KLEMM KR 702-2 User manual

TECHNICAL MANUAL
Description
Maintenance
Operation
for
Hydraulic crawler drill rig
KR 702-2
KLEMM Bohrtechnik GmbH
Wintersohler Str. 5
D-57489 Drolshagen
Tel: [phone]
Fax: [phone]

2
KR 702- 2 / Serial no. 1910404/2008
SCOPE OF LIABILITY
Information and data in this operatio-
nal manual may be changed without
prior notice
Although compiled with all care, the
manual may be incomplete.
KLEMM Bohrtechnik will not any ac-
cept claims resulting from missing
data in this manual.
Technical specifications and data
subject to modifications.
In case of doubt, the German text
shall prevail.
COPYRIGHT REGULATIONS
Layout and content of this manual is
subject of international copyright re-
gulations.
 KLEMM Bohrtechnik 2008
Reproduction or use in any form
whatsoever, except within the legal
limits of copyright laws, and without
prior written permission of the com-
pany KLEMM Bohrtechnik is not
permitted.
KLEMM Bohrtechnik GmbH
Wintersohler Str. 5
D-57489 Drolshagen
Tel: [phone]
Fax: [phone]

3
KR 702- 2 / Serial no. 1910404/2008
Bei Anfragen und für schnelle und
reibungslose Ersatzteillieferung
bitte stets folgende Informationen
angeben:
1. Maschinennummer
2. Maschinentyp
3. Ersatzteilmenge
4. E.Nr.
Für elektrische Bauteile bitte zu-
sätzlich:
5. Spannung (V)
6. Frequenz (Hz)
7. Leistung (kW)
Durch Weiterentwicklung bedingte
Konstruktionänderungen behalten
wir uns vor.
When making enquiries or orde-
ring spares, please specify the fol-
lowing data to ensure prompt and
reliable delivery:
1. Number of Rig
2. Type of Rig
3. Quantity required
4. P/No.
For electrical components please
state also:
5. Voltage (V)
6. Frequency (Hz)
7. Power (kW)
We reserve the right to modify
equipment in the process of deve-
lopment.
Crawler drill rig type : KR 702-2
Serial no. : 19104
Year of manufacture : 04/2008

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KR 702- 2 / Serial no. 1910404/2008
Table of Contents
1 Safety instructions 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.1 General references to the avoidance of accidents, damages
and excessive wear 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.2 General safety instructions 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.3 Safety instructions for operation the drill rig 11. . . . . . . . . . . . . . . . . . . . . . . . .
1.3.1 Special requirements and recommendations for combined drill rigs
with connected mobile power-packs 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.3.1.1Disconnecting the Power Pack PP-95-DS from the drill rig KR 702-2 17
1.3.2 Safety recommendations for tramming operations of drill rig KR 702-2 18
1.4 Safety instructions for maintenance of the drill rig 21. . . . . . . . . . . . . . . . . .
2 Preface 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 Technical description 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1 Base frame with crawler tracks and boom 26. . . . . . . . . . . . . . . . . . . . . . . . .
3.1.1 Crawler undercarriage 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1.2 Boom assembly 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1.2.1Special swivel head (6 x 90°)28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2 Drill mast 164 and attachments 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2.1 Safety instuctions for roller chains for drill feed system
(only drill mast with feed chain) 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3 Engine and central hydraulics (Power Pack PP-95 -DS) 31. . . . . . . . . . . . .
4 Operation 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1 Operating Instructions 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1.1 Hydr. rapid couplings on connection plate KR 702-2 33. . . . . . . . . . . . . . . .
4.1.2 Hydr. rapid couplings on connection plate Power Pack PP-95 -DS 34. . .
4.2 Control elements on Power Pack PP- 95-DS 35. . . . . . . . . . . . . . . . . . . . . .
4.2.1 Engine control box PP-95 -DS 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2.2 Engine control system Power Pack PP-95 -DS 41. . . . . . . . . . . . . . . . . . . .
4.2.3 Electronic engine regulator (EMR) 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3 Prior to start-up 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4 Engine start-up 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4.1 Starting procedure of an Power Pack in cold ambient
temperature conditions 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.5 Tramming the crawler drill rig 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.5.1 Tramming the drill rig on slopes 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.5.2 Manoevrability 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.6 Setting up and alignment 49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.6.1 Safety instructions for operation with telesc. drill mast
type 164 and lateral slidable glide slide 51. . . . . . . . . . . . . . . . . . . . . . . . . . .

