Mesin Bor XR220D Operating Instructions

XR220D Rotary Drilling Rig
Operation Instruction
简介
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Xuzhou Construction Machinery Group Co;Ltd

XR220D RotaryDrilling Rig Operation Instruction
Description
Thank you for your purchase the XR220D rotary drilling rig.
This instruction presents the information in terms of equipment description, overview, safety
precautions, technical specification, operating control and display, operation, electrical system,
hydraulic system and some other precautions.

This manual contains important information that will help you and your crew set up and safely
operate the XR220D. DO NOT operate or permit anyone to operate or service this machine until you
have read this Manual. Use only trained operators who have demonstrated the ability to operate and
service this machine correctly and safely.
Make sure this Manual is complete and in good condition. Contact the XCMG factory to obtain
additional manuals and for further information about or assistance with your machine. Your XCMG
factory has approved service parts and technicians with special training that know the best methods of
repair and maintenance for your machine.
XCMG will not responsibility for any equipment breakage or safety accident caused by any of the
following cases:
1. Equipment refitting without permission.
2. Operating in mode not complying with the normal use.
3. Exceeding the prescribed range of equipment use.
XCMG will not afford compensation for any equipment breakage caused by any of the following
cases:
1. Incorrect operation.
2. Undue and insufficient maintenance.
3. Use of fuel or lubricant which are not recommended.
Wth the process of the technology,the products will be improved continuously, if you find some
difference with the object, please make the object as the standard. The XCMG reserve the right of
updating the contents and improvement.XCMG will continue to update its product manuals with
current operational information, but some units maybe retrofitted independently by the customer or by
the manufacturer per a customer request at the factory, or while in service, and the information herein
may not reflect those changes.
Notice
This instruction must be kept together with the drilling rig and placed in the
easy reach of the operator orrelated persons.
Contents
Description ....................................................................................................................... 3
Contents ............................................................................................................................ I
Use of This Instruction ...................................................................................................... 1
Chapter1 Overview ........................................................................................................ 5
1.1 Features of products .......................................................................................................... 5
1.2 Construction range of equipment ...................................................................................... 5
1.3 Name of main components ................................................................................................ 7
Chapter 2 Safety Precautions........................................................................................ 11
2.1 Equipment safety ............................................................................................................11
2.2 Main hazards ...................................................................................................................12
2.3 Preparation before equipmentstart ...................................................................................19
2.4 Precautions for cold area ................................................................................................21
2.5 Safety installation ............................................................................................................22
2.6 Equipment stability..........................................................................................................23
2.7 Allowable wind velocity..................................................................................................27
2.8 Hazardous zones during transfer and drilling ..................................................................28
2.9 Description of safety symbols .........................................................................................29
2.10 Nameplate ......................................................................................................................34
Chapter 3 Technical Specification ................................................................................. 37
3.1Main dimensions of equipment ........................................................................................37
3.2 Main parameters of equipmen .........................................................................................38
3.3 Drilling status parameters ................................................................................................39
3.4 Composition and structure...............................................................................................40
3.5 Specification of wire rope ...............................................................................................58
3.6 Kelly bar and drilling bit .................................................................................................65
Chapter4 Operating Control and Display ....................................................................... 82
4.1 Schematic of manipulation ...........................................................................................82
4.2 The driving cab plan ........................................................................................................83
4.3 Pedal .............................................................................................................................84
4.4 Control Panel ................................................................................................................85
4.5 Right Operation Box........................................................................................................86
I
4.6 Left Operation Box ..........................................................................................................87

4.7 Display operating instructions .........................................................................................88
4.8 Seat adjustment................................................................................................................97
4.9 Use of the air conditioning ..............................................................................................98
Chapter5 Operation ................................................................................................... 102
5.1 Preparation before starting ............................................................................................102
5.2 Engine start and stop .....................................................................................................107
5.3 Traveling .......................................................................................................................109
5.4 Slewing ..........................................................................................................................111
5.5 Main winch ....................................................................................................................112
5.6 Mast ...............................................................................................................................114
5.7 Rotary drive ...................................................................................................................115
5.8 Crowd cylinder ..............................................................................................................116
5.9 Auxiliary winch .............................................................................................................117
Chapter 6 Installation, Removal and Transportation ................................................... 120
6.1 Unloading the Drilling rig in jobsite .............................................................................120
6.2 Installation of drilling rig...............................................................................................121
6.3 Drilling rig shift .............................................................................................................131
6.4 Disassembly of drilling rig ............................................................................................132
6.5 Transportation of drilling rig .........................................................................................135
Chapter 7 Repair and Maintenance ............................................................................ 141
7.1 Safety measures .............................................................................................................141
7.2 Interval of repair and service .........................................................................................142
7.3 Schedule of repair and service .......................................................................................143
7.4 Service of electrical system ...........................................................................................149
7.5 Service of hydraulic syste ..............................................................................................152
7.6 Maintenance of wire rope ..............................................................................................159
7.7 Maintenance of rotary joint ...........................................................................................171
7.8 Maintenance of rotary drive ..........................................................................................171
7.9 Maintenance of traveling mechanism ............................................................................177
7.10 Service when out of service .........................................................................................178
7.12 Description of engine service ......................................................................................184
II
7.13 Lubrication and service of drilling rig .........................................................................190

7.14 Operation and Maintenance of Centralkized Lubrication System ...............................194
Chapter 8 Hydraulic Pressure System .......................................................................... 202
8.1 Hydraulic Schematic Diagram ......................................................................................202
8.2 List of hydraulic parts....................................................................................................205
Chapter 9 Electrical System ........................................................................................ 209
9.1 Electrical System Program ............................................................................................209
9.2 List of electric parts .......................................................................................................214
Conclusion .................................................................................................................... 226
III
IV
Use of This Instruction

This instruction is divided into seven chapters.
1. Overview
2. Safety Precautions
3. Technical Specification
4. Operating Control and Display
5. Operation
6. Installation, Removal and Transportation

7. Repair and Maintenance
8. Hydraulic Pressure System
9. Electrical System
Each chapter is divided into several sections, pages of which are in serial. The page number is
indicated at the lower of each page for easy read from the contents and quick search.
Example:
Precautions
1. Operate XR220D rotary drilling rig according to the description in the Operation Instruction.
2. Any use of this rotary drilling rig for other purpose not indicated in the instruction is forbidden.
3. The winch provided for XR220D rotary drilling rig is to match the drilling operation and cannot
be used as lifting appliance.
4. The safety items established for the staff must be implementd during the assembly of the
drilling rig.
5. No untrained or unauthorized person is allowed to operate this rig.
6. To avoid scuffing, the operating staff must wear the appropriate clothing and should not wear
the ring,watch, necklace or clothing not buckled.
1
7. Maintain the cab floor, foot pedal and lever clean, leave sufficient activity space and frequently
check the oil circuit, grease and dust to avoid cracking or enwinding.
8. Do not jump on or off the cab directly; when the driver want to get off the cad ,please make
sure at least two hands and one foot or two feet and one hand contact the pedal and handle tightly.
9. Do not use the control lever and hose as the handle because these are non-fixed support; to
avoid incorrect operation, please do not pull them.
10. Always operate this rig in the cab and do not control it outside the cab.
11. Always keep an emergency kit in the cab.
12. Line out the job region of drilling rig, separate it with the rails and hang the warning plate
during operation.
13. The ambient temperature range for the machine operation and maintenance is -15 ℃~ 40℃.
14. When the operation and maintenance are made by two persons, they both should receive
training, one of which should be in the master operation position to monitor the safety and operation of
the other one.
15. The repair and maintenance can be made by one person only when the complete machine is
shut off.
16. The supervisor should be able to access to the emergency stop switch in any case while
repairing or maintaining the devices.
17. The operating position of field operation should be provided with enough lighting.
18. The proper and reliable communication should be established between the operator and
supervisor or they should be familiar with the signal transmission mode and meaning.
19. Check the emergency stop switch before and after operating the rig.
Warning
The gas exhausted by engine is toxic! When operating in the limited space, take measures to avoid
the exhaust gas entering the working area to ensure safety.
Danger
Before starting up the machine, it shall be ensured that the machine is operating on the compacted
and flat ground; otherwise, there will be a danger of tip-over.
2
Sales and Services
Address: No. 36 Tuolanshan Road, Economic development Zone, Xuzhou

National service hotline: (+86)-400 - 110 - 9999
Tel.: (+86) - 0516 - 87738167 87738169 (for sales), 87738150 (for service)
Fax: (+86) - 0516 - 87892627-103 (for sales), 87738150 (for service)
Post code: 221004
3
4
Chapter1 Overview
Chapter1 Overview
1.1 Features of products

1. XR220D rotary drilling rig is developed by XCMG basing on the experiences of pile driving
machinery R&D. It absorb the advanced technologies of home and abroad and adopts the top-class
fabrication means to allow excellent quality and high reliability. The main performance parameters of
this rig have achieved or even exceeded the international level of like products.
2. The high quality key elements are provided by the suppliers all over the world and the spare
parts are readily available.

3. With the parallelogram hinge mechanism of own patent and back-inclination technology of
mast which make the rig have a high stability and easy transfer.
4. The dedicated undercarriage of rotary drilling rig made by advanced means and tools which
enables the rig travelling flexible,construct credibility and super excellent stability.
5. The mast allows rise and fall automatical without using any auxiliary tool. The mast is designed
to high strength box type construction to enable higher strength and excellent toughness, guarantee the
drilling accuracy and achieve transportation of 3-section folding type.
6. With advanced intelligent control and monitoring technique, the operator can control the rig in
the cab easily. The new type silicon oil shock pad are fixed in the bottom of the cab which could
greatly reduce the inertia shock of the cab and the use of sound insulation effectively reduces the
operation noise of the diesel engine to allow comfortable operation; the cab design adopts the
ergonomics principle to make the internal layout more reasonable.

7. With engine of famous brand, the peak dynamic effect can be achieved with ease. The perfect
combination of high pressure direct injection turbo supercharging, high power output and high
efficiency hydraulic system ensures the strong power output.

