Hydracore Drills Ltd.

7702 Progress Way, Delta, B.C. V4G 1A4, Canada Phone (604) 940-4937, Fax (604) 940-4919

Parts and Service Manual

Hydracore 2000 Drill

With 115 HP John Deere 4045TF150A, 96 HP Deutz BF4M914, or Isuzu 137 HP 4BG1ABFB

Serial numbers 288 and up

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Gopher Manportable Drill

Table of Contents
1. Title page 2. Table of contents 3. Introduction and Warranty 4. General Description 5. General Description 6. Specifications 7. Specifications 8. Drill components list 9. Ordering parts 10. Drill Head 11. Drill Head picture 12. 13. Chuck 14. Mast, Back Legs, and sheavewheel assembly 15. 16. Cylinder 17. Power pack 18. Panel 19. Pump Diesel operated 20. Pump, Hydraulic operated 21. 22. Admiral pump 23. KL 45 pump assembly 24. KL45 pump internal parts 25. 26. Winch 27. 28. Mixer 29. Footclamp 30. Description of hydraulic circuit 31. 32. 33. 34. Hydraulic schematic 35. Hooking up hoses 36. Maintenance 40. Operating Instructions 46. Timax pop valve

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INTRODUCTION The purpose of this manual is to provide the operator with detailed information, instructions, and specifications pertaining to the operation of the Hydracore 2000 Drill. Familiarization with this manuals contents will improve the Drills performance and provide a long trouble free service life. HYDRACORE STANDARD WARRANTY It is agreed that there are no warranties, express or implied, made by Hydracore Drills Ltd., except its following standard warranty. Hydracore Drills Ltd. warrants each new Hydracore Drill and related parts sold by Hydracore to be free from defects in material and workmanship under normal use and service for ninety days from the date of first use, but not to exceed six months from the date of shipment. The obligation under this warranty is limited to the replacement or repair at the Richmond, B.C. , plant of Hydracore, or at a point designated by Hydracore, of such part or parts as shall appear upon inspection at this point to have been defective in material or workmanship at the time sold, provided that the part or parts claimed defective are returned to the inspection point, transportation charges prepaid. This warranty applies only to new and unused Hydracore Drills and parts, which, after shipment from the Hydracore plant, have not been altered, changed, or repaired in some manner. This does not extend to power units, pumps and other trade accessories not manufactured by Hydracore, though sold or operated with Hydracores drills, same being subject to warranties of the representative manufacturers thereof. In no event shall Hydracore be liable for consequential damages or liabilities caused by the failure of any drill or parts to operate properly. Hydracore is constantly striving to improve its products and , therefore reserves the right to improve its products, specifications, and price without prior notice.

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General Description and Weights

Drilling Unit The drilling unit is equipped with two 70 inch stroke hydraulic cylinders. The cylinder bore is 2.5 the rod size is 1.75. The drill head has a hollow spindle 3 7/8 inside diameter. The spindle is driven by a belt. A variable displacement bent axis motor has a small pulley directly attached to its shaft. The speed of the head, can be varied by a knob on the hydraulic panel. A hydraulic clamp is also fitted. The drill is normally mounted on an aluminum skid. There are telescopic back legs that allows the drill to be set at any angle from 90 to 45 degrees. Rod pulling is accomplished by means of the hydraulic cylinders. The tower is only used for the wireline cable. A heavy tower is therefore not required. The drill on its aluminum skid with the winch, hoist, back legs, head and clamp is 1950 lbs. The drill head complete with the steel hood and 160 cc motor is 590 lbs. Hydraulic Power Pack The Hydraulic powerpack is made so that it can be split into two pieces to make moving it easier. The hydraulic module separates from the engine by removing only a few bolts. The throttle also has to be disconnected. Two lifting points are provided. The one that is centered over the engine is for when the engine is lifted on its own. The one that is closer to the middle of the powerpack is for lifting the whole powerpack at once with a big helicopter. The panel does not have a lifting lug. Two equal length slings should be attached one to each side of the upper frame. A bracket is welded onto the upper frame so that the slings cannot slip from the center of the frame. The weight of the two pieces is sometimes stamped into each frame. The hydraulic module is 900 lbs. The John Deere engine unit is about 1235 lbs. The Deutz engine is 1050 lbs. The Isuzu engine is 1135 lbs.

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Control Panel Not exactly as shown

1. Clamp and chuck lever 2. Clamp lock valve 3. Water pump fast lever ( it looks like valve 8 but is to the left of 4) 4. Drill head speed 5. Rotation 6. Winch 7. Cylinder Fast feed 8. Water Pump 9. Fine feed 10. Cylinder slow feed 11. Engine Throttle 12. Engine stop A. Water guage B. Torque gauge ( Main Pump) C. Cylinder off pressure guage Not Shown, to the left of 3 is the small winch control lever Not shown, on the left side of the drill low down, two mud mixer controls, the triconing valve, and the main pump by pass valve.

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Hydracore 2000 Drill 115 HP Specifications Capacity A size 3000 feet (900 m) 1800 feet (540 m) 900 feet (270 m) 4000 feet (1200 m)

B size N size H size

Drill Head Motor Displacement RPM Torque

Maximum 522 1075 Ft- lbs Minimum 1550 336 Ft- lbs Weight (including chuck) 580 lbs ( steel version) Speed/ Torque is continuously variable between maximum and minimum values. More torque is available in reverse for rod breaking, (1790 ft-lbs) because the reverse pressure is set at 5000 PSI and the maximum pressure in forward is only 3000 psi. Hydraulic Chuck Operation Spring closed, Hydraulic opened Axial Thrust 24,000 lbs Capacity No. of Jaws 3 Maximum rod size 3 Foot Clamp Operation Accumulator closed, Hydraulic opened 25,000 lbs 2 3 90 lbs Drill Slide and Feed Cylinder Maximum Pull Maximum Thrust 24,000 lbs 16,000 lbs