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KR 702-2 / Serial no. 1910404/2008
4.7 Drilling controls 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.7.1 Drilling controls on base drill rig 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.7.2 Drilling controls on slewable control panel 53. . . . . . . . . . . . . . . . . . . . . . . . .
4.7.2.1Safety Instructions for rope winches mounted on drill masts 55. . . . . . . . .
4.8 ESS control box on slewable control panel 56. . . . . . . . . . . . . . . . . . . . . . . .
4.9 Telescopic function of the drill mast 57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.10 Operation 58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.10.1 Drilling 60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 Crawler tracks 61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.1 Adjusting Track Tension 61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2 Repairs on crawler chains 62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.3 Controls on tramming gear box 62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 Care and maintenance of the KLEMM crawler
drill rig type KR 702-2 63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.1 Maintenance intervals 65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.2 Recommended Oil- and grease-types for drill rig KR 702 -2
with Power Pack PP-95-DS 66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.2.1 Characteristics of different hydraulic oils for Klemm drill rigs 67. . . . . . . . .
6.3 Filters and filter inserts for KR 702- 2 and PP-95-DS 69. . . . . . . . . . . . . . .
6.3.1 Filter and filter inserts for KR 702- 2 69. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.3.2 Filter and filter inserts for Power Pack PP- 95-DS 70. . . . . . . . . . . . . . . . . .
6.4 Scope of the 100 hour inspection 75. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.5 Lubrication Chart Maintenance and Service Intervals 76. . . . . . . . . . . . . . .
6.5.1 Maintenance of piston rods of hydraulic cylinders 78. . . . . . . . . . . . . . . . . .
6.6 Special instructions for Deutz Diesel engine TCD 2012 L04 2V 78. . . . . .
6.6.1 Permitted fuels for DEUTZ diesel engine 78. . . . . . . . . . . . . . . . . . . . . . . . . .
6.6.2 Dark coloration of diesel fuel due to oil ingress 78. . . . . . . . . . . . . . . . . . . . .
6.6.3 Cooling liquid 79. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.6.4 First filling and refilling of cooling liquid on Deutz diesel
engine type TCD 2012 L04 2V 80. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.7 Hydraulics 82. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.7.1 Hydraulic oil 82. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.7.2 Filtration 82. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.7.3 Oil Changes 83. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.7.4 Repairs and maintenance of the hydraulic system 84. . . . . . . . . . . . . . . . . .
6.7.4.1Trouble shooting 84. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.7.5 Reference to repairs at the hydraulic system 87. . . . . . . . . . . . . . . . . . . . . . .
6.7.5.1Special guarantee remarks 87. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.8 Special Remarks (Welding Instructions) 88. . . . . . . . . . . . . . . . . . . . . . . . . . .

