Geax XD5 User manual

MAINTENANCE MANUAL
Rev. 01/17
GEAX s.r.l.
XD5

Serial number:
020J005X
GEAX s.r.l
via Campoceraso 13
60027 Osimo (AN)
ITALY
Tel. [phone]
Fax [phone]
www.geax.it [email protected]

GEAX s.r.l. Chapter 1
GENERAL INFORMATION ABOUT MAINTENANCE ON THE DRILLING M.
1-1
Chapter 1
GENERAL INFORMATION ABOUT MAINTENANCE ON THE DRILLING
MACHINE
1.1 Organisation of maintenance operations on the drilling machine.
1.1.1 Foreword
This manual is to inform operators about the specific characteristics of the
drilling machine and intervention methods. The purpose is to keep the
machine in perfect working order, reliable and safe in operating conditions.
The manual highlights potentially dangerous situations and the procedures to
reduce the risks connected to the maintenance operations.
1.1.2 Characteristics of the personnel in charge of maintenance
The personnel in charge must have previous experience in the field of
mechanical maintenance and know the general safety regulations. Before
performing any operation on the drilling unit of the machine one must read the
“XD5 MAINTENANCE MANUAL” and only then, after having understood the
contents, one can proceed. For operations not described in the manual or if
unsure about the meaning of the contents, one must contact GEAX s.r.l..
For interventions on the tracked undercarriage refer to the JCB manual
1.1.3. Symbols used in this manual
Danger (or other) signs are used in various points of the manual to call the
reader’s attention to issues regarding potentially more dangerous activities..
Situation, procedure, context or other factor that can lead to increased risk.
Situation, procedure, context or other factor that can lead to increased risk of
electrocution.
Situation, procedure, context or other factor that can lead to increased risk of
getting caught and dragged by rotating parts.
Situation, procedure, context or other factor that can lead to increased risk of
fire.
Situation, procedure, context or other factor that can lead to increased risk of
burns from contact with parts that reach high temperatures during operation.

GEAX s.r.l. Chapter 1
GENERAL INFORMATION ABOUT MAINTENANCE ON THE DRILLING M.
1-2
Situation, procedure, context or other factor that can lead to increased risk of
intoxication or poisoning by harmful substances.
Situation, procedure, context or other factor that can lead to increased risk of
intoxication or poisoning by harmful substances.
Situation, procedure, context or other factor that can lead to increased risk of
being burnt by corrosive substances.
Situation, procedure, context or other factor that can lead to increased risk of
loss of balance and falling.
Situation, procedure, context or other factor that can lead to increased risk of
being hit by suspended loads falling.
Improving safety measures is a never-ending task; should you encounter a
potentially dangerous situation that is not adequately covered in this manual,
please let us know.
1.1.4 General summary diagram
Maintenance
on non urgent
faults B2
Maintenance
on urgent
faults B1
Maintenance
according to the
condition A2
Periodic
Maintenance A1
Non Scheduled
Maintenance B
Scheduled
Maintenace A
Fault
signaling by
the operator
Maintenance
on the drilling
machine
GEAX
PRIORITY
fig.1.1.4.1
•The activities indicated with the letter A are those connected with the
consumption/wear of materials, components, fluids;
•the activities indicated with the letter B are those connected with the
malfunction/breakage of a component: if they are type B1 they require
machine downtime and urgent intervention, if they are type B2 one can
complete the work session by adopting appropriate measures.

GEAX s.r.l. Chapter 1
GENERAL INFORMATION ABOUT MAINTENANCE ON THE DRILLING M.
1-3
1.2 Interventions to adapt the drilling machine to new specifications.
1.2.1 Interventions to adapt the drilling machine to special work requirements.
Interventions to adapt the drilling machine to special work requirements must
necessarily be implemented by GEAX s.r.l..
Any changes made by the customer to the machine will void any warranty
and relieves the manufacturer GEAX s.r.l.. from any type of responsibility in
relation to machine operation.