Axial Thrust Capacity No of jaws Maximum rod size Weight

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Stroke Weight

70 550 lbs Power Pack

Engine John Deere 4045 115 HP Main Pump 60 GPM, 3000 PSI Auxiliary Pumps(2) 10 GPM, 2500 PSI Feed Pump 1 GPM, 3000 PSI Hydraulic Tank 12.5 Gallons (US) Cooling Water cooled, heat exchanger Weight 1850 lbs The powerpack is designed to quickly split into two parts one weighing 800 lbs and the engine,which weighs 1050 lbs in its frame with the battery. Options 20 GPM 1000 PSI Water Pump hydraulic ( IB 1029 Admiral) 45 GPM 1000 PSI Water Pump hydraulic (Cat 3545) Wireline hoist 2000 foot capacity Wireline hoist 3000 foot capacity Hydraulic Mud mixer Weights These are the weights for helicopter moves Hydraulic module 880lbs Engine module (John Deere) 1250lbs (Isuzu) 1150lbs (Deutz) 1050lbs Drill on skid with clamp, 1100lbs Back legs, and winch Drill head 580lbs

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Drill Component List 2000 Drill #288 and up DESRIPTION MANUFACTURER Engine John Deere 115 HP Deutz 96 or 106 HP Isuzu 137 or 114 HP HC 2000 STEEL Gates Rexroth Sauer Danfoss HC Char Lynn Walvoil Gresen Compact & Aktiv 4045 914 or 913 4BG1T or

MODEL NUMBER

Drill Head Belt Rotation Motor (100HP) Pulleys 36 AND 100 TOOTH Winch Motor Main Valve Bank Slow feed lever Water pump Valve in special manifold with compensator and relief. Fine Feed Clamp and chuck valve Speed Valve, motor displacement control Guide Bearing These two bearings, go in special housings Water pump fast valve Heat Exchanger Heat exchanger Triconing Valve, this was deleted after serial number 304 Hoist valve (on some machines) Water Pump Motor Pressure pump Clamp Lock Valve Clamp Accumulator Mud Mixer Return Filter Tank Top

8M-1200-90 A6VM160HD2/63W-V2B010B 51V160 RF 1N HZB1 BHG5 NNN 36 tooth 1 - 13 and 100 tooth 104-1198 SD25/3/AC(XG3)/211L.UX2 (G3)513L/513LRC-SAE V20R-K4X1-HH-Closed CP620-1-B-8S-10-10-DR ,AC676 manifold CP310-4-B-0-080 compensator, CP200-3-B-O-A-C pressure relief MV800 CP640-1-B-6S-5-3-D CP230-1-B-6S-K-B UCFL-212-206T UCFL-215E 48 6019 6024 CP620-1-B-8S-5-10-DR A-624-2-4-T-BR A-624-2-4-T-BR J04E2ZN 1249705 1259068, closed center plug 104-1022 420, CA 1029, KF 40 GE2-N 3/8 A4N0116D1K 129-0002, TIE-25-10 Element T125N1AHN Assembly

Parker Compact Compact BQ or BTW BW,NQ or NTW NW,HQ or HTW HW, or PQ Compact Thermal Transfer Thermal Transfer Sterling BLB BM 40 BLB BM 40 Char Lynn FMC, Admiral, Emperror MP Parker Char Lynn. Gresen Gresen

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3 micron filter Main Hydraulic Pump Auxiliary Hydraulic pumps (1) JD Auxiliary Piston pump Feed and reverse pump Drive Plate SAE 12

PTI Sundstrand Sundstrand

Element F4F-030-HC-B CPA 1176 (060) (2 gear housing) on JD Isuzu, (050) on Deutz SNP2-14,-17 on Isuzu or

Sauer Danfoss Dynex KTR

LRR030D (B-A) PF104-J746 FLE-65

Ordering parts Because all these machines are made one at a time there are quite a few variations in the parts that may have been used. We try to keep track of these changes, but we dont always succeed completely. Some problems have appeared to do with supplying parts that it is worth being aware of. The listing of parts shown on this drill components list is likely to be a bit more accurate than the part numbers in the parts book pages. We can supply replacement parts for your machine without in most cases without you having to tell us the part numbers. The drill head motor, most of the drills have been supplied with the Sauer Danfoss 51V160 motor. Some drills have used the 110 cc motor which will also fit onto any of these drill head. The 110 cc motor normally uses a 32 tooth small pulley rather than the 36 tooth one on the 160 cc motor. Some drills have also used the Rexroth motors, either 160cc or 107cc. They are almost a direct replacement for the Sauer. The only difference is that the Sauer has a 1 o ring case drain port, and the Rexroth uses . Also the A and B ports on the Rexroth 160 are -20 where the Sauer uses- 16. The 107 Rexroth has -16 ports. Usually we would supply the same motor as a replacement, but if a substitution has to be made because of availability we would supply the fittings as well. There are some differences on the main hydraulic gear pumps on the different drills. Depending on the engine the drill will have either a 5 or 6 cubic inch main pump. The 5 cubic inch pump measures about 1 on the iron part. The 6 cubic inch pump measures 2. The 5 cubic is used on the Deutz engine, the 6 cubic inch on the JD or Isuzu. The problem is that there have been a few machines that have gone out that may have had a different size than normal on pump ports. Because of this when you order a pump we may ask you to measure the ports on your existing pump. We can

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probably supply an exact replacement, but if not we will be able to supply the different sized fittings that you would need. The pressure compensated Sauer 45 series pump has been supplied either with a 13 tooth by 7/8 shaft, or a 15 tooth 1 shaft. If we are not sure which kind you need we will send the coupling as well so that it is sure to fit.

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Parts List Hydracore 2000 Steel HQ head with 107cc 110cc or 160cc motor Description 1. Screen 2. Pulley 100 teeth 2 keys X X 1 7/8 3. Sealing ring 4. Seal 5. Housing, steel 107cc 6. Shaft 7. Yoke, steel 8. Bushing retainer plate 9. Bushing, available in sizes AQ to HW 10. Nut, 12 bolt Also 12 allen bolts 3/8-16 UNC X 1 11. Hardened ring 12. Opener Cylinder Opener Cylinder seal kit Bolts -13UNC X 1 13. Outer race separator 14. Inner race separator 15. Bearing (2 required) 16. Bearing retainer plate Seal 17. Allen Bolts 5/16-18 UNC X 1 18. Cover 19. Opener cylinder (again) Opener cylinder hose Opener cylinder elbow Opener cylinder tee 20. Belt 21. Pulley 30 teeth 22. Motor (Rexroth) Motor (Sauer Danfoss) 23. Head hold down bolt Part number HC2000-1-107 8MGT-100S-90-2000 HC2000-2 HC2000-3 CR67533 or CR417596 HC2000-107S HC2000-4 HC2000-5S HC2000-6 HC2000-7(size)

HC2000-8 HC2000-9 HC2000-9-SK HC2000-10 HC2000-11 6226C3 HC2000-12 CR60000 HC2000-13 HC2000-9 F4210303-6-6-6-15, (12 1/2 cut) 3503-6-6 063T-6-6 8MGT 1200-90 8MGT-30S-90-1 -13T AA6VM107HD2/63WVSC520B, 51V110 RF 1N H2B BHG5 NNN 032 AAF3 0500, or 51V160HD2 etc HC2000-10

Not shown VA 150 water excluder seal, and seal holder ring.

