Hutt HBR 204 Manual

Drill rig
HBR 204
Operation and maintenance instruction
manual
(Translation of the original instructions)

Hütte Bohrtechnik GmbH authorisation
Any repairs for warranty require prior authorisation from Hütte Bohrtechnik GmbH. The authorization number must appear on the repair order.
HÜTTE BOHRTECHNIK GmbH
Ziegeleistraße 36
D-57462 Olpe / Biggesee - GERMANY
Tel. [phone] / 9644-0
Fax [phone] / 63852
E-mail: [e-mail]
Web site: www.casagrandegroup.com

WARRANTY CLAIM
Hütte Bohrtechnik GmbH authorisation
Any repairs for warranty require prior authorisation from Hütte Bohrtechnik GmbH. The authorization number must appear on the repair order.
[phone]
[e-mail]
Date:
__________________
CLIENT
Company name
Address
(country, city, zip code)
Applicant’s name
| | @
EQUIPMENT
Model
Serial number
Date of failure
Hours of operation at
the time of the failure
Job site address
FAILURE DESCRIPTION
Effects of the failure on the machine
Failure type
101 Machine standstill
201 Electric failure
102 Irregular working
202 Electronic failure
103 Oil leakage
203 Hydraulic failure
104 Faulty components
204 Diesel engine failure
105 Overheating
205 Mechanical failure
106 Poor maintenance
206 No failure
107 Machine overturning
207 Peumatic failure
108 Structural failure
208 Radio control failure
109 Wear
209 Other failure
Detailed description of the effects and of the
cause (if known) of the failure
Detailed description of the correction
For internal (Casagrande group) use only
Subject to warranty? Yes No Reasons:_______________________________________
Further reports: ______________________________________________________________________
Further actions:_______________________________________________________________________

Hütte Bohrtechnik GmbH authorisation
Any repairs for warranty require prior authorisation from Hütte Bohrtechnik GmbH. The authorization number must appear on the repair order.

CORRECT TRANSLATIONS
THIS DOCUMENT IS THE PROPERTY OF HÜETTE BOHRTECHNIK GMBH - TOTAL OR PARTIAL REPRODUCTION IS PROHIBITED
CORRECT TRANSLATIONS
Huette GmbH agrees to translate this document in the best possible way. To help us to
continuously improve the service we offer, we kindly ask you to notify us if anything has been
translated badly, if there are any incorrect terms, or anything else..
Please send this information by Fax or email, specifying the text which is unclear, the reason
why it is unclear and the correct text..
[phone]
[e-mail]
This information will be taken into careful consideration. If any amendments are made to the
document , a corrected version will be sent out..

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GENERAL INFORMATION
OPERATION AND MAINTENANCE INSTRUCTION MANUAL HBR204-MU-6-eng.doc
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GENERAL INFORMATION
This operation and maintenance instruction manual accompanies the machine produced by
Hütte Bohrtechnik GmbH. This manual must be kept in a suitably protected location inside the
cab and it must be available for consultation at all times.
The machine is designed and manufactured to ensure long-lasting reliability and operation
provided it is used as set forth in this manual and in consideration of all safety instructions.
All constructional elements, connection and control parts, have been designed and
manufactured with a degree of safety so that they can withstand stress which is abnormal or
greater than those set forth in this manual.
The machine undergoes regular testing prior to delivery. Proper operation of the machine over
time is contingent upon proper use and adequate preventive maintenance as set forth in the
instructions of this manual.
WARNING!
Before using the machine and before working on it, this manual must be read carefully,
and warnings and instructions contained herein must be understood; it is especially
important to adhere to all instructions contained in the chapter “SAFETY
INFORMATION”.
WARNING!
It is prohibited to use the machine differently than indicated in this manual or in
conditions different than those set forth in this manual.
Hütte Bohrtechnik GmbH shall not be held liable for breakdowns, failures or accidents
caused by using the machine in a manner which is different from that set forth in this
manual or in conditions which are different from those set forth in this manual.
WARNING!
It is prohibited to tamper with, alter or modify the components, systems and equipment
of the machine, especially the guards provided to protect persons.

