Drill Rigs Australia MP1200 Multi-Purpose Drill Rig Operation and Maintenance Manual 2010

Description

Drill Rigs Australia MP1200 Multi-Purpose Drill Rig Operation and Maintenance Manual

This is the Drill Rigs Australia MP1200 Multi-Purpose Drill Rig Operation and Maintenance Manual, published under document number 11-DRA-02 Rev A and dated 2010. It is the working reference for the MP1200 truck-mounted multi-purpose drill rig, taking the operator and maintenance technician from daily pre-start checks through to engine and compressor operation, hydraulic system theory, rod handling with the Sandvik rod handler and Safe-T-Spin, drill string breakout, and fault isolation on the load-sensing hydraulic circuits.

Every section is written around the MP1200 as built – the CAT C18 DITA deck engine, the MAN TGS 41.480 8×8 carrier, the Sullair two-stage 500 psi air compressor, the DRA D1600 two-speed drive head and the Rexroth load-sensing pump and valve package that powers rotation, rapid feed, the haul and wireline winches and the auxiliary functions.

File Details

• Manual type: Operation & Maintenance Manual
• Brand: Drill Rigs Australia (DRA)
• Model: MP1200 Multi-Purpose Drill Rig
• Document number: 11-DRA-02 Rev A
• Date of issue: 2010
• Language: English
• Format: PDF
• Length: approximately 290 pages across 9 chapters and 9 appendices
• Coverage: operation, maintenance, drilling technique and troubleshooting

Chapters Covered

• Chapter 1 – Introduction: Purpose and Scope, Contact Addresses, Abbreviations, Reference Documents, Safety Summary
• Chapter 2 – Machine Safety: Drilling Safety Guide, Individual Protective Equipment, Housekeeping, Maintenance, Clearing Area, Start Up, Drilling Operations, Hoists and Hoisting, Batteries Fuels & Lubricants, Flushing Media Hazards, Fire and Explosion, Towing Drill Rigs
• Chapter 3 – Machine Specifications: General, Basic Dimensions, Carrier Specifications, Engine Specifications, Compressor Specifications, Feed System, Hydraulic System Specifications, Drill Functions, Cooling Fan & Fine Feed, Secondary Functions, Drive Head Gearbox, Water Injection, Lubricant Specification
• Chapter 4 – Preventative Maintenance: Export Shipments Advice, Daily/Weekly/Bi-Weekly/Monthly/500/1000/2000/4000 hour schedules, Adjustments & Normal Wear Inspection, Wire Rope Inspection and Maintenance, Hose Use & Replacement, Welding, Rig Storage
• Chapter 5 – Drilling Guidelines: Operator Responsibilities, Calculating Bit Weight, Air Rotary, Air Foam Rotary, Mud Rotary, Auger Drilling, Core Drilling, Down the Hole Hammer, Rotary Drilling
• Chapter 6 – Operating Guidelines: Pre-Start Check List, Engine Operation and Shut Down, Drill Rig Set-Up, Raising and Lowering the Mast, Auxiliary Functions, Feed System, Fine Feed, Back Ream, Rapid Feed, Wireline Winch, Haul Winch, Rotation, Water Pump, Hammer Oiler, Foam Injection, Rod Spinner
• Chapter 7 – Troubleshooting Guide: Engine, Electrical, Safety Circuit, Hydraulics, Control Panel, Tank & Filtration, Pumps and Pump Drive, Valves, Actuators, Cooling System, Load Sensing diagnostics
• Chapter 8 – Schematic Diagrams: Hydraulic Schematic, Electrical Schematic
• Chapter 9 – Compressor: General Description, Compression Principle, Oil Separation, Air Flow, Oil Flow, Control System, Start Up and Shut Down, System Controls, Maintenance, Troubleshooting, Removal of Compressor
• Appendix 1: Drilling Safety Guide
• Appendix 2: Rod Handler Guide (Sandvik UDR-KL Rod Handling System)
• Appendix 3: Rod Spinner Unit (Sandvik Safe-T-Spin Operation & Maintenance Manual)
• Appendix 4: LD Breakout Unit (Metzke MakorBreak LD Operation & Maintenance Manual)
• Appendix 5: Fan Control Module Operation & Maintenance Manual
• Appendix 6: DTH Hammers General Information
• Appendix 7: Sullair Compressor Operation & Maintenance Manual
• Appendix 8: Hydraulic Symbols
• Appendix 9: Engine Performance Data

What the MP1200 Manual Gives You

Taken as a whole, this manual is a single-source reference for the MP1200 rig. It opens with the safety framework – a Job Safety Analysis requirement before work starts, warnings on hydraulic pressures up to 350 bar, rotating drill string and spindle hazards, hydraulic fluid handling, and the compressed air and water flushing media hazards specific to this class of rig. From there it lays out the machine as delivered: dimensions, axle loads, mass, outrigger strokes, the D1600 drive head with its two gear ranges and torque/speed tables, the feed cylinder and rope arrangement with its 2:1 mechanical advantage, and the full hydraulic system breakdown by function and by pump.

