Sany Sr400r User manual

Quality Changes the World

Rotary Drilling Rig

SR400R

Safety, Operation & Maintenance Manual

mengkf 2022-04-21

Safety, Operation and Maintenance Manual-September 30, 2019 1

feiyezhengmian

SR400R

Rotary Drilling Rig

Safety, Operation & Maintenance Manual

WARNING

Read and follow the safety precautions and instruction in this manual and on the machine

decals. Failure to do can cause serious injury, death or property damage. Keep this manual with

the machine for reading and future reference.

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2Safety, Operation and Maintenance Manual-September 30, 2019

SR400R Rotary Drilling Rig

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Safety, Operation and Maintenance Manual-September 30, 2019 1

feiyefanmian

Sany Group

Sany Heavy Industry Co., Ltd,

Beijing Sany Intelligent Technology Co., Ltd,

Sany Industry Park,

Liliu Road, Nankou,

Changping District, Beijing, China, Zip code:102202

Service hotline (complaint/enquiry): 0086 4006098318

Email: crd@sany.com.cn

http://www.sanygroup.com

reproduced, used, distributed or disclosed except during normal operation of the

machine as described herein. All information included within this publication was

accurate at the time of publication. Product improvements, revisions, etc., may result in

differences between your machine and what is presented here. Sany Group assumes

no liability. For more information, contact Sany Group.

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Safety, Operation and Maintenance Manual-September 30, 2019 1

Important Safety Information

Most accidents that involve product operation, maintenance and repair are caused by failure to ob-

serve basic safety rules or precautions. An accident can often be avoided by recognizing poten-

tially hazardous situation before an accident occurs. A person must be alert to potential hazards.

This person should also have the necessary traning, skills and tools to perform these functions

properly. Improper operation, lubrication, maintenance or repair of this product can be dangerous

and could result in injury or death.

Do not operate any lubrication, maintenance or repair on this product, until you have read and

understood the operation, lubrication, maintenance an d repair information. Safety precautions

and warnings are provided in this manual and on the product. If these hazard warnings are not

heeded, bodily injury or death could occur to you or to other persons. The hazards are identified by

the Safety Alert Symbol by a Signal Word such as DANGER, WARNING, CAUTION OR NOTICE.

DANGER

Indicates an imminent hazard which, if not avoided, will result in serious injury or death.

WARNING

Indicates a potentially hazardous situation which, if not avoided, could result in injury or

possibly death.

CAUTION

Indicates a possible potential hazardous situation which, if not avoided, could result in

minor or major injury.

NOTICE

Indicates a situation which can cause damage to the machine, personal property and/or

the environment, or cause the equipment to operate improperly.

SANY cannot anticipate every possible circumstance that might involve a potential hazard. The

warnings in this manual and on the product are, therefore, not all inclusive.

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Safety, Operation and Maintenance Manual-September 30, 2019 1

Exemption Clauses

Specific Declaration

Rotary drilling rig is a foundation machine used for drilling piles. Any other use or any operation be-

yond the specified working range is not authorized use. Sany expressly bears no liability for any

consequence due to any unauthorized use.

Information on this manual is used to guide qualified operators to operate and maintain rotary drill-

ing rigs correctly. Sany expressly bears no liability for any consequence due to any use not observ-

ing the information on this manual.

It is forbidden to convert the rotary drilling rig without authorization. Sany expressly bears no liabil-

ity for any consequence. When crack or electrical malfunction on the rotary drilling rig occurs,

please contact the supplier, and don’t conduct welding or make changes without permission, or

else, for any consequence due to such contravention, Sany shall not bear any liability.

Use genuine spare parts from Sany. Sany expressly bears no liability for any machine damage or

accident due to the use of untested or unauthorized spare parts or tools.

Operate and maintain parts (such as engine, a/c) on the rotary drilling rig, and observe related reg-

ulations on Users’ guide supplied from their manufacturer.

Sany expressly bears no liability for any machine failure or damage due to force majeure of natural

disasters (earthquake, typhoon) and wars.

Sany cannot predict every circumstance that might involve a potential hazard in operation or main-

tenance. Operators and owners should highly attach importance to safety. Local specific safety

rules of the countries may be stricter. If they differ from the regulations on this manual, observe the

stricter one.

