rotating parts

Rotating drillpipes, tools and particularly soil augers are extremely dangerous to handle. Augers turn with high torque and can cause severe injury if personel is caught by extruding parts.

►Never touch a rotating auger or any part of an auger string.

►Never reach behind, or around an auger.

►Don't try to remove cuttings from a rotating auger. Augers may be cleaned only when brought to full stop.

WARNING Emergency situation

An emergency situation can occur due to material failure or incorrect handling.

►Stop the operation by pushing the emergency stop button or if available pull the trip wire.

►Check proper function of the safety equipment at least once beginning of each shift.

WARNING Gas line pressurized, Explosion hazard

If the equipment comes in contact with gas lines and explosives, an explosion could occur. Explosions will lead to severe injuries or death.

►Never operate the machine in any explosive environment.

►Never use the machine near flammable materials, fumes or dust.

►Make sure that there are no undetected sources of gas or explosives.

►When working in areas where gas lines are buried, make sure that your equipment is placed on the windward side.

►Shut down all combustion engines, like hydraulic power pack, generators etc.

►Leave the machine immediately. ►Warn people to evacuate the area. ►Contact emergency personnel.

►Contact the gas company to shut the gas off. ►Stay out of the area until the gas company declares

the area to be safe.

WARNING Electric Shock

When overhead electrical power lines exist at, or near a drilling site, consider all wires to be alive and dangerous. If the rig comes in contact with electric circuits or other electrical power sources, there is a risk of severe injury or death.

►Always look up to check for overhead electrical power lines when raising the mast.

►Never work in the proximity of electric circuits or other electrical power sources.

►Make sure there are no hidden electric circuits in your working area.

►Do not step off grid mat if such are used. If you stand on ground, stay put and do not touch any equipment.

►Alert people in the area; order them to stay out of the immediate area and not to touch any of your equipment, including the support container. ►Ask the supervisor to contact utility company in

order to switch off the system.

►If the strike occurred during drilling, retract down-hole tool. Do not attempt to break any rod connection.

►Do not add or remove any drill pipes.

71000005 A

Maintenance, precautions

WARNING Hydraulic oil

Spilled hydraulic oil can cause burns, accidents by slippery conditions and will also harm the environment. ►Take care of all spilled oil and handle it according to

your safety and environment regulations.

►Never dismount the hydraulic components when the hydraulic oil is hot.

WARNING Hydraulic system under high pressure

Maintenance and repair on the machine and the hydraulic equipment under pressure can lead to severe injuries. Connections can loosen suddenly, parts can suddenly move and hydraulic oil can be ejected.

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►Depressurize the hydraulic system before

performing maintenance on the hydraulic equipment. ►Never replace high pressure hoses with hoses of

lower quality than the original or with hoses that have removable couplings

Pressure settings are always performed on a pressurized system.

►Always exercise the greatest caution.

►Pressure settings must only be performed by trained personnel.

WARNING Machine modification

Any machine modification may result in bodily injuries to yourself or others.

►Always contact your Atlas Copco Customer Center before you modify the machine.

►Always use original parts and accessories approved by Atlas Copco.

WARNING Heavy machine can cause serious injury

►During service and maintenance work, all

components that may be brought into motion or fall must be supported or tied secure.

WARNING Thermal cracks may arise when welding

►Do not do any welding on the equipment without consulting Atlas Copco.

WARNING The paint contain substances hazardous to health

Substances are formed when the paint is heated which are hazardous to health.

►Welding, grinding and other hot work involving paint being heated must only be carried out where sufficient ventilation can be used.

►Always use compressed air powered breathing protection, eye protection and gloves.

WARNING Hot engine parts can cause burn

►Make sure the engine is turned off before all maintenance work and before refueling ►Be careful when draining hot oil and fluids

►Do not handle flammable fluids in the vicinity of hot surfaces, sparks or naked flames.

WARNING Pressure vessel can cause serious injury

►Discarded accumulators must be rendered harmless.

►A discarded pressure vessel that has not been punctured must be treated like a pressure vessel. ►Take care when evacuating the accumulator.

WARNING Electric shock

►Only authorized electricians may carry out work on the electrical system.

►Only qualified electricians should perform any electrical troubleshooting or maintenance. Remove all watches and rings that could contact live electric circuits.

►Make sure all power to the system has been cut before carrying out any maintenance work.

►All electric cabinets should remain locked when not under direct control of qualified electrician.

►Do not use the cabinets as a toolbox or spare parts storage container. The inherent vibration and magnetism associated with transformer and motor starters can cause inadvertent contact of foreign objects with live circuits.

►Some electrical components may have power when the main circuit breaker is open, verify that power is disconnected before servicing.

►Do not tamper with safety interlock circuits, safety guards or other safety devices, except as required during normal maintenance and troubleshooting. ►Confirm that all safety devices and circuits are

replaced and functioning before operation is resumed.

►Shut of electrical power while making or breaking electrical cables.

CAUTION Skin eczema

Hydraulic oil can cause eczema when it comes in contact with the skin.

►Avoid getting hydraulic oil on your hands. ►Always use protective gloves when working with

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03 Signs and stickers Ed.0

Signs and stickers

The machine is fitted with signs and stickers containing important information about personal safety and machine maintenance. The signs and stickers shall always be easy to read.