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28342-5 Special bolt for holding corebarrel

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Parts list
Hydracore 2000 5 mast with double hollow cylinders Top picture
Item 1. 2. 3. 4. 5. Description Sheave Wheel ( Jet ) Sheave bracket Cylinder Hollow rod type Rod slide assembly Back leg pivot bracket Back leg pin Jaw serrated for inner leg Aluminum Jaw for lower leg Bolts NC X 4 Nuts NC Nylock Drill head Back leg inner Double back leg Back Leg Outer Skid Foot Point Saddle liner set (plastic) Saddle Foot clamp assembly HW Mast pivot clamp Part Number 131105 43636H H2000-20 H2000-20 H2000-21 J1 J3 Quantity 1 1 1 1 2 2 2 2 2 1 2 1 2 1 2 2 1 1 1 2

6. 7. 8. 9. 10. 11.

HQS-107 H2000-24 H2000-22 H2000-23 H2000-25 H2000-26 H2000-27 43694-U H2000-28 H2000-29 43692-C

12. 13. 14. 15.

Bottom picture
Item 1. 2. 3. 4. 5. 6. 7. 8. 9. Description Sheave Wheel Rod rack end tubes Rod rack cross bar outer Rod rack cross bar inner Rod rack end bracket Mast raising cylinder Mast raising Bracket Sheave wheel mast, Upper Inner leg 2 X 12 Outer leg 2 X 12 Foot Part Number 3800101 H2000-30 H2000-31 H2000-32 H2000-33 1200225 H2000-34 H2000-35 H2000-36 H2000-37 H2000-26 Quantity 1 1 1 1 1 1 1 1 2 2 2

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On machine #273 the cylinders are similar to above, except the piston rod is hollow. The seal kit is the same. The part number for the hollow rod is 43707H. The part number for the piston is 43708H. The part number for the cylinder is 43704H. On machines #274 and up the piston is changed to a 43708H2 which also requires different seals. The two seals 43710 are replaced by one, 18702125-375UNI.

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Hydraulic Power Pack

Item Description Part Number BF4M914 Quantity 1 1. Engine, Deutz Or JD or Isuzu 2. Heat Exchanger 3. Hydraulic Oil filter Hydraulic filter element 4. Tank 10 X 18 X 16 5. Main Pump Sundstrand Main pump filter element 6. Sundstrand 14 cc pump for water pump 7. Sundstrand 14 cc pump Auxiliary 8. Main power pack skid 9. Hydraulic module frame 10. Auxiliary pump spool valve 11. Whipple Pump Valve 12. Main pump Bypass valve 13. Check valve for cooler bypass 14. Air filter (Donaldson) (metal canister) Or Baldwin (plastic canister) 15. Whipple pump relief valve Parts not shown Hydraulic pump coupling Hub

A-624-2-4-T-BR 1 T125N1AHN 1 T1E-25-10 1 H2000-35G 1 CP 222 ( 040, 050, or 060) 9700810 1

H2000-36G H2000-37G BLB 1249721 J04D3ZN

C085004 PA2805 A0482HZN

1 1 1 1 1 1 1 1

M-65-1/14

1
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Flywheel drive plate Pressue gauge cylinder Pressure gauge torque Pressure gauge water Throttle lever assembly Throttle Knob (Brand AO755) Oil filter 2011 Fuel filter 2011

FLE 65X10 SPG-63-3000-PN SPG-63-3000-PN SPG-100-1500-PN H2000-38 SF311 B288 BF587-D

1 1 1 1 1 1 1 1

Item Description Part Number Quantity 1. Cylinder off pressure gauge MPG-1P-3000-B 1 2. Water Pump control valve 1 CP620-1-B-8S-20-2-DR AC676 3. Main pump pressure gauge MPG-1P-3000-B 1 4. Drill head displacement control CP230-1-B-6S-K-B 1 5. Check valve 3/8 C600S 1 6. 3 way ball valve (mixer) 1 7. Clamp, Chuck valve CP640-1-B-6S-5-3-D 1 8. Clamp lock valve GE2 N3/8 1 9. Main valve bank SD25/3/AC(XG3)/211L.UX2(G3)513L/513LRC-SAE 1 10. Slow feed valve V20R-K4X1-HH-Closed 1

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11. 12.

Check valve ( Snap-tite) Fine feed valve

6C4F-F65 MV 800S

1 1

Diesel Driven Water Pump 18 GPM

Water pump with Kubota and two types of Yanmar engine have been supplied The Kubota engines are all model number OC 95 The Yanmar engines are two kinds one with the crankshaft power take off ( like the Kubota) and one with the cam shaft power take off, which requires different pulleys and belts because the output speed is half what it is on the crankshaft drive engines. Crankshaft Power take off engines Item Description 1. Driven Pulley 2. Bushing 35mm 3. Motor Pulley 4. Belt 5. Engine ( Yanmar) Engine (Kubota) 6. Tank 7. Pump 8. Frame Throttle (Paupco) on Kubota s

Part Number 8M-112S-36 3020 X 35mm 8M-22S-36-1 8M-1000-36 L100EE-DE15A OC 95 E M036T CA-1029 M036
310-181

Quantity 1 1 1 1 1 1 1 1

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Camshaft power take off engines Item Description 1. Driven Pulley 2. Bushing 35mm 3. Motor Pulley Bushing 4. Belt 5. Engine ( Yanmar) 6. Tank 7. Pump 8. Frame

Part Number 8M-90S-36 3020 X 35mm 8M-34S-36 1610-30mm 8M-1000-36 L100AE-SEYC-2 M036T CA-1029 M036c

Quantity 1 1 1 1 1 1 1 1

Hydraulic Driven Water Pump 27 GPM Parts list

Item 1. 2. 3. 4. 5. 6. 7. 8. Description Quick coupler Hydraulic Motor Bell Housing Coupling Pump Frame Pop valve Suction Fitting Outlet fitting Part Number Quantity 1 1 1 1 1 1 1 1 S40-4 104-1023 M032 CHJS6-1 3/8+ JS6B+ CHJS6-1 1/4 CA-1029 M033 PRV BR M034 M035

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Pratisolli KL 45 Pumping unit.