8.Excellent kelly bar configuration scheme creates a higher work efficiency and lower fuel
consumption, meeting the requirements of economy.
1.2 Construction range of equipment

Main purpose and scope
XR220D rotary drilling rig is the construction machinery suitable for building foundation bored
concrete pile and foundation pore-forming operation and widely used for the foundation construction of
port, railway bridge and high-rise building.
5
XR220D Rotary Drilling Rig Operation Instruction
Operating environment
The operating environment temperature is -15 ℃~ +40℃with wind velocity ≤20 m/s.
Operating conditions
Level and solid ground with the slope ≤2°, far from the high voltage supply line (cable).
Front Rear
XR220D Rotary Drilling Rig

a. Standard configuration: telescopic 5-section friction kelly , 60m maximum hole depth and 1.8m
maximum diameter.
b. Optional configuration: telescopic 4-section locking kelly , 46m maximum hole depth and 1.8m
maximum diameter.
6
Chapter1 Overview
Notice
In order to ensure efficient output of the rig and extend its life, the mounting
of drill bit with the largest diameter is not recommended when drilling the hole
with the largest diameter during the construction period.
1.3 Name of main components
1 20
0
19
3
4
18
8
17
9 16
10 15
11 14
12
13
7
NO Name NO Name
1 Pulley 11 Cab
2 Cathead 12 Undercarrage
3 Slewing joint 13 Slewing bearing
4 Bracket 14 Counterweight
5 Kelly bar 15 Main winch
6 Back wheel 16 Lifting cylinder of luffer
7 Mast 17 Luffer
8 Crowd winch 18 Rope of main winch
9 Auxiliary winch 19 Rope of auxiliary winch
10 Drilling bit 20 Rotary drive
8
Chapter1 Overview
Memo
9
Memo
10
Chapter2 Safety Precaution
Chapter 2 Safety Precautions

The instruction specifies the safety precautions in the precautions column and the customer must
observethe safety regulations and requirements for the equipment.
Prevention can effectively reduce the hazards!
All the persons related to the equipment construction should read and comprehend these safety
precautions in advance to handle the equipment safely and prevent accidents.
The safety information involved in this instruction is classified as follows:
Danger
This symbol is to remind you that ignoring or failing to observe the
specifications in the instruction will immediately result in serious personal injury
or even death and may cause equipment breakage.
Warning

specifications in the instruction will result in potential hazards which may render
serious personal injury or even death and may cause equipment breakage.
Caution
specifications in the instruction will result in serious personal injury or
equipment breakage.
Notice
This symbol is to remind you of the details to be noted during equipment
installation, maintenance and operation.
2.1 Equipment safety

All the related persons including the operator and repair man should observe the equipment
safety specification to eliminate the hazard factors, prevent accidents and ensure the correct and high
efficiency construction. Otherwise, the serious personal injury or equipment breakage may occur.
11
2.2 Main hazards

1. Slewing parts
As the equipment is provided with slewing

dill tools, all persons should keep away from it to
ensure the personnel safety, otherwise, it might
result in mortal injury.
2. Safety device and limit switch
Do not move these safety installations and do
not use any faulty safety installation or part.
3. Tilting
Do not endanger the equipment stability. If
the equipment capacity is exceeded or the
equipment is operated by the damaged lifting limit
switch, it will result in equipment tilting and cause

serious personal injury or equipment breakage.
Notice
With the mast being lifted, before the

slewing motion starts, ensure the crawler is
on the hardstand, otherwise the equipment
may tilt.
12
4. Leak of hydraulic oil
a. Check the leak of hydraulic system oil

carefully; where there is oil leak, locate the
causes and fix it.
b. Where there is no pressure release, check

or repair the pressure pipe. Remember to screen
the pipe with a thin slab or paperboard as the
liquid ejected under high pressure may penetrate
the skin and cause severe injury.
Notice
The liquid is harmful to the human
body,to avoid contact the liduid
when checking the pressure pipe for
leak and ensure to screen the pipe
with a thin slab.
5. Repair
Ensure the equipment is shut down in the
normal way (including all the controllers, engine
andmain power switch) before carrying out the
equipment maintenance, repair or cleaning.
6. Leaving the equipment
Lower the drill bit to the ground, ensure all
the operating levers are in the middle position, stall
the engine and pull the key out. Lock the safety
lever and cab doors and windows before leaving.
13
7. Precautions on stop
When the drilling rig stops operation and

them as t is in upright position, the drill bit must be
supported by the ground; if there is gap between
the drill bit and ground, no one should approach in

any case (to prevent the incorrect operation
making the drill bit fall to injure persons).
8. Change or add hydraulic oil

Where the hydraulic oil should be changed or
added, stall the engine first and then loosen the air
filter on the hydraulic oil tank to release the
pressure inside and prevent scalding caused by the
hot oil splashing.
9. Coolant
As the coolant anti-rusting agent contains
strong alkali material which may cause burning or
scalding and personal injury if contacting the body,
it is necessary to avoid the contact of it with the
skin, eyes or mouth; do not ingest the coolant.
To fill water or coolant to the radiator, stall
the engine first, wait the radiator to cool down and
then loosen the cover slowly to release the
pressure and prevent scalding.
10. Crawler tensioning cylinder
14
Do not remove the pressure relief valve
(one-way valve) of the oil filler before the pressure

is completely released. Otherwise the personal
injury might occur. Loosen the pressure relief
valve (one-way valve) by one turn only when

releasing the crawler. As the grease pressure in the
tensioning cylinder is very high, the direct
injection of high pressure grease on the human
body will cause severe or even fatal injury, do not
check whether the grease flows out of the pressure
relief valve (one-way valve) closely.Instead,
observe whether the crawler is slack directly.
11. Fire and explosion prevention
The fuel including the mixture of most
lubricants and some coolants is inflammable. It is
necessary to prevent such substances leaking onto
the hot object surface or electrical elements. Keep
away from the source of ignition when cleaning
the parts with the inflammable oil. Remove the oil
and chipping on the equipment in time, keep away
from the naked flame when controlling or
repairing the equipment and eliminate any factor
which may induce fire. In addition, do not carryout

welding or flame cutting on or near the fuel tank.
12. Command gesture
Get familiar with the meaning of various

command gestures in the site, know who releases
these gestures and accept the command gestures of
one person only. In particular when the visual field

of the drilling rig driver is restricted, for example,
when reversing, shifting or carrying out auxiliary
action, the instruction outside the cabby the person

specially assigned will be required.
15
13. Preparation of safety installation
To prevent accidents or fires, make sure to

learn about the location and use of the fire
extinguisher and first-aid kit.
14. Lightning protection

When lightning occurs near the drilling rig,
the driver should not climb onto the drilling rig or
get off it. In such cases, the driver must stay in the
cab. If the driver is standing on the ground when
the lightning occurs, he (or she) should leave the
drilling rig far away quickly.
15. Accumulator
As the accumulator is a pressure vessel, to
avoid explosion and personal injury, do not expose
it to the flame and do not weld or drill it. Release
the pressure first before removing it.
When the engine is flame out, tread on the
footboard which is controlled the rotary's walking
for about three times,so that it can release the
pressure of accumulator.
16. Get in and off the machine
Get in and off the machine through the ladder
and handrail only. Check the ladder and handrail

and clean or repair them if necessary before
getting in or off the machine. When getting in or
off the machine, face it directly and keep three

contact swith the ladder and handrail (two hands
and one foot or two feet and one hand). Do not get
in or off the machine while it is working. Do not

use the control lever as the handrail when entering
or leaving the cab.
16
17. Hydraulic hose
Frequently check the conditions of the

hydraulic hoses and replace them in time if any
differential expansion, leak or breakage is detected.
Make sure to use the genuine spare parts of the

manufacturer or the products of suppliers
recommended by XCMG (the same for the brake
shoe, wire rope and pipe). For the sake of safety,
do not check the hoses by the bare hands. Release
the pressure before repairing the pipeline and
component under pressure After replacement,
tighten all the joints and fasteners to the
recommended torque.
18. Electric shock
a. If the operation should be made near the
powerline, contact with the power company in
advance,arrange the auxiliary person to command
in the vicinity and keep away from the wires and
cable as far as possible to avoid accidents.
b. However, if the wire is touched, warn the
operating staff around and do not touch the
machine.
19. Battery
As the electrolyte contains strong acid which

is easy to cause personal injury, do not allow the
electrolyte to contact the skin or eyes. Wear the
safety glasses when operating the battery and wash
the hands after contacting the battery and
connectors.
17
20. Operation
The operation should be soft and continuous.

Avoid too fast action or intermittent control to
protect the machine against vibration.
21. Requirements for the operator
a. The operator must wear the regular
clothing, carry the qualification certificate and
wear the protection articles such as the safety
helmet, safety shoes, body-contact work clothes

Caution
and eye protection, which is one of the essential Exhaust gas wented by engine is toxic for
conditions for safety. people, so if the machine is used in the narrow and
b. The operator should not over do if he small room, please make sure the exhaust gas can
cannot operate the machine normally due to be leading-out and far away form the people.
fatigue, disease or drug reaction.
22. Handling of waste oil
As the oil is pollutive, do not pour the waste
oil in the sewer or river course or spray it on the
ground; hold the waste oil in the proper container
and handle it in pursuance of relevant legal
regulations.
18
23. Machine service
a. Where the repair should be made under the

drilling rig, make sure to fix the crawler with the
safety blocks, support it firmly and do not use the
hydraulic oil cylinder as the support. If the control

lever is moved or the pipeline bursts, the machine
will fall and result in unexpected personal injury.
b. During service, check the slewing table for
impurity or grease and take care to avoid falling
when traveling on the drill floor.
c. During service, the operator should check
whether the repair men on the machine have A strong noise could be harmfule to
grasped the machine firmly before operating. people, if the people must have to work in
24. Vibration and Noise the dangerous area, protective measures
According to ISO 2631-1, Under the normal arresting the noise should be provided for
working conditions, the arm vibration is 3.41 m/s2. people.
Vibration measurement uncertainty is 1.5
m/s2.
According to ISO/DIS 6396:2004 testing, the
noise value at the driver does not exceed 80 dB(A)
and the measured value is 76 dB(A).
According to 2000/14/EC testing, the
radiation noise outside the machine does not
exceed 105 dB(A).
Uncertainty of measurement of the noise is
2dB (A).
2.3 Preparation before equipmentstart

Pay special attention to the requirements
indicated in the safety precautions column.
19
2.3.1 Safety check before equipment

running
1. Remove all the obstacles in the drilling rig

operation passage.
2. Learn about the cable trench, earth backing
and other complex terrain.