Maintenance is handled by hour-based schedules rather than a generic list – 10, 50, 100, 250, 500, 1000, 2000 and 4000 hour intervals – each naming the component, compartment, task, lubricant type and quantity. Wire rope inspection and replacement criteria are treated in detail, including the broken-wire and diameter-reduction limits that mandate replacement, plus hose selection, installation, maintenance and safety guidance.

Drilling Guidelines and Operating Technique

Chapter 5 covers the operator’s role and responsibilities, how drilling performance affects the wider mining process, and how to calculate bit weight from the holdback gauge reading. It explains the force/area relationship of the feed cylinder, the annulus area calculation, and how the 2:1 rope advantage halves the force at the drive head. Drilling methods described include air rotary, air foam rotary, mud rotary, auger and core drilling, with down the hole hammer and rotary drilling techniques broken into step-by-step procedures covering rotation speed, holdback and downfeed equilibrium, hammer oiling and water injection.

Controls, Set-Up and Auxiliary Functions

Chapter 6 walks through the pre-start check list, deck engine starting with and without compressed air, normal and emergency shut down, raising and lowering the mast for vertical and angled drilling, mast dump, cabinet fold and unfold, and the auxiliary valve banks. It explains head slide, breakout, rod trough, foot clamp, slips table, bottom spanner and air tap operation, then covers the feed system controls in depth – fine feed direction and adjustment, bit weight gauge calibration, negative bit weight from water pressure, back ream pressure adjustment, rapid feed, wireline and haul winch control, and rotation pressure and speed trimming.

Diagnostics and Schematics

The troubleshooting chapter is organised by system: engine will not turn, engine turns but will not start, lack of full power, overheating, charging faults, fuses and circuit breakers, the safety circuit for electronic engines, and hydraulic faults including cavitation noise, cylinder creep, cylinder inoperative, slow feed inoperative and systems running hot. The load sensing section explains the LS pump, the M4 directional control valve and the HRC remote control, then gives pressure test sequences for no rotation in either direction, no rotation in one direction, and rotation that fails to develop maximum pressure. Hydraulic and electrical schematics close out the chapter set.

Rod Handling and Drill String Tooling

The appendices are substantial in their own right. The Sandvik UDR-KL Rod Handling System guide covers the control centre layout, tilt, slew, lift, clamp, tram, arm rotate and rod bin functions, with step-by-step loading and unloading procedures between the rod bin, support truck and rotation head. The Safe-T-Spin appendix covers installation, height adjustment, swing procedures, make-up torque pressure settings for B, N, H and HW rod sizes, and complete break out and make up sequences. The Metzke LD Breakout Unit appendix documents breakout mode and backup mode with the sequence changing valve positions, and the Fan Control Module appendix explains the temperature-driven fan speed logic with its default engine coolant, hydraulic oil and compressor oil thresholds.

Appendix 6 gives DTH hammer operating guidance including penetration rate charts for limestone and granite/basalt, recommended rotation speeds by bit diameter, and average tool life figures. Appendix 9 reproduces the CAT C18 industrial engine performance data with power, torque, fuel rate, heat rejection and emissions tables across the 1100 to 2100 rpm range.

One Thing to Know Before You Buy

This is a revision A document. A small number of sections – the machine layout, the rod spinner installation and removal steps, and the basic dimensions table – are marked in the original as still to be added or updated at the next revision. Everything else in the manual is complete as published.

Who This Manual Suits

It suits MP1200 operators working through start-up, mast set-up, drilling technique and shut-down; maintenance personnel carrying out the scheduled service intervals; and technicians diagnosing hydraulic, engine, compressor or rod handling faults. It is equally useful for training new crew on the machine, or for anyone maintaining a fleet of DRA rigs who needs the correct pressures, torque values, lubricant specifications and service intervals rather than a generic guide.

Because the manual is built around one specific rig, the specifications, part references and settings in it apply to the MP1200 as configured – the CAT C18 DITA engine, MAN TGS 41.480 8×8 carrier, Sullair 0225 0119-827 compressor, DRA D1600 drive head and Rexroth load-sensing hydraulic package. Getting the downfeed and holdback settings, make-up torque pressures and wire rope replacement limits right is what keeps a rig productive and keeps crews safe, and those are exactly the values this document supplies.

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Instant PDF Delivery

The MP1200 Operation and Maintenance Manual is delivered as a PDF download immediately after payment. There is no shipping and nothing to wait for – the file opens on a workshop laptop, a tablet on the drill deck or a phone in the field, and any page or section you need can be printed and taken to the machine. Whether you are chasing a single torque figure during a rod change or working through a full 250 hour service, the answer is a few clicks away.