Duty of Sany

•Be responsible for providing qualified products and correct documents.

•Fulfill their promises on after-sales service, and document all maintenance and repair working

done by after-sales service personnel.

•Train the operation and maintenance personnel based on their needs.

Duty of Owners or Other Authorized Personnel

•Only after each person involved in the product’s operation, maintenance and repair is trained

and fully understands the Parts Book and Operation and Maintenance Manual, can they operate

and maintain the rotary drilling rig.

•Ensure the operation and maintenance personnel are qualified and know their related

responsibilities.

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•Periodically check related personnel’s safety consciousness during working.

•If any fault which will lead to unsafety occurs, stop the rotary drilling rig immediately.

•If necessary Sany service personnel have the right to check the rotary drilling rig for safety.

•Besides check items regulated by Sany, observe local laws and regulations to check the rotary

drilling rig.

•Ensure timely maintenance and repair on the rotary drilling rig.

•Carefully plan the use of the rotary drilling rig.

Duty of all working personnel

•If there is any abnormal symptom which may cause abnormal working of the rotary drilling rig or

potential hazard, report to your leader. If possible, correct fault in time.

•All personnel working around the rotary drilling rig must observe all warning signals and take

care of their own and others’ safety.

•All personnel should know their working tasks and procedures.

•Watch something like high voltage wire, unrelated personnel and poor ground for potential

danger, and report to the operators and signalmen.

Duty of managers

•Ensure the operators are trained and fully understand the Operation and Maintenance Manual

supplied by Sany. Ensure they are in physical fitness and have the certification of operation.

Otherwise, it is forbidden to operate the rotary drilling rig.

•Ensure the operators have good judgment ability, teamwork consciousness and psychological

quality. Otherwise, it is forbidden to operate or repair the rotary drilling rig.

•Ensure the signalmen have good vision and acoustic judgment, master standard command

signals. At the same time, they should have enough experience in recognizing danger factors

correctly, and inform the operators of danger factors to avoid them in time.

•Ensure assistant workers can identify the model and working condition to choose a proper rotary

drilling rig.

•Publicize safety consciousness to working personnel, and make them aware of safety

precautions and their related responsibilities.

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Safety, Operation and Maintenance Manual-September 30, 2019 I

Table of Contents

1 INTRODUCTION ...............................................................................................................1-1

1.1 Overview.................................................................................................................................1-3

1.2 Your Documentation Package.............................................................................................1-3

1.3 Organization of This Manual................................................................................................1-4

1.4 Your Sany Machine...............................................................................................................1-5

1.4.1 Special Tips ...................................................................................................................1-5

1.4.2 Application of Rotary Drilling Rig................................................................................1-6

1.4.3 Machine Directions.......................................................................................................1-6

1.4.4 Machine information.....................................................................................................1-6

1.4.5 Product nameplate .......................................................................................................1-7

1.4.6 Product nameplate .......................................................................................................1-8

1.5 Contact Information ..............................................................................................................1-9

2 Safety.....................................................................................................................................2-1

2.1 Foreword ................................................................................................................................2-5

2.2 Hazard Words........................................................................................................................2-5

2.2.1 Hazard word levels.......................................................................................................2-5

2.2.2 Other signal words .......................................................................................................2-6

2.3 Safety and Informational Machine Decals.........................................................................2-7

2.3.1 Locations .......................................................................................................................2-7

2.3.2 Meaning .......................................................................................................................2-11

2.4 Safety Equipment............................................................................................................... 2-24

2.4.1 Hydraulic lock lever ................................................................................................... 2-24

2.4.2 Fire extinguisher ........................................................................................................ 2-24

2.4.3 Emergency exit .......................................................................................................... 2-25

2.4.4 Seat belt...................................................................................................................... 2-25

2.4.5 Emergency stop button............................................................................................. 2-26

2.4.6 Limit switches............................................................................................................. 2-27

2.5 Safety Precautions............................................................................................................. 2-28

2.5.1 Be cautious of high pressure fluid........................................................................... 2-28

2.5.2 Dust hazard .............................................................................................................. 2-29

2.5.3 Mechanical injury....................................................................................................... 2-29