3. Fix the door and window in the open or
close position.
4. Ensure the horn and other warning devices

are normal.
5. Check the position of traveling unit before
moving the drilling rig. The normal driving
direction is that the driving wheels are behind the
cab.
6 Check whether the operation of the safety
equipment and controllers is normal.
2.3.2 Check the following items before

starting the engine:
1.Check whether all the threaded connections
are tightened and whether the bolts and pin rolls

are robust and in the proper postion.
2.Check the hydraulic oil and fule pipeline Release the hydraulic system
for leak. pressure before inspection and the
parts to be checked by contact
3.Check the lubricating oil level of the drive
must completedly cool down.
rotary.
4. Check the wear conditions of the kelly bar

driving sleeve (ring)and the guide sliding carriage
wear resistant block.
5.Check the abrasion and breakage conditions

of all wire ropes.
6.Check the abrasion and breakage conditions
of the kelly bar.
20
7. Check the abrasion and breakage conditions of the drilling bit
2.4 Precautions for cold area

1.After operation,wipe off the water,snow or
dust on the wire,wire connector,switch or sensor
and coverings of them.If not,the moisture will ice

up and cause machine malfunction and even
unforeseen fault in the next operation.
2.Carry out sufficient preheating operation

(up to 30 minutes).If the preheating is not finished
before the control lever is operated,the machine
reaction will be slow, which may cause unforeseen
consequence.
3. Operate each control lever to cycle the
hydraulic oil inside the hydraulic system andwarm
up the oil (operate the machine under 30%rated
load at a slow speed and then carry out fullload
operation after the system temperature rises 40℃-
50 ℃ ). This will ensure the good reaction of
machine and prevent malfunction.
4. If the battery electrolyte has iced up, do
not charge the battery or start the engine through
other power supply. Otherwise it will make the
battery catch fire.
Melt the battery electrolyte and check for
leak before charging the battery or starting the
engine through other power supply.
21
2.5 Safety installation

2.5.1 Emergency exit
The cab rear side is provided with a hand
hammer for emergency. In the event of hazard

while the cab door is locked, the operator may
break the glass with this hammer to escape.
2.5.2 Emergency stop button
The right control panel inside the cab is
provided with an emergency stop button, through
which the operator can shut down the drilling
functions in case of emergency. To restart the Caution

equipment,make sure to pull this button to the
Check the emergency stop button
normal operating position before starting the
before andafter equipment transfer
engine. and drilling!
2.5.3 Safety lever
The left control box in the cab is provided
with a safety lever. When the lever is rotated to
position A1, the hydraulic system will cut off to
stop any hydraulic operation. When the lever is in
position A2, the hydraulic system will switch on to
restore all the functions.
22
2.5.4 Height limit switch
With the drilling rig operating, the height
limitswitch can prevent the over-winding of the

winch to prevent the collision of kelly bar and
mastcathead because of incorrect operation and
thus to avoid parts breakage.

Check the main winch height limit switch:
Lift the kelly bar to make the kelly bar
carriage contact the limit switch. At this point, the

main winch cannot be lifted any more;
otherwise,repair or replace the limit switch.
2.6 Equipment stability

The recommended distance between the
equipment slewing center and the hole axis is 3560
~ 3900 mm. Component Name Weight

The equipment stability is calculated
Standard confinguration，5-section
according to EN 791 under the following 7.89t
friction type kelly bar
conditions:
The actual service status and condition of Standard rotary drill bit (with a diameter of 1.3 m) 2.67t
components to guarantee the equipment stability

are detailed in the following chapters and sections.
23
2.6.1 Hole site transfer
The operation procedures of hole site

transfer are detailed in Section 6.3 rig transfer of
Chapter 6.
Essential conditions
1. The equipment upper structure is aligned
with the main unit crawler.
2. The rotary and drilling bits are in the low
estposition as much as possible.
3. The site ground or working platform
must be firm (≥150 kPa) and level (≤2°).
24
2.6.2 Rated load

Caution
The rated load of main/auxiliary

winch wire rope and crowd winch set
forth below must comply with the
above working conditions. The
different rated operating loads cannot
1. Mast vertical status
be employed at the same time and the
a. Main winch wire rope.
extra auxiliary parts are not allowed.
With the allowable rated load of main winch
Mind the added auxiliary parts.
wire rope being 14.5 t, the upper structure (slewing
platform) can operate within 5° of the under
carriage right ahead.
Conditions:
1) The equipment must be parked on the firm
andlevel ground.
2) The equipment crawler must be completely
stretched.
b. Auxiliary winch wire rope
With the allowable rated load of auxiliary
completely stretched.
winch wire rope being 5 t: the equipment can
slew by360°.
Conditions:
andlevel ground.
2) The equipment crawler must be

completely stretched.
25
c. Boosting/winding system
With the upper structure operating within 5°

of equipment right ahead, the system boosting is
16t and the lifting capacity is 18t.
Conditions:
andlevel ground.
2) The equipment crawler must be completely
stretched.
2. Mast tilting status
a. Main winch wire rope
1) With the upper structure under carriage δ
=100° (the shaded portion), the maximum
allowable load of main winch wire rope is 14.5 t.
2) With the upper structure undercarriage at
any angle (the shaded portion), the maximum
allowable load of main winch wire rope is 9.8 t.
Conditions:
·The equipment must be parked on the firm
and level ground.
·The equipment crawler must be completely
stretched.
·The equipment must be stable.

·The forward rake of mast must be less than
5°while the side rake must be within 3°.
b. Auxiliary winch wire rope.

With the allowable rated load of auxiliary
winch wire rope being 5 t: the equipment can slew
by360°.
Conditions:
·The equipment must be parked on the firm
andlevel ground.
·The equipment crawler must be completely stretched.
26
·The equipment must be stable.
·The forward rake of mast must be less than

5°,while the side rake must be within 3°.
2.7 Allowable wind velocity

The impact of wind velocity must be taken into account if the wind velocity is high. The wind
velocity should be measured at the cathead.
Compare the measured wind velocity with the values shown in below table to check whether the
wind velocity will impair the equipment stability.
the maxmium allowable speed of the wind
Maximum allowable wind velocity of equipment operation:
Warning
The equipment may tilt!
Stop operation if the wind velocity exceeds the maximum allowable value.
Where the wind velocity exceeds the value specified in the above table, carry out the following
operation to protect the equipment:
1. Lower the drilling bit (including the other load or heavy things) on the ground.
2. Lower the rotary to the lowest position.
3. Align the upper structure (slewing platform) with the main unit crawler and lock the upper
structure.
4.Stretch out the drill mast support oil cylinder (if the component is adopted) to the ground.
27
2.8 Hazardous zones during

transfer and drilling
The hazardous zones during transfer (see the
right figure) is a circle with the slewing center as
center and radius being 7 m.
The hazardous zones during drilling (see the
right figure) is a circle with the slewing center as
center and radius being 6 m.
28
2.9 Description of safety symbols
Safety marke explanation
Do not open or remove the

safety guard with the engine
running.
Keep away from the

equipment to prevent the side
pressure squeezing the body.
No smoking
Hydraulic oil symbol
29
Diesel oil
No pass without permission
Electric shock
Shut down the engine and

take out the key before maintenance
and repair.
Maintain the safe distance to

prevent the bruise caused by
balance weight.
30
Maintain the safe distance to

prevent the thrown-out or burst-out
object impacting the body.
Read the operation and

maintenance instruction
Keep away from the equipment to

prevent the upper pressure
squeezing the body.
Do not touch hot surface
Refer to the operating

procedures detailed in the technical
manual to avoid the discharge of
liquid under pressure.
31
Mind safety
Fire extinguisher
Wear safety helmet
Apply grease
Hoisting position
32
Drilling rig driving direction
No step on
紧急出口
Espcapt exit
Battery symbol
Tool kit symbol
33
Fixing position
Drilling warning symbol
2.10 Nameplate
34
Memo
35
Memo
36
Chapter3 Technical Specification
Chapter 3 Technical Specification
3.1Main dimensions of equipment

Dimension unit: mm
Main size under the working condition
37
3.2 Main parameters of equipmen
Name Unit Parameter Values

Maximum drilling diameter mm  2000
Standard configuration:67 (5-section);
Maximum drilling depth m
optional configuration: 46 (4-section),
Allowable safe drilling operating scope (fromthe
mm 3560～3900
slewing center)
Drilling rig size under transportation state(L*W*H) mm 8350×4200×20480
Drilling rig size under transportation state(L*W*H) mm 14255×2960×3450
Overall weight
t 72
(including the drilling bits forstandard configuration)
Engine model Cummins QSB6.7-C260
Engine Engine rated power/speed kW 194 /2200r/min
Maximum torque N.m 987 /（1500r/min）
Hydraulic Maximum working
Mpa 32
system pressureof main pump
Maximum torque kN.m 220
Rotary
Speed rpm 7~27
Max.pull-down piston push kN 220

Pull-Down
Max.pull-own piston pull kN 220
cyclinder
Max.pull-down piston stroke mm 5000
Hoisting force kN 220
Main winch Maximum single rope speed m/min 65
Wire rope diameter mm 28
Hoisting force kN 50
Auxiliary winch Maximum single rope speed m/min 70
Wire rope diameter mm 16
Side rake ° 3/3
Mast
Forward rake ° 5
Table slewing Slewing angle ° 360
Maximum traveling speed km/h 1.5
Traveling
Maximum grade ability % 40
Crawler Width mm 700
38
External width
mm 2960～4200
(maximumand minimum)
Distance between crawlers mm 4270
3.3 Drilling status parameters

The figure shows the drill bit of 1.8m diameter.(in m)
Kelly bar L T W
4-section
50.64 48.145 0.865
locking kelly bar
5-section friction
63.14 60.645 0.865
kelly bar
Notice
L---- Maximum projected length of kelly bar
T----Maximum drilling depth
W----Height of drilling bit
39
3.4 Composition and structure