Item 1. 2. 3. 4. 5.

Description Pop valve ( Timax) Pump Pump bell housing Pump motor coupling Hydraulic motor (White) Hydraulic fittings

Part Number PVR-BR-3/4 KL 45

Quantity 1 1 1 1

HB 08 58 54 7 F

6. 7. 8. 9.

Skid Suction fittings Outlet fittings Plug

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Winch Parts List

Hydracore 2000 winch, and other similar winches. We have manufactured several winches using the same basic components. The Drum is available in three lengths, 6, 12, and 18. Two different diameters have been used for the drum, 14 and 16. Various different hydraulic motors have been fitted to meet customer requirements.

DESRIPTION Drum 14 X 6 Drum 14 X 12 Heavy Duty Drum 14 X 12 Drum 14 X 18 Drum 16 X 12 Bearing Motor end Bearing Drum end Splined Hub Winch Base for 14 X 6 Drum Winch Base for 14 X 12 Drum Winch Base for 14 X 18 Drum Winch Base for 16 X 12 Drum Various hydraulic motors have been used and are all interchangeable as far as the fit is concerned. Hydraulic Motor (standard) Hydraulic Motor(heavy duty) Hydraulic Motor (very heavy duty) Hydraulic Motor (very heavy duty) Hydraulic Motor on Level wind Note if the Parker Ross or 104 motor is used then a spacer must be used between the motor and winch base Spacer The only other parts are the bolts and nuts Motor mounting bolts (2 req.)

MANUFACTURER Hydracore Hydracore Hydracore Hydracore Hydracore FYH FYH Hydracore Hydracore

PART NUMBER ITEM # W1 W2HD W2 W3 W4 UCFL-209-112T UCFL-206-103T W5 W6 W7 W8 W9 2

3 1 6 5

Char Lynn Parker Ross Parker Ross Char Lynn Parker

101-1085-FW-B2-SPL TF-1-120-B-S-(E) TG-1-247-B-S-(E) 104-1198 TF0195BS010AAAB

Hydracore

W10

- 13 NC X 2

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Bearing mounting bolts (4 reqd.) Nuts (6 reqd.) Lock washers (6 reqd.)

- 13 NC X 1 1/2 - 13 NC

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Mud Mixer
Item 1. 2. 3. 4. 5. Description Mounting Grommets Propeller Motor Housing Frame Hoses Quick disconnects Adapters Adapters Adapters Part Number Quantity 3 1 1 1 1 2 1 2 2 2

M037 MGG200-16-BA-1A3 M038 M038F F4210606-6-6-240 S40-3 0103-6-6 0603-8-6 0353-8-8

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Foot Clamp 3 Item 1. Description Part Number Quantity 2 2 2 2 2 2 4

2. 3. 4.

5. 6. 7

Cylinder Seal kit Piston rod Inner gland Outer gland Piston Spacer Housing Bearing (not shown) available in sizes BQ NQ HQ HW Fittings Hoses Jaws

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DESCRIPTION OF HYDRAULIC CIRCUIT FOR #288 & UP DRILL

These Drills have one CP222 gear pump, One 45 series pressure compensated pump, one SNP2 gear pump, and a Dynex 4 piston pump. The CP222 pump is the main pump, it operates the main motor, cylinder fast feed and winch. The pressure compensated pump runs the slow feed, clamp, chuck, mixers, and is used for bypassing oil to the main circuit for triconing, also oil can be used from this pump for the water pump fast valve to make the pump go fast to pump the tube. The small gear pump is used for the water pump only. One piston from the four piston pump supplies oil to the hydraulic accumulator. The other three pistons are used to provide the 5000 psi for rod breaking, when the head is in reverse.

Main Pump
The main pump supplies 54 GPM on the 100 HP machines, or 62 GPM on the 115 or 137 HP machines, to the main valve bank, through a check valve. It sucks its oil from the bottom of the tank, but the position of the suction hose is right below the outlet of the main filter, so the oil is pushed into the suction to some extent. Also teed into the main outlet line is a big ball valve. By opening this ball valve all the oil from the main pump can be diverted back to tank. This is only done when it is necessary to slow the rotation motor down to about 100 RPMs for tri coning.

Pressure Compensated Pump

This pump sucks oil through a 1 suction line from near the bottom of the tank. It has a case drain line which is routed straight back to tank. The case drain line requires very low pressure for this pump to work properly, that it why it goes straight back to tank. On some machines, that have two heat exchangers the return line may be routed through one of the heat exchangers, but in this case, that heat exchanger will then be routed straight back to tank so that there will never be any back pressure on this case drain line. The pressure compensator is on the right side of the pump. A screw pointing back towards the engine is used to adjust the pressure compensator to 2500 PSI. To adjust this screw a small set screw in the side of the compensator that locks the screw must first be loosened. This pressure can be raised to 3000 psi or even 4000 psi if more pull back pressure is required. 4000 psi must be used only for emergencies because it is to much pressure for the hydraulic chuck. While the pump is set this high the chuck would have to remain closed.

Main Valve Bank

The main valve bank has a built in relief valve that is set at 3000 PSI ( or 3500 psi on the 137HP machines). The three spools control the main rotation motor, the winch, and the cylinder fast feed. The spool that controls the main motor has a 3 position detent. This valve section has been specially modified to make rod breaking possible. It has a port relief on its B port which controls the pressure for rod breaking. It is set by us at 5000 psi, setting it much higher will damage the pump and the valve. The other two spools
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have 4 postions with a detent only for the fourth (float position) ( some machine just have three position valves. The main valve bank can be supplied with oil from the main pump, but also when necessary the triconing valve can be screwed in to transfer some oil from the pressure compenstated pump. This is normally done with the main pump bypass ball valve open and then allows extra slow rotation that is required for Triconing.

