SUNWARD SWDM40 Manual

SWDM40 ROTARY DRILLING RIG
（809X00000000）
OPERATION & MAINTENANCE MANUAL
September, 2023
SUNWARD INTELLIGENT EQUIPMENT CO., LTD.

SWDM40 OPERATION & MAINTENANCE MANUAL
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Foreword
This manual will help users to operate and maintain the machine correctly.
It is particularly important that the machine operator should read these instructions carefully
not only prior to using the machine for the first time (in order to become acquainted with its
operation and special features), but also to take full advantage of its capabilities during use,
or for lubricating and servicing operations. Otherwise accidents or damage may occur.
The manual should be regarded as the permanent part of machine and kept in the cab for
consultation at any time. And the manual should be attached when the machine is transferred
or sold.
The machine is designed according to the metric system, all the data presented are metric
and only metric parts and apparatus can be used.
Position definition: RIGHT and LEFT always mean the left and right of an operator seated
correctly in the machine. The drive sprockets of undercarriage are located at the rear.
Sunward guarantees to keep machine in good repair in term of service. The service details
are showed in Maintenance Card supplied by distribution.
Maintenance Card guarantees can you get service or not in service period. Warranty claims
will not be considered provided：1. Reassemble and repair machine without any notice to
Sunward; 2.Disaassemble, welding and add parts in machine; 3.Use the parts which is not
from Sunward or do not get approval by Sunward; 4.Assemble, operate, park the machine
which do not follow the operator’s manual; 5. Fuel oil and lubricating grease is not fit for
the manual request; 6.Do not complete routine maintenance base on the manual.
Possible warranty claims may be considered only provided that all operations are made by
qualified operator and scheduled inspections are made at the specified times by qualified
technician.
Regarding SAFETY in particular, we recommend carefully reading the SAFETY RULES in
this manual and complying with all the safety rules.
The equipment covered by this manual meets the applicable technical specifications
effective as of its date of issue. The manufacturer SUNWARD reserves the right to make
from time to time and without prior notice any modification or amendment of any nature,
deemed useful or necessary, to any machine component, without any obligation to amend
the content of this manual accordingly. Pictures and data contained in this manual are not
binding. Consequently, no claim raised in this respect will be considered.
Sunward Intelligent Equipment Co., Ltd.

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TABLE OF CONTENTS
1 SAFETY RULES ......................................................................................................... 8
1.1 SAFETY INSTRUCTION ..................................................................................................................8
1.1.1 Safety Level ................................................................. 8
1.1.2 Safety Signs ................................................................. 8
1.1.3 Safety Sign .................................................................. 8
1.1.4 Other Signs .................................................................. 9
1.2 ALLOWED WORKING SLOPE ...................................................................................................... 9
1.2.1 Regulation of Parking Space ................................................. 9
1.2.2 Travel on Slope .............................................................. 9
1.2.3 Regulation of Cross Fall ................................................... 10
1.2.4 Regulation of Working Fall ................................................. 10
1.3 EQUIPMENT STABILITY ..............................................................................................................11
1.3.1 General Conditions ..........................................................11
1.3.2 Rated Load .................................................................. 11
1.4 WORKING AREA ............................................................................................................................ 12
1.5 OPERATOR VISIBILITY ............................................................................................................... 13
1.6 SAFETY PRECAUTIONS ............................................................................................................... 13
1.6.1 Preparation and Solutions for Emergencies ................................. 13
1.6.2 Wearing Protective Devices ................................................. 14
1.6.3 Keeping Machine Away From Power Transmission Line and Aerial Obstacles ... 14
1.6.4 Fire Prevention ............................................................. 14
1.6.5 Avoiding Incontrollable Accidents .......................................... 15
1.6.6 Safety Maintenance ..........................................................16
1.6.7 Machine Cleaning ............................................................16
1.7 SAFETY PRECAUTIONS ............................................................................................................... 17
1.7.1 Precautions Before Working ................................................. 17
1.7.2 Precautions for Working .................................................... 18
1.7.3 Precautions When Assembly and Disassembly ................................. 19
1.7.4 Precautions for Winch Operation ............................................ 20
1.7.5 Precautions for Drilling ................................................... 20
1.7.6 Precautions for Travelling ................................................. 21
1.7.7 Precautions for Transportation ............................................. 21
1.7.8 Preventing Accidents While Backing or Swinging ............................ 21
1.7.9 Preventing Battery Explosion ............................................... 22
1.7.10 Prevention of Splashing Objects ........................................... 22
1.7.11 Prevention of Flying-out Parts ............................................ 22
1.7.12 Keeping Away From Transmission Parts ......................................22
1.7.13 Preventing Inhaling Asbestos Dust ......................................... 23
1.7.14 Be Cautious of Inhalation of Smoke or Exhaust Gas ........................ 23
1.7.15 Preventing Scald ...........................................................23
1.7.16 Be Cautious of High Pressure Liquids ......................................23
1.7.17 Be Careful of High Pressure Gas ........................................... 23
1.7.18 Avoiding Heating near Pressure Oil Pipes ................................. 24