This drilling rig mainly consists of undercarriage traveling mechanism, mast, derricking
mechanism (fourbarlinkage), main winch, auxiliary winch, rotary, kelly bar, drill bit, slewing table,
engine system, cab,roof, balance weight, hydraulic system and electrical system etc.
1. Lower structure driving: the engine drives
The hydraulic main pump to supply oil under

pressure, which passes through the center slewing
body to the traveling motor and traveling gear box
to bring the driving wheel to rotate. In this way,the
undercarriage traveling, steering and braking are
realized. 1 2 3 4
2. Crowd cylinder: the force of this cylinderis
transmitted to the rotary, which drives the rotary
drive to move up and down
3. Drive rotary: the rotary pressure makes the
rotary bump-resistant body move the drill bit
locking switch to open the drill bit bottom door
and dump the earth.
4. Display: the drilling depth is displayed in

digital. Stop the operation when the required depth
is reached.
40
5. Earth dump: the rotary pressure makes the
rotary bump-resistant body move the drill bit

locking switch to open the drill bit bottom door
and dump the earth.
6. Display: the drilling depth is displayed in

digital. Stop the operation when the required depth
is reached.
41
3.4.1 Operating mechanism

The operating mechanism mainly consists of derricking mechanism, mast, rotary, main/auxiliary
winch,athead, crowd cylinder, kelly bar and drill bit etc.
42
NO Name NO Name
1 Mast assembly 5 Drive rotary
2 kelly bar 6 Auxiliary winch
3 Tilt cylinder 7 Drill bit
4 Crowd cylinder
1.Rotary drive
a. As the power source for drilling rig operating, the drive rotary is one of the critical components
to convert the hydraulic energy into mechanical energy. The main function of it is to drive the kelly bar
and drilling bit slew and achieve the drilling and formation cutting by supplying pressure.
b. Operating principle: it adopts double-point variable hydraulic motor to drive the gear box, the
power transmission gear engages the slewing bearing external teeth and the slewing bearing connects
the driving gleeve to drive the kelly bar to boost and rotate. The rotary speed and output torque can be
adjusted according to the geological conditions.
43
2 Mast
a.The mast is the important working part of
drilling rig and the important support component
for the kelly bar, rotary drive and kelly bar
carriage.
The mast is vertical under operating status and
horizontal under transportation status when it
contacts the balance weight mast bracket. Under
operating status, the rotary and kelly bar carriage
perform vertical motion along with the guide rail
at both sides of the mast. The guide rail directs the
drilling operation. The crowd cylinder is fixed to
the front end of mast and is connected to the rotary
under operating status.
b. The telescopic motion of crowd cylinder

bring the rotary drive to up and down movement
and consequently applies pressure to the kelly bar
repeatedly. The telescopic motion of mast lifting
cylinder changes the mast rake from the horizontal
plane and adjusts the mast vertical state under
operating status.
NO Name
1 Cathead assembly
c. The mast is mainly equipped with cathead
2 Mast III
assembly, crowd cylinder and main winch
3 Guide rail
assembly. The mast is divided into three sections.
4 Mast II
During transportation, fold the cathead, mast I 5 Tilt cylinder
and mast III to reduce the entire transportation
6 Crowd winch
height and length.
7 Mast I
44
4. Cathead assembly
The cathead assembly is at the top end of the
mast and mainly includes the cathead, main winch
pulley and auxiliary winch pulley. During 1
operation, the cathead assembly should be
connected with the mast III through bolts. With the
principle of fixed pulley, the cathead assembly 2
changes the direction of main and auxiliary winch
wire rope motion through the main and auxiliary 3
pulley to change the lifting and lowering of the
kelly bar and accessories directly.
5. Main winch
a.The main winch includes the hydraulic
motor,gear box, drum, winch bracket, wire rope,
rope guide and shaft end supports etc. The function
of it is to lift and lower the kelly bar through the
drum enwinding the rope and to lift and lower the
kelly bar during construction. Therefore, the main
1
winch is the important component for the drilling
3
rig to completion drilling. The lifting and lowering
of kelly bar is realized by the hydraulic motor
which drives the gear box and drum to rotate and 2
4
draw or release the wire rope.
45
NO Name
1 Rope
2 Motor+reduce
3 Drum
4 Ropr holder
5 Winch bracket
b. When the drilling rig is drilling, make sure

to apply the main winch brake to allow the main
winch motor oil inlet and return passage to connect
each other and make the winch in floating position.
In this way, the crowed cylinder will apply
pressure to the rotary to allow higher efficiency of
drilling.
c. The rope guide can effectively prevent the
rope disorder during rope drawing or releasing,
enwind the rope to the drum orderly, relieve the
rope abrasion and enhance the rope service life.
1 2 3
6. Auxiliary winch
a. The auxiliary winch mainly includes the
hydraulic motor, gear box, drum, wire rope and
rope guide etc.
b. As the auxiliary hoisting equipment for
drilling rig operation, the main function of it is to
hoist the drilling bit, casing, reinforcement cage
and other heavy things not more than 5 t.
46
3.4.2 Hydraulic system
1. Base frame type schematic diagram
Principle description:
The engine drives main pump 1 and 2 to make them operate and feed high pressure oil to the
system. The driver operates the control lever and pedal in the cab to make the main valve spool reverse.
Then the oil circuit of main pump to actuating mechanism will connect and the high pressure oil will
pass the main valve to reach the hydraulic motor and hydraulic oil cylinder to start operation. When the
control lever is reset and the main valve spool returns to the middle position, the oil circuit of main
pump to actuating mechanism will disconnect and the actuating mechanism will stop operation.
47
2. Main pump
The function of kawasaki tandem plunger pump is to supply oil under pressure to the main
hydraulic system and it adopts negative flow control plus constant power control.
NO Name NO Name
1 Oil draining pipe 5 Oil outlet pipe of jack-head pump
2 Oil outlet pipe of jack-head pump 6 Main pump
3 Pilot pressure controlled oil tube 7 Main oil suction pipe
4 Oil outlet pipe of main pump 8 Oil outlet pipe of main pump
48
3. Main valve
The high pressure oil from the main pump flows into the main valve via the oil inlet, the pilot oil
pushes the main valve spool to reverse and then the oil circuit of pump and actuating mechanism will
connect to make the actuating mechanism operate; when the pilot oil is disconnected, the main valve
spool will restore, the oil circuit of pump to actuating mechanism will disconnectand the actuating
mechanism will stop operation.
The system regulates the main pump displacement through controlling the main valve return oil
size..The pump displacement decreases as the control pressure increases. The feature is that it can take
full advantage of engine power, regulate the pump output flow according to the load demand
automatically and adapt to the external loadvariation.
NO Name NO Name
1 Main overflow valve 5 Valve spool
2 Main working oil line 6 Main working oil line
3 Main working oil line 7 Main working oil line
4 Main working oil line
49
4.Auxiliary valve
a.The redundant flow control value and load

sensing control value (the auxiliary value )forms
the sub-loop and the oil is fed by the main pump.
b.The feature of this loop is that the auxiliary

value pressure is fed back to the axxiliary pump
through ressure compensator,so that when the
pressure is changed,the flow will not change.
c.In this system,the auxiliary value supplies
oil to the crowd cylinder ,slewing table ,crawler
telescopic mechanism and mast lifting cylinder.
No. Name
1 Ls feedback pipe
2 Oil inlet pipe
3 Secondary overflow valve
4 Valve spool
50
5. Pilot valve block
The pilot control section is the important component of the hydraulic system. Through the on-off
of pilot oil circuit and signal acquisition, the functions of the actuating mechanisms are achieved.
No. Name
1 Pilot tube
2 Pilot switch electromagnetic valve
51
6. Slewing mechanism
The high pressure oil flows into the rotary motor via the auxiliary valve and the motor drives the
gear box to drive the slewing bearing and consequently achieve the rotary motion of the upper
structure..
NO Name NO Name
1 Motor 4 Main working oil line
2 Measuring pressure joint 5 Braking line
3 T-junction 6 Main working oil line
52
7. Main winch
The high pressure oil flows into the main winch motor via the main valve and the motor drives
the main winch gear box to drive the drum and achieve the main winch lifting and lowering.
When the self-discharge solenoid valve is energized, the chamber A and B of main winch motor
will be connected and the free lowering of main winch will be achieved under the gravity of the kelly
bar and drilling bit.
No. Name No. Name

1 Motor drain line 4 Motor
2 Motor feed line 5 Braking line
3 Self-charge line 6 Main oil line
53
8.Rotary drive
The high pressure oil flows into the rotary motor via the main valve, the motor drives the gear
box to rotate and drive the power transmission and consequently makes the driving sleeve to drive the
kelly bar and achieve the drilling.
No. Name
1 Main working oil line
2 Motor
3 Oil drain line
54
9. Traveling mechanism
The high pressure oil flows into the motor via

the main valve, the motor drives the traveling gear
box to rotate and the gear box drives the crawler
driving wheels to make drilling rig travel.
No. Name
1 Working port
2 Motor oil draining port
3 Motor
10.Crowd mechanism
The high pressure oil from the auxiliary 1
valve flows into the rod chamber of the crowd 2
cylinder or rodless chamber via the balance valve 3

to achieve the crowd cylinder boosting and lifting.
NO Name
1 balanced valve
2 Pipe line
3 Crowed winch
55
11. Mast derricking mechanism
The high pressure oil from the operating

pipeline flows into the chamber of the mast lifting
via the balance valve to achieve the mast lifting
and lowering.
NO Name
1 Mast lifting cylinder
2 Balance valve
12 Pilot oil source block 3 Working port
The oil under pressure from the pilot pump
flows into the accumulator via the pilot filter and
the accumulator stores the hydraulic oil under
certain pressure to supply the continuous and

5
stable oil under pressure to the pilot pipeline.
3 4
56
No. Name No. Name

1 Return line 4 Pilot oil source block
2 Pilot road flowlines 5 Accumulator
3 Filter
14. Auxiliary winch
The oil under pressure from the main valve
flows into the motor of the auxiliary winch, the

motor drives the auxiliary winch gear box to rotate
and the gear box drives the drum to achieve the
auxiliary winch lifting and lowering.
No. Name
1 Motor
2 Oil draining port
3 Pipeline
Notice
The pressure of all valves is set before
delivery and the non-professional people
should not regulate it at will.
57
3.5 Specification of wire rope

1. Specification
The wire ropes of main and auxiliary winch comply with GB8918 - 2006
Main winch wire rope Auxiliary winch wire rope

Wire rope model 28NAT35(W)×K7+1770ZS 16NAT6×19W+IWS1770ZS
Length 70m 70m
diameter 28mm 16mm
variation of diameter 2%~4% +4%
Weight per meter 4.00kg/m 1.38kg/m
Tensile strength 1770 N/mm2 1770 N/mm2
Rated load 732kN 266kN