2.5.4 Battery hazards.......................................................................................................... 2-31

2.5.5 Fire prevention ........................................................................................................... 2-32

2.5.5.1 Away from fire .................................................................................................... 2-32

2.5.5.2 Daily checks........................................................................................................ 2-33

2.5.5.3 Fire treatment .................................................................................................... 2-34

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2.5.6 Scald prevention ....................................................................................................... 2-34

2.5.7 Safety information of hose ....................................................................................... 2-35

2.5.8 Fluid leakage.............................................................................................................. 2-36

2.5.9 Crawler safety information ...................................................................................... 2-37

2.5.10 Lightening and strong wind precautions ............................................................. 2-38

2.5.11 Falling protection ..................................................................................................... 2-38

2.5.12 Noise protection ...................................................................................................... 2-39

2.5.13 Vibration.................................................................................................................... 2-39

2.5.14 Wire rope safety information.................................................................................. 2-39

2.5.15 Climbing on/off drilling rig....................................................................................... 2-40

2.5.16 Kelly bar and drilling tools ...................................................................................... 2-41

2.5.17 Working at areas with underground pipelines .................................................... 2-41

2.5.18 Working at areas with high voltage power lines.................................................. 2-42

2.5.19 Electrical accident ................................................................................................... 2-43

2.6 Safety during Operation .................................................................................................... 2-44

2.6.1 Personnel requirements ........................................................................................... 2-44

2.6.2 Personal protective equipment................................................................................ 2-45

2.6.3 Keeping the drilling rig in good service condition.................................................. 2-46

2.6.4 Safety on construction site ....................................................................................... 2-47

2.6.5 Signals to control operation .................................................................................... 2-49

2.6.6 Drilling rig danger area ............................................................................................. 2-54

2.6.7 Avoiding tipping ......................................................................................................... 2-55

2.6.8 Before entering the cab ............................................................................................ 2-56

2.6.9 Before starting the engine ....................................................................................... 2-57

2.6.10 Before operating the drilling rig ............................................................................. 2-57

2.6.11 Drilling rig operation ................................................................................................ 2-58

2.6.12 Construction of drilling rig ...................................................................................... 2-59

2.6.13 Drilling rig dismantling ........................................................................................... 2-60

2.6.14 Parking safety ......................................................................................................... 2-61

2.6.15 Transporting drilling rig .......................................................................................... 2-62

2.6.16 Drilling rig maintenance ......................................................................................... 2-63

2.6.17 Winch operation ...................................................................................................... 2-64

2.7 Maintenance Safety ........................................................................................................... 2-64

2.7.1 Maintenance personnel ............................................................................................ 2-64

2.7.2 Risks in maintenance ............................................................................................... 2-64

2.7.3 Preparing for maintenance....................................................................................... 2-68

2.7.4 During maintenance ................................................................................................. 2-70

2.8 Environment Protection..................................................................................................... 2-72

2.8.1 Proper waste disposal ............................................................................................. 2-72

2.8.2 Mud pollution.............................................................................................................. 2-72

2.8.3 Fuel discharge .......................................................................................................... 2-73

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Safety, Operation and Maintenance Manual-September 30, 2019 III

3 System Function .............................................................................................................3-1

3.1 General Structure .................................................................................................................3-5

3.2 Machine Description .............................................................................................................3-7

3.2.1 Traveling mechanism...................................................................................................3-7

3.2.2 Upper carriage ..............................................................................................................3-7

3.2.3 Hydraulic system ..........................................................................................................3-8

3.2.4 Electrical system...........................................................................................................3-9

3.2.5 Main winch.................................................................................................................. 3-10

3.2.6 Auxiliary winch ............................................................................................................3-11

3.2.7 Mast............................................................................................................................. 3-12

3.2.8 Rotary drive ................................................................................................................ 3-12

3.2.9 Kelly bar ...................................................................................................................... 3-13

3.3 General View of the Operator’s Cab ............................................................................... 3-14

3.4 E-pad.................................................................................................................................... 3-15

3.5 Operation Control Panel.................................................................................................... 3-17

