KLEMM KR 806-2 User manual

TECHNICAL MANUAL
Description
Maintenance
Operation
for
Zweigniederlassung der
Bauer Maschinen GmbH
Germany
tel: ++49 (0) 2761 705- 0
fax: ++49 (0) 2761 705 - 49
++49 (0) 2761 705 - 50
All hydraulic crawler drill rig
KR 806-2

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07/2004 KR 806-2 / Serial No. 64004
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 2004.
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.
Zweigniederlassung der
Bauer Maschinen GmbH
Germany, Drolshagen
tel: ++49 (0) 2761 705- 0
fax: ++49 (0) 2761 705 - 49
++49 (0) 2761 705 - 50

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07/2004 KR 806-2 / Serial No. 64004
Bei Anfragen und für schnelle und
reibungslose Ersatzteillieferung
bitte stets folgende Informationen
angeben:
1. Maschinennummer
2. Maschinentyp
3. Ersatzteilmenge
4. E.Nr. / CPN-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. / CPN
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.
Rig type : KR 806-2
Serial no. of rig : 64004
Year of manufacture : 07/2004

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07/2004 KR 806-2 / Serial No. 64004
Table of Contents
1 Safety instructions 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.1 General safety instructions 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.2 Safety instructions for operation the drill rig 9. . . . . . . . . . . . . . . . . . . . . . . . . .
1.3 Safety instructions for maintenance of the drill rig 13. . . . . . . . . . . . . . . . . .
2 Preface 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 Technical Description 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1 Base frame with crawler tracks and boom 17. . . . . . . . . . . . . . . . . . . . . . . . .
3.1.1 Engine and central hydraulics 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1.2 Crawler Undercarriage 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2 Boom Assembly 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3 Drill mast type 202 with attachments 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3.1 Safety Instuctions for roller chains for drill feed system 21. . . . . . . . . . . . . .
4 Operation 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1 Prior to start-up 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2 Operating Instructions 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2.1 Engine control box KR 806-2 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2.2 Engine control system KR 806-2 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2.3 Electronic engine regulator (ECM) 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2.4 Engine start-up 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2.5 Starting procedure of an KR 806-2 in cold ambient
temperature conditions 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2.6 Operating instructions crawler drill rig KR 806-2 31. . . . . . . . . . . . . . . . . . .
4.2.7 Release switch for oscillating undercarriage / oscillating automatic 32. . .
4.2.8 Tramming the Crawler Drill 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2.8.1Tramming the drill rig on slopes 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2.8.2Manoevrability 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2.9 Setting up and alignment of the boom 36. . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2.10 Drilling controls on slewable control console 38. . . . . . . . . . . . . . . . . . . . . . .
4.2.11 ESS control box on slewable control panel 42. . . . . . . . . . . . . . . . . . . . . . . .
4.2.12 Operation the drill rig with single hydr. drifter or double head unit 43. . . . .
Operational instructions for DHD application in combination with
hydr. hammer 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2.12 Drilling operation 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2.13 Drilling method 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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07/2004 KR 806-2 / Serial No. 64004
5 Preventative Maintenance 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.1 Adjusting Track Tension 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2 Repairs and Replacement Operations on crawler chains 49. . . . . . . . . . . .
5.3 Oil Level Control on Tramming Motor of Gear Box 49. . . . . . . . . . . . . . . . .
6 Care and maintenance of the KLEMM crawler drill rig
type KR 806-2 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.1 Recommended Oil- and grease-types for drill rig KR 806-2 52. . . . . . . . .
6.1.1 Characteristics of different hydraulic oils for Klemm drill rigs 53. . . . . . . . .
6.2 Filter and Filter inserts for drill rig KR 806-2 55. . . . . . . . . . . . . . . . . . . . . . .
6.3 Lubrication Chart Maintenance and Service Intervals 62. . . . . . . . . . . . . . .
Special instructions for Caterpillar Diesel Engine 3056 EATAAC 64. . . . . .
6.4 Hydraulics 65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.4.1 Hydraulic oil 65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.4.2 Filtration 65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.4.3 Oil Changes 66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.4.4 Repairs 67. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.5 Service Intervals 67. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.6 Special Remarks (Welding Instructions) 68. . . . . . . . . . . . . . . . . . . . . . . . . . .
6.7 Battery 69. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.7.1 Cold start 69. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.7.2 Installing the battery - danger of short-circuiting 69. . . . . . . . . . . . . . . . . . .
6.8 Accumulators 70. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.8.1 Introduction and precaution instructions 70. . . . . . . . . . . . . . . . . . . . . . . . . . .
6.8.2 Works at accumulators 71. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.8.3 Assembly of cpl. Accumulator 72. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.8.4 Putting into operation 72. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.8.5 Using of accumulators 72. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.8.6 Accumulators option for hydr. drifter KD 1624 73. . . . . . . . . . . . . . . . . . . . . .
6.8.7 Servicing Accumulators (OPTION) 73. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.1 Repairs and Maintenance 74. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.1.1 Trouble shooting 74. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.1.2 Special guarantee remarks 77. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.1.3 Warranty 77. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.10 Conservation of hydraulic piston rods and machine components 78. . . . .
7 Attachment points for truck transport 79. . . . . . . . . . . . . . . . . .