Minimum breaking load 569kN 217kN
Number of load bearing wire ropes 245 114

Core material Steel Fiber(IWS)
Wire surface Plain wire（NAT） Plain wire(NAT)

Enwinding and direction Right-handed helix（ZS） Right-handed helix（ZS））
Characteristics Low stress Low stress
Corrosion protection Grease lubrication Grease lubrication
Rotation-resustabt and surface contact
Feature Non-rotating
irregular strand wire rope
Refer to GB/T5974.2-2006modification Refer to GB/T5974.1-2006 common
Thimble
of heavy duty thimbles thimbles
Notice
After the wire rope abrades, replace it with the rope of same specification
and ensure the diameter, rated strength and strand lay direction are the same as
those of the old rope.
If wire rope of different type is used, the customer should ensure the
property of new rope is not less than that of old one and the new rope matches
the groove of drum and pulley.
58
2. Precautions of wire rope use

a. Correct reeling mode of wire rope
During the wire rope reeling and enwinding,

to prevent the strand structure breakage, adopt the
correct method to avoid rope kinking; in addition,
when enwinding the wire rope to the drum, note to

protect the wire rope surface against the sand soil
so as to avoid abrasion and ensure the service life
of the rope.
b. Cutting of wire rope
If the entire wire rope coil should be cut, tie
up the wire rope with steel wire at both sides of cut
before cutting, in particular for the multilayer
rotating-resistant stranded wipe. Blow the wire
rope off if possible.
59
c. Installation of rope clip
When installing the rope clip, the U-shaped section of the clamp must contact the longer end of
the wire rope (as shown in below figure). U-bolts should contact the ring end of the rope. It is not
acceptable if the U-shaped section of the clamp or the U-bolt does not comply with the above
arrangement principle.
Wire rope diameter(mm) 6 ~16 17~27 28~37 33 ~45

Rope clip(PCS) 3 4 5 6
Spacing of two clamps(approx) Generally 6~7times the diameter of wire rope
d. Enwinding of wire rope
The wire rope should be enwound to the drum orderly without random winding; otherwise the
rope squeezing or crush may occur operation and impair the service life.
Squeezing breakage caused by rope disorder
Squeezing breakage caused by rope disorder
60
e. Lowering of wire rope
When using the wire rope for drilling, note to

calculate the distance exactly and do not reel off
the rope excessively; otherwise the slack wire rope
will enwind each other to break the structure and

discard the entire rope.
f. Reinforced lubrication
Rope winding is the common cases during rotary drilling rig operation. It is wise to check the
rope winding part frequently and apply more grease;
g. Unwinding of wire rope
Coil unwinding: the wire rope of the coil can be unwound through the rotary disc or rolling on
the ground (as shown in the right figure).
Rope pulley unwinding: it is recommended to unwind the wire rope by the rotary disc or rope
pulley on the supporting frame (as shown in the under figure).
61
Notice
Do not unwind the wire rope from the side in any case.
The unwinding manner shown in the below figure is wrong.
wrong
Unwinding the rope from the side will result in rope twisting and change the load distribution on
the rope.
Unwinding the rope from the reel or rope pulley side will resist the torque force applied to the
rope and cause the rope coil knot. When the rope under such state is stressed, the knot will be pulled
straight under the function of external force to form kinking (as shown in the right figure), which is the
irreparable deformation and will reduce the rated tensile of rope by 15 ~ 20%.
wrong
Notice
The kinky wire rope is unreliable and must be discarded!
Do not pull the knot forcibly. Untie the twisted wire rope when the rope is
not stressed and stretch the kinking.
62
h. Installation of wire rope
Observe the following regulations when mounting the new wire rope:
1) The wire rope must be avoided of corrosion, breakage or stain.
2) The new rope must have the same driving device as that of the original rope. Pay special
attention to the mounting seat of the rope end,ensure the new rope is anchored to the mounting seat in
the same way as that of the old rope and do not change.
3) Where the new rope is cut from the supply, ensure the wires and strands at the end do not bend
or twist unless the wire rope installation requires.
4) Ensure the diameter of drum and grooved pulley matches the wire rope diameter before
installation.
5) Ensure the rope is correctly enwound and fits the drum and grooved pulley well before
operating the new rope. To test this, apply low load and move the wire rope up and down for several
times to check whether the installation is correct. In general, the load should not exceed 10% of the
rated load.
6) After installing the new rope, for the sake of safety and working sequence, check all the parts
related to the wire rope driving, such as the excessive lifting limiter and rope guide etc.
7) In the first few weeks of new rope use, check the rope and rope end fixing more frequently
than usual.
The customer should determine whether the rope has passed all the guides or whether the rope on
the reel and rope pulley is enwound to the drum and then pass through the rope by hand or by the
auxiliary rope.
63
i. Rewind to the drum
Each wire rope has the specific curve. When

enwinding the rope to the drum from the rope
pulley, ensure the curve direction of them is the
same (as shown in the right figure).
When the rope enwinding direction is reverse to
the curve, knot and twisting will occur, which
might change the construction of wire rope (as
shown in the right figure).
j. Pre-tightening enwinding
When enwinding multilayer wire rope to the drum,
it will be necessary to tension the rope in advance.
The initial pre-tightening force of the rope is
around 1 ~ 2% of the rope breaking load.
Brake the rotating shaft flange with wood plate
(see right figure) to generate the initial
pretightening force or control the brake grooved
pulley outside the rotating shaft to generate this
force (see right figure).
Clamp the wire rope not subjected to
pretightening.For example: when the rope passes
the wood clip, it will present irreparable
deformation (as shown in the right figure).
64
3.6 Kelly bar and drilling bit

3.6.1 Kelly bar
1. Kelly bar classification and structure
The kelly bar is very important for the

adaptive capacity of drilling rig to the formation.
During operation, the kelly bar not only transmits
the rotary torque to the drilling bit, but also
transmits the pull-down cylinder pressure and
rotary weight to the drilling bit. Therefore, if the
formation is hard, the kelly bar will have to
withstand high torque and overcome the high
bending moment.
The kelly bar carriage is the auxiliary device
for the vertical motion of the kelly bar during
operation. It connects the flange of kelly bar
extension rod top through the slewing bearing to
allow the rod slewing. The inside is provided with
a slide to contact the mast guide rail and slides
along with the drillrod to enhance the verticality of
pile hole.
The kelly bar falls into 4 types in terms of
crowd mode during drilling:
a. Friction kelly: the dental plate is linear strip

type structure over full length of kelly bar. The
friction kelly
advantage of such kelly bar is that no unlocking is
required for pulling out, which makes the

operation simple and easy. While the disadvantage
is that it can transmit limited pressure through the
friction force only.
65
b.Locking kelly: the dental plate is not linear
strip type structure over full length of the rod;

instead, it adopts sectional type structure, having
the axial boosting point to transmit stable and high
pressure. Therefore, the locking kelly has strong

adaptive capacity to the formation and can drill the
stiffer formation. However, this kelly requires locking kelly

reverse unlocking for pulling out, which makes the
operation complex.
c. Combined kelly: the kelly bar combining
the features of friction kelly and locking kelly.
This should be specially made upon customer's
demand in general.
d. Multi -locking kelly: more crowd parts,
difficult to unlock, not recommended in general.
multi-locking kelly
66
Comparison of service performance of different kellys:

Type locking rod Friction kelly Multi - locking kelly Locking kelly
Operability ●●● ●● ●
Formation adaptability ● ●●● ●●●
Crowd availability ●●● ● ●●
Wear resistance ●●● ●● ●
Maintainability ●●● ●● ●
Pull-out property ●●● ●● ●
Note:
Operability The convenience degree of kelly bar use during drilling rig
Formation adaptability
operation
The functioning capability of kelly bar to various formation during
crowd availability The convenience degree of finding the boosting point during drillingon
Wear resistance The wear resistance of interior and exterior driving key during drill
Maintainablity The difficulty degree of repair
Pull-out property The difficulty degree of the rod pulling
●●● Excellent
●● Good
● Common
Depending on the formation conditions, XR220D drilling rig can match the following kelly bars:
friction kelly bar or locking kelly bar.
1) Kelly bar of standard configuration: φ4065×13.5m friction kelly with maximum effective
drilling depth of 67 m.
2) Kelly bar of optional configuration: φ406 4×13m locking kelly with maximum effective
drilling depth of 46 m.
67
Structure of friction kelly:
68
Structure of locking kelly:
No. Name No Name

1 Flat end 8 First rod external key
2 First rod stop collar 9 First rod internal key
3 1st section kelly bar 10 Spring seat (pallet)
4 2nd section kelly bar 11 Kelly bar spring
5 Third section kelly bar 12 Square end
6 Fourth section kelly bar 13 Pin roll
7 Damper assembly
2. Precautions of kelly bar use
The kelly bar is designed to transmit torque and axial force to the drill bit, withstands repeated
shock during operation and subjects to severe and complex working conditions. To avoid kelly bar
breakage and incorrect operation, observe the following regulations:
a. The rotary maximum torque and pressure should not exceed the maximum allowable value of
kelly bar.
b. When installing the kelly bar to the drilling rig, operate slowly to prevent collision with the
drilling rig and protect the rotary and pull-down cylinder against breakage.
c. When installing the drilling bit, lift the tool through the auxiliary winch and arrange the
drilling bit connection square hole vertically upward to facilitate the installation of drilling bit. Do not
push the horizontal drilling bit with the kelly bar square end directly to set up the tool. The incorrect
operation will bend the kelly bar square end or result in square end fracture if worse.
d. When fitting the casing, do not use the pull-down cylinder to apply pressure, instead, drive the
drilling bit to press the retaining cylinder. When the retaining cylinder is pressed in, as the drilling bit is
under stress and becomes eccentric, the kelly bar square end might be bent or even broken.
e. The kelly bar and the drilling bit connected to it must be used for drilling only and cannot be
used for blading or grading.
69
f. During drilling (the kelly bar in the hole), do not make the drilling rig travel, regulate the
derricking, adjust the mast or slew side to side; otherwise the kelly bar may bend and deform. Restore
the kelly bar to the original status in time after it changes due to stress.
g. In the early stage of kelly bar use, the operating staff should get familiar with the kelly bar
performance and parameter as soon as possible such as the rated torque, rated depth, boosting mode
and length of each section rod, learn about the drilling bit depth when the kelly bar is lowered to the
bottom and know which section kelly bar is rising at the corresponding depth during rod pulling out so
as to avoid severe rod smash due to the ignorance of rod slip.
h. Make sure to use the mechanical locking kelly bar for the hard formation. If the kelly bar
section is not correctly locked during operation, the abnormal wear and breakage of kelly bar will occur.
When the mechanical locking drillrod is boosting, rotate the rotary and apply the pressure slowly to
make the boosting planes contact completely; otherwise it will aggravate the abrasion or damage the
kelly bar.
i. When drilling the hard formation with the mechanical locking kelly bar, do not jack the
drilling rig while boosting to accelerate the drilling rate, since this will make the kelly bar withstand
additional bending moment and might abnormal wear or serious damage or kelly bar.
j. In the extremely severe working conditions (for example, the drill bit can contact the hard
formation at one side only, that is, partial load), do not apply any external force to the kelly bar except
for the torque and axial stress; otherwise the severe deformation and breakage of kelly bar will occur.
k. When drilling the small diameter hole or extremely sticky formation, if the earth dump is
difficult, it is recommended to replace the type drill bit immediately for the next construction. At this
point, do not dump the earth through quick change of rotary forward and negative rotation and repeated
impact of kelly bar; otherwise the kelly bar may crack and rotary breakage may occur.
l. In the event of rod slip during kelly bar lifting, lower the rod to the bottom immediately,
reverse the rotary to unlock and then lift the rod again. Do not unlock the rod by shaking the rotary side
to side so as to avoid rod smash and breakage.