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1.7.19 Avoiding Heating Pipes Containing Flammable Liquids ...................... 24
1.7.20 Precautions for Welding ................................................... 24
1.7.21 Safe Disposal of Liquids .................................................. 24
1.7.22 Safe Disposal of Chemicals ................................................ 24
1.8 SAFETY FACILITIES ..................................................................................................................... 25
1.8.1 Emergency Exit .............................................................. 25
1.8.2 Fire Extinguisher ...........................................................25
1.8.3 Emergency Stop .............................................................. 25
1.8.4 Safety Handle ............................................................... 26
1.8.5 Height Limit ................................................................ 26
1.9 Prohibition of Private Modification ................................................................................................ 27
2 OVERVIEW ............................................................................................................. 28
2.1 APPLICABLE RANGE ....................................................................................................................28
2.2 CONDITIONS OF USING ENVIRONMENT ...............................................................................28
2.3 TECHNICAL CHARACTERISTICS .............................................................................................29
2.3.1 Machine Structure ...........................................................29
2.3.2 Undercarriage ............................................................... 30
2.3.3 Upper-Carriage and Luffing Mechanism .......................................31
2.3.4 Power System ................................................................ 34
2.3.5 Air-Conditioning System .................................................... 35
2.3.6 Rotary drive ................................................................ 36
2.3.7 Kelly Bar, Drilling Tools .................................................. 37
3 OPERATION ............................................................................................................ 39
3.1 CONSOLE OPERATION INSTRUCTIONS .................................................................................39
3.2 INTERIOR OPERATION INSTRUCTIONS ................................................................................45
3.2.1 Operating Interfaces of Display Screen .....................................48
3.2.2 Membrane Key Panel ..........................................................67
3.3 ENGINE USE .................................................................................................................................... 72
3.3.1 Precautions for Engine Use ................................................. 72
3.3.2 Precautions for Engine Preheating and Idling .............................. 72
3.3.3 Precautions for Engine Shutdown ............................................ 72
3.3.4 Correct Filling of Coolant ................................................. 73
3.3.5 Other Operation Precautions ................................................ 73
3.4 USE AND MAINTENANCE OF POST-PROCESSING SYSTEM .............................................74
3.5 AIR CONDITIONER ........................................................................................................................75
3.5.1 Use of Air Conditioner ..................................................... 75
3.5.2 Common Failures and Solutions .............................................. 79
4 CONTROL ...............................................................................................................81
4.1 TRAVEL .............................................................................................................................................81
4.2 CRAWLER EXTENSION AND RETRACTION ..........................................................................83
4.3 UPPER-CARRIAGE SLEWING .................................................................................................... 84
4.4 BOOM LUFFING ............................................................................................................................. 86
4.5 ERECTING MAST ........................................................................................................................... 88