GENERAL INFORMATION
HBR204-MU-6-eng.doc OPERATION AND MAINTENANCE INSTRUCTION MANUAL
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I
TABLE OF CONTENTS
OPERATION AND MAINTENANCE INSTRUCTION MANUAL HBR204-MU-6-eng.doc
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TABLE OF CONTENTS
1. FOREWORD...........................................................................................................1
1.1. Foreword................................................................................................................................ 1
2. TECHNICAL CHARACTERISTICS...................................................................3
2.1. General................................................................................................................................... 3
2.2. Field of application................................................................................................................ 5
2.3. Basic machine........................................................................................................................ 8
2.4. Propulsion unit....................................................................................................................... 9
2.5. Hydraulic system................................................................................................................. 10
2.6. Electrical and electronic system .......................................................................................... 11
2.7. Mast..................................................................................................................................... 12
2.8. Rotary head.......................................................................................................................... 14
2.9. Clamps................................................................................................................................. 15
2.10. Application on rotary head.................................................................................................. 16
2.11. Winch................................................................................................................................... 17
2.12. Stabilizing the machine ....................................................................................................... 20
2.13. Equipment with setups......................................................................................................... 21
2.14. Dimensions.......................................................................................................................... 23
2.14.1. Parking and transportation configuration ............................................................................ 23
2.14.2. Configuration with mast in vertical position ....................................................................... 24
2.14.3. Working range..................................................................................................................... 25
2.15. Stability................................................................................................................................ 28
2.15.1. General conditions of use .................................................................................................... 28
2.15.2. Parking configuration.......................................................................................................... 30
2.15.3. Setup with mast with gear motor......................................................................................... 31
2.15.3.1. Mast in basic configuration................................................................................................31
3. SAFETY INFORMATIONS................................................................................34
3.1. Foreword.............................................................................................................................. 34
3.2. Staff ..................................................................................................................................... 35
3.3. Limitations of use of the machine ....................................................................................... 40
3.4. Work area ............................................................................................................................ 42
3.5. Vibrations and sound level.................................................................................................. 51

II
TABLE OF CONTENTS
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3.6. Oil, grease and anti-freeze....................................................................................................53
3.7. Safety devices.......................................................................................................................55
3.8. Operation..............................................................................................................................63
3.9. Maintenance.........................................................................................................................69
3.10. Assembly and disassembly ..................................................................................................76
3.11. Transport ..............................................................................................................................77
3.12. Spare parts............................................................................................................................78
4. OPERATION ........................................................................................................ 79
4.1. Foreword ..............................................................................................................................79
4.2. Operator position..................................................................................................................81
4.2.1. Radio remote control (A) (positioning, work, machine movement).................................... 81
4.2.2. Control panel (B) (Start-up, adjustments, controls)............................................................. 82
4.2.3. Wired remote control (C)..................................................................................................... 83
4.2.4. Radio remote control (D) - Device for lifting rods and casing pipes (optional).................. 84
4.3. Command and control devices.............................................................................................85
4.3.1. Control panel (start-up, adjustments, controls).................................................................... 85
4.3.2. Radio remote control (work, machine movement).............................................................. 89
4.3.3. Radio remote control - Device for lifting rods and casing pipes (optional) ........................ 92
4.3.4. Manual emergency controls................................................................................................. 93
4.3.5. Wired remote control........................................................................................................... 95
4.4. Electronic control system.....................................................................................................97
4.4.1. General description.............................................................................................................. 97
4.4.2. Initial page........................................................................................................................... 98
4.4.3. Page “MENU” ................................................................................................................... 101
4.4.3.1. Diesel engine (ENGINE).................................................................................................102
4.4.3.2. Jet grouting (SETUP) ......................................................................................................106
4.4.3.3. Machine setup (SETUP MACC.) ....................................................................................108
4.4.3.4. Parameters (PARAM)......................................................................................................110
4.4.3.5. Black box (BLACK BOX) ..............................................................................................111
4.4.3.6. Display setup (SETUP DISPLAY)..................................................................................114
4.4.3.7. Management page and pump check (P1 - P2….).............................................................115
4.4.3.8. General information.........................................................................................................116
4.4.3.9. Page service (general information) (emergency conditions) ...........................................116
4.4.4. Page “SERVICE” .............................................................................................................. 118
4.4.4.1. Checking the outputs (OUTPUT)....................................................................................119
4.4.4.2. Checking the inputs (INPUT)..........................................................................................120
4.4.4.3. Diesel engine ...................................................................................................................120
4.4.4.4. Check the command and control devices.........................................................................121
4.4.5. Page “Warning and alarm messages” ................................................................................ 122