m. When drilling the deep hole or large diameter hole, take special care to ensure the drilling bit
teeth working normally, replace the worn teeth in time and do not attempt to compensate the abrasion
through increasing the pressure.

n. Where the rod slip is detected continuous during operation, lower the kelly bar in time and
disassemble it to check and repair.
70
o. After the kelly bar is out of use, rinse the interior teeth section and ensure there is no slurry
inside. If the slurry is not removed in time, when it stiffens, it will seize the kelly bar and make the rod
pulling and lowering difficult.
p. Support the kelly bar at both ends and middle during transportation to reduce the deformation
caused by shock.
During storage, do not place the kelly bar together with the broken stone, unsolidified concrete or
other fine objects that may enter the kelly bar.
71
3.6.2 Drilling bit
As the drill bit has many types, the operator must
choose the drilling bit reasonably according to the

different formation conditions. The correct
selection of drilling bit is the key to ensure the
smooth rotary drilling. Before the drilling starts,

the operator or construction technologist should
learn about the actual geological prospecting data
of the construction site in details to establish the

optimal construction scheme.
1. Type of drilling bit
The rotary drilling bits main fall into 3 types:
1.)rotary drilling bucket (bit);
2.) short auger bit;
3.)tubular rock drill.
a. Sand drilling bucket:
1) Cutter teeth drill bucket and bucket teeth
drill bucket, in terms of teeth type
2) Double bottom bucket and single bottom
bucket, in terms of bottom number
3) Double gate bucket and single gate bucket,
in terms of gate number
4) Cone cask drill bucket and straight cask
drill bucket, in terms of cask taper
5) Pan bottom drill bucket and bottoming drill
bucket, in terms of bottom shape
The combination of the above structures
together with the variation of vent hole and
opening mechanism will combine dozens of drill
buckets.
72
Type Structure feature range of application
Single gate bucket teeth

Single bottom large earth inlet Clay soil or good cementation soil layer
drill bucket
Double gate bucket teeth Loose soil layer or good cementation small
Double bottom,smooth drilling
Rotary drill bucket diameter gravel and pebble
Excavating Side opening double gate Single bottom, large earth inlet,
Clay soil or loose soil containing gravel
drill bucket teeth smooth drilling
bucket Semi-close bucket teeth Two half cylinder, easy forearth

Adhesive soil and silt layer
drill bucket dump
Single gate cutter teeth Large diameter pebble, frozen soil or strong
Double bottom, large earthinlet
drill bucket weathered rock formation
Double gate cutter teeth Small diameter pebble, frozen soil or strong
Double bottom, two earth inlets
drill bucket weathered rock formation
b. Short auger bit
1) Double end dual auger (suitable for solid bedrock)
2) Double end single auger (suitable for moderately hard and solid bedrock)
3) Single end single auger (suitable for weathered bedrock, pebble and frozen soil)
The above drill bits together with various cutting picks may derive many types of drill bits
through the change of tooth shape, pitch and pitch angle.
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c. Cutting teeth straight auger:
1) Double end dual auger (suitable for sand soil

and poor cementation small diameter gravelly
layer)
2) Double end single auger (suitable for sand soil

and soil layer)
3) Single end single auger (suitable for poor
cementation large diameter pebble, clay soil and
hard clay mottar)
d. Cutting pick straight auger:Dual, three and
four-auger, suitable for moderate hard bedrock or
gravel.
e. Tubular rock drill
1) Cutting pick tubular drill, suitable for moderate
hard bedrock and gravel
2) Cutter tubular drill, suitable for solid bedrock
and large boulder
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2. Other special drilling bits
a. Base enlarging drill bit:To increase the pile
bearing capacity, the use of belled pile is an
economical and practical way. Presently, the

mechanical base enlarging drill bit is widely used
as the structure is simple, the cost is low, the
operation is easy and the maintenance and service
are convenient. When used in the rotary drilling rig,
the equipment requires no alteration except that the
soil should be removed by the cask after the hole
enlarging. The operating principle: when the base
hole is drilled in position, replace the base
enlarging drill bit to the hole base. As the bottom is
supported by the drill bit undercarriage, the drill
bit enlarging wing will expand under the function
of drilling pressure. When the wing expands in
position, it will be stopped by the limiting device.
Then pull up the drill bit to retract the wing and
finish the base enlarging. The wing expansion has
upper open type and lower open type.Depending
on the formation to be drilled, the cutting teeth can
be provided with common alloy tool bit, cutting
pick, cutter or hobbing cutter.
b. Split drill bucket:Suitable for clay or silt
formation, easy to dump the earth.
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c. Impact drill bit and grab-type drill bit
When drilling the pebble, boulder or solid bedrock, it will be highly effective to use the impact
drill bit and grab-type drill bit. The rotary drilling rig often adopts other drill bits for drilling.
3. Rock drillability and classification:

Rock class Rock category Typical rock
1 Rock category Allochthonous soil, loamy soil and infusorial earth
2 Floppy and loose Loess, clay and ice
3 Soft and loose Weather - degenerated surface rock, phyllite, marlite and soft coal
4 Soft Shale, dense marlite and halite
5 Less soft Argillite, fine grain limestone and serpentinite

6 Hard Micro - silicification limestone and quartz mica schist
7 Moderate hard Silicon limestone, quartz monzonite and hornblende
8 Moderate hard Skarn, phyllite and slightly weathered granite
Highly silicified limestone, coarse grain granite

9 Hard
and silicification volcanic tuff
10 Hard Fine grain granite, granite gneiss and solid quartz pegmatite
11 Solid Emery rock, quartzite and jasper rock containing iron ore
12 Solid Non-weathered dense quartzite, jasper rock and firestone
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4. Bit teeth:
5. Precautions of drilling bit use
a. Transportation and storage
1) Tie up the drilling bits firmly during transportation to ensure safety. Prevent the tipping caused
by the drilling bit motion or rolling in the case of transport vehicle braking or steering.
2) Before shipping the equipment, the driver of transport vehicle should check whether all the
parts are fixed to the vehicle in a correct and safe way.
3) When lifting the drilling bits by the auxiliary winch wire rope, the drilling rig operator must
face the drilling bits and connect them correctly and safety to prevent rotation. In the event of drilling
bit rotating, stop hoisting immediately and arrange the tools again.
4) The drilling bit must be hoisted by other equipment vertically; do not hoist the drilling bit
horizontally with the auxiliary winch wire rope in any case. After unloading the drilling bits, deliver
them to the designated safe place immediately or connect them with the kelly bar immediately.
5) Store the drilling bits horizontal and do not allow rolling or motion, in particular on a slope.
Strictly observe the above regulations even if the storage time is very short.
6) During the drilling bit storage, cover the edges and sharp corners of the drilling bit and the
cutting teeth and cutting pick and take necessary safety measures.
7) Before connecting the kelly bar square shaft with the drilling bit, maintain the drilling bit
vertical on the ground with the aid of the auxiliary equipment or tool until the connection is completed
and the safety pin is fitted.
b. Installation of drilling bit

1) Dig a small pit in the ground where the drilling bit is to be installed.
2) Fix the auxiliary winch wire rope to the drilling bit lifting point securely;
3) Lift the drilling bit with the auxiliary winch wire rope slowly and smoothly and prevent the
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drilling bit rotating.
4).Lifting the drill bit and keep it vertical, lowing the drill bit and insert the cutting tooth of it into
soil pit which has been digged, simultaneously keep the drill bit vertical.
5).If the drilling bit is not vertical,it should be adjusted until meeting the standard.
6).Adjust the location of the drilling bit until the square shaft of the drilling bit on the top of the
contect-box of the drilling bit.

7) Start the rotary and rotate the square shaft
slowly to align with the square hole of the fishing
box. Lower the kelly bar and insert the square

shaft in the fishing box.
8) Install and connect the fixing pin roll and

Warning
safety pin. The worn parts or wrong size parts Do not push or transfer the drill bit by
must be replaced immediately. human effort as the smallest auger bit will
9) Remove the auxiliary winch wire rope on be hundreds of kilogram while the large
the drilling bit, connect the end to the mast bottom
diameter drill bit may be several tons. Any
accident will be fatal.
fixing bracket and tension the rope slightly.
10) Frequently check the drill bit mechanical
locking device for abrasion and normal function;
the worn or damaged parts must be replaced.
c. Precautions
In general, the rotary drill bucket can perform
slurry drilling while cutting, delivering and
accepting detritus and closing the soil residue etc.