3.6 Engine Ignition Switch and Engine Speed Control Dial................................................ 3-19

3.7 Freewheel Pedal (not Equipped In This Model) ............................................................ 3-20

3.8 Air Conditioning System.................................................................................................... 3-21

3.8.1 Control panel.............................................................................................................. 3-21

3.8.2 Operation method...................................................................................................... 3-24

3.9 Radio.................................................................................................................................... 3-33

3.9.1 Control panel.............................................................................................................. 3-33

3.9.2 Radio Operation......................................................................................................... 3-35

3.10 Traveling Lever/pedal...................................................................................................... 3-38

3.11 Left and Right Operation Handle ................................................................................... 3-39

3.11.1 Left operation handle .............................................................................................. 3-39

3.11.2 Right operation handle............................................................................................ 3-39

3.11.3 Directional function of operation handle............................................................... 3-40

3.11.4 Directional function of right operation handle...................................................... 3-41

3.12 Mast Lever ........................................................................................................................ 3-41

3.13 Display............................................................................................................................... 3-43

3.13.1 Start-up interface..................................................................................................... 3-43

3.13.2 Drilling operation interface ..................................................................................... 3-44

3.13.3 Menu interface ......................................................................................................... 3-48

3.13.4 Common function - function................................................................................... 3-50

3.13.5 Common function - switch...................................................................................... 3-53

3.13.6 Common function - operation ................................................................................ 3-55

3.13.7 Common function - calibration............................................................................... 3-58

3.13.8 Parameter calibration interface ............................................................................. 3-60

3.13.9 Locking recess parameter calibration interface.................................................. 3-62

3.13.10 Lubrication operation information interface....................................................... 3-64

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3.13.11 Lubrication operation information interface - parameter setting..................... 3-65

3.13.12 GPS status interface............................................................................................. 3-66

3.13.13 GPS unlock interface............................................................................................ 3-67

3.13.14 Enter information interface .................................................................................. 3-68

3.13.15 Output information interface ................................................................................ 3-69

3.13.16 Maintenance interface.......................................................................................... 3-70

3.13.17 History query interface ......................................................................................... 3-72

3.13.18 Ancient fault interface........................................................................................... 3-73

3.13.19 Overload record interface .................................................................................... 3-74

3.13.20 User settings interface.......................................................................................... 3-75

3.13.21 Language selection interface .............................................................................. 3-76

3.13.22 Time settings interface ......................................................................................... 3-77

3.13.23 Brightness adjusting interface............................................................................. 3-78

3.13.24 Construction method interface ............................................................................ 3-79

3.14 Seat.................................................................................................................................... 3-82

3.15 Level ................................................................................................................................. 3-84

3.16 Alarm Lamp....................................................................................................................... 3-85

3.17 Electric Cabinet ................................................................................................................ 3-86

3.18 Hydraulic Cooling Fan Reverse Flow Button (optional) ............................................. 3-87

4 Operation.............................................................................................................................4-1

4.1 Basic Operation.....................................................................................................................4-7

4.1.1 Job preparations...........................................................................................................4-7

4.1.2 Visual checks ................................................................................................................4-7

4.1.3 Job set-up ......................................................................................................................4-8

4.1.4 Checks before starting the engine .......................................................................... 4-10

4.1.4.1 Checking coolant level ...................................................................................... 4-10

4.1.4.2 Checking engine oil level .................................................................................. 4-10

4.1.4.3 Draining water and sediment in fuel tank........................................................ 4-10

4.1.4.4 Checking fuel amount and refuel ..................................................................... 4-10

4.1.4.5 Checking hydraulic oil level .............................................................................. 4-10

4.1.4.6 oil separator ........................................................................................................ 4-10

4.1.4.7 Checking the electrical circuit............................................................................4-11

4.1.4.8 Checking horn function.......................................................................................4-11

4.1.5 Starting the engine .................................................................................................... 4-12

4.1.5.1 Normal start-up................................................................................................... 4-12

4.1.5.2 Starting the engine in cold weather ................................................................. 4-14

4.1.6 After starting the engine ........................................................................................... 4-14

4.1.6.1 Breaking in a new machine............................................................................... 4-14

4.1.6.2 Warming-up operation....................................................................................... 4-15

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Safety, Operation and Maintenance Manual-September 30, 2019 V