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07/2004 KR 806-2 / Serial No. 64004
8 Rope attachment points (A-D) on the drill rig type
KR 806-2 for loading with the help of a crane 80. . . . . . . . . . .
9 Bridge with rigging (max. 20t) for loading the drill rig
KR 806-2 81. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 Technical Data KR 806-2 82. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.1 Technical data of sound level measurement
acc. to DIN EN 791 and 2000/14/EC (Outdoor-Noise-Directive) 83. . . . .
11 Mast movements KR 806-2 84. . . . . . . . . . . . . . . . . . . . . . . . . . . .

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07/2004 KR 806-2 / Serial No. 64004
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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07/2004 KR 806-2 / Serial No. 64004
1.1 General safety instructions
Directive 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.
Make sure all persons are clear of the machine before moving or starting any
drilling operation.
All personnel involved in operating and maintaining this equipment
must first read and thouroughly understand the operating instructions.
Operating 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.
Personal 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.

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07/2004 KR 806-2 / Serial No. 64004
1.2 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.
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.

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07/2004 KR 806-2 / Serial No. 64004
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. Special instruction to stability with mounted drill mast (7000mm lenght)
If the drill rig is equipped with a drill mast of 7000mm length or longer, the
mounting plate for the drill mast displacement cylinder must be bolted in the
red marked position (see picture below). Cause of stability reasons it is strictly
forbidden to bolt the mounting plate in another position of the drill mast!
mounting plate for
mast displacement
cylinder bolted in the
red marked position
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.

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07/2004 KR 806-2 / Serial No. 64004
10. 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 coordinated and exclusively used between operator
and the person giving signals.
The signalling person’s attention must not be diverted by additional tasks.
11. 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.
12. 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.
13. Safety precaution trailer coupling.
The trailer coupling P/No. 40333 is approved for max. 40 kN = 4 tons
14. Operational intervals
The operator must park the crawler drill rig on bearing and level ground, and
secure against inadvertent or unauthorised movement, prior to each operatio-
nal break and at the end of each working day.
If the drill rig must be parked on a slope or incline, the tracks must be secured

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07/2004 KR 806-2 / Serial No. 64004
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.
15. Always operate the basic rig from the operators platform when tramming.
16. Before tramming the drill rig, the drill mast must be placed on the drill mast
support in horizontal transport position.
17. The operating device must be activated only from the control panel.
18. For shifting the drill rig through the darkness the lights in tramming direction
shall be switched on.
19. The point of drill hole shall be illuminated, if necessary from the job site.
20. While working in a closed room a exhaust hose shall be used. Otherwise it can
cause intoxication.
21. If you must operate the rig underground or in a confined area, consult your
KLEMM Representative for assistance in safe operation.
22. 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.
23. 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.
24. The drill rig shall be used in areas, where no down-falling items cause danger.