III
TABLE OF CONTENTS
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4.4.6. Machine password............................................................................................................. 123
4.4.7. Stopping the machine ........................................................................................................ 124
4.4.8. List of alarm codes ............................................................................................................ 125
4.4.9. Historical list of general operating anomalies (Black Box)............................................... 130
4.5. Start-up .............................................................................................................................. 132
4.5.1. Checks before starting the diesel engine ........................................................................... 132
4.5.2. Diesel engine start-up........................................................................................................ 134
4.5.3. Emergency starting............................................................................................................ 135
4.5.3.1. Starting with jumper leads...............................................................................................135
4.5.3.2. Starting with emergency starter .......................................................................................136
4.5.4. Checks after starting the diesel engine .............................................................................. 137
4.5.5. Activation of hydraulic controls........................................................................................ 138
4.5.6. Activation of radio control ................................................................................................ 139
4.6. Diesel engine ..................................................................................................................... 141
4.7. Machine movement ........................................................................................................... 144
4.7.1. Radio remote control......................................................................................................... 144
4.7.2. Wired remote control......................................................................................................... 147
4.8. Positioning the machine..................................................................................................... 149
4.8.1. Stabilizing the machine ..................................................................................................... 149
4.8.1.1. Radio remote control .......................................................................................................150
4.8.1.2. Wired remote control.......................................................................................................152
4.8.2. Mast positioning................................................................................................................ 154
4.9. Work.................................................................................................................................. 157
4.9.1. Rotary head movement...................................................................................................... 159
4.9.2. Head rotation ..................................................................................................................... 162
4.9.3. Rotary head side movement............................................................................................... 165
4.9.4. Winch ................................................................................................................................ 166
4.9.5. Telescopic and rotating jib ................................................................................................ 167
4.9.6. Clamps............................................................................................................................... 168
4.9.7. Commands and controls for accessories............................................................................ 169
4.10. Deactivation electrical safety limit switches..................................................................... 171
4.11. Device for lifting rods and casing pipes............................................................................ 172
4.11.1. Foreword............................................................................................................................ 172
4.11.2. General description............................................................................................................ 174
4.11.3. Limits of use of lifting device............................................................................................ 175
4.11.4. Activation of radio control ................................................................................................ 175
4.11.5. Deactivation of radio remote control................................................................................. 176
4.11.6. Controls on radio remote control....................................................................................... 177
4.11.7. Loading rods and casing pipes on the machine ................................................................. 178
4.11.8. Unloading rods and casing pipes from the machine.......................................................... 181
4.11.9. Loading rods onto the machine ......................................................................................... 183
4.11.10. Unloading rods from the machine .................................................................................. 184