4.1.7 Shutting down the engine......................................................................................... 4-16

4.1.8 Checks after each workday...................................................................................... 4-18

4.1.9 Traveling ..................................................................................................................... 4-18

4.1.9.1 Traveling operation ............................................................................................ 4-18

4.1.9.2 Traveling on slopes............................................................................................ 4-22

4.1.10 Upper carriage swing.............................................................................................. 4-24

4.1.11 Adjusting drilling center distance........................................................................... 4-25

4.1.12 Raising and lowering the mast .............................................................................. 4-27

4.1.13 Adjusting mast to verticality ................................................................................... 4-29

4.1.14 Crowd control........................................................................................................... 4-31

4.1.15 Main winch operation.............................................................................................. 4-33

4.1.16 Auxiliary winch operation ....................................................................................... 4-35

4.1.17 Rotary drive control................................................................................................. 4-37

4.1.18 Depth measuring control ........................................................................................ 4-38

4.1.19 Calibration ................................................................................................................ 4-38

4.1.19.1 Depth measurement calibration..................................................................... 4-38

4.1.19.2 Swing angle calibration ................................................................................... 4-40

4.1.19.3 Verticality calibration........................................................................................ 4-41

4.1.20 Crawler extending and retracting.......................................................................... 4-42

4.1.21 Parking the drilling rig ............................................................................................. 4-43

4.1.21.1 Regular parking................................................................................................ 4-43

4.1.21.2 Checks during parking .................................................................................... 4-44

4.1.21.3 Machine locking ............................................................................................... 4-45

4.1.21.4 Long-term storage ........................................................................................... 4-45

4.1.22 Operation in cold weather ...................................................................................... 4-47

4.1.22.1 Checks in cold weather ................................................................................... 4-47

4.1.22.2 Operation tips in cold weather........................................................................ 4-48

4.1.22.3 After daily operation......................................................................................... 4-50

4.1.22.4 After cold season ............................................................................................. 4-51

4.2 Drilling Rig Construction.................................................................................................... 4-51

4.2.1 Construction preparation.......................................................................................... 4-51

4.2.1.1 Drilling rig checks .............................................................................................. 4-51

4.2.1.2 Drilling tool selection.......................................................................................... 4-53

4.2.2 Drilling rig in place ..................................................................................................... 4-53

4.2.3 Drilling ......................................................................................................................... 4-54

4.2.3.1 Drilling in clay layer ............................................................................................ 4-54

4.2.3.2 Drilling in sand layer........................................................................................... 4-54

4.2.3.3 Drilling in pebble layer ....................................................................................... 4-55

4.2.3.4 Drilling in shale layer.......................................................................................... 4-55

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VI Safety, Operation and Maintenance Manual-September 30, 2019

4.3 Rigging & Derigging........................................................................................................... 4-56

4.3.1 Requirements for Rigging and Derigging............................................................... 4-56

4.3.1.1 Guidelines for rigging and derigging................................................................ 4-56

4.3.1.2 Notes on rigging and derigging ........................................................................ 4-57

4.3.1.3 Preparation for rigging and derigging.............................................................. 4-58

4.3.2 Rigging Drilling Rig.................................................................................................... 4-58

4.3.2.1 Removing locking bar ........................................................................................ 4-58

4.3.2.2 Extending the crawlers ...................................................................................... 4-59

4.3.2.3 Mounting counterweight.................................................................................... 4-59

4.3.2.4 Fixing the supporting trestle ............................................................................. 4-61

4.3.2.5 Installing middle mast and mast cylinder........................................................ 4-63

4.3.2.6 Installing main winch.......................................................................................... 4-66

4.3.2.7 Installing upper mast and masthead ............................................................... 4-66

4.3.2.8 Installing wire ropes ........................................................................................... 4-68

4.3.2.9 Raising the Mast................................................................................................. 4-74

4.3.2.10 Mounting rotary drive....................................................................................... 4-75

4.3.2.11 Drilling rig test run ............................................................................................ 4-77

4.3.3 Installing Drilling Tool ................................................................................................ 4-78