Prohibition signs

GDE00000 A

♦ No admittance

♦ No admittance for unauthorized personnel. ♦ Violation can cause personal injury.

GDE00001 A

♦ Don't step here

Warning signs

General warning signs

GDE00002 A

High noise level can cause permanent hearing impairment.

♦ Use approved ear protectors. Slip risk

GDE00003 A

GDE00004 A

There is a risk of scalding and pressure which can cause severe injuries or death.

♦ The pressure must be released before the cap can be removed

GDE00005 A

The air pressure can cause severe injuries or death.

♦ The pressure must be released before the cap is removed.

GDE00006 A

Moving and rotating parts can cause severe injuries.

♦ Keep out of the machine's working area when it is in operation

GDE00007 A

Swinging and crushing parts can cause severe injuries.

♦ Keep out of the hazardous area during operation.

GDE00034 A

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Service work

GDE00008 A

In the event of breakdown or during service work the boom falls diagonally, which can cause injuries and damage to machinery.

♦ During service work the boom must be secured in place with straps or supports.

Stability Max. Max. GDE00009 A Electrical system GDE00010 A

Be aware of high voltage, incorrect handling can be fatal.

♦ All work on the electrical system must be carried out by electricians accredited for the purpose.

Regulatory signs

General regulatory signs

GDE00011 A

♦ Read the instructions.

♦ Incorrect use of the machine can cause personal injury and damage to machinery.

♦ Observe the indications given by the warning signs and follow given instructions in order to avoid serious injuries.

GDE00012 A

♦ The rig is equipped with a battery switch.

GDE00013 A

♦ The carrier's battery supplies the hydraulic oil level switch with current.

♦ The battery switch must be turned on when drilling is in progress.

♦ Switch off the battery switch when rig is not in operation. If this is not done the battery will be discharged.

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GDE00014 A

♦ The hydraulic system must be filled with hydraulic oil.

GDE00015 A

♦ Read the instructions. ♦ Fill with engine oil

GDE00016 A

♦ Read the instructions. ♦ Fill with brake fluid.

GDE00017 A

♦ Read the instructions. ♦ Fill with lubricant.

GDE00018 A

♦ Read the instructions. ♦ Emergency stop.

GDE00019 A

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A _B

C _D

A. The foot protection symbol means that you have to wear boots.

B. The eye, ear and head protections symbol means that you have to wear a hard hat, eye and ear protection.

C. The hand protection symbol means that you have to wear hand protection.

D. The instruction book symbol means that you have to read the Safety and Operating instrictuins before the equipment is used for the first time.

Alternating current generator

GDE00020 A

♦ This rig is equipped with an alternating current generator (alternator).

♦ Disconnect the battery cables before removing the generator or regulator and when giving the battery a booster charge.

♦ When performing electrical welding of the rig or fitted equipment, detach the charging regulator cable as well.

Rig with PLC cabinet

PLC

GDE00021 A

♦ This rig is equipped with data boxes.

♦ Isolate or remove data boxes when giving the battery a booster charge or carrying out welding on the rig.

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Information signs

Fire extinguisher

GDE00022 A

Actuator for the fire fighting system

GDE00023 A Lifting eye GDE00024 A Water inlet GDE00025 A Air intake GDE00026 A Fuel GDE00027 A Fuel cock GDE00028 A Battery switch GDE00029 A Draining GDE00030 A Washer fluid GDE00031 A

Emergency reverse button

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Other signs

Rig data plate

See the Technical specifications section for further information.

Atlas Copco Craelius AB

Name Type Serial No. Max. pull up kN Rotation speed r/m Power installed kW Gross weight kg xxxx xxxx xx Made in Sweden MÄRSTA - SWEDEN A B C D GDE00033 A A. Machine type B. Serial number

C. The warning symbol together with the book symbol means that the user must read the safte and operating instructions before the machine is used for the first time.

D. The CE symbol means that the machine is CE-approved. See the CE Declaration of Conformity which is delivered with the machine for more information.

E.

Identity plates

All elecrical components have their own sign with an identifying name.

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E220 RC Engine start and tramming position quick guide SOI version Ed.2

Quick guide - Engine start and tramming

Engine start procedure

Unpack and install the control panel. It is located in the yellow box, placed at the front end of the rig. ►Place the control panel in the swing arm located at the rear end of the rig.

►Connect the cable between the control panel (A) and connection box (B) on the rig. ►Connect the joystick cable to the connection box (B) on the rig.

A)

B)

1. Turn ON main power switch. Check that switch 2 is in position DRILL.

26000151 A

2

2. Tic the box on the control panel display by pressing the RETURN button

26000152 A

3. Press the ESC button

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4.

►Turn until click

►Push approx. 10 seconds ►Turn again

2

6000154 A

Jack control levers

The rig jacks must be in transport position before switching to Tramming Mode. Use the Jack Control Levers for setting the jacks in the correct position.

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Tramming mode

NOTE: Make certain that the rig’s mast is in the correct tramming position!

1. Turn on the radio transmitter by pulling out the Emergency Stop Button and pushing the ON button (A)

26000157 A

A

26000158 A

2. Push and hold the button OVERRIDE (1). Turn switch (2) to RRC position. Turn switch (3) to LO-position.

1 2 3

3. Hold buttons until the green LED indicates ready.

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4. Push the ON button (A) again to activate the remote control.