GEAX s.r.l. Chapter 2
DRILLING MACHINE SCHEDULED MAINTENANCE
2-1
Chapter 2
DRILLING MACHINE SCHEDULED MAINTENANCE
2.1 General information concerning scheduled maintenance
2.1.1 Scheduled maintenance operations
This refers to periodic maintenance operations with or without replacement of
parts or fluids. The frequency is related either to the period of effective
operation of the machine, marked by the relevant "hour counter" instrument
on board, or to the time elapsed regardless of the use of the machine. This
last aspect is due to the fact that the chemical and physical characteristics of
the materials change over time, regardless of effective operation.
2.1.2 Scheduled operations for replacing parts
This refers to periodic maintenance operations with the replacement of parts
or fluids at the end of their life cycle. It is necessary to replace parts when
visual inspection is difficult or impossible and a possible fault could cause
knock-on damage.
Fluids in general and especially lubricants are subject to changing their
chemical and physical characteristics and therefore suffer a deterioration in
performance.
2.1.3 Disposal of damaged parts and used fluids
Such used parts and fluids cannot be disposed of in the environment and
should be taken to waste collection centres in compliance with the regulations
in force in the country where the machine operates.

GEAX s.r.l. Chapter 2
DRILLING MACHINE SCHEDULED MAINTENANCE
2-2
2.2 Scheduled lubrication
2.2.1 Scheduled lubrication operations with grease
The machine features a series of isolated points where lubrication must be
made manually, as they are not equipped with pressurised circuits. These
points feature a connection for the lubricator.
TYPE OF LUBRICATION GREASE
GREASE
TYPE
DESCRIPTION
TECHNICAL DATA
A
Agip GR MU 2
Iso
DIN 51825
NLGI consistency
2
Manipulated penetration
280
dmm
ASTM dropping point
120
°C
Base oil viscosity at 40°
103
mm2/s
B
Agip GR MU EP 2
Iso
DIN 51825
L-X-BCHB2
KP2K-20
NLGI consistency
2
Manipulated penetration
280
dmm
ASTM dropping point
185
°C
Base oil viscosity at 40°
160
mm2/s
C
Agip Rocol Wire Rope Dressing
Appearance
Semi-fluid black grease
NLGI consistency
00
Penetration (IP50)
420450
dmm
Molybdenum disulphide
3
%
Base oil viscosity at 40°
465
mm2/s
tab.2.2.1.1

GEAX s.r.l. Chapter 2
DRILLING MACHINE SCHEDULED MAINTENANCE
2-3
fig.2.2.1.2
LUBRICATION INTERVENTIONS FREQUENCY
LUBRICATION
POINT
DESCRIPTION OF INTERVENTION POINTS
INTERVENTION
FREQUENCY
[hours]
TYPE OF
GREASE
NOTES
1
Swing post (2 point)
600
A
2
Swing post cylinder (2 points)
600
A
3
Pull-push hydraulic cylinder (2 points)
600
A
4
Rotary slewing ring (2points)
50
B
5
Rotary gears (2 points)
200
B
6
Sliding guides (8 points)
50
A
+ every wash with
pressure washer
7
Swivel bearing (1 point)
50
B
8
Kelly guide
50
A
To be done with a
brush
Main winch rope
200
C
During slow descent
of the kelly bar into a
rather deep hole
Auxiliary winch rope
600
C
By unwinding it
without letting it touch
the ground
tab.2.2.1.3

GEAX s.r.l. Chapter 2
DRILLING MACHINE SCHEDULED MAINTENANCE
2-4
2.2.2 Operations relating to the replacement of lubrication / hydraulic oils
First of all:
•operate when the components are not hot;
•provide a container to collect the lubricant drained from the machine and
for any leakage during the loading stage;
•wear impermeable gloves;
•work in a ventilated area;
•bear in mind that used lubricant is toxic therefore handle with care and
rinse immediately with soap and water if it comes into contact with eyes or
parts of the body;
•work in absence of open flames;
2.2.3 Winch gear unit scheduled lubrication operations
The lubricant of the winch gear unit must be replaced at a frequency shown in
tab. 2.2.3.1-2
MAIN WINCH GEAR UNIT LUBRICATION Brevini BWF 2000
LUBRICATION DESCRIPTION
Replacement
frequency
[hours]
Quantity
[c.c]
AGIP ROTRA MP 80W-90
API GL5
2000
350
tab. 2.2.3.1
AUXILIARY WINCH GEAR UNIT LUBRICATION Brevini DW 090
LUBRICATION DESCRIPTION
Replacement
frequency
[hours]
Quantity
[c.c]
AGIP ROTRA MP 80W-90
API GL5
4000
150
tab. 2.2.3.2
Alternatively one can consult the manufacturer manual to find equivalent lubricant
producers
2.2.4 Hydraulic circuit oil periodic replacement
For this operation refer to the manual of the JCB excavator.
2.2.5 Periodic replacement of the internal combustion engine lubricant
For this operation refer to the manual of the JCB excavator.