4.3.3.1 Connecting rope swivel to Kelly bar ................................................................ 4-78

4.3.3.2 Connecting Kelly guide to Kelly bar................................................................. 4-79

4.3.3.3 Aligning drilling rig with Kelly bar upper end................................................... 4-80

4.3.3.4 Connecting wire rope and rope swivel ............................................................ 4-80

4.3.3.5 Installing Kelly bar .............................................................................................. 4-81

4.3.3.6 Installing drilling bucket ..................................................................................... 4-85

4.3.4 Disassembling Drilling Tool...................................................................................... 4-85

4.3.4.1 Disassembling drilling bucket........................................................................... 4-85

4.3.4.2 Removing Kelly bar............................................................................................ 4-86

4.3.5 Disassembling Drilling Rig ....................................................................................... 4-88

4.3.5.1 Removing rotary drive ....................................................................................... 4-88

4.3.5.2 Mast forward Inclination .................................................................................... 4-90

4.3.5.3 Removing main and auxiliary rope .................................................................. 4-91

4.3.5.4 Removing masthead and upper mast ............................................................. 4-93

4.3.5.5 Removing middle mast and mast cylinder...................................................... 4-94

4.3.5.6 Removing supporting trestle............................................................................. 4-96

4.3.5.7 Removing counterweight .................................................................................. 4-97

4.4 Wire Rope ........................................................................................................................... 4-98

4.4.1 Installing wire rope .................................................................................................... 4-98

4.4.2 Unloading and storing wire rope............................................................................ 4-104

4.4.3 Discarding wire rope ............................................................................................... 4-105

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Safety, Operation and Maintenance Manual-September 30, 2019 VII

4.5 Drilling Rig Transport ....................................................................................................... 4-107

4.5.1 Transport requirements .......................................................................................... 4-107

4.5.2 Safety guidelines for transport............................................................................... 4-107

4.5.3 Transport Parameters............................................................................................. 4-109

4.5.3.1 Transport dimensions A (without rotary drive, upper mast and

masthead)........................................................................................................ 4-109

4.5.3.2 Transport dimensions B (without rotary drive, upper mast, masthead and

counterweight)..................................................................................................4-111

4.5.3.3 Transport dimensions C (without rotary drive, mast assembly,

counterweight and main winch) .....................................................................4-113

4.5.4 Loading and Unloading the Machine .....................................................................4-117

4.5.4.1 Requirement for loading and unloading the machine ..................................4-117

4.5.4.2 Loading the machine ........................................................................................4-117

4.5.4.3 Fastening method ............................................................................................ 4-120

4.5.4.4 Unloading the machine.................................................................................... 4-120

4.5.5 Requirements for sea transportation .................................................................... 4-120

4.6 Kelly Bar ............................................................................................................................ 4-122

4.6.1 Instructions ............................................................................................................... 4-122

4.6.2 Welding ..................................................................................................................... 4-123

4.6.3 Transport and storage............................................................................................. 4-128

4.7 Drilling Tool........................................................................................................................ 4-130

4.7.1 Overview................................................................................................................... 4-130

4.7.2 Kelly box ................................................................................................................... 4-130

4.7.3 Drilling Tool Categories........................................................................................... 4-131

4.7.3.1 Drilling bucket double-edge ............................................................................ 4-131

4.7.3.2 Cone auger ....................................................................................................... 4-133

4.7.3.3 Straight auger ................................................................................................... 4-135

4.7.3.4 Core barrel ........................................................................................................ 4-136

4.7.3.5 Double-layer core barrel.................................................................................. 4-138

4.7.3.6 Underreamer bit ............................................................................................... 4-139

4.7.3.7 Casing drive adapter........................................................................................ 4-139

4.7.3.8 Easily worn parts of drilling rig........................................................................ 4-140

4.7.4 Drilling Tool Operation ............................................................................................ 4-140

4.7.4.1 Drilling bucket ................................................................................................... 4-140

4.7.4.2 Auger.................................................................................................................. 4-141

4.7.4.3 Core barrel ........................................................................................................ 4-142

4.7.4.4 Belling tool......................................................................................................... 4-143

5 Maintenance.......................................................................................................................5-1

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VIII Safety, Operation and Maintenance Manual-September 30, 2019

5.1 Maintenance Precautions ....................................................................................................5-5