IV
TABLE OF CONTENTS
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4.12. Stop ....................................................................................................................................185
4.13. Operating notes ..................................................................................................................186
4.13.1. Foreword............................................................................................................................ 186
4.13.2. Drilling with single rod...................................................................................................... 187
4.13.3. Drilling with rod and casing .............................................................................................. 188
4.13.4. Jet grouting ........................................................................................................................ 193
5. MAINTENANCE................................................................................................ 195
5.1. Foreword ............................................................................................................................195
5.2. Tightening torque...............................................................................................................197
5.3. Basic machine ....................................................................................................................198
5.3.1. Scheduled maintenance...................................................................................................... 198
5.3.2. Special maintenance .......................................................................................................... 235
5.3.2.1. Special checks of ropes....................................................................................................235
5.3.2.2. Filling and cleaning fuel tank ..........................................................................................238
5.3.2.3. Cleaning/washing the machine........................................................................................239
5.3.2.4. Flexible pipes (hoses) ......................................................................................................239
5.3.2.5. Track chain......................................................................................................................240
5.3.2.6. Device for lifting rods and casing pipes (optional)..........................................................241
5.3.2.7. Mast with gear motor (DM 300 –150 kN) –Replacement of worn chain ......................242
5.3.2.8. Mast with gear motor (DM 300 –150 kN) –Replacement of broken chain ...................243
5.3.2.9. Mast with gear motor (DM 300 –150 kN) –Reduction of number of chain links..........244
5.3.2.10. Adjustment of wired safety system on mast ....................................................................245
5.3.2.11. Warnings for using the machine in oxidising environments............................................246
5.4. Rotary head ........................................................................................................................247
5.5. Replenishments ..................................................................................................................248
6. TRANSPORT...................................................................................................... 256
6.1. General standards...............................................................................................................256
6.2. Loading on trailer (movement of the machine)..................................................................259
7. DISPOSAL........................................................................................................... 260
7.1. Disposal..............................................................................................................................260

1
FOREWORD Foreword
OPERATION AND MAINTENANCE INSTRUCTION MANUAL HBR204-MU-6-eng.doc
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1. FOREWORD
1.1. Foreword
Contents of manual:
- Information regarding technical features of the machine;
- Information on risks and safety instructions;
- Instructions for correct use and functioning of the machine;
- instructions for correct machine maintenance;
-instructions for correct transportation of the machine;
Enclosed documents:
- diesel engine: instructions manual and spare parts catalogue;
- radio remote control: instructions manual and spare parts catalogue;
- rotary heads: instructions manual and spare parts catalogue;
- service crane (if included): instructions manual and spare parts catalogue.
- sludge pump (if included): instructions manual and spare parts catalogue.
- water pump (if included): instructions manual and spare parts catalogue.
- foam pump (if included): instructions manual and spare parts catalogue.
- cement injector (if included): instructions manual and spare parts catalogue.
- rod loader (if included): instructions manual and spare parts catalogue.
- electrical diagrams
- hydraulic diagrams
Some of the figures in this manual may represent components which are partially different from
those which are actually included on the machine.
Who is to consult the manual
This manual is intended for the operator and maintenance personnel.
The operator and maintenance personnel must read and understand the information contained
in this manual using the machine or working on it.

2
FOREWORD Foreword
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Conservation of the manual
This manual must be kept in a safe place, and it must be available for consultation at all times.
If the manual is lost or damaged, ask Hütte Bohrtechnik GmbH. for a new copy; with the
request, include the manual code and the machine serial number.
Structure of the manual
A Page number
B Paragraph title
C Chapter title
D Manual code
NOTE: The manual code must be included with the
request for an additional manual
Warning!
The conventional symbol shown in the figure highlights safety
requirements that must be carefully read and followed, to avoid
endangering persons.
1.1
1.2

3
TECHNICAL CHARACTERISTICS General
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2. TECHNICAL CHARACTERISTICS
2.1. General
General description
The machine is composed of a drilling tool mounted on a self-propelled tracked crawler.
The self-propelled tracked crawler is composed of the following main groups:
-propulsion unit
-power hydraulic system
-hydraulic oil tank
-fuel tank
-mast joint group
-adjustment and start-up control panel - radio remote control
The drilling tool is composed of the following main groups:
-mast
-rotary head
-double rotary head (if included)
-winch rope return jib (if included)
-latticed extensions for jet grouting (if included)
-rod loader (if included)
-clamp assembly
Applicable standards
The machine has been designed and manufactured in compliance with the essential safety
requirements as set forth in the following standards and directives:
- Directive 2006/42/CE - (attachment I)
- Standard UNI EN ISO 12100-1
- Standard UNI EN ISO 12100-2
- Standard UNI EN ISO 14121-1.
- Standard EN 16228.