A

26000161 A

5. Set selector (B) in Tramming Mode

B

26000162 A

6. Activate positioning button on the control panel

7. Tram the rig using levers (C) and (D).

D C

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04 Overview Explorac 220 RC Ed.0

Overview

Design and function

Atlas Copco has a history of designing and manufac-turing a great number of drilling rigs since the early fifties. Atlas Copco Craelius is a division within Atlas Copco dedicated primarily to mineral investigations with preference for underground core drilling.

The Explorac 220 RC is a 22 ton rig intended for 150-200 mm RC drilling. A rigid platform equipped with four powerful hydraulic jacks provides the necessary strong base for mounting of the rig components. The frame design allows convenient adaption to lorries and trailers with a capacity of 20 ton. The Explorac 220RC functions are powered by four independent hydraulic pumps, three in-line mounted on the Caterpillar engine main shaft flange and one mounted on the cam shaft PTO. These pumps provides hydraulic oil at high pres-sure and are used for positioning of the rig, for rotation of the drill unit spindle, for pull down and retraction of the drill string, and for auxiliary functions such as pipe tongs and water flush pumps.

The rig is installed in drilling position by hydraulic, steel encased hydraulic jacks. The mast is supported and pivoted in a welded ”H-frame”. Two hydraulic cylinders elevates the mast to drilling position (45° to vertical). The rig set-up operation is carried out using a manually operated valve block assembly located at the right hand side of the rig.

Two hydraulic feed cylinders mounted inside the mast pull the rotation cradle by means of chains and pul-leys. The basic rig is intended for max. 6 m. (20 ft) long drill pipes.

Hydraulic motors drives the drill spindle via a heavy duty mechanical gearbox. The spindle is provided with a threaded adapter, for the joining of drill pipes and hammers, and with a swivel for injecting compressed air, foam or water into the drill string.

The feed and rotation functions are conveniently moni-tored by digital gauges and governed by hydraulic gauges and valves grouped in the main control panel mounted on the left hand side of the drill mast. Drill pipes are stored in a pipe rack on the platform deck until needed. A hydraulically operated winch, lift-ing over the jib boom pulley in the top of the mast fa-cilitates handling of heavy hammers, drill bits, collars, and casings.

The break-out table which is fitted in the lower end of the mast guides the drill string and provides support and hold for making and breaking of threaded tool joints. The mast may be hydraulically shifted 1900 mm up/down to a comfortable working position.

The Explorac 220RC has been designed with focus on mineral exploration drilling with dual pipe reversed circulation.

The dual-wall method uses flush-jointed double-wall pipe. Compressed air is fed between the two pipes to the hammer- or three cone drill bit and the cuttings moves through the center tube back to the surface without any direct contact with the surrounding forma-tion. The external pipe specification must be in level with drill pipes for conventional rotary drilling and also able to take the expected tensile, column and col-lapse pressure foreseen for the actual bore hole. The internal rod is under little physical stress but is worn by the abrasion from cuttings moving with high speed upwards inside the tube. The speed when using com-pressed air must be 25 to 30 m/s. The multiple seal inner tube is easily replaceable when necessary. Atlas Copco uses special DTH hammers for RC drill-ing. The compressed air fed through the annular space between the tubes enters the hammer and drives the piston to strike on the drill bit anvil. The exhaust leaves the piston cylinder at the shoulder of the drill bit and returns through the center of the bit and hammer and back to the surface through the inner drill pipe tube. The design of the bit and hammer screens the air from flowing via the outside of the hammer/drill pipe back to surface. Back pressure produced by the formation will also act as a seal during drilling.

After moving back via the inner tube and through a top head swivel the air with the formation sample is sepa-rated in a cyclone and dumped through a door into the sample bag for the geologist to examine.

RC pro

Continuous representative formation samples ob-tained

Aquifer yield at many depths

Fast penetration through coarse alluvials and bro-ken rocks

Reduced or eliminated problems with lost circulation Washout zones reduced or eliminated

RC con

Limited hole diameter

Requires high air volume and pressure.

The Explorac 220RC will also perform well using con-ventional methods like direct rotary drilling, DTH drill-ing, solid stem auger and hollow stem auger drilling. Direct rotary mud drilling requires a mud circulation system (optional). Limitation of drilling diameter and depth is the rig’s lifting force (22 tons), rotation speed and torque. The bit producer recommends 0,5 to 2 tons per inch bit diameter depending on formation, and a mud lift velocity of 0,3 m/s. As the bit weight should

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be obtained by collars and stabilizers near the drill bit and not by machine pull-down, the diameter of the di-rect drilling bit in average formation would be max 20” in soft formation. Mud speed and volume are calcu-lated using drill pipe diameter and bore diameter. The required mud pump pressure depends on friction and geometry of the drill string.

Direct air percussion drilling with Down the Hole Hammers

DTH drilling is fast and simple in hard crystalline for-mations. The limiting factors are the rig’s pull-back ca-pacity and the compressor’s air delivery and pressure. The air flow speed must be 25 to 30 m/s to carry the cuttings unless chemicals (foam) is used. The volume of air required for a 12” hole is something like 1500 dm3 /s FAD (Free Air Delivery, or air expanded to at-mospheric pressure).

Solid-stem Auger drilling performance is limited by the size of the break-out table, the physical strength of the augers and the torque of the drill rig.