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4.6 MAIN WINCH .................................................................................................................................. 90
4.7 AUXILIARY WINCH .......................................................................................................................94
4.8 Rotary drive ROTATION .................................................................................................................96
4.9 PRESSURIZATION ..........................................................................................................................99
4.10 MAST OUTRIGGER ................................................................................................................... 102
4.11 CROWD WINCH WIREROPE TENSION ............................................................................... 103
4.12 CATHEAD LIFT CYLINDER .................................................................................................... 105
4.13 MOVEMENTS OF ROTARY BRAKE CYLINDER ................................................................107
5 DRILLING .............................................................................................................109
5.1 PREPARATION AND CHECK-UP BEFORE WORKING .......................................................109
5.2 STARTING ENGINE ......................................................................................................................109
5.3 MACHINE POSITIONING ...........................................................................................................110
5.4 MACHINE ASSEMBLY .................................................................................................................111
5.4.1 Machine Positioning ........................................................111
5.4.2 Self-Assembly and Self-Disassembly of Drill Mast ......................... 111
5.4.3 Kelly Bar Mounting .........................................................111
5.5 MACHINE WORK ......................................................................................................................... 114
5.5.1 Rig Trial Running ..........................................................114
5.5.2 Drilling Tool Selection ................................................... 114
5.5.3 Hole Opening and Sleeve Installation ......................................114
5.5.4 Drilling ................................................................... 115
5.5.5 Machine Transposition ..................................................... 116
5.5.6 Machine Shutdown and Emergency Stop ....................................... 117
5.5.7 Steps of Changing Drilling Mode to Transportation Mode ................... 118
6 ASSEMBLY, DISASSEMBLY AND TRANSPORT ............................................................ 119
6.1 MACHINE ASSEMBLY .................................................................................................................119
6.1.1 Upper/Under-carriage Assembly Installation (Case of disassembly of upper/
under-carriage) ......................................................................119
6.1.2 Drill Mast Installation ................................................... 120
6.1.3 Steel Rope Assembly of Main and Auxiliary Winch .......................... 120
6.1.4 Assembly of Rotary drive .................................................. 121
6.2 MACHINE TRANSPORT ............................................................................................................. 122
6.2.1 Transport Rules ............................................................ 122
6.2.2 Transport Parameter ........................................................123
6.3 DRIVING ONTO / OFF A PLATFORM TRAILER ...................................................................128
6.3.1 Requirements ............................................................... 128
6.3.2 Driving Onto a Platform Trailer ........................................... 128
6.3.3 Tying Down the Machine .................................................... 129
6.3.4 Driving Off a Platform Trailer ............................................ 129
6.4 REQUIREMENTS FOR SEA TRANSPORT .............................................................................. 130
6.5 PRECAUTIONS FOR TRANSPORTATION ..............................................................................131
6.5.1 Notes for Machine Assembly and Disassembly ............................... 131
6.5.2 Tying Machine Down .........................................................131
6.6 STORAGE ....................................................................................................................................... 132

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6.6.1 Storage Preparation ........................................................132
6.6.2 During Storage ............................................................. 132
6.6.3 After a Long-Term Storage ................................................. 132
6.6.4 Remote Operation ...........................................................133
7. KELLY AND DRILLING TOOLS ................................................................................135
7.1 KELLY ............................................................................................................................................. 135
7.1.1 Introduction of Kelly ..................................................... 135
7.1.2 Correct Model Selection for Kelly ......................................... 137
7.1.3 Correct Operation of Kelly ................................................ 137
7.1.4 Kelly Disassembly ..........................................................140
7.1.5 Maintenance for Kelly ..................................................... 142
7.1.6 Requirements of Long-time Storage and Transport for Kelly ................143
7.1.7 After-Sale Service Code for Kelly ......................................... 143
7.1.8 Simple Repair Technology for Kelly ........................................ 145
7.2 DRILLING TOOLS ........................................................................................................................147
7.2.1 Common Drilling Tools and Application .....................................147
8 MAINTENANCE AND SERVICE ................................................................................ 152
8.1 SAFETY INSTRUCTIONS FOR MAINTENANCE .................................................................. 152
8.1.1 Overview ................................................................... 152
8.1.2 Note for Maintenance ...................................................... 152
8.2 REGULAR MAINTENANCE ....................................................................................................... 160
8.2.1 Lubrication Maintenance Chart ............................................. 160
8.2.2 Oil ........................................................................ 166
8.2.3 Regular Check .............................................................. 167
8.3 EVERY 10 HOURS MAINTENANCE .........................................................................................168
8.3.1 Checking And Adjusting Track Tension ......................................168
8.3.2 Hydraulic Cylinder Maintenance ............................................ 170
8.3.3 Checking Oil Level in Rotary drive Gearbox ............................... 172
8.3.4 Checking cushion device of Rotary drive ...................................172
8.3.5 Check Track Components for Lost or Damaged ............................... 172
8.3.6 Wire Rope Inspection ...................................................... 173
8.3.7 Discarding Criteria of Wire Rope .......................................... 174
8.3.8 Wire Rope Maintenance ..................................................... 175
8.3.9 Checking Swivel Joint for Flexibility .....................................176
8.3.10 Lubrication of Wire Rope Swivel Joint ....................................176
8.3.11 Checking Engine Oil Level ................................................ 178
8.3.12 Draining Water and Sediment in Diesel Tank .............................. 179
8.3.13 Checking Hydraulic Oil Level and Quality ................................ 180
8.3.14 Checking Gear Oil Level for Reduction Gearbox ........................... 180
8.3.15 Checking Coolant Level ................................................... 181
8.3.16 Checking Fuel Capacity and Filling Fuel Oil ............................. 183
8.3.17 Checking Switches, Buttons and Operating Handles ........................ 184
8.4 MAINTENANCE FOR INITIAL 50 HOURS OF OPERATION ..............................................185
8.4.1 Changing Engine Oil and Filter ............................................ 185