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KR 702-2 / Serial no. 1910404/2008
6.9 Maintenance of the starter battery 89. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.9.1 Cold start 89. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.9.2 Installing the battery 89. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.10 Accumulators 90. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.10.1 Introduction and precaution instructions 90. . . . . . . . . . . . . . . . . . . . . . . . . . .
6.10.2 Works at accumulators 91. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.10.3 Assembly of cpl. Accumulator 92. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.10.4 Putting into operation 92. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.10.5 Using of accumulators 92. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.11 Conservation of hydraulic piston rods and machine components 93. . . . .
7 Attachment points for truck transport 94. . . . . . . . . . . . . . . . . .
7.1 Attachment points for drill rig KR 702-2 94. . . . . . . . . . . . . . . . . . . . . . . . . . .
7.2 Attachment points for Power Pack PP-95- DS 95. . . . . . . . . . . . . . . . . . . . .
8 Rope attachment points (1-4) on the drill rig type
KR 702-2 for loading with the help of a crane 96. . . . . . . . . . .
9 Technical data 97. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.1 Technical data KR 702-2 97. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.2 Technical data Power Pack PP- 95-DS 98. . . . . . . . . . . . . . . . . . . . . . . . . . .
9.3 Technical data of sound level measurement
acc. to DIN EN 791 and 2000/14/EC (Outdoor-Noise- Directive) 99. . . . .
10 Kinematic possible mast movements
KR 702-2 basic version 100. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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KR 702- 2 / Serial no. 1910404/2008
1Safety instructions
All personnel involved in operating and/or maintaining this equipment must first
read and thoroughly understand the operating instructions before attempting to
operate or perform maintenance on the drill rig. Non- authorised or untrained per-
sonnel must not under any circumstances attempt to operate or repair the machine.
Safety first must always be the primary consideration of all personnel while opera-
ting or maintaining the drill rig under normal and especially in unusual conditions.
Since these safety precautions cannot cover every possible situation, everyone is
expected to exercise good judgement, foresight and common sense while operating
or working with, on, or near the drill rig.
The signs CAUTION and PLEASE NOTE
are to be defined as follows :
CAUTION
This word is used to point out that inadequate or
non -compliance with operating manuals, working instructions, operational
sequences etc. will substantially damage property or cause severe
personal injury which could be fatal.
PLEASE NOTE
PLEASE NOTE is used to make people aware of installations
and gives hints for operation and maintenance which are important but not
hazard related. It generally indicates an operational aid.

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KR 702- 2 / Serial no. 1910404/2008
1.1 General references to the avoidance of accidents, damages
and excessive wear
1 Drill rig
The drill rig has multiplicity kinematic degrees of freedom for positioning of the basic
rig and particularly the drill mast.
But not each kinematically possible configuration is meaningful or permissible. This
particularly depends on the mounted drill mast, the drilling unit and drilling equip-
ment.
Therefore among other things the permitted drilling positions given in the stability
calculations, the setting-up sequences and the specific ground pressure as well as
all other references in the manual must be observed.
KLEMM Bohrtechnik refers to the fact, that not each theoretically possible drilling
position can be described.
If other drilling positions are to be aligned, then this lies in the technical discretion
of the operator. Otherwise consultation with KLEMM Bohrtechnik must be taken.
The following points must be particularly considered:
1.1 Extreme displacement of the center of gravity
Special attention must be paid when setting-up the drill mast with far out overhan-
ging center of gravity. The center of gravity of the drill mast with its attachments e.g.
drill heads and hydr. drifters, drilling equipment and if necessary rod magazines
must be placed as near as possible to the ground contact area of the drill rig. The
ground contact area of the drill rig is defined by the tipping edges of the crawler
tracks.
1.2 Collision
Causes of the multiplicity of kinematic possibilities, the setting- up of the drill rig has
to be done with maximum attention, appropriate speed and if necessary with a se-
cond instructing person.
With inattentive setting-up operations, collisions e.g. between the drill mast and
parts of the boom or the basic rig are possible.
1.3 Overlay of the degrees of freedom
The kinematic degrees of freedom are for example realized by hydraulic cylinders
or slewing drive units. The degrees of freedom can be redundant in certain positions,
that means for example, that a tilting motion around a certain spatial axle can be
achieved by two or more methods. Within the methods, the most favorable method
regarding endangerment and damage must always be selected.