Slow Feed Lever

This valve is a closed center valve, it gets its pressure from the pressure compensated pump. It has a built in relief valve which is set at a higher pressure than the compensator on the pump so that oil is not normally relieved by this valve. The valve has 4 detented positions, up down, neutral and float.

Dynex Pump
This is the blue pump that is furthest from the engine. It is a very special pump. It has four pistons operated by a swash plate. This pump gets its oil supply from the return circuit rather than the tank. This is because this pump requires a pressurized suction line in order to work at this speed. The entry of oil into and out of each piston is controlled by check valves. This makes this pump much more resistant to the effects of contamination that a typical piston pump. These valves also make it possible to separtate the flow of oil from each piston. Each piston pumps about 1 GPM. On this drill the flow from one of the pistons goes to charge the accumulator which is used for the clamping and chucking. The accumulator charging pressure is set by a relief valve at 1700 psi. The other three pistons provide the high pressure that is necessary to break rod joints. The pressure in reverse is controlled by the port relief built into the B port on that valve. This is set at the Hydracore shop at 5000 psi. This pressure does not show on the torque gauge, and extra guage has to be installed to check this pressure.

SNP2 Gear Pump

This pump is in between the 45 series pressure compensated pump and the dynex pump. It has a capacity of 10 GPM . The pump is connected to the water pump control valve on the right side of the top of the panel. This valve has a built in relief valve that is set at 2800 or 3000 psi.

Rotation Motor
The rotation motor is a Rexroth, or Sauer bent axis variable displacement motor. Maximum displacement is 160cc. Minimum displacement is adjusted by means of a screw on the underside of the motor so that the motor cannot turn faster than its maximum rated speed. At this speed the head turns at 1500 RPMs. While drilling the speed of the head can be adjusted by a pressure reducing valve on the panel. This valves pressure source is the foot clamp hose. As long as the foot clamp is open there is pressure in this hose so the pressure reducing valve will set the displacement of the main motor. As soon as the foot clamp is closed there will be no pressure in the footclamp hose, and therefore no pressure to the pressure reducing valve. There is also a check
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valve that connects the speed control hose to the clamp hose. Because of these circuits the drill head is automatically in slow speed whenever the footclamp is closed. This way the drill head will always have the maximum torque available for rod breaking, when the footclamp is closed. It is very important that if this motor is ever replaced the case is filled with oil before the motor is operated.

Hydraulic Chuck and Footclamp

The hydraulic chuck and footclamp are operated by a single lever on the main control panel. The pressure for this valve comes from the pressure compensated pump, through a check valve, which is there to keep the pressure on the valve constant even when there are momentary losses of pressure in this pump circuit due to sudden movements of the cylinder slow feed lever. The lever has three positions, in the middle position both the chuck and footclamp are closed , in the two side positions either the footclamp or the chuck is open. The footclamp hose also has a ball valve so that the footclamp can be locked open or closed.

Hydraulic Chuck Closing Line

There is a valve near the tank that gets pressure from the accumulator. A line from this valve goes to the piston rod end of the chuck release cylinders on the drill head. This line provides a constant 350 PSI to make the chuck release cylinders retract away from the hood while the chuck is closed.

Footclamp
The hydraulic footclamp is closed by gas pressure in the accumulator that is mounted near the winch in an aluminum pipe. The accumulator is charged with 1200 PSI of nitrogen. The normal operating pressure of the accumulator is 2400 PSI. The accumulator is charged to 1700 psi with oil from the single piston of the dynex pump, this pressure is controlled by a relief valve. The oil pressure in the accumulator gets up to a higher pressure, than this relief valve setting because of the surges of pressure due to the opening and closing of the footclamp. Oil is prevented from going out of the accumulator by a check valve. The 2400 PSI accumulator pressure pushes constantly on the pistons of the footclamp. When the footclamp is opened 2500 PSI is applied to the inner side of the two pistons. The pistons of the footclamp have a larger area on the opening side than the closing side of the piston due to the piston rods on the outside side being larger than the inner piston rod. Due to the larger area of the opening side of the piston the cylinder will open even though the pressure on the two sides of the piston is equal. Sometimes it is possible because of surges in the pump pressure or re setting of the pump pressure that the accumulator build up more than the system pressure. If this happens the foot clamp will not work and some oil will have to be drained from the accumulator to restore function, by loosening one of the hose fittings. This footclamp has some of the advantages of a spring operated footlamp (failsafe operation, only one hose required) and some of the advantages of a hydraulic one ( large operating range, less problem with corrosion, and compactness)

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Small Winch
Most of these machines are equipped with the small winch for hoisting drill rods into position. This winch is operated by a small 4 way 4 position valve on the left side of the panel. This valve gets its oil supply from the pressure compensated pump. The valve has a pressure relief valve screwed onto the port that is for hoisting. This way the strength of the winch is reduced so it will not pull too hard on the hoist line. Also if the driller forgets to put the valve in float as he should when drilling, this relief valve prevents the winch from locking which would also break the cable. This valve has a built in relief which normally is just screwed right in so that no oil will be relieved from the pressure compensated circuit.

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1. Instructions for Hooking up Hoses

Heat Exchanger
The heat exchanger has to have water running through it most of the time while the engine is running to keep the hydraulics cool. The water must not be under pressure. Usually the water supply line is run through the cooler before it goes into the water tank. Do not hook the heat exchanger to the waterswivel hose, the pressure will be too much.

Quick Disconnect fittings

Some of the hoses are connected by quick disconnect fittings. It is very important that these fittings are cleaned before plugging them together to prevent contamination of the hydraulic circuits. If the machine is going to be unitized it might be preferable to eliminate some of the quick disconnects particularly on the rotation circuit to avoid problems, and back pressure from the quick disconnects, or contamination of the system. On new machines we usually color code the various fittings with colored zap straps to make it easy to hook up the hoses the first time.

Foot Clamp
There is only one hose that connects dirrectly to the foot clamp. It is a 3/8 inch hose with a female quick disconnect fitting. It could be confused with one of the hoses for the hydraulic chuck except that it is a lot shorter and would not reach the chuck especially if the head was all the way up. There is also a hose that goes from the powerpack to the accumulator, which is mounted in the aluminum pipe near the winch. This hose has a special screw together quick disconnect that is the only one of this type on the machine. This type of connection is used because it can be connected and disconnected under pressure.