Additional guides and adapters required

Hollow-stem augers offers access to the bottom of the bore for retrieving undisturbed samples and can be used for temporary work casing in loose formations such as sand and clay.

Please consult the nearest Atlas Copco representative for additional information.

Recommended equipment

Method Cutting, recommended

additional equipment

DTH hammer drilling (in hard crystalline rock & consolidated formations)

DTH- hammer, drill pipes, compressor, bits, dust collector

Rotary drilling with mud, water or air flushing (cementary rocks; slate, sandstone, limestone and similar)

3-cone bits, mud pump, stabilizers, drill pipes

ODEX and Symmetrix Methods: simultaneous drilling/casing method (decomposed rock, mo-raine, gravel, sand, chist formations)

DTH hammer, drill bits, casing, drill pipes, com-pressor, foam pump

RC drilling method Hammer, bit, drill pipe, cyclone, rotation head adaption, compressor, sampler

26000062 A

Diagram, size vs. depth

Geological conditions changes from one site to anoth-er, drilling accessories used are not always the same and the operators skill and experience varies. Regard this chart as a reference only. Contact your local Atlas Copco dealer for further information regarding suitable drilling tools and expected performance under local conditions.

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General dimensions

10 560 Travel length 7 680 4 350 2 520 12 400 26000073 A

General dimensions, truck version

Weight, mounted on 8x8 Scania carrier 33 000 kg Total length in transport position 12 400 mm Height in transport position 4 350 mm

Width 2 520 mm

Height w. mast in vertical position 10 560 mm Gradeability (climbing capacity)

General dimensions, crawler version

Weight, mounted on IVA crawler carrier 33 000 kg Total length in transport position 11 200 mm Height in transport position 4 500 mm

Width 3 200 mm

Height w. mast in vertical position 10 562 mm Gradeability (climbing capacity)

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Main parts

Explorac R220 basic unit

A. Mast

B. Winch and jib boom

C. Engine/compressor/hydraulics canopy D. Integrated fire extinguisher

E. Hydraulic jack

F. Auxiliary air connections G. Sample hose

H. Cyclone I. Splitter J. Hydraulic jack

K. Fuel tank with platform L. Hammer oil tank

Q O R S M N P 26000074 A M. Rod handler N. Rotation unit O. Sample hose P. Upper hose chain Q. Lower hose chain R. Engine start panel S. Slips table

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06 Operation Explorac 220 RC Ed.1

Operation

Rig control system

The RCS (Rig Control System) monitors and governs the drill rig functions. It is intended for the following use:

Comparing important parameters against preset val-ues

Reporting rig performance data to Operator’s control panel

Forwarding of information given through Operator’s panel instructions to rig components

The control system using CAN technology comprises the operator’s panel with the main computer and a rigid display, a number of I/O modules and sensors, solenoids and hydraulic valve blocks.

The “CAN” protocol (Controller Area Network) was de-fined in the mid eighties for improved serial communi-cation. The aim was to reduce the complexity, number and weight of wires used in automobile vehicles. Today CAN is widely spread in many technological fields e.g. industrial automatization, medical electronics and net-works with relatively small amounts of data in need of reliable serial communication.

The control system used in Atlas Copco Explorac 220 consists of a processor with a rigid 141 x 77 mm screen, a control panel with five joysticks and a num-ber of on-off buttons. The control panel is connected to the drill rig via a 10 m cable. A separate 24 volt DC system provides current to four “I/O” (Input / Output) modules, to an engine surveillance unit and to a sepa-rate multi function joystick for rod handling. From the I/O units current is directed through wires to hydraulic valve block control spools and system sensors. CAN serial wires carries instructions from the control panel and reports data back to the control panel.

Data communication is constantly taking place in the system. The information is tagged with an address and will be read by all I/O modules, but ignored by receiv-ers not affected. Signals from, for instance, a tempera-ture gauge will travel through the system to the control panel as soon as it detects a gap in the traffic. The gap required might be no more than a microsecond. The control panel processor is also used for diagnosing and programming of the parameters used for hydraulic valve blocks and gauges settings.

Control panel I/O module 24 V fuse & check box Engine surveillance unit

Cable from rig to control panel

26000076 A

Display w. processor

Rig control system

26000167 A

Operator’s control panel connected to rig

26000166 A

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26000168 A 1 2 3 4 5 6 7 ₉ 8 10 11 12 13 14 15 16 17 ₁₈ 19 20 21 ₂₂ 23 ₂₄ 25 26 28 27 29 31 32 30 33 26000164 A

Operator’s control panel, left side

1. Winch arm in 2. Activate drilling 3. Winch arm out 4. Activate positioning 5. Compressor load/unload 6. Winch

7. Engine rpm decrease

8. Blow down mode control button 9. Engine rpm increase

10. Blow down mode control button 11. Cyclone knife close

12. Cyclone knife open 13. Cyclone trap door close 14. Cyclone trap door open 15. Slips holder close 16. Slips holder open 17. Rod rest out 18. Rod rest in

19. Rotation torque, drill -20. Rotation torque, drill + 21. Rotation torque, break -22. Rotation torque, break + 23. Fast feed pressure up -24. Fast feed pressure up + 25. Horn

26. Down feed decrease (joystick) 27. Down feed increase (joystick) 28. Hold-back decrease (joystick) 29. Hold-back increase (joystick)