4
TECHNICAL CHARACTERISTICS General
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Machine identification plate
The information required to identify the machine are shown on a data plate attached to the
frame:
1) name and address of manufacturer;
2) EC mark;
3) model;
4) type;
5) serial number;
6) year of construction;
9) weight.
2.2
Identification tag of machine components
On some of the main components of the machine
(for example the rotary head) there is a tag that
identifies the component.
1) name and address of manufacturer
2) type
3) serial number
4) year of construction
2.2.1

5
TECHNICAL CHARACTERISTICS Field of application
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2.2. Field of application
Intended use of the machine
- Drilling of earth for small-scale geo-technical drilling (drainage, micropile, anchor,
consolidation, …). Based on the geological characteristics of the terrain, drilling systems
are adopted with direct circulation with water or sludge, or dry with continuous flight
auger; it is also possible to mount hole-bottom hammers and hydraulic hammers.
- Geological surveys (sampling, coring, ….).
The service winch must be used only to facilitate working operations, to move the following
objects:
-drilling rods
-tools
-continuous flight auger
-casing tubes
-reinforcements
The machine must be used only with suitable accessories and equipment provided by Hütte
Bohrtechnik GmbH. The installation of other accessories and equipment must be authorized by
Hütte Bohrtechnik GmbH.
Prohibited use of machine
Since it is not possible to foresee all improper uses of the machine, only those which are
foreseeable based on experience are listed.
WARNING!
It is prohibited to use the machine improperly, since this would endanger individual
safety and may damage the machine.
The clamps must not be used to service rods, tools or other components of the machine.
The machine is not suitable, in the basic version, to work in tunnels. Special devices are
required to do so (further information is available from Hütte Bohrtechnik GmbH).
Since there is no built-in lighting, the machine cannot work, and must not be driven, in the dark
or in poor lighting.
Do not use the machine, or parts of it (stabilizers, tracks, mast joints) to straighten or shape
metal bars, drilling rods, …
Do not use moving parts of the machine to lift persons (rotary head, mast, …).

6
TECHNICAL CHARACTERISTICS Field of application
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Winch
The lifting of a load applied to the winch rope must never make use of the mast joint, the
stabilizers or the mast where the winch is installed; in this case the pressure relief valve may
not be able to protect the winch from very dangerous overloads.
Tampering with the pressure relief valve for loads in excess of those allowed is prohibited.
Winch may not be used for the direct or indirect transport or lifting of persons.
It is forbidden to carry out any lifting operations liable to cause risks to, first and foremost, the
safety of workers, and, secondly, to the vehicles and equipment connected with the lifting
operations. 2.2.3
WARNING!
This machine is not a crane.
This machine has a limited picking zone and capacity.
The work tool (utensil and accessories) must be selected based on the type of terrain.

7
TECHNICAL CHARACTERISTICS Field of application
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Ambient operating conditions
Minimum ambient temperature for use: -10 °C
Maximum ambient temperature for use: +40 °C
Maximum use without loss of power (height above sea level): 0÷2500 m (maximum ambient
temperature for use: +40°C)
Maximum relative humidity (90% @ 40°C)
Maximum allowable wind speed (mast in vertical position): 20 m/s
Contact Hütte Bohrtechnik GmbH before using the machine in conditions different from those
indicated.
The main parts of the machine are protected against corrosion by a layer of paint. The paint
applied to the cab and body complies with corrosiveness class C4-M according to the standard
QUALISTEELCOAT (Final v. 1.0 February 2009) and is suitable for settings with moderate
salinity

8
TECHNICAL CHARACTERISTICS Basic machine
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2.3. Basic machine
MAXIMUM SLOPE ALLOWED IN TRANSPORT
CONFIGURATION
20(36%)
MAXIMUM GROUND
PRESSURE
TRANSPORT
CONFIGURATION
15 N/cm2
WORKING
CONFIGURATION
50 N/cm2
MAXIMUM SPEED OF MACHINE MOVEMENT
2,5 km/h
EQUIPMENT WEIGHT (STANDARD)
15500 kg