Drill Head
There are 6 hoses that have to be connected to the drill head. The two main rotation hoses are 1 inch hoses one with a 5,000 PSI pressure rating. The case drain line hooks on just below the main rotation hoses. It is a 5/8 inch hose. If this line is not installed the main rotation motor will be damaged. There are two 3/8 inch hoses for the chuck cylinders. A hose is used on the line for the displacement control on the top of the motor. All these hoses except the case drain and the two 1 hoses have quick disconnects. These hoses should be grouped together and held with bungee cords so that they can move freely when the head goes up and down.

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The Cylinder
Two separate hoses inch with quick disconnects are provided for the cylinder. The longer one should be used for the top fitting on the cylinder. Make sure they are hooked up so that they dont hook on anything when the cylinder goes up and down.

The Winch
Two separate hoses 5/8 inch by 10 feet long are provided for the winch. These hoses are also used for the lifting cylinder when adjusting the angle of the mast.

The Water Pump

Two hoses are provided to run the water pump. They are permanently screwed onto the power pack. Some water pumps may also require a case drain line going straight back to tank.

The Mud Mixer

If a mud mixer was provided by Hydracore it will have two 3/8 inch hoses permanently connected to it. The hoses are 3/8 inch and connect to the power pack on the right side just below the hydraulic tank. There are connections for two mixers.

The Whipple Pump

If a whipple pump is going to be used it can be hooked onto one of the mud mixer connections.

The Rod Hoist

Most of these machines are equipped with a small hoist for lifting the rods into position above the drill head. This winch has three lines, two 3/8 lines with quick disconnects and one case drain line that is directly screwed onto the winch.

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Maintenance of Hydracore 2000 Power Pack

The following maintenance intervals should be adhered to based on usage of two shifts per day, five or seven days a week, for maximum life of the hydraulic components.

Daily
The hydraulic oil level should be checked, the level should be checked only when the hydraulic cylinder is fully retracted (down). The level should be within the range of the sight level guage. Only clean oil from a closed container should be added. AW 32 hydraulic oil is recommended, but any good quality mineral based hydraulic oil can be used. If the oil goes down every day the leak should be located and fixed. The engine oil level should be checked, with the dipstick. The coolant level can be checked visually in the transparent reservoir. The fuel filter can be drained with the valve at the bottom to check for water in the fuel.

Weekly
Change the engine oil and oil filter. manufacturer. Use the oil recommended by the engine

Monthly
The hydraulic return filters and fuel filter should be changed.

Every Two Months

The hydraulic oil in the tank should be drained and replaced with fresh oil. The return filters should be replaced, and the high pressure filter.

Once a Year
The hydraulic pumps and the main hydraulic motor should be removed and sent to a qualified hydraulic repair shop for overhaul. The auxiliary hydraulic pump is a cheaper pump and it is probably cheaper to replace it than to repair it. While the pumps are off it would be a good time to check the condition of the drive coupling on the flywheel. Seal should be replaced in the main rams and the clamp cylinders. Also one year is the expected life of the main bearings in the drill head.

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Feed Frame Winch and Foot Clamp Daily

The whole drill should be washed every day to reduce the amount of dirt accumulating on the slides. The foot clamp should be greased as well as the winch.

As Required
If the hydraulic cylinder leaks it will have to be removed from the feed frame to replace the seals. Keeping the cylinder clean will reduce the wear on the seals. Metal shavings from the chuck jaws are particularly bad for the cylinder, they tend to fall out of the chuck when pulling rods. Using the proper sized hood bushing when pulling helps to prevent the rods dragging on the jaws. If the saddle has more than 1/8 free play, then plastic sliders need replacing. To do this the head will have to be removed and the saddle will have to be removed from the mast for new sliders to be inserted.

Drill Head Daily

The 3 grease nipples should be greased thin lithium based grease. The main head bearings are large and should have about six shots per shift. There is a hidden grease nipple that is only visible when the chuck is open it is on a seal ring, just under the yoke that opens the head this should be greased a few shots each shift. Keeping this seal well greased will prevent any water from entering the head bearings. The three grease nipples on the bowl that are for the jaws need to be greased with the chuck open as well, otherwise no grease can be forced in. The chuck will operate much better if this is not overlooked. Also one of the grease nipples at the top of the bowl should be greased.

Monthly
The tension in the drive belt should be checked. The belt should be adjusted so that there is at least 1/8 (3mm) of movement in the belt when the full force of all your fingers is applied to the back of the belt midway between the pulleys. The tension should be checked when the head is at operating temperature. ( On the aluminum head especially the expansion of the head when it is hot causes the belt to tighten) Operating with the belt very slack may damage the belt. Operating with the belt tight may break the motor shaft.

As Required
If the belt snaps it can be replaced by removing the two covers on the front of the head and unbolting the motor so that it can be tilted forwards. It may also help to To remove the front pulley flange, that is screwed into the pulley. If the bearings require
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replacement it is not necessary to remove the chuck. If the bearings are to be replaced on the job the easiest way to dismantle the head may be by using the machines hydraulic cylinder to remove the bearings. There are several ways of doing this. These are the steps I recommend. 1. Remove the covers belt and hydraulic motor. 2. Remove the chuck hood, opener yoke and cylinders. 3. Remove the 12 bolts from the nut on the bottom end of the main shaft then unscrew the nut, and remove the hardened washer behind it. 4. Install an HQ rod or NW casing in the footclamp with a sub to a smaller size rod screwed in the end. Have the end of this rod or casing sticking up out of the footclamp about 18. 5. Install a BQ or NQ rod bushing in the lower end of the main shaft 6. This will push the main shaft out the top of the head with the chuck still attached to the rod. The main pulley and the keys and maybe a spacer will drop out. Be carefull not to lose the keys Then unscrew the rod from the rod that is still in the footclamp. 7. Remove the cover plate that holds the bearings. 8. Find a sub that is just a bit bigger than the hole in the inner race of the bearings. 9. Screw the sub onto the rod which is sticking up from the footclamp, and them bring the head down again. The two bearings, and the inner and outer race spacers will be pushed out. 10. Re assembly is basically the opposite of the disassembly. It may be necessary to use the same subs as before, but with the rods turned upside down, so that the big part of the sub can be above the head to push the bearings back in first, and then the shaft. All the seals should be replaced along with the bearings. If the bearings are purchased locally make sure that they are the C3 fit bearings. These loser fit bearings have the greater axial load capacity required in this drill head. The head bearings are fitted fairly loosely to the shaft and are quite a loose fit in the housing. The bearings are prevented from spinning on the shaft by being clamped by the twelve bolts on the nut on the end of the shaft. By using many small bolts a lot of pressure is created without having to use a lot of torque on a huge nut. The bearing is clamped in the housing also by the pressure of the cover plate bolts. Greasing the outside and inside of the bearings helps with assembly. The bearings should be packed about half full of grease before installation. The hardest part of re assembly will likely be getting the shaft to go through the upper seal in the plate without displacing the spring on the seal. It may be easier to leave the plate loose and before the shaft is right down into the bearing the plate can be lifted into position, the seal checked and then the shaft pulled down the last bit into the bearings. To re install the pulley once it is started on the shaft it can be pulled in using the nut with the twelve bolts as pushers. Make sure the sealing ring goes behind the pulley and the hardened washer goes between the pulley and the nut with the twelve bolts. The washer is hardened so that the bolts will not dig into the washer. There is a total of at least 30,000 lbs of force on the twelve bolts.