30. Spanner break-out function (joystick) 31. Spanner break-out function (joystick) 32. Spanner in (joystick)

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26000169 A A B C D E F G H I J K L M N O P Q T R S 26000165 A U

Operator’s control panel, right side

A. Water pump off B. Water pump on C. Water pump bleed D. Water pump flow control -E. Water pump flow control + F. Hammer oil OFF

G. Hammer oil ON 1liter/h

H. Hammer oil ON 2 liters/h I. Hammer oil ON 3 liters/h J. Hammer oil ON 4 liters/h K. Stop watch start/stop L. - (not used)

M. Stop watch reset N. Rotation in parallel O. Drill string balance P. Rotation in series Q. Feed start (joystick) R. Feed stop (joystick)

S. Rotation decrease (joystick) T. Rotation start/increase (joystick) U. Rotation stop (joystick)

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Layout CAN-system E220 RCS

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Menu overview

Drill

Direct menus

Safety menu

Operator Settings

Engine

Compressor

Service Information

Main menu

Information

System

Settings

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Direct Menus

D1:1 - Direct Menu Drilling

The menu is viewed when F1 is pressed.

Left column from above: Intermediate pressure, re-ceiver pressure, air valve indication (yellow in crack position and green in fully open position) and down the hole pressure. Middle left column from above: Net drill feed pressure, hold back pressure and down feed pressure.

Middle right column from above: Main pump pressure (gauge and digits).

Right column from above: Hammer oil indication (green when hammer oil is on), hammer oil pump pulse, water indication (green when water is on) and water flow (%).

D1:2 - Direct Menu Operator Settings

The menu is viewed when button F1 is pressed. Button F1 toggles between D1:1 and D1:2.

The percentage settings are related to the min. and max currents in the parameter settings menu. 0% = Min. current and 100%. = Max. current.

D2 - Direct Menu Engine

The menu is viewed when button F2 is pressed.

Left column: Fuel level.

Middle left column: Coolant temperature.

Middle right column from above: Rpm, oil pressure, boost pressure and engine hours.

Right column from above: Engine load, boost tempera-ture and engine battery voltage.

D3 - Direct Menu Compressor

From above: Intermediate pressure, receiver pressure, low stage temperature and high stage temperature.

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D4 - Direct Menu Service Information

Left column from above: Engine oil, engine oil filter, en-gine air filter and enen-gine fuel filter.

Middle column from above: Hydraulic oil, hydraulic oil filter, compressor oil, compressor oil filter.

Right column from above: Compressor air filter, water filter, engine hours and drill hours.

Safety Menu

The safety menu is displayed after startup of the con-trol system.

M1 - Information

Left column from above: Fuel rate, fuel pressure and fuel temperature.

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System

M2 System Menu

M2:1 - Module Menu

In the module menu the CAN-nodes are symbolized with boxes. If a box is red it has no CAN communica-tion or there is another fault. All modules except for the rod loader have a diagnostic menu. Mark the box and press enter to go to the diagnostic menu.

I/O-Module Diagnostic Menu

Below is showed the diagnostic menu for D510. The menus for the other 3 modules are similar.

Operator Panel Diagnostic Menu

Below is showed the diagnostic menu for the left de-coder module in the operator panel D510:1. The menu for the right decoder module is similar.

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M2.2.1.1 D510 Digital Output Menu

Each row from left: Contact name, description, input field for output (0 = off, 1 = on) when actuating manu-ally, the output (0 = off, 1 = on) and valve name. Each output can be actuated manually when logged in at AC-level. Set 1 in the field for actuation, go to “actu-ate desired value” and press enter. The output is now set to on.

M2.2.1.1.1 D510 Input Menu

Each row from left: Contact name, description, input field for coefficient, input field for offset, value on the input and sensor name.

Typical values for coefficient and offset:

50 bar pressure sensor: Coefficient 0.061 and offset 102.

350 bar pressure sensor: Coefficient 0.427 and offset 102.

Level sensor prototype: Coefficient 0.098 and offset 0. Level sensor rig 1: Coefficient 0.279 and offset 0.

M2:2 - I/O-Module Menu

For each I/O-module there are 3 menus, one for PWM-outputs, one for digital outputs and one for inputs. Below is showed the menus for D510, the other mod-ules are similar.

M2.2.1 D510 PWM Output Menu

Each row from left: Contact name, description, input field for output current when actuating manually, the output current and valve name.

Each output can be actuated manually when logged in at AC-level. Set the desired current in the field for ac-tuation current, go to “actuate desired value” and press enter. The current in the output field is now actuated on the output.

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M2:3 - ECM Menu

The SPN (Suspect Parameter Number) and FMI (Failure Mode Indication) for the fault codes sent from the engine.

Each row from left: The CAT sensor number, sensor name and sensor status.

With arrow up and down it is possible to scroll the menu.

M2:4 - Operator Panel Lever Menu

The 3 upper rows from left: Analogue lever name, scaled lever X (forward/backward) value, scaled lever Y (left/right) value, scaled lever Z (lever button up/ down) value and status of the lever. The lever status can be “Ok”, “Not Calibrated”, “Mid pos. Error” and “End pos. Error”.

The 2 lower rows from left: Digital lever name and lever value (right = 1, left = 2, forward = 4, backward = 8).