GEAX s.r.l. Chapter 2
DRILLING MACHINE SCHEDULED MAINTENANCE
2-5
2.2.6 Management of all waste fluids drained from the machine
Such fluids cannot be disposed of in the environment and should be taken to
waste collection centres in compliance with the regulations in force in the
country where the machine operates.
2.3 Scheduled checks on ropes and pulleys
2.3.1 Visual inspection of ropes
The machine is equipped with two winches and relative ropes:
•the main winch for telescopic Kelly bar sliding;
•the auxiliary winch for lifting the machine accessories or elements related to
making the hole;
The tables below illustrate the frequency and methods for checking
the ropes.
Main winch rope inspection
Diameter 9 mm
Operation
Frequency
[hours]
Diameter
[mm]
Visual inspection with the mast in transport position of the
section of rope from the winch to the swivel and rope terminal.
This last part can get damaged more easily in the event of
operating abnormalities of the swivel.
at the
beginning
of each
work shift
Inspection of the entire rope while making a hole; when the hole
has been completed, one must check the descent of the Kelly
bar into the hole at low speed, inspecting the rope closely during
the rotation of the winch drum.
If one finds worn points measure the diameter, with the engine
off, (it must not fall below more than 7% of the nominal value);
200
>8.4
If one finds anomalies in shape or broken wires, refer to paragraph 3.2.1
tab.2.3.1.1

GEAX s.r.l. Chapter 2
DRILLING MACHINE SCHEDULED MAINTENANCE
2-6
Inspection of the auxiliary winch rope
Diameter 7 mm
Operation
Frequency
[hours]
Diameter
[mm]
Inspection with the mast in transport position of the section of
rope from the winch to the rope terminal.
at the
beginning
of each
work shift
Check the entire rope with the mast tilted; by unwinding the rope
and keeping it taught so that it does not touch the ground.
If one finds worn points measure the diameter (it must not fall
below more than 7% of the nominal value).
200
>6.5
If one finds anomalies in shape or broken wires, refer to paragraph 3.2.1
tab.2.3.1.2
One must measure holding the gauge in the position indicated on the right in
fig.2.3.1.3 .
fig.2.3.1.3
In the event an anomaly is detected, refer to paragraph 3.2.1.
In any case, if the anomaly is not considered serious enough to replace the
rope, the inspection interval must be reduced accordingly.

GEAX s.r.l. Chapter 2
DRILLING MACHINE SCHEDULED MAINTENANCE
2-7
2.3.2 Pulleys scheduled inspection
The pulleys are made of synthetic composite material and are subject to
wear. The table tab.2.3.2.1 indicates the inspection frequency.
Pulleys inspection
Operation
Frequency
[hours]
Inspection, with the mast tilted, of the integrity of the pulleys of
the main winch.
at the beginning of each
work shift
Inspection, with the mast tilted, of the integrity of the pulleys of
the auxiliary winch.
at the beginning of each
work shift
Size inspection of all pulleys according to the tolerances of tab.
2.3.2.2
200
tab.2.3.2.1
Pulley grooves dimensions
Main Winch Pulley
Condition:
new
A= 13,5 [mm]
Condition:
maximum wear C
A+c= 15,5 [mm]
Auxiliary Winch Pulleys
Condition:
new
A= 11 [mm]
Condition:
maximum wear C
A+c= 12,5 [mm]
tab.2.3.2.2

GEAX s.r.l. Chapter 2
DRILLING MACHINE SCHEDULED MAINTENANCE
2-8
2.4 Scheduled inspection of bolts tightness
2.4.1 Inspection of tightness torque of component bolts.
Due to the vibrations and adjustments that may cause loosening, should
periodically check the tightening of the bolts of the main components. The
table tab.2.4.1.2 supplies the indications and frequency. The table tab.2.4.1.3
supplies the tightening torque according to the dimensions.
fig.2.4.1.1

GEAX s.r.l. Chapter 2
DRILLING MACHINE SCHEDULED MAINTENANCE
2-9
FREQUENCY OF BOLT TIGHTENING OPERATIONS
Position
NUTS AND BOLTS
fig.2.4.1.1
DESCRIPTION
FREQUENCY OF
INTERVENTION
[hours]
SELF-LOCKING
NUT
CLASS
1
Slewing ring fixing bolts (outer side)
Slewing ring fixing bolts (inner side)
200
No
Yes
10.9
2
Main Winch fixing bolts
200
No
10.9
3
Main Winch fixing bolts
200
Yes
10.9
4
Auxiliary Winch fixing bolts
200
No
10.9
5
Auxiliary Winch fixing bolts
200
Yes
10.9
6
Rotary box structure fixing bolts
200
Yes
10.9
7
Rotary motors fixing bolts
200
No
12.9
tab.2.4.1.2