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Operating Instructions Hydracore 2000

Serial Number 288 and up
The operating instructions will be split into two sections. The first section will explain the function and location of each of the controls and gauges. The second section will describe how the controls and gauges can be used to perform all the tasks to do with drilling.

Control Functions Controls

From the left to the right on the control panel these are the controls listed in order. 1. The foot clamp and hydraulic chuck valve, a small rotary handle, three positions. Turning the handle right, opens the chuck and closes the foot clamp. Turning the handle left, opens the foot clamp and closes the chuck. In the center position both the clamp and chuck are closed.

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2. The clamp lock valve is just below the foot clamp and chuck valve, on the front of the panel and can be used to lock the foot clamp open or closed. 3. Water pump fast lever. This is not as shown in the photo. It actually looks the same as valve 8. This valve should be used to make the water pump go extra fast for pumping the tube. It should not be used when drilling, except if just a bit more water is needed for example when drilling HQ. Using it while drilling will cause a loss of efficiency. The valve can then be run one two or three clicks open. Beyond that the feed pressure may be reduced. 4. The displacement control pressure reducing valve knob is above the mud mixer valve. Turning this knob in will increase the speed of the drill head and reduce the available torque. This valve is only functional when the foot clamp is open. Because of this the drill head will automatically be in the slow speed high torque mode, whenever a rod joint it being made up or broken. 5. The main rotation lever, vertical handle sticks out of the top of the panel. Out is forwards back is reverse. Moving the lever back slightly is slow reverse and up to 5000 PSI is possible. When the lever is moved back more then higher speeds are possible in reverse , but only up to the main relief pressure, which is set at 3000 PSI. The high pressure in reverse is set by the small relief valve that is just behind the main rotation lever. This was pre set at 5000 PSI and should not be tampered with. A separate guage is required to set this rod breaking pressure. 6. The winch lever, is vertical, four positions. Out is down, back is up. Back all the way is float. The lever is spring centered to neutral with a detent for float. 7. The cylinder fast feed valve, vertical handle, four positions, Out is down , back is up. Back all the way is float.

8. The water pump lever a black lever on the front of the panel controls pump speed. 9. The cylinder fine feed valve, controls the oil flow out of the cylinder in conjunction with the slow feed lever. 10. The cylinder slow feed lever, horizontal handle, controls the slow movement of the cylinder. It has four positions, all detented. 11. Engine throttle. 12. Engine stop Not Shown, to the left of 3 is the small winch control lever. This has 4 positions up down neutral and float.

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Not shown, on the left side of the drill low down, two mud mixer controls, the triconing valve, and the main pump by pass valve. Gauges From left to right A. The water pressure gauge. B. The Main pump pressure gauge, indicates the pressure of the main pump which indicates the drill head output torque. The normal range for drilling is 1500 to 2800 PSI. C. The cylinder pressure gauge, which is used to estimate bit weight. Every 1000 Lbs of cylinder off pressure is about 8000 Lbs of cylinder force. (when both cylinders are connected) D. Filter indicator gauge. This gauge should stay in the green area when drilling, once the oil has warmed up. If not the filter is clogged and should be renewed. E. The hydraulic reservoir temperature gauge, on the right side of the tank. The oil normally runs about 120 to 150 degrees F. The maximum allowable temperature is 180 degrees. The heat exchanger must have water flow at all times to keep the oil cool. If the reservior gets hotter than this maximum the cause will have to be determined and the problem fixed. Be carefull that if the Triconing valve is backed out all the way if it is not being used.

Drilling Tasks
These are the tasks that have to be performed to drill. 1. Positioning the drill. 2. Collaring the hole and anchoring. 3. Drilling a run. 4. Pulling the tube. 5. Pulling rods and putting them back in.

1. Positioning the drill

The drill has a lifting cylinder and double telescoping legs so that it can be lifted to and supported at any angle from vertical to 45 degrees. Before lifting the mast the rod rack, rod rack leg, and sheave wheel assembly should be bolted on, and the wireline cable threaded around all three sheave wheels. The sheavewheels should also be greased at this time. The sheave assembly has two positions, on that is for 10 foot tubes and the shorter one that is for 5 foot tubes. The rod rack also can be set up either for 10 foot or 20 foot pulls. Since the lifting cylinder is used only when positioning the drill, it is not provided with its own control valve.
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The hoses from the small winch can be connected to the lifting cylinder to set the angle. The mast raising cylinder has a restricted fitting to slow the raising and lowering of the mast. The drill head should be positioned at the bottom of its stroke while setting the angle. Once the angle is set the legs will have to be attached to the top of the mast with the 1 pins, and locked to the correct length with the clamps.

2. Collaring the Hole and Anchoring

When collaring the hole, drilling the anchor bolt holes, or pulling to change the bit it is helpful to be able to grab the corebarrel with the chuck. There is provision for this on this drill. Three 5 long bolts have been provided for the chuck bowl, the standard ones are only 4 long. By installing the 3 longer bolts the chuck will open enough to hold the corebarrel. Once you get used to this you will realize this is easier than the alternative methods.