Lever Calibration Menu

The bars show the scaled lever values and the digits the lever raw values. Calibration is started when the box “Calibration mode” is ticked with enter. See sepa-rate chapter regarding lever calibration.

M2:5 - Rod Loader Lever Menu

Left: The statuses of the lever buttons are showed, 0 = off and 1 = on.

Right: The values from the lever are displayed (X = forward/backward, Y = left/right).

NOTE: This lever is factory set and does not require calibration.

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Settings

M3 - Settings Menu

Left column from above: Access level login and save of logged data.

Right column: SI/Imperial units, date and time, screen brightness and service.

M3.3 - Service Menu

M3.3.1 - Parameter Settings Menu

This is the main menu for the parameter settings. Most of the parameter settings are min. and max. currents for a valve. The min. current corresponds to 0% and the max current corresponds to 100%. Only the param-eters that are not min. or max currents are described below.

M3.3.1.1 Slow Feed Settings Menu

Slow feed pressure down, max current requires ACP-login.

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M3.3.1.2 Fast Feed Settings Menu

The “Fast feed speed, boost level” is the lever value there the fast feed boost is turned on. “Fast feed pres-sure limit, down” and “Fast speed, acc limit” requires ACP-login.

M3.3.1.3 Rotation Settings Menu

“Rotation speed, acc limit” requires ACP-login.

M3.3.1.4 Water and Air Settings Menu

M3.3.1.5 Winch Settings Menu

M3.3.1.6 Fan Motor Settings Menu (ACP-Level)

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M3.3.1.8 Hydraulic Oil Settings Menu (ACP-Level)

M3.3.2 – Set Persistent Data Menu

The drill hours can be set on this menu.

M3.4 – Sensor Override Menu

If one of the sensors for oil level, oil temperature, com-pressor low stage temperature or comcom-pressor high stage temperature is out of function the rig can be operated temporarily if the not working sensor is over-ridden.

The override does not stay in memory if the control system is turned off.

The hydraulic oil level sensor can be overridden at operator level. The other 3 sensors needs login at AC-level.

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If a sensor is overridden a warning message and a crossed over sensor symbol is displayed. The warning message is also displayed every time the diesel en-gine is started.

M3.5 – Save Log Menu

The logs can be saved to the USB memory stick. The event log remains in memory when the control system is shut down. Developer log and assert log is for the software developer.

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Lever Calibration

The purpose of the lever calibration is to adjust for tol-erances in the mounting of the levers. Calibration has to be done when a new operator panel is attached. Once calibrated the calibration values are stored in the parameter file.

Perform the calibration with the engine off. Login as SE and step down through the menus as described below.

To calibrate the levers tick the box “Calibration mode”. After that move the 3 levers (winch/air, drill and fast feed) to their end positions in left – right (Y) and for-ward – backfor-ward (X) direction. Also move the buttons (Z) on the levers to their end positions. Hold the lever/ button in each end position for a short time (1 second is enough). When the levers are moved the lever val-ues are displayed on the screen with the bars. When all levers and lever buttons are moved as de-scribed above remove the tick in the box or just leave the menu and the calibration is ready.

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After calibration the statuses of the levers are set to “Ok”.

Program and Parameter

Loading

General

The settings, “parameters” in the display can be saved to a file, the parameter file. The parameters can also be loaded back in to the display.

Before loading program the parameter file shall be saved. Loading program will set the parameters to default values. After the program is loaded the param-eters are loaded back again. If doing so no settings are lost.

When program is loaded the program in the display is always loaded. The I/O-modules and operator panel is loaded with program if the program on them is not of correct version.

Note that a new I/O-module or operator panel do not have a correct program loaded. This means that if an I/O-module or operator panel is replaced it needs to be loaded with the current program.

Save of Parameters

Connect the cable to the back of the display (X7). The USB memory for the parameters can be inserted be-fore the power is turned on or after that the display has fully started up.

Login in as SE. Go to the menu “Service” and choose “Load/save parameters”. Choose the upper button and press enter, se below. The parameters are now saved to the USB memory.

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Load Program

Turn off the power. Insert the USB memory for the program. Turn on the power. The program is now load-ing and you can follow the loadload-ing on the screen. I/O-modules and operator panel will also be loaded with program if they do not have the correct program on. When loading is ready it will write “reboot”.

Turn off the power and remove the USB memory for the program. Turn on the power.

When a program is loaded the parameter settings is lost so it is important to reload the parameters, see below.

Load Parameters

Insert the USB memory for the parameters. Login in and go to the menu “Service” and “Load/save param-eters”. Choose the lower button and press enter. The parameters are now loaded from the USB memory.

When loading is ready, remove USB memory and cable.

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Pre-start procedure

NOTE

Do not start the engine if there is a DO NOT OPE-RATE” tag attached to the start switch or on any of the rig controls!

Before starting the main diesel engine, certain checks and measures must be carried out in order to prevent accidents, unnecessary stops or breakdown. Some of these measures must be carried out regularly as a part of the preventive maintenance schedule.

►Make a thorough inspection of the engine before starting.

►Look for oil leaks, coolant leaks, loose bolts and damaged parts.

►Keep the engine compartment clean. Remove any waste objects. Inspect the alternator belt and ac-cessory drive belts for cracks, breaks or any other damage.

►Inspect the wiring for loose connections and for worn or exposed wires!