GEAX s.r.l. Chapter 2
DRILLING MACHINE SCHEDULED MAINTENANCE
2-10
Ø screw hexagon
mm Nm Nm Nm
4.9 6.9 8.3
6.0 8.5 10
8.5 12 14
10 15 18
14 20 24
17 24 29
20 29 34
25 35 42
40 57 68
50 70 84
69 97 116
85 119 143
110 154 185
135 190 228
128 240 287
212 298 357
235 330 397
290 402 490
332 467 561
413 580 697
454 639 767
568 798 958
574 808 969
714 1,004 1,204
840 1,181 1,418
1,050 1,477 1,772
1,146 1,611 1,933
1,429 2,009 2,411
1,549 2,179 2,614
1,941 2,729 3,275
1,997 2,809 3,370
2,497 3,511 4,213
2,584 3,633 4,360
3,242 4,559 5,471
3,203 4,504 5,404
4,011 5,640 6,768
Screws tightening torques
DIN 267
thread
pitch
8.8
10.9
12.9
M5
M6
M7
M8
M12
M14
M10
M16
M18
M20
M22
M24
M27
M30
M33
M36
M39
M42
8
10
11
13
17
19
22
24
27
30
34
36
41
46
50
55
60
65
0,8
1,0
1,0
1,25
1,5
1,75
2,0
2,0
2,5
2,5
2,5
3,0
3,0
3,5
3,5
4,0
4,0
4,5

mm
eur
tab.2.4.1.3

GEAX s.r.l. Chapter 2
DRILLING MACHINE SCHEDULED MAINTENANCE
2-11
2.5 Mast guide clearance inspection
2.5.1 Mast guide slide consumption check.
fig.2.5.1.1

GEAX s.r.l. Chapter 2
DRILLING MACHINE SCHEDULED MAINTENANCE
2-12
Tolerance
notes
A+A’
0÷1
[mm]
Measurement in points
1,2,3 and 4
B+B’
0÷1
[mm]
Measurement in points
1,2,3 and 4
tab.2.5.1.2
The measurements indicated in tab.2.5.1.2, can be verified using a thickness
gauge. One must not measure close to the edge (where consumption is
higher) but at a certain depth (dotted area fig.2.5.1.1).
In the event of deviation from the above measurements, bring the values
back to the tolerance range using the relevant shims.

GEAX s.r.l. Chapter 3
MAINTENANCE ACCORDING TO THE CONDITIONS OF THE DRILLING M.
3-1
Chapter 3
MAINTENANCE ACCORDING TO THE CONDITIONS OF THE DRILLING
MACHINE
3.1 General information concerning maintenance according to the
conditions of the drilling machine.
3.1.1Non-scheduled maintenance operations
This refers to the operations that are carried out when certain
situations/conditions occur on the drilling machine, regardless of the work
time. Such anomalies appear during scheduled inspections on the machine or
during operation. They may relate to the replacement of parts or to the
adjustment or setting to compensate for normal wear. The diagram in
fig.1.1.4.1 shows A2 class activities.
3.2 Maintenance on ropes according to the conditions of the drilling
machine.
3.2.1 Conditions requiring the replacement of the rope or intensification of
inspections
While inspecting the rope one must check:
a) the diameter of the rope;
b) the amount of broken or extremely worn wires;
c) the presence of any anomalies in shape and/or damages
and/or localised wear.
The replacement must be immediate in the following conditions
(standard ISO 4309/90):
aa) if the diameter is lower than 93% of the initial nominal diameter (even in
just one point); consult par. 2.2.2.2 for further details;
bb) if the amount of broken wires in the most worn section exceeds one of the two
values indicated in the table tab. 3.1.2.1; in the count one must also consider
the wires which due to wear are lower than 50% of the initial section;
main winch rope
Broken wires every 6d
(54mm)
Broken wires every 30d
(270mm)
9
1
2
auxiliary winch rope
Broken wires every 6d
(42mm)
Broken wires every 30d
(210mm)
7
1
2
tab. 3.1.2.1

GEAX s.r.l. Chapter 3
MAINTENANCE ACCORDING TO THE CONDITIONS OF THE DRILLING M.
3-2
cc) if cases such as those below occur, according to standard ISO 4309/90;
the pictures are taken from the Teci manual

GEAX s.r.l. Chapter 3
MAINTENANCE ACCORDING TO THE CONDITIONS OF THE DRILLING M.
3-3