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KR 702- 2 / Serial no. 1910404/2008
2 Extreme environmental condition
If the drill rig is to be operated under extreme or outside the of KLEMM Bohrtechnik
specified site conditions, previous clarification with KLEMM Bohrtechnik is necessa-
rily. These are e.g.:
- Extremely low or high temperatures and or humidity
- Special geographical altitudes
- Particularly high dusty condition
- Operations in tunnels or underground
3 Changeable equipment
3.1 Equipment from KLEMM Bohrtechnik
For the drill rigs of KLEMM Bohrtechnik many equipment components, which can
be changed or additional mounted are available.
For example these are rotary drill heads, hydr. drifters, rod magazines, drill masts
and drill mast extensions, flushing pumps, lubricants and fuels and other compo-
nents. All combinations of changeable equipment with the drill rig cannot be descri-
bed. To avoid endangerments and damages, the following points must be strictly ob-
served when self changes of the drill rigs equipment are made:
- permissible stabilities und strengths
- permissible pressures in the hydraulic system
- permissible flow rates in the hydraulic system
- permissible operation modes of hydraulical and electrical components
(e.g. preferred rotation direction of hydraulic motors)
- electrical control- and monitoring functions
- use of safety devices or safety components
- permissible contamination for lubricants and operating materials
- conformity with the european regulation for machines when substantial
changes are done (only in the marketing area of the European union).
3.2 Adaptation at or of equipment of other manufacturers
Fundamental the same points as being considered above are to be observed.
The adaptations takes place in the discretion of the operator if they are not coordina-
ted with KLEMM Bohrtechnik.
In principle the in the manual and further attached documentation
contained safety and warning reference must be observed.
If there is none or a contradictory information to a specified question in
the documentation, KLEMM Bohrtechnik must be consulted before
operation or conversion.

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KR 702- 2 / Serial no. 1910404/2008
1.2 General safety instructions
FDirective of application
The KLEMM drill rig must be used only as directed in DIN EN ISO 12100-1
(safety of machinery), and as described in the operators manual for drilling
operations. Another using of the drill rig as directed (e.g. for lifting operations
as a crane or ground moving operatios) is striktly forbidden.
FMake sure all persons are clear of the machine before moving or starting any
drilling operation.
FAll personnel involved in operating and maintaining this equipment
must first read and thouroughly understand the operating instructions.
FOperating instructions
Operating instructions for the KLEMM Bohrtechnik drill rig must be
complied with for operation, maintenance, service, repairs and transport. The
contractor is obliged to amend safety regulations to meet local requirements.
Operating instructions and amendments must be kept securely on the working
site.
FPersonal Safety Equipment
Wear Personal Safety Equipment - Working gloves
- Safety boots
- Safety hat
- Hearing protection
- Safety glasses
- Nose mask (only if dust)
Wear tight clothes (protection clothes according to DIN).
Keep hands, arms, legs and clothing away from all moving parts.
Do not touch heated up parts with your bare hands. Wear protection gloves.
FVibrations
The weighted value of the vibrations of the body (feet, seat face) of 0,5m/s2,
which can shake the operator during the drilling work, is not exceeded. The
value of the hand/the arm vibrations, which shake the operator during the dril-
ling work, is under 2,5m/s2.

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KR 702- 2 / Serial no. 1910404/2008
1.3 Safety instructions for operation the drill rig
1. Operation and maintenance of KLEMM drill rig
Independent and unassisted operation (operator) and maintenance
(fitter) is to be entrusted only to persons who:
1.1 Are at least 18 years of age (Check for local stipulations)
1.2 Are physically and mentally suited
1.3 Have been instructed in operating and maintaining
the crawler drill rig and have proven their ability to the
contractor / user
1.4 Can be expected to perform responsibly
And are designated for the job by the contractor/user.
2. Danger zone
Be sure that no one is within the drill mast’s danger zone.
The danger zone is the area around the drill rig within which persons may be
endangered by the rig’s slewing range or its components working movements.
The operator must work the machine only if no one is within the danger zone.
In case of danger the operator must give warning signals. Warning signals are
generally given with horns.
Pre-determined hand warning signals must be used if on- site noise is liable
to drown audible signals.
If persons do not leave the danger zone despite having been warned the ope-
rator must stop working immediately.
3. Safety distance
A safety clearance of min. 0,5 metres must be kept from buildings, scaffolding
and other equipment to prevent the danger of being squashed.
Keep in mind the drill rig’s slewing facilities.
If the safety clearance cannot be complied with the area must be cordoned off.