5.2 Maintenance Information .....................................................................................................5-6

5.2.1 Lubrication points .........................................................................................................5-6

5.2.2 Drilling rig oil............................................................................................................... 5-10

5.3 Maintenance Schedule...................................................................................................... 5-13

5.4 Maintenance Procedures.................................................................................................. 5-27

5.4.1 Every 10 Service Hours............................................................................................ 5-27

5.4.1.1 Crawler tension - check and adjust ................................................................. 5-27

5.4.1.2 Hydraulic cylinders- check ................................................................................ 5-29

5.4.1.3 Gearbox gear oil level- check........................................................................... 5-31

5.4.1.4 Shock absorbing device of rotary drive - check and replace ....................... 5-32

5.4.1.5 Crawler track - visually inspect ........................................................................ 5-34

5.4.1.6 Wire rope - inspect ............................................................................................ 5-36

5.4.1.7 Wire rope - maintain .......................................................................................... 5-37

5.4.1.8 Rope swivel flexibility - check........................................................................... 5-38

5.4.1.9 Rope swivel - check and lubricate ................................................................... 5-38

5.4.1.10 Engine oil level - check and refuel................................................................. 5-39

5.4.1.11 Water and sediment in fuel tank - drain ........................................................ 5-40

5.4.1.12 Hydraulic oil level - check ............................................................................... 5-41

5.4.1.13 Coolant level - check ....................................................................................... 5-43

5.4.1.14 Fuel amount - check and refuel ..................................................................... 5-44

5.4.2 Initial 50 Service Hours............................................................................................. 5-45

5.4.2.1 Engine oil and filter - change and replace ...................................................... 5-45

5.4.2.2 Fuel filter - check and replace .......................................................................... 5-48

5.4.2.3 Filter of water oil separator - replace............................................................... 5-49

5.4.2.4 Fuel tank strainer - clean................................................................................... 5-51

5.4.3 Every 50 Service Hour.............................................................................................. 5-51

5.4.3.1 Winch reducers oil level - check....................................................................... 5-51

5.4.3.2 Switches, buttons and operation handles - check......................................... 5-52

5.4.3.3 Rope hold-down rollers - check........................................................................ 5-52

5.4.3.4 Rotary drive mounting bolts - check ................................................................ 5-53

5.4.3.5 Driver strip - check and change ....................................................................... 5-54

5.4.3.6 Rotary drive sliding strip - check and replace ............................................... 5-55

5.4.3.7 Crawler track mounting bolts - check .............................................................. 5-56

5.4.3.8 Air intake and exhaust system - visually check ............................................. 5-57

5.4.3.9 Window wiper - check........................................................................................ 5-57

5.4.3.10 Window washer - check .................................................................................. 5-57

5.4.3.11 Kelly guide swing bearing - replace............................................................... 5-58

5.4.3.12 Impact ring - check and replace..................................................................... 5-59

Table of Contents SR400R Rotary Drilling Rig

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Safety, Operation and Maintenance Manual-September 30, 2019 IX

5.4.3.13 Spring of Kelly bar- check and replace ......................................................... 5-60

5.4.3.14 Shock absorber - check .................................................................................. 5-61

5.4.4 Initial 250 Service Hours........................................................................................... 5-61

5.4.4.1 Winch reducer oil- change ................................................................................ 5-61

5.4.4.2 Bolts connecting swing bearing - check.......................................................... 5-62

5.4.4.3 Reducer gear oil - change................................................................................. 5-62

5.4.5 Every 250 Service Hours.......................................................................................... 5-64

5.4.5.1 Wire rope sheaves - check ............................................................................... 5-64

5.4.5.2 Rotary drive gear oil - check............................................................................. 5-64

5.4.5.3 Hoses - check and replace ............................................................................... 5-64

5.4.5.4 Kelly guide sliding strip - check and replace .................................................. 5-65

5.4.6 Initial 500 Service Hours........................................................................................... 5-65

5.4.6.1 Gearbox gear oil - change ................................................................................ 5-65

5.4.6.2 Gear oil for swing reducer - change ................................................................ 5-66

5.4.6.3 Travel reducer oil - change ............................................................................... 5-67

5.4.7 Every 500 Service Hours.......................................................................................... 5-68