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07/2004 KR 806-2 / Serial No. 64004
1.3 Safety instructions for maintenance of the drill rig
1. Service and maintenance intervals must be adhered to as specified. Non-
compliance leads to immediate loss of all warranty entitlements.
2. The setting of pressure limiting valves and safety valves in the hydraulic
circuits of the drill rig must be changed only by KLEMM Bohrtechnik
approved personnel.
3. Welding of static and bearing components on the machine is to be carried out
only by the manufacturer or KLEMM Bohrtechnik approved personnel.
4. The rigs hydraulic plant must be checked regularly.
Replacement hoses or hydraulic components must be ORIGINAL spare parts
of KLEMM Bohrtechnik.
This requirement must be complied with for safety reasons and applies also
for all static and bearing components, such as
* Screws
* Bolts
* Springs and washers
* Boom components
* Drill mast components
* Undercarriage components
5. Replacement of wear parts
Repairs and replacement of wear parts can be carried out by qualified person-
nel in addition to standard maintenance and service intervals which must be
complied with.
If in doubt contact KLEMM Bohrtechnik for assistance.
6. Be sure to bleed accumulators before repair (see chapter 6.8 on page 70 in
this manual) and be sure to make them completely pressure - free before ope-
ning.

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07/2004 KR 806-2 / Serial No. 64004
Safety reqirements for hydraulic lines
1. Markings :
a) Hydraulic hoses must carry continuous markings at intervals not greater
than 50 cm. These markings must be clearly readable and supply the
following data:
- Name of manufacturer
- Type
- Nominal diameter
- Date of manufacture
Example : ” 1 Q 04 ”
= 1st. Quarter 2004
b) Hose lines must carry the following data in durable markings:
- Name of the manufacturer
- Date of manufacture
- max. permissible
dynamic operat. pressure
2. Storage
Hydraulic hoses must be stored tension-free, in a dry and clean environment.
Direct sunlight and UV-irradiation must be avoided.
Storage time should not exceed four years.
3. Operating hydraulic lines
a) After 6 years operation hydraulic lines must be exchanged for safety re-
asons even if there are no apparent technical faults.
Hoses are subject to a natural ageing process,
their life-time is limited.
b) Hoses which have been operated as part of a hydraulic line must not under
any circumstances be reprocessed
4. Inspection
Hydraulic lines must be inspected by qualified personnel to assess their opera-
tional safety before the initial start-up, and subsequently at least once every
year.
Defective and faulty lines must be exchanged immediately.

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07/2004 KR 806-2 / Serial No. 64004
2 Preface
This manual describes the KR 806-2,
an all-hydraulic crawler drill rig, manu-
factured by the Company KLEMM
Bohrtechnik, the assembly of technical
components, operational procedure as
well as service measures and preven-
tive maintenance requirements.
Hints and instructions for repairs and
trouble shooting are also included.
The manual comes complete with a
parts catalogue, which depicts and des-
cribes modules and individual compo-
nents. Use the catalogue to identify part
number of the required component
prior to ordering.
Your KLEMM KR 806-2 drill represents
”State of Art” in mobile drilling equip-
ment. Apart from a pressurized water or
air supply required for flushing purpo-
ses, the rig operates fully independent,
ready to tackle the most extreme
ground conditions in almost any loca-
tion.
The rig’s boom is adjustable on three
planes and together with the special
slewing mechanism and mast carrier,
allows for vertical and horizontal drill
mast alignment. Besides boom can be
rotate around ist axle (+15/-45),
which is particularly advantageous
when spotting in areas with limited ac-
cess, e.g. corners and recesses.
The drill rig’s main power source is an
fluid-cooled 6-cylinder diesel engine.
An open centre 3-circuit system with
max. operating pressures of 4060 psi,
supplies hydraulic power for all (tram-
ming, alignment and drilling) of the rig’s
functions.
The rig’s crawler tracks are of the oscil-
lating type, which means that both
tracks move on a fixed axle. Hydraulic
cylinders are used to align the tracks,
relative to the base frame, either paral-
lel, or with the required inclination.
This oscillating feature counteracts
ground undulations during tramming,
keeping base frame with diesel engine
automatically levelled at all times, or al-
lows for the base frame to be fixed at an
angle when tramming on slopes and
ramps.
The drill mast is fitted in guiding strips
on the boom slewing mechanism, and
carries all the drilling accessories.
A twin-clamp/breaking device (part of
drill rig) ensures rapid rod changes.
All operating levers of the hydraulic drill
rig are conveniently positioned, and
clearly labelled with symbols indicating
their functions.
At the back of the base frame is a dri-
vers stand, from which, using only two
levers (left and right track), tramming is
activated. The control lever for track
oscillation is placed alongside these
controls.
The control console for boom, slewing
mechanism and mast carrier alignment
is fixed on the slewable control panel.