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KR 702- 2 / Serial no. 1910404/2008
4. Safety devices
Safety devices and protective equipment of moving machine components
must be opened, removed, or disabled only with the rig’s engine stopped and
secured against inadvertent or unauthorised start- up.
Safety devices are e.p. ESS- system (System KLEMM), engine cover doors,
protective gratings, coatings.
All safety devices and protective equipment must be reinstalled after comple-
tion of maintenance service and repairs.
5. Transport of persons
The transport of persons on the drill rig is strictly forbidden!!
6. Step on the drill rig
While operation the drill rig is forbidden to step on the machine. Before step-
ping on the machine the engine of the drill rig must be stopped and secured
against inadvertent or unauthorised start-up.
7. Stability
The stability (according to DIN EN 791 “Drill rigs - safety”) of the crawler drill
rig must always be assured.
Stability may be impaired by:
Excessive load, unsecure ground, jerky acceleration and stopping of tramming
and slewing movements, slopes.
The operator is responsible for the rig’s stability, and must, if necessary, modify
procedures to allow for special site conditions.
8. Truck loading process
In order to avoid chutes of the drill rig in the case of the loading process onto
the truck, ramps must be coated with skid- proof materials (e.g. wood slats or
rubber mats).
9. Securing against fall
To forestall danger of falling and crashing, the drill rig must at all times keep
a safe distance from ledges, pits and slopes.
It is the contractor’s responsibility to assess the ground’s bearing capacity, and
assert a safety distance for the rig.
Be sure of the bearing capacity of bridges, floors, and structures prior to
moving the basic rig on to them.
10. Alignment of the drill mast
If the drill rig is equipped with a telescopic drill mast type 164 / 2370mm long,
a cat head with rope winch, a hydr. drifter or a rotary drill head and a clamping
and breaking device, the rig should be preferably operated with driven out front
and rear support. It is to be paid absolutely attention, that the drill mast is prop-
ped with the front console on the soil during drilling operations.

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KR 702- 2 / Serial no. 1910404/2008
11. Signalling
If the operators vision is impaired during tramming and working, someone
must give signals for assistance, or the tramming / working area must be
cordoned off.
Only reliable persons must be designated to give signals.
They must be instructed as to their responsibility.
Communication must be co- ordinated and exclusively used between operator
and the person giving signals.
The signalling person’s attention must not be diverted by additional tasks.
12. Working in the area of utility lines (gas, water, electricity,...)
The contractor is responsible to ascertain if utility or not visible lines are buried
on the drilling site. The site’s owner is obliged to supply this information.
If utility or not visible lines are present their location must be clearly marked.
Plans clearly detailing the location (run and depth) of utility or not visible lines
must be kept for reference on the working site.
The operator must stop working immediately and inform the site manager if a
utility line or its protective cover should be found or damaged.
Uncovered utility lines must be secured against swaying or slipping.
13. Working near overhead electrical lines
The following minimal safety distances must be complied with if working near
overhead power lines, unless local or national stipulations require otherwise:
Rated voltage:
up to 1000 V safety distance = 1 m. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
above 1kV to 110 kV safety distance = 3 m. . . . . . . . . . . . . . . . . . . . . . . . . . .
above 110 kV to 220 kV safety distance = 4 m. . . . . . . . . . . . . . . . . . . . . . . .
above 220 kV to 380 kV safety distance = 5 m. . . . . . . . . . . . . . . . . . . . . . . .
or if rated voltage unknown safety distance = 5 m. . . . . . . . . . . . . . . . . . . . .
If a min. safety distance can not be respected, the contractor must arrange
other safety steps (e.g. cut off or move the electr. line) in accordance with the
owner or operator of the electr. lines.
14. Safety precaution trailer coupling.
The trailer coupling P/No. 40333 is approved for max. 40 kN = 4 tons
15. Guards and safety devices are for your protection. Do not remove or disable
them under any circumstances. The ESS requires particular attention. Mal-
function of the Emergency Stop System may cause delays in switching the drill
rig off, leading to severe or fatal injuries.
16. Replug the 2 mast slewing cylinders (option slew head 6 x 90°) only in
horizontal mast position.