5.4.7.1 Engine crankcase breather - clean ................................................................. 5-68

5.4.7.2 Kelly bar baffle - check ...................................................................................... 5-69

5.4.7.3 Kelly bar drive gibs - check ............................................................................... 5-70

5.4.7.4 Kelly bar tube - check ........................................................................................ 5-70

5.4.7.5 Kelly bar locking recesses - check................................................................... 5-71

5.4.7.6 Engine oil and filter - change ............................................................................ 5-71

5.4.7.7 Bolts connecting swing bearing - check.......................................................... 5-71

5.4.7.8 Fuel filter - replace ............................................................................................. 5-71

5.4.7.9 Filter for water oil separator - replace.............................................................. 5-71

5.4.7.10 Fuel tank strainer - clean ................................................................................ 5-71

5.4.7.11 Gearbox gear oil - change .............................................................................. 5-71

5.4.7.12 Winch reducer oil- change.............................................................................. 5-72

5.4.8 Initial 1000 Service Hours ........................................................................................ 5-72

5.4.8.1 Hydraulic oil - change ........................................................................................ 5-72

5.4.8.2 Oil suction filter - clean ...................................................................................... 5-75

5.4.9 Every 1000 Service Hours ....................................................................................... 5-75

5.4.9.1 Hydraulic hose - check ...................................................................................... 5-75

5.4.9.2 Hydraulic hose - change ................................................................................... 5-76

5.4.9.3 Aux. pump filter element - change................................................................... 5-76

5.4.9.4 Pilot filter element - replace .............................................................................. 5-77

5.4.9.5 Return filter - replace ......................................................................................... 5-79

5.4.9.6 Battery - clean and recycle ............................................................................... 5-86

5.4.9.7 Air recirculation filter - inspect and replace ................................................... 5-87

SR400R Rotary Drilling Rig Table of Contents

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XSafety, Operation and Maintenance Manual-September 30, 2019

5.4.9.8 Winch reducer oil - change ............................................................................... 5-88

5.4.9.9 Gear oil for swing reducer - change ................................................................ 5-88

5.4.10 Every 2000 Service Hours ..................................................................................... 5-88

5.4.10.1 Oil suction filter - clean .................................................................................... 5-88

5.4.10.2 Gearbox gear oil - change .............................................................................. 5-88

5.4.10.3 Travel reducer oil - change ............................................................................. 5-88

5.4.10.4 Hydraulic oil - change...................................................................................... 5-88

5.5 Storage of Drilling Rig........................................................................................................ 5-88

5.5.1 Preparations before storage .................................................................................... 5-88

5.5.2 Machine Storage ....................................................................................................... 5-89

5.5.2.1 Maintenance to the drilling rig during storage................................................ 5-89

5.5.2.2 Maintenance to the drilling rig be fore moving from the warehouse ........... 5-90

6 Troubleshooting ..............................................................................................................6-1

6.1 Motor System - Troubleshooting.........................................................................................6-3

6.2 Electrical System - Troubleshooting................................................................................ 6-21

6.3 Hydraulic System - Troubleshooting ............................................................................... 6-23

6.4 Work Equipment - Troubleshooting................................................................................. 6-29

6.5 Air Conditioning System - Troubleshooting.................................................................... 6-41

7 Specifications ...................................................................................................................7-1

7.1 Overall Dimensions...............................................................................................................7-3

7.2 Performance Parameters.....................................................................................................7-3

7.3 Wire Rope Specifications.....................................................................................................7-6

7.4 Kelly Bar Configuration.........................................................................................................7-7

8 Appendix..............................................................................................................................8-1

8.1 Bolt Tightening Torque..........................................................................................................8-3

8.2 Common Misoperation .........................................................................................................8-5

8.3 Central Lubrication System .................................................................................................8-7

8.3.1 Functional description of the central lubrication system.........................................8-7

8.3.2 Components of the Central lubrication system ........................................................8-9

8.3.3 Method of operation ...................................................................................................8-11

8.3.4 Troubleshooting ......................................................................................................... 8-14

Table of Contents SR400R Rotary Drilling Rig

mengkf 2022-04-21

Table of contents

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