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07/2004 KR 806-2 / Serial No. 64004
Controls for all drilling functions are
mounted on the slewable control panel
at the left side of unit. During transpor-
tation or tramming control panel is in
parallel position to boom and tracks.
For drill operations control panel will be
slewed by several steps up to 90.
The KLEMM KR 806-2 has 2 EMER-
GENCY switch - off buttons.
One EMERGENCY switch off is moun-
ted on the slewable control panel. The
other one is mounted besides the tram-
ming control levers on the top-back-
side of the rig. Activation of these swit-
ches stops all of the rig’s functions
immediately.
The EMERGENCY switches are com-
posed of a red button with electrical
shut-off of the diesel engine; this reac-
tion is immediate !!
ATTENTION:
You must check daily the correct func-
tion of the EMERGENCY switches.
Do not operate the machine, if the
EMERGENCY switches fail and show
no function.
The power pack is fitted with a sound
prooved cover to meet current noise le-
vel regulations.
The rigs electrics are based on the 24V
D.C. standard.
The KLEMM Company reserves the
right to modify the drill rig and technical
documentation without prior notice, in
the interest of development.

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07/2004 KR 806-2 / Serial No. 64004
3 Technical Description
3.1 Base frame with crawler tracks and boom
The base frame with oscillating crawler
tracks carries power pack, tanks (hy-
draulic fluid and diesel), as well as con-
trol and monitoring elements.
The boom assembly consisting of sle-
wing column, swivel mechanism and
mast carrier are hinged on the front
plate of the base frame. The mast car-
rier acts as support and guide for the
drill mast.
KR 806-2

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07/2004 KR 806-2 / Serial No. 64004
3.1.1 Engine and central
hydraulics
The main power source is an fluid-coo-
led 6-cylinder four-stroke diesel en-
gine with an output of 129,5 kW at 2300
rpm (for details see engine manual).
The multipurpose anchor drill rig type
KR 806-2 with a output of 129,5 kW is
equipped with a Load-Sensing hydrau-
lic system, which provides among other
things the following advantages:
pump flows are indipendent from the
engine acceleration (rpm); exactflow
supply as per “user-requirement” is
always provided.
feed and retraction speed is nearly
doubled.
engine acceleration can be reduced,
if one pump circuit is unused running
idle;
no pressure looses;
reduced noise emissions and reduce
fuel consumption.
All operations functions (tramming,
aligment and drilling) are powered by a
3-circuit hydraulic system with max.
operating pressure of 4060 psi.
The open centre hydraulic system is
supplied from a hydraulic oil tank with a
capacity of 500 litres.
The entire system is sealed-off to fore-
stall contamination.
Installed is an automatic temperature
regulator. Cooling starts at 45C oil
temperature and will have full perfor-
mance at 60C.
Cooling of the hydraulic fluid is required
to maintain the right operational tempe-
rature and retain optimum viscosity.
This is assured by a hydraulic oil coo-
ling device, consisting of the cooler with
hydraulically driven fan motor.
3.1.2 Crawler Undercarriage
Each crawler consists of base frame,
track chain, sprocket drive wheel, guide
wheel and seven idlers, two support
wheels, as well as a track tensioning
device and the transmission.
The transmission consists of a plane-
tary gear box with hydraulic motor. Hy-
draulic motor is integrated in the gear
box. Both are one unit and located in-
side width of tracks.
The gear box is equipped with a multi-
disk brake on the motor.
This multi-disk brake is activated by
constant spring pressure, and acts as
parking brake only.
The brake is opened by oil pressure,
e.g. oil flow of approx. 232 psi or greater
releases the brake
Special axial seal rings protect the
transmission from dirt and contamina-
tion.
Axle receptions to mount and fix the un-
dercarriages on the base frame, are
welded on to the track frames.
This type of floating hinged connec-
tion, complete with two hydraulic cylin-
ders between base frame and track fra-
mes, provides adjustment facilities of
base frame in relation to the undercar-
riage by +/-15.
The assembly compensates like a
shock absorber on rough terrain and
eases tramming on slopes and ramps.