The rotary drill bucket is connected to the bottom
of telescopic kelly bar and the rotary supplies
rotary torque and downward boosted feeding force

to it through the transmission of the kelly bar.
When the soil residue enters the cylinder and
reaches the lifting volume, the drill bit should

rotate counterclockwise (reversely) to ensure the
bottom board closes the cylinder bottom opening
and then the drill bit will be lifted onto the ground
78
to dump.
To dump the soil, lift the main winch slowly

or operate the pull-down cylinder to make the drill
bit unlocking device (jacking strut) contact the
anti-collision disc and in turn to open the drill bit

bottom hopper gate to dump the soil.
Close the drill bit in the following steps:
1) Lower the drill bit to the ground first and
then operate the main winch to lower while
operating the slewing platform to rotate to the
proper position until the lowest part of the bucket
bottom contacts the ground.
2) Rotate the drive rotary, maintain the swing
axle of drill bit bucket bottom in the front of the
slewing platform rotation direction and slowly
operate the main winch to lower and slewing
platform to rotate.
3) Once the bucket bottom is nearly parallel
with the ground, stop operating the slewing
platform, continue to unwind the wire rope and
close the bucket bottom by the gravity of the kelly
bar and drill bit. If the bucket gate is difficult to
close though the lift of main winch is subjected to

repeated fine adjustment, remove the redundant
soil on the bucket bottom or check the wear
condition of the locking mechanism.
79
Memo
80
Memo
81
Chapter4 Operating Control and Display
4.1 Schematic of manipulation
82
Chapter4 Operating Control And Disply
4.2 The driving cab plan
Description of Diagram:
No Name and function No. Name and function
1 Main winch monitor 6 Main winch free fall (float)pedal
2 Walking pedal of left crawler belt 7 Electrical control panel
3 Walking pedal of right crawler belt 8 PLC display
4 Centralized lubrication control box 9 Right operation box
5 Horizontal detector 10 Lleft operation box
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4.3 Pedal
Figure 4-3 Pedal Switch
NO Name Function NO Name Functions

1 pedal valve left track walks 3 pedal switch main winch free fall
2 pedal valve right track walks
Notice
It is not allowed to press No.3 pedal
switch when lifting or lowering the kelly
bar.
Pressing the No.3 pedal switch is
allowed only when in the drilling
process.
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4.4 Control Panel
Description of Diagram:
NO Name Function NO Name Function
Rocker Relief of warning
1 Button Emergency stop 8
swich lamp
Warning Control oil filter clogging Rocker
2 9 Wiper spray
light alarm swich
Warning Main return oil filter Rocker
3 10 Travel lock
light clogging alarm swich
Rocker Rocker Rotary drive /track
4 Headlamp 11
swith swich switch
Rocker Rocker
5 Top lamp 12 Relief of height limit
swich swich
Rocker Rocker Pull-down/luffing
6 Rearview lamp 13
swich swich switch
Rocker Main winch /auxiliary Rocker Relief of
7 14
swich winch switch swich luffing limit
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4.5 Right Operation Box
NO Name Operation Function

I Rotary low speed
H1 Stretch out the landing leg/ lower the swing arm
1 Joystick H2 Retract the landing leg / raise the swing arm
G1 Stretch out track /rotary turns forward
G2 Retract the track /rotary turns reverse
2 Key switch Start the engine
3 Accelerator knob Engine accelerator control
4 Switch Windscreen wiper
5 Switch Spare
6 Switch Spare
K1 Mast lifts
K2 Mast falls
7 Mast joystick
L1 Mast leansto the left
L2 Mast leans to the right
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4.6 Left Operation Box
NO Name handling explanation
A1 Hydraulic system off

1 Safety handle
A2 Hydraulic system on
F1 Main/auxiliary winch lowering
F2 Main/auxiliary winch lifting
B+F1 Main winch quick lowering
2 Left joystick B+F2 Main winch quick lifting
A horn
C+E1 Upper structure turn left
C+E2 Upper structure turn right
3 Radio control panel
4 Air conditionercontrol panel
注意
87
Notice
For the control section, one point should be noted that the movement speed
of each function unit has direct relation with the joystickdisplacement. The less
the displacement, the lower the movement speed of controlled mechanism, vice
versa. When the joystick displacement reaches the maximum position, the
movement speed of controlled mechanism is the fastest, that is, the movement
speed of controlled mechanism can be regulated by the change of joystick
displacement. Besides, the speed of the joystick operating should not be too fast.
4.7 Display operating instructions

4.7.1 Starting-up screen
The display will show this page upon system
start-up and then the main working page will
appear after 2 ~ 3s;
4.7.2 Main working page
1. This page includes the mast verticality
display, hole depth, drill tool position, single
drilling depth, fault point number and some current
fault display and operating state display.
2. “Rotation Reset” After determining the
hole, press "Rotation Reset" and you will be
prompted whether to reset rotation, and press
"OK" to reset rotation angle to 0 degree; then the
system begins to automatically measure rotation
angle and displays it on the main page of the
display;
3. “Depth Reset” After determining the hole

position and begin to drill,, when the bit makes
contacts with the ground for the first time, press
this button and you will be prompted whether to

reset depth and press "OK" to reset depth to zero;
88
then the system begins to automatically measure
the depth of hole and displays it on the main page

of the display;
4.7.2 Main working page
1. This page includes the mast verticality
display, hole depth, drill bit position, single
drilling depth, fault point number and some current
fault display and operating state display.
2. “Rotation Reset” After determining the
hole, press "Rotation Reset" and you will be
prompted whether to reset rotation, and press
"OK" to reset rotation angle to 0 degree; then the
system begins to measure rotation angle
automatically and displays it on the main page of
the display;
3. “Depth Reset” After determining the hole
position and begin to drill, when the tool contacts
with the ground for the first time, press this button
and you will be prompted whether to reset
depth .Press "OK" to reset depth to zero; then the
system begins to measure the depth of hole
automatically and displays it on the main page of
the display;
4.Press "Parameter Calibration", enter
passwords to log in the “Calibration” page; this
function has been calibrated before leaving the
factory, which shall not be changed by the user
without authorization, otherwise it will affect the

control functions.
5. Alarm information:
1、Give an alarm when the oil pressure is

lower than 60 kPa;
89
2、Give an alarm when the hydraulic oil
temperature exceeds 80 C°;

3、Give an alarm when the cooling water
temperature exceeds 96 C°;
4、Press the "Return" to return to the main

page;
5、Press the "Set"button to enter into the
setting page, and the brightness, contrast ratio, etc.
of the display screen and buttons can be adjusted.
4.7.3 Mast action page
1. Manual operating mode page
a. Press F1 to access verticality adjustment
jogging mode page;
b. Press F2 to access leaning adjustment
automatic mode page;
c. Press F3 to access verticality adjustment
d. Press F8 to return home page;
2. Jogging working page
a. Allowing mast jogging verticality
adjustment at low speed, fine adjustment of mast

angle;
b. Press F1 to achieve fine adjustment
forward of mast angle;

c. Press F2 to achieve backward fine
adjustment of mast angle;
d. Press F3 to achieve leftward fine

e. Press F4 to achieve rightward fine

f. Press F5 to stop current fine adjustment;
90
g. Press F7 to access manual operating page;
h. Press F8 to return main working page.
3. Automatic correction page
a. Press F1 to access manual operating mode

page;
b. Press F2 to access verticality adjustment
jogging mode page;
c. Press F3 to access verticality adjustment
d. Press F8 to access main working page;
e. On this page, if the mast angle is within
automatic lift/lower angle range (Y-axis angle is
more than -60°, can be reset again), then the
system will access automatic lift/lower mast mode.
The Y-axis of the mast joystick (forward and
backward) controls the mast move forward and
backward and the action speed is controlled by the
joystick displacement.
4. Automatic vertical adjustment page
a. Press F1 to access manual operating mode
page;
b. Press F2 to access jogging vertical
/horizontal mast mode page;
c. Press F3 to access automatic correction
operating mode page;
d. Press F8 to access main working page;
e. In this page, if the mast angle is within the
automatic vertical adjustment angle range (reset it

if X and Y-axis ±2°), the mast verticality will be
adjusted automatically.
91
4.7.4 Parameter setting page
1. Password page
a. This password consists of six digits, range

of which is 1 to 9. Word prompt will occur if the
password is wrong; the set page will occur if the
password is correct.
b. Onthis page, press F1 to shift the cursor
leftward;
c. Press F2 to shift the cursor rightward;

d. Press F3 to increase the value indicated by
the cursor;
e. Press F4 to decrease the value indicated by
the cursor;
f. Press F5 to finish input;
g. Press F8 to return main page.
2. Parameter set menu page
a. Press F1 to shift the cursor upward;
b. Press F2 to shift the cursor downward;
c. Press F3 to confirm the check item;
d. Press F8 to return home page.
3. System parameter set page
c. Press F3 to increase the value indicated by
the cursor; long press this key will make the value
increase automatically;
d. Press F4 to decrease the value indicated by
thecursor; long press this key will make the
valuedecrease automatically;
e. Press F5 to skip the reference among
0.01,0.1, 1, 10 and 100;
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f. Press F6 to finish the set of item indicated
by the cursor;
g. Press F8 to return home page.
4. PWM set
decrease automatically;
e. Press F5 to skip the reference among 0.01 ,
0.1 ,1 ,10and100;
f. Press F6 to finish the set of item indicated
by the cursor;
5. Depth and verticality set page

a. Press F7 set enable key and then operate
the following keys;
b. Press F1 to achieve X-axis zero set;

c. Press F2 to achieve Y-axis zero set;
d. Press F3 to increase the value indicated by
f. Press F5 to skip the reference among 0.01 ,
0.1 , 1 ,10and100;
g. Press F6 to set depth;
93
h. Press F8 to return home page.
6. Joystick set page

the following keys. Press F7 once for each set;
b. When the mast joystick is pushed to the

X-axis maximum value, press F1 and then the
screen will display reading; after the reading
completes, the set is finished;
c. When the mastjoystick is pushed to the
X-axis minimum value, press F2 and then the
d. When the mast joystick is in the middle
position (under natural state), press F3 and then

the screen will display reading; after the reading
completes, the X-axis middle position set is
finished;
e. When the mast joystick is in the middle
position (under natural state), press F6 and then the
completes, the Y-axis middle position set is
finished;
f. When the mast joystick is pushed to the

Y-axis maximum value, press F5 and then the

g. When the mast joystick is pushed to the
Y-axis minimum value, press F5 and then the

h. Press F8 to return home page.
94
7. WM value modification page

the following keys;
b. Press F1 to make the cursor shift up and
down;
e. Press F4 to skip the reference among 0.01 ,
0.1 , 1 ,10and100;
f. Press F5 to read MW value;
g. Press F6 to set MW input;
h. Press F7 to access MW annotation page
and set WM value according to this page (see
below figure);
i. Press F8 to return home page.
8. Restore factory setting page
a. Press F7 to \ restore the factory setting of
the display;
b. Press F8 to return home page.
9. Time setting page

a. Press F1 to shift the cursor upward; Press
F2 to shift the cursor downward;