►Check the engine lubrication oil level. Maintain the oil level between “ADD” mark and “FULL” mark on the oil level stick (a2). Oil viscosity and quality re-commendations are given in the CAT engine manu-facturers manual.

a1

a2

26000077 A

Engine oil check: oil level stick (a1), oil fill cap (a2) ►Check the fuel supply. Fuel consumption during RC

drilling is approximately 100 l/h. The tanks hold 500 liters.

►Open fuel supply valve. Drain condensate from the prefilter water separator (b1).

b1 b2 b3 b4 26000078 A

Engine filter compartment: fuel priming pump (b1), secondary fuel filter (b2), primary fuel filter (b3), en-gine oil filter (b4)

►Check the coolant level. Maintain the coolant level within 12-13 mm off the bottom of the filler pipe. ►Check the engine air intake filter. Clean or replace

cartridge. The turbine pre-cleaner need no pre-start attention. (Empty bowl according to preventive maintenance schedule).

►Check oil level in hydraulic oil tank (level indicator b3) Add as required using the fill pump.

b1

b2

b3

b4

26000079 A

Compressor oil tank (b1), oil fill tube (b2), level indica-tor (b3), compressor oil filter (b4)

NOTE

All valves in the fuel return line must be open be-fore and during engine operation in order to pre-vent incorrect fuel pressure. (To high fuel pressure could damage the filter housing etc).

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►Check the compressor air intake filter. Replace car-tridge if necessary. The turbine pre-cleaner need no start attention. (Empty bowl according to pre-ventive maintenance schedule).

c1

c3

c2

26000081 A

Compressor module. Air intake cleaning turbine (c1), filter (c2), compressor air loading valve (c3)

►Reset all Emergency Stop buttons.

►Set all hydraulic valve block levers to neutral. ►Connect the drill rig control panel.

►Activate master circuit switch MCS1.

START PROCEDURE (before actually starting the diesel engine)

1. Ensure that the master switch is in OFF position. 2. Connect control panel (and rod handler control if

the rig is equipped with rod handler). 3. Place the controls well clear of the machine. 4. Turn the master switch to ON.

5. The rig control system (RCS) will boot within ap-proximately. 15 seconds.

6. Read and tic SAFETY NOTICE on operator’s screen.

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Engine start

►Make sure the RCS (Rig Control System) is running. ►Set all hydraulic valve block levers to neutral. ►Clear areas around engine and drill rig rotating

parts.

►Turn the ignition handle to position “1”. The “CHECK ENGINE/DIAGNOSTIC“ lamp will flash while the en-gine is cranking. The lamp should turn off when the proper engine oil pressure is achieved. If the lamp fails to flash, consult your authorized Caterpillar dealer. If the lamp continues to flash, the ECM (Electronic Control Module) has detected a problem in the system. Refer to the Caterpillar Operation and Maintenance Manual “Diagnostic Flash Code Retrieval” (Operation section) for more information on engine diagnostics.

►Push and turn the ignition handle in clockwise direc-tion in order to crank the engine. Do not move the throttle controls while the engine is cranked! The system will automatically provide the correct amount of fuel needed to start the engine.

►If the engine fails to start within 30 seconds, release the start handle. Wait for two minutes in order to allow the starter motor to cool before attempting to start the engine again.

►Allow the engine to idle for approximately 3 minutes when it has started. Idle the engine until the en-gine coolant temperature gauge has begun to rise. (Drillers control panel, main menu, next F1: menu D2). Oil pressure and fuel pressure should be in the normal range. Do not apply a load, e.g. starting the compressor “load” or moving a hydraulic valve block lever. (Drillers control panel, main menu, next F1: menu D2).

►At temperatures below +10º C starting performance will be improved if a cylinder block coolant heater, coolant air heater or crankcase oil heater is used. ►Prime the fuel system. Fuel may have drained if

the engine hasn’t been in operation for some time (weeks, months). Air may have moved into the filter housing. Also, when fuel filters have been changed, some air will be left in the filter housing. Refer to Caterpillar Operation and Maintenance Manual (fuel system - PRIME).

►If batteries are down it might be necessary to start the engine from an external electrical source. First determine the reason that makes it necessary to start with an external source. Refer to Caterpillar Special instruction SEHS7768: use of starting/ charging analyzer.

26000082 A

Ignition handle

NOTE

The “CHECK ENGINE/DIAGNOSTIC “ lamp may come on also after the engine is started. If this occurs, the ECM system has detected a problem with the engine system. Refer to the Caterpillar Operation and Maintenance Manual “Diagnostic Flash Code Retrieval” (Operation section) for more information on engine diagnostics!

NOTE

Disconnect any battery charger that is not protect-ed against the high current drain that is creatprotect-ed while the electric starter motor is engaged! NOTE

Do not engage the starting motor when the fly-wheel is turning! Do not start the engine under load!

NOTE

Engine oil pressure should rise within 15 seconds after the engine start. Do not increase engine speed until the oil pressure gauge (Menu D2) in-dicates normal. If oil pressure is not indicated on the gauge within 15 seconds, DO NOT operate the engine. Stop the engine, investigate and correct the cause.

NOTE

Improper jump start cable connections can cause an explosion resulting in personal injury. Prevent sparks near the batteries. Sparks could cause vapors to explode. Do not allow jump cable ends to contact each other or the engine. After jump starting the alternator might not be able to fully re-charge batteries that are severely disre-charged. NOTE

Do not use ether (starting fluids) unless specifi-cally instructed to do so. If the engine is equipped with an air inlet heater (electrically or fuel ignited manifold heater) do not use ether (starting fluids) at any time. The use could result in engine damage and/or personal injury!