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07/2004 KR 806-2 / Serial No. 64004
3.2 Boom Assembly
The boom assembly features allow for
perfect setting-up and alignment of the
drill mast, and consist basically of sle-
wing table, slewing column, boom arm,
swivel head and mast carrier, complete
with hydraulic cylinders.
Normally booms are only to move in two
levels, horizontal and vertical. The de-
sign of KR 806-2 allows an additional
movement of boom. This is a turn
around his own axle.
A rotary table mounted onto frontplate
of base frame gives a rotation around
boom axle by a hydraulic cylinder. The
possibe rotations of the rotary table are
15clockwise and 45anticlockwise
(seen in tramming direction).
These possibilities allow a set up and
alignment under difficult circumstances
e.g. in corners of buildings or structure.
The swivel head is mounted with bolt
bearings on the upper end of the boom.
A hydraulic cylinder is used to tilt the as-
sembly in the desired position.
This swivel head arrangement allows
the entire drill mast to be slewed from
vertical to horizontal.
Swivel head movement is such, that for
tramming and transport purposes the
mast complete with drill heads is
”shouldered” parallel to the boom.
All hydraulic cylinders are equipped
with load-bearing valves, which
maintain the cylinder in a fixed posi-
tion in the event of a sudden loss of
hydraulic pressure (pump failure or
hose damage).
Additional all hydraulic cylinders are
equipped with special load holding
valves (parachute valves) which per-
mit a controlled and low speed move-
ment of the boom and drill feed in
case of a hose/pipe rupture.

20
07/2004 KR 806-2 / Serial No. 64004
3.3 Drill mast type 202 with attachments
The drill mast consists of square sectio-
ned steel profiles.
The bottom end is fitted with a centrali-
ser, a twin clamp / breaking device and
a toothed support plate. The drill mast
is attached to the mast carrier.
The drill unit is mounted on a glide slide
which is guided on the drill mast. Axial
movement is assured by a feed chain
driven by a hydraulic feed gear. The
feed chain is tensioned automaticly!
Caution: Ensure that no one is within
the danger zone of the drill mast during
drilling operation. Operating the drill rig
when drilling personnel is within the
danger zone is forbidden, because per-
sons are endangered by slewing parts
of the drill mast.
When drilling mast has to be pressed
and fixed to ground or to the wall in or-
der to prevent mast from damages.
Safety Instructions for preparing to install
or remove the feed chain.
1. Mast in horizontal position and in working
height.
2. Block slide carriage.
3. Shutt off main engine of crawler drill.
Remove starter key (diesel engine).
4. Place both feed control levers to 0- posi-
tion (neutral).
5. Installing or removing of feed chain has to
be made only by trained technical perso-
nel.
6. Before operating the feed chain you
must ensure that the feed chain is slacke-
ned by the chain tension device.
PLEASE NOTE:
Mast with feed chain mechanism:
The tension of the chain is controlled by a
special cylinder at the front of the drill
mast. This is a high pressure cylinder. Do
never disassemble it yourself.
Hydr. drifter
KD 1624
Drill mast
Feed gear
with two-
speed
motor
Clamping-/
breaking
device