3. Drilling a Run
There are several ways the controls can be used while drilling a run. First the tube must be locked and the water pump set to run at a suitable speed. In order to get the water pump to pump the tube really quickly the oil from the pressure compensated pump can be added to the pump circuit by using the water pump fast lever on the left side of the panel. The rods should be started turning gradually by pulling the rotation lever out. To start the feed the slow feed lever should be used in conjunction with the fine feed valve. The slow feed lever is pushed down one notch from neutral to feed the rods in. The cylinder has an initial surge when the slow feed lever is put into the down position. This lever also has a float position which can be useful to find the bottom of the hole, or on down holes where after a certain depth when there is no off pressure you can drill with the weight of the rods. In this float position the fine feed valve still controls the feed rate, and can still be used to hold the cylinder back. The cylinder fast feed lever also has a float but it is not much use for anything. If while drilling it is necessary to back up to ream the hole or to try to run over a block the machine can be backed up using the slow feed lever and fine feed valve on down holes. At the beginning of each run the rotation pressure with the rods off bottom turning at full speed should be noted so that once drilling commences you will know exactly how much torque pressure is being used at the bit. The bit torque pressure will remain in the same range right from the beginning to the end of the hole; only the torque to turn the rods will increase. Also at the beginning of each run note the cylinder pressure gauge reading before the bit is on bottom with the slow feed lever in the position you are using for drilling which may be down or float. This way the amount of off pressure can be

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noted once drilling commences, this will remain in the same range also right from the beginning to the end of the hole. Also every once in a while it is good to measure the penetration rate in inches per minute so that in combination with the pressure readings the performance of the bit can be judged.

4. Pulling the tube

The wire line winch is bolted onto the back of the skid so no mater what angle the hole is it can be left in the same position. The sheave wheel mast assembly fits on the top of the feed frame. There are three sheaves two at the top and one near the bottom. The wireline cable must be threaded around all three sheaves so that the force on the cable will pull straight on the long mast and not bend it. The mast can be telescoped so that pulling a 10 foot tube is possible, if only a 5 foot tube is used it can be left in the lower position. The winch is equipped with a float position which can be used when pumping the overshot. The float can also be used on down holes, once enough cable is out so that the weight of the cable will turn the winch fast enough in float. When the engine is wide open the main hydraulic pump provides too much oil for the winch. It is best to slow the engine down when pulling the tube. That way fuel, and wear is saved. Also this will reduce the heating of the hydraulic oil.

5. Pulling the rods and putting then back down.

For pulling rods a rod slide is provided that can be adjusted to support the end of the drill rod. For the rod clamp and chuck to work properly the drill must be lined up with the drill hole. Also to prevent problems caused by misalignment the proper sized guide bearing and hood bushing should be used. If the rods are not centralized between the footclamp jaws when it grabs them, it may not grab the rod well enough to prevent it dropping. Although the operation of the footclamp and head are not synchronized with the cylinder rod pulling is made easy by the simple layout of the controls. The foot clamp and chuck are both operated by the same lever, and in no lever position are both the foot clamp and chuck open at the same time. The only time when the rods could be dropped is when a rod joint has just been broken. If the foot clamp is opened after the rod joint is broken but before the drill head has been moved back forward the rods will be dropped. For breaking rod joints the machine has up to 1800 ft-lbs of torque available in reverse . While pulling or lowering rods it is best to leave the cylinder slow feed lever in the float position with the fine feed valve cracked open turn. The cylinder will work much more smoothly with the valve in this position. The engine will not have to work as hard. Also the head will follow the rod threads as they are screwing or unscrewing. To break rods the joint should be positioned

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about 3 feet behind the foot clamp. The clamp and chuck lever should be put in the center position so that both the clamp and chuck are closed, then the rotation lever can be put in reverse to break the rod joint. Oil at up to 5000 psi is provided by the Dynex pump when the rotation lever is pushed back a bit. When the lever is pushed back further the pressure available goes down , but the speed is faster. Caution; the drill head is screwed onto the spindle with a left hand thread which can come undone when a rod joint is broken especially when the drill is new or the chuck was recently overhauled. If the drill head does come unscrewed as long as it only came undone a few threads it can be quickly screwed back on by putting the machine in float and running the head forward fairly fast until the thread suddenly bottoms out. It is best if this is done with a rod in the clamp and chuck with no joint in between otherwise the rod joint will be excessively tightened. If the chuck comes unscrewed again, then tighten it a little more by screwing it on a little faster. The rod joint should be tightened slowly, with the fast feed lever in float, so that it doesnt get too tight when the joint bottoms out.

6. Triconing
Warning, using this valve can cause excessive heat, you will have to be carefull to make sure the temperature of the hydraulic oil remains below 180 degrees F. The drill in its standard drilling mode can only rotate at a minimum speed of 500 RPMs. This is too fast for Triconing, so a separate circuit is provided that can slow the rotation right down to 100 RPMs or less required for Triconing. To use this circuit the big ball valve on the side of the machine first has to be opened. This will bypass all the oil from the main pump back to tank. Then the Triconing valve, which is the small red valve on the left side of the machine will have to be screwed in a few turns. This bypasses some of the oil from the pressure compensated pump to the rotation circuit. This valve can only be adjusted when the machine is turned off, other wise it will be to stiff. Screw the triconing valve in the minimum amount that you need so that you have enough power. You should start triconing with the head speed control turned all the way out. Once you start Triconing the torque pressure should be between 1800 and 2500 psi. If the torque pressure is lower than 1800 PSI then it would be best if you turned the triconing valve out a bit and then speed the head up using the speed control to bring the torque up. This is mainly to reduce the amount of heat caused by the triconing valve. The valve will create more heat the more oil that is being pumped through it. If the pressure is being used it doesnt create heat, it is only when it is not being used. If you are not triconing, idle the engine down so less heat is caused, and keep looking at the temperature gauge. If it gets up to 180 degrees then turn the engine off, unscrew the triconing valve, turn the engine back on, and then the oil will quickly cool back down. Once the oil has cooled you can start drilling again. You may even find that the oil will cool down while you are advancing the bit and will heat up just while you are adding rods. It doesnt matter as long as the temperature remains below 180 degrees F.

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