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8.4.2 Replacing Fuel Filter ..................................................... 188
8.4.3 Changing Oil-water Separator .............................................. 189
8.4.4 Cleaning Filter Screen for Fuel Tank ......................................190
8.5 MAINTENANCE FOR EVERY 50 HOURS ............................................................................... 191
8.5.1 Checking Wire Rope Retainer Parallel with Roller ......................... 191
8.5.2 Checking Slewing Bearing Junction Bolts ...................................191
8.5.3 Checking Bolts Tightening for Key Parts of Rotary drive .................. 191
8.5.4 Checking and Changing Drive Key Bar for Kelly ............................ 192
8.5.5 Checking and Changing Rotary drive Wear Plate ............................ 193
8.5.6 Checking Mounting Bolt of Track Shoe for Secure .......................... 193
8.5.7 Visual Inspection of Air Intake System ....................................194
8.5.8 Checking Wiper ............................................................. 194
8.5.9 Checking Front Window Clean Device ........................................ 194
8.5.10 Changing Slewing Bearing of Servo-frame ................................. 194
8.5.11 Checking Air Compressor Belt ............................................. 195
8.6 MAINTENANCE FOR EVERY 100 HOURS ............................................................................. 196
8.6.1 Checking Oil Level for Swing Reduction Gearbox ........................... 196
8.6.2 Checking Oil Level for Travel Reduction Gearbox .......................... 196
8.6.3 Checking Oil Level for Auxiliary Winch Reduction Gearbox .................197
8.6.4 Checking Hydraulic Oil Filter Element .....................................197
8.6.5 Draining Water and Sediment in Hydraulic Oil Tank ........................ 199
8.7 MAINTENANCE FOR EVERY 250 HOURS ............................................................................. 200
8.7.1 Checking and Changing Servo-frame Wear Plate ............................. 200
8.7.2 Inspection and Repairing of the Pressing Plate of Kelly Bar ..............200
8.7.3 Rotary drive Gear Oil Sample and Inspection .............................. 201
8.7.4 Checking and Changing Hoses ............................................... 201
8.7.5 Cleaning Fuel Tank Filter Screen –see chapter 8.4.4 ..................... 202
8.7.6 Cleaning Air Conditioner Condenser ........................................ 202
8.8 MAINTENANCE FOR INITIAL 250 HOURS OF OPERATION ............................................203
8.8.1 Changing Gear Oil for Main Winch Reduction Gearbox ....................... 203
8.8.2 Change Gear Oil for Rotary drive Reduction Gearbox ....................... 204
8.8.3 Changing Gear Oil for Swing Reduction Gearbox ............................ 204
8.8.4 Changing Gear Oil for Travel Reduction Gearbox ........................... 205
8.8.5 Changing Gear Oil for Auxiliary Winch Reduction Gearbox .................. 205
8.8.6 Changing Gear Oil for Rotary drive Gearbox ............................... 206
8.8.7 Changing Air Filter, Return Filter Element and Pilot Filter Element see
–chapter 8.6.4 ......................................................................206
8.8.8 Checking and Replacing Air Filter .........................................206
8.9 MAINTENANCE FOR EVERY 500 HOURS ............................................................................. 208
8.9.1 Checking Wire Rope Sheave ................................................. 208
8.9.2 Changing Main Winch Reduction Gear Oil- see 8.8.1 ........................ 208
8.9.3 Replacing Rotary drive Gearbox Gear Oil- see 8.8.2 ....................... 208
8.9.4 Changing Engine Oil and Filter -see 8.4.1 ................................ 208
8.9.5 Changing Fuel Filter- see 8.4.2 ........................................... 208
8.9.6 Changing Oil-Water Separator Filter- see 8.4.3 ........................... 208
8.9.7 Checking and Changing Inner and Outer Air Filter Element of Air Conditioner