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Engine running

Observe the following conditions when the engine is idling during warm-up:

►Check for any fluid or any air leaks at idle speed and at ½ speed (no load) before operating the engine under load.

►Operate the engine at low idle speed until all sys-tems achieve operating temperature and pressure. Check all gauges during the warm-up period ►Gauge readings should be observed and data

should be recorded frequently while the engine is operating. Comparing the data over time will help to determine normal readings for each gauge. Comparing data over time will also help to detect abnormal operating developments. Significant changes in the readings should be investigated.

NOTE

In ambient temperatures from 0 to 60°C, the up time is three to five minutes. Additional warm-up time may be required in temperatures below 0°C.

NOTE

Ensure that the self test for the monitoring system is completed before operating the engine under load.

26000084 A

Increase and decrease engine speed. Push “+” button one to four times for speed 1000, 1200, 1500 or 1800 rpm

26000085 A

Select menu D2 (press F2)

1 3 4 5 6 7 8 9 26000083 A 13 12 11 10 2

Driller’s control panel, engine surveillance 1. Fuel level. (1/1 equals 500 liters)

2. Engine water jacket temperature. (87-98°C) 3. Engine crankshaft speed in rpm.

4. Engine lubrication oil pressure. (3-6 bar) 5. Turbo pressure. (2,5-7 bar)

6. Engine operating hours.

7. Engine load factor (percent of max).

8. Combustion air intake temperature. (Max. 85°C) 9. Battery voltage.

10. Red color: Extremely low fuel level 11. Red color: Compressor failure 12. Red color: Surveillance system error 13. Red color: Engine air intake filter clogged

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Caterpillar engine monitoring

system

The engine monitoring system incorporates the follow-ing features:

Coolant system level Coolant temperature Engine speed Fuel pressure Fuel temperature

Inlet manifold air temperature Oil pressure

The engine is programmed for warning, derate and stop:

I Warning. Orange icon

Warning icon on driller’s control panel turn on in order to alert the operator that one or more of the engine pa-rameters is not within normal operating range.

II Warning - Derate. Orange Icon

Warning icon on driller’s control panel turn on in order to alert the operator that one or more of the engine pa-rameters is not within normal operating range.

After the warning the engine will derate speed and power output. Fully derated, the engine speed will be 1350 r/min and output max. 120 kW. The icon will flash during the derate phase.

III Warning - Derate-Stop. Red Icon

Warning icon on driller’s control panel turns on in order to alert the operator that one or more of the engine pa-rameters is not within normal operating range.

After the warning the engine will derate speed and power output until a shutdown of the engine occurs. A shutdown of the engine may occur within 20 sec-onds. The engine can be restarted after a shutdown for use in an emergency. However, if the cause of the initial shutdown still exists, the engine may shut down again within 20 seconds.

Coolant system level

Correct coolant level is of vital importance. The engine may be seriously damaged if the coolant level is too low and the engine is allowed to overheat.

Fault type FMI Warning Result

Coolant level low 17 Yellow warning Warning Coolant level low 18 Yellow warning Engine derate Coolant level low 1 Red warning Engine stop

Coolant system temperature

The engine coolant temperature sensor monitors the temperature of the engine coolant. The coolant temperature signal is sent to the ECM for engine monitoring and for improved engine control. The sig-nal is used by the ECM for all of the following engine functions: Engine timing control, operating mode and engine protection. The ECM is capable of adjusting the engine timing relative to the engine operating tem-perature. The concept of dynamic timing provides the engine with the ability to control exhaust emissions. Timing control also aids in white smoke cleanup during cold engine operation. The ECM also uses the signal from the engine coolant temperature sensor to deter-mine the mode of operation for the engine. Several aspects of engine operation are affected by the engine operating mode: acceleration ramp rates, engine tim-ing, and fuel injection timing.

Fault type FMI Warning Result

Sensor error - Yellow warning ECM error Coolant temp high 15 Yellow warning Engine high temp Coolant temp high 16 Yellow warning Engine derate Coolant temp high 0 Red warning Engine stop

AC Explorac 220 RC specification

Explorac - Reverse circulation

drilling

Safety and Operating instructions

Explorac 220 RC

Contents

Introduction

Safety instructions

Safety signal words

Personal precautions and

qualifications

Hoisting and transport

Storage, repair, maintenance and

disposal

Operation

Personal protective equipment

Drugs, alcohol or medication

Safety area

Hoisting and transport

Operation, precautions

Maintenance, precautions

Signs and stickers

Prohibition signs

Warning signs

Regulatory signs

Information signs

Other signs

Quick guide - Engine start and tramming

Engine start procedure

A)

B)

2

Jack control levers

Tramming mode

Overview

Design and function

General dimensions

Main parts

Operation

Rig control system

Layout CAN-system E220 RCS

Menu overview

Drill

Direct menus

Safety menu

Operator Settings

Engine

Compressor

Service Information

Main menu

Information

System

Settings

Direct Menus

System

Settings

Lever Calibration

Program and Parameter

Loading

Pre-start procedure

Engine start

Engine running

Caterpillar engine monitoring

system