14
KR 702- 2 / Serial no. 1910404/2008
17. Operational intervals
The operator must park the crawler drill rig with Power Pack on bearing and
level ground, and secure against inadvertent or unauthorised movement, prior
to each operational break and at the end of each working day.
If the drill rig must be parked on a slope or incline, the tracks of the Power Pack
must be secured with wedges, in addition to the hydraulic brakes.
Drill rigs should be parked only where they do not impede public or site traffic.
If necessary they must be secured with warning triangle, signalling lines, or
warning lights.
During working breaks and at the end of each working day, the operator must
rest drill mast and drill string on the ground, and secure them against inadver-
tent or unauthorised movement.
The operator must:
- not leave the site if drill rig and tools are not secured
- set all operating levers in ”O” position prior to leaving the control panel
- stop the drill rig’s engine and secure it against inadvertent or unauthorised
start- up, prior to leaving the drill rig.
Inadvertent or unauthorised start-up is avoided, if the engine is stopped, the
starter key taken out of the ignition lock, and cover doors and lids are locked.
18. Always operate the basic rig from the operators platform when tramming.
19. Before tramming the drill rig, the drill mast must be placed on the drill mast
support in horizontal transport position.
20. All operations must be activated directly from the corresponding control
positions only.
21. The drill rig must only be driven within ranges, in which is no risk to cant over!
The drivers position of the drill rig is not equipped with a rollover protection sy-
stem (ROPS).
22. For the shifting the drill rig through darkness, a lighting with a minimum lumi-
nous intensity of 10 lux must be given in a distance of 7m from the drill rig to-
ward shifting direction.
23. The point of drill hole shall be illuminated, if necessary from the job site.
24. While working in a closed room a exhaust hose shall be used. Otherwise it can
cause intoxication.
25. If you must operate the rig underground or in a confined area, consult your
KLEMM Representative for assistance in safe operation.
26. The drill rig shall be used in areas, where no down- falling items cause danger.
27. Use only the purpose-made craneage lugs when lifting the rig. For loading the
drill rig with help of a crane please contact KLEMM comp.

15
KR 702- 2 / Serial no. 1910404/2008
1.3.1 Special requirements and recommendations for combined
drill rigs with connected mobile power-packs
Tramming mode
The mobile power pack is connected to the drill rig with electrical control ca-
bles and the cluster of hydraulic hoses.
ATTENTION
Before tramming and before starting the diesel engine check all cable and
hose couplings mounted on the drill rig and the power pack; if loose, tighten
them correctly.
After starting the diesel engine and after pressurizing the total system,
check again couplings to be leakage - free !
Avoid tramming and unstable slopes and grounds. In the case of bad ground
conditions use wood or mats or special sheets to stabilize the drill rig posi-
tion.
The power pack is connected to the drill rig by a special traction bar with trai-
ler coupling end (eye). The trailor coupling is inserted in the counter part,
bolted with 4 steel bolts to the crawler frame.
The trailor coupling is linked with the crawler frame by inserting the appro-
ved lock bolt with handle and safety chain with splint.
CAUTION
Check always before tramming the trailor coupling system with mounted
and secured lock bolt!
Never replace the genuine block bolt by normal pin or other non - approved
materials.
For proper mounting and operation of the trailor coupling: (see picture).
genuine block bolt
with safety chain
and split pin
trailor coupling