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..................................................................................... 208
8.9.8 Changing and Replacing Air Filter see-chapter 8.8.8 ...................... 208
8.10 MAINTENANCE FOR EVERY 1000 HOURS ......................................................................... 209
8.10.1 Changing Air Filter, Return Filter Element, Pilot Filter Element see –chapter 8.6.4 ..209
8.10.2 Changing Swing Reduction Gearbox Oil see-chapter 8.8.3 .................. 209
8.10.3 Changing Travel Reduction Gearbox Oil see–chapter 8.8.4 ................209
8.10.4 Changing Auxiliary Winch Reduction Gearbox Oil see–chapter 8.8.5 ...... 209
8.10.5 Changing Rotary drive Reduction Gearbox Oil see –chapter 8.8.6 ........ 209
8.10.6 Hydraulic Hoses Inspection ............................................... 209
8.10.7 Hydraulic Hoses Replacement .............................................. 210
8.10.8 Cleanness Control for Hydraulic System ...................................210
8.10.9 Hydraulic Oil Temperature Control ........................................ 210
8.10.10 Use of Battery ...........................................................211
8.11 MAINTENANCE FOR EVERY 2000 HOURS ..........................................................................214
8.11.1 Changing Hydraulic Oil ................................................... 214
8.12 MAINTENANCE FOR EVERY TWO YEARS OR 3000 HOURS .........................................215
8.12.1 Changing Coolant ..........................................................215
8.13 MACHINE STORAGE ................................................................................................................ 216
8.13.1 Cleaning Machine ..........................................................216
8.13.2 Storing Machine ...........................................................216
8.13.3 Daily Maintenance .........................................................217
8.13.4 Maintenance for a Long-term Storage ......................................218
9 TROUBLESHOOTING ..............................................................................................219
9.1 COMMON FAILURES AND SOLUTIONS ................................................................................ 219
9.2 ACCIDENTS AND SOLUTIONS DURING DRILLING ...........................................................220
10 ENVIRONMENT PROTECTION /WASTE DISPOSAL .....................................................221
10.1 OVERVIEW .................................................................................................................................. 221
10.2 STORAGE AND TRANSPORT FOR AUXILIARY & RUNNING MATERIAL OF
MACHINE AND SYSTEM .................................................................................................................. 221
10.3 NOTE FOR MACHINE CLEANNESS ...................................................................................... 222
10.4 MACHINE SHUT-DOWN ........................................................................................................... 222
10.5 MACHINE DISASSEMBLY........................................................................................................222
10.6 WASTE DISPOSAL ......................................................................................................................223
10.6.1 Waste Disposal for Running Material, Lubrication Material and Auxiliary Material ...... 223
10.6.2 Waste Disposal for Metal Parts and Plastic Parts ........................ 223
10.6.3 Waste Disposal for Electrical Engineering and Electrical Components .... 223
10.6.4 Special Garbage ...........................................................224
10.6.5 Recycling ................................................................. 224
11 APPENDIX ...........................................................................................................225
11.1 SWDM40 CONFIGURATION AND DIMENSION .................................................................. 225
11.2 MAIN PARAMETERS ................................................................................................................. 226
12 MANUFACTURER INFORMATION ...........................................................................227

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1 SAFETY RULES
1.1 SAFETY INSTRUCTION
1.1.1 Safety Level
The security matters of this regulation are divided into three grades: “Danger”
“Warning” ”Attention”
Danger：If not avoided, death or serious injury may occur.
Warning：If not avoided, death, serious injury and heavy equipment loss may occur.
Note：If not avoided, operator may be hurt or equipment may be damaged.
1.1.2 Safety Signs
Safety signs are used to alert safety. If you see this sign in the machine or in the operating
instructions, you should be aware of the danger of injury.
Read and understand carefully, follow all the safety on the machine, as well as the safety
of this manual.
Need to maintain and update the security logo in time,
always keep the sign clear, eye-catching and firm.
1.1.3 Safety Sign
Different parts of the machine have different safety
signs, which are labeled with different degrees of hazard,
such as “Danger”“Warning”“Attention”(See right
figure).
Danger---indicates an imminently hazardous situation which, if not avoided, will result in
death or serious injury.
Warning---indicates a potentially hazardous situation which, if not avoided, could result in
death or serious injury.
Attention---indicates a potentially hazardous situation which, if not avoided, may result in
minor or moderate injury
“Danger” and “Warning” are set to specific locations within the range of possible hazards.

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General Announcements are on “Attention”. In this manual, “Attention” is also used remind of
safety instructions.
1.1.4 Other Signs
Oil level sign Temperature sign Battery sign
Hoist direction sign Warning sign Direction sign
1.2 ALLOWED WORKING SLOPE
1.2.1 Regulation of Parking Space
The allowable grade of slope is calculated on firm ground without any ascend, so when the
machine is on rough and loose ground, the valve should be reduced.
Forbid to travel over the allowable value so as to prevent the tilting danger.
1.2.2 Travel on Slope
When travel in falling gradient，grade of slope in longitudinal must be no more than 5°，and
adjust the mast backward no less than 10°～15°.
When travel in up grade，grade of slope in longitudinal must be no more than 5°, and adjust the
mast backward no less than 10°～15°.