16
KR 702- 2 / Serial no. 1910404/2008
Drilling mode
- Stabilize the drill rig with the two rear propping cylinders.
- Block the two wheels of the mobile power pack with the steel wedges
included in the scope of supply and attached to the power pack
(see picture).
- Make the ground plane before drilling to keep the machine in horizontal
position!
- In special cases the mobile power pack will be disconnected from the drill
rig, the maximum distance can be appr. 25m by using long hoses.
This drilling mode requires special attention for the leakage - free
connection of the hose couplings to the power pack which will be out of
the visual control of the operator.
(operator inside the building, power pack outside)
Important
The diesel engine produces vibrations which may reposition the power
pack!
- Block the remote operated power pack to avoid collisious and accidents
by putting the wedges under the wheels.
- Before drilling check all safety devices like emergency stop switches and
the special drill feed safety cables with hydraulic switches, solenoid
valves (ESS).
Parking mode
- Keep the drill rig with power pack on a safe place, avoiding slopes and
soft grounds.
- Stabilize the rig with the rear hydr. propping cylinders and use wood bars
in muddy conditions under the bottom plates.
- Lock the wheels of the power pack with two steel wedges.
- Slew drill mast in horizontal position with drill unit between mast
carrier and mast support bracket.
- Remove starter key of the diesel engine.

17
KR 702- 2 / Serial no. 1910404/2008
1.3.1.1 Disconnecting the Power Pack PP -95- DS from the drill rig
KR 702-2
It is important to work after the following points in the right order!
1. Block the tracks of the Power Pack with the steel wedges.
2. Lift down the propping wheel of the Power Pack. Ensure the weel is pushed
into the fully locked position before uncoupling the drill rig.
3. Take the split pin out of the bolt of the trailor coupling.
4. Take the bolt out of the trailor coupling.
5. Move the drill rig forward until the hitch of the Power Pack is not in contact
with the trailor coupling anymore.
6. Switch off the engine of the Power Pack and pull out the start key.
7. Screw off the connecting hoses and the connecting cable from the Power
Pack.
trailor coupling with
lock bolt, safety
chain and split pin
connecting hoses
and cable
propping wheel
steel wedge rear and front (option)
hydr. propping cylinders

18
KR 702- 2 / Serial no. 1910404/2008
1.3.2 Safety recommendations for tramming operations of drill rig
KR 702-2
Tramming or any activation of the crawler tracks of KR 702-2 drill rig inside buildings
or at the job site are only permitted with fully spreaded (telescoped) crawler chassis
to 1250 mm width.
Non-respect of these recommendations may be the reason for heavy accidents due
to reduced stability when tramming with retracted crawler chassis !!
The retracted mode for tramming is only permitted during passage of doors and
small entries.
ATTENTION:
Tram with fully telescoped crawler chassis (1250mm) just before you pass doors/
entries; then retract during passage manoevres and spread to full width immediately
after te passage.
Tramming operations of the KR 702- 2 rig are only permitted with drill mast in trans-
port position and laying on the special support frame. The rotary head must be posi-
tioned in the middle of the drill mast.
ATTENTION:
Prior to tramming on the job site prepare the ground and remove obstacles and on-
dulations like deep holes and small walls.
Permitted slope Permitted side inclination
Tramming and working
condition
1010
Transport conditions
(mast down)
2010

19
KR 702- 2 / Serial no. 1910404/2008
10
10
Tramming and working condition
sketch of permitted slope
sketch of permitted side inclination

20
KR 702- 2 / Serial no. 1910404/2008
Transport conditions
20
sketch of permitted slope
10
sketch of permitted side inclination