95
e. Press F5 to finish set;
f. Press F8 to return home page.
10. I/O testing page

a. This page is used to test the line fault;
b. To monitor the mast valve output, F1 must
be pressed; otherwise there will be no output.
11. QD decoding page
a. If the GPS signal around the machine is
very weak while the machine is locked, feedback
the QD number to the manufacturer, who will
supply a password. Enter this password to get the
decoding number for 48 h, 150 h and 500 h.
b. Press F1 to make the cursor shift leftward;
Press F2 to make the cursor shift rightward;
c. Press F2 to shift the cursor rightward;
f. Press F5 to finish password input;
96
4.8 Seat adjustment

1. The neck support up and down
Notice
adjustment:pull or push it directly to adjust the
height.
The operator can adjust the seat
2. Handrail adjustment: the handrail allows according to the demand to achieve
rotatable adjustment. During operation, lower the
comfort, It is better to stop the engine
when the seat is adjusted. If the engine
handrail. The handrail slope can be adjusted to be
is not stopped, ensure to turn the
parallel with the back rest to save space.
safety lever in OFF position to prevent
accident.
3. Back rest gradient adjustment: loosen lever
3 to adjust the gradient.
4. Height adjustment: pull up the seat and it
will lock in the higher position; pull up the seat
againto unlock and then the seat will return to the
lower position.
5. Front and rear adjustment: turn the lever 5
to move the seat fore-and-aft.
6. Seat rigidity adjustment: rotate the lever 6
to adjust the seat cushion rigidity.
97
4.9 Use of the air conditioning

4.9.1Brief Introduction to Air Conditioning Operation Panel
TYJ3 - 140 LCD - Air Conditioning Manipulator

 Power key:
After pressing the Power Switch to connect the power, the LCD backlight lights up, and the
manipulator remembers the state before the last shutdown, Press the power switch again to disconnect
the power, the backlight lights off.
 Refrigeration Button
After pressing the Refrigeration Button, the system enters into the refrigeration mode, and the
screen displays the refrigeration icon and the set temperature and wind speed in the last refrigeration
state. When the refrigeration icon starts flashing, it indicates that there is a pressure failure in the
system, and the air conditioning system should be stopped for maintenance.
 Heating Button
After pressing the Heating Button, the system enters into the heating mode, and the screen
displays the refrigeration icon and the set temperature and wind speed in the last heating state.
 Defrost Button
After pressing the Defrost Button, the system enters into the core defrost mode, and the screen
displays the defrost icon.
 Fresh Air Button
At refrigeration or heating mode, press Fresh Air button on the control panel, then the screen
displays the External Circulation Icon lighted, and then the system enters external circulation mode to
98
provide fresh air to cab. When you press this button again, the Outer Circulation Icon on the screen
disappears and the Inner Circulation Icon lights on to make the air in the cab start an inner circulation.
 Temperature Increase (or Decrease) Buttons
Under the state of displaying the set temperature, press the Temperature Increase (or Decrease)
Button to increase (or decrease) the set temperature for 1 degree. Press the Temperature Increase (or
Decrease) Button for 3S and the system enters into the forced refrigeration state. Press any button to
exit (except for the Wind Speed Button, the Luminous Button and the temperature Settings Button),
and remember the last state.
 Wind Speed Increase (or Decrease) Button
Wind speeds include L (low), M (medium), and H (high), and press Wind Speed Increase (or
Decrease) Button to adjust between L (low), M (medium), and H (high).
 Lighting Button
After pressing the Light Button, the luminous lights behind all buttons light up.
4.9.2 Operation methods of the air conditioning manipulator
1、Start the engine.
2、Press the Power Button of the air conditioning to turn on the power switch, the LCD backlight
lights up, and the screen displays the icons shown before the last shutdown.
3、When the screen displays the refrigeration (or heating) mode and the operator needs the
refrigeration (or heating) function, you do not need to re-set. When heating (or refrigeration) mode is
required by the operator, press heating (or refrigeration) button for mode resetting.
4、The Wind Speed Setting Button is used to increase /decrease the wind speed to a comfortable
speed.
5、The Temperature Setting Button is used to increase /decrease the preset temperature to a
comfortable temperature. With air conditioning on, when the room temperature is 3 ℃ lower than the
preset temperature, the system will automatically stop cooling; when the temperature in the cab is 3 ℃
higher than the set temperature, the system will automatically start cooling.
99
Memo
100
Memo
101
Chapter5 Operation
Warning
When all the hydraulic pilot control levers are operated in the same direction, do not operate in
theopposite direction suddenly; otherwise it will greatly reduce the service life of hydraulic elements
andeven result in the breakage of hydraulic elements!
Notice
Unless necessary, do not apply oversize load to the drilling rig with the engine idling; otherwise
theengine will stall due to underpower, which will damage the engine. If full throttle operation is
notrequired, regulate the engine speed to 1000 ~ 1400 r/min and then carry out auxiliary operation.
5.1 Preparation before starting
Notice
Before working, check the tightening torque of each connecting pin'sfixing bolt and the
lubricating oil (grease) state of each lubricating point carefully. Check the oil state of the hydraulic oil
tank, traveling mechanism, main/auxiliary winch gear box, rotary case, gear box and slewing platform
gear box particularly, check and tighten the bolts (screws) of the gear boxs. In addition, check the level
of engine system's coolant and the oil in sump and check whether the grease on the slewing platform
and kelly bar slewing bearing is sufficient. After finishing the inspection and adjustment above,
confirm the drilling rig operating conditions are met and then you can start the engine.
Caution
To avoid breakage of starting elements, the time to operate the starting motor should not exceed
10 s. If two continuous attempts fail, turn the key switch to OFF and wait for 2 minutes at least before
the next attempt. After the start attempts fail, the continuous engine starting or too short waiting time
will bringengine breakage.
Caution
Check the meters after starting the engine
Significance: ① Prevent the possible breakage of engine. If the relevant device blinks or tweets
after the engine is started, stop the engine immediately to check and solve the fault. ② After the engine
102
Chapter5 Operation
is started, maintain idling for 3 - 5 minutes (longer in winter, but not exceeding half an hour). Verify:
① The AC generator (charge) indicator lamp is turned off. ② The engine oil low pressure alarm does
not tweet. ③ The electrical meter indication is normal.
5.1.1 Power unit
Carry out the comprehensive routine check
before operating the equipment:
a. Check the bolts, nuts and pin rolls for
loose or falling.
b. Check the protecting cover structure and
bolts for loose or falling.
c. Check the hydraulic oil and fuel for leak.
d. Check whether the oil level of hydraulic
oil, fuel rotary case and each gear box is correct.
e. Check whether the safety functions are
effective: including the emergency stop button,
safety lever, main winch height limiting,
derricking cylinder and mast lifting cylinder
locking, main/ auxiliary winch brake and mast
lifting cylinder lever action.
1. Before starting the new equipment, check
the condition of the engin fan according to
operation and maintenance instruction of the diesel
engine. The belt's slack will result in battery
charging failure, overheating of engine and belt
slipping and undue abrasion.
The belt slack will result in battery charging
failure, overheating of engine and belt slipping and
undue abrasion.
a. Inspection
Check whether the fan belt tension is proper.
103
Push the middle of belt between the
alternator and water pump by finger (about 10 kg

force).If the is approximately 10 mm, then the belt Caution
is acceptable.
a. After adjustment, do not tighten the
bolts and nuts too much so as to avoid
breakage of bolts and bearing.
b. Do not stain grease to the belt;
otherwise the service life of the belt will be
shortened due to slipping.
c. Replace the belt if it is too long to

adjust or presents or crack.
d. If the belt consists of two belts, both
should be replaced togather.

e. After replacing the belt, carry out test
running for about 1 h and then check the
tension.
2. Check the oil level and coolant level to
prevent the burning of crank shaft or other parts.
a. Check the oil level: pull out the oil
dipstick and check the level as shown in the right
figure.
If the level is below L (the low oil level)

Notice
mark or above H (the high oil level), do not start
the engine. Check the oil level at least 5 minutes Do not fill any material other than
after the engine stops to allow the oil to flow back coolant prescribed to the cooling system;
to the oil sump. The volume of oil between the low otherwise the cooling system may be
level and high level (L to H) is 3.8L. clogged, which can causeoverheating of
b. Check the coolant level as shown in the engine.
right figure and take care to prevent scalding.
104
Chapter5 Operation
c. Coolant level: the water tank should not
be full; the level should be lower than water
filler neck tube (around 40 mm from the upper of
the water tank).
This machine adopts degassing water tank
and the coolant should not be filled up.
注意
Notice
a. Check the coolant level every
day.
b. Unscrew the water tank filler
cap only after the diesel engine is
stopped and the water temperature
is below 70℃; otherwise the too high
temperature coolant may splash on
the human body.
105
5.1.2 Electrical equipment
Check the wires and cables for breakage and check the connectors forupcoupled; check the
function of switchs, all the light indicators, safety equipment alarm, acidity of battery electrolyte and
fuse,whether they can work normally.
5.1.3 Fuel reserve
The capacity of diesel oil tank is 440L. To prevent diesel oil spilling ,when traveling on the
slope or bumping, do not fill up the tank. In general, there should be 40L diesel oil in the tank at least.
5.1.4 Hydraulic oil level
Pay attention to the following items when filling oil to the tank:
1. With the rotary drilling rig being horizontal (as shown in below figure), the hydraulic oil tank
oil level should be at 2/3 of the level meter.
2.Choose the same hydraulic oil in the tank,including the grade ang manufacturer; otherwise,
discharge the oil of the overall system and fill another kind ofoilin the tank.
3. When filling oil, filtrate the new oil with the oil filter to make the cleaning degree reach NAS9
or ISO17 / Grade 14 and then fill the oil in the tank.
Notice
Check the hydraulic oil level every day.
106
Chapter5 Operation
5.2 Engine start and stop

The initial start of the equipment should be
made by the manufacturer and customer together,

with the manufacturer supplying training and
actual operation in the site. Before operating the
equipment for the first time, the operator must read

this Operation Instruction and get familiar with the
functions of all control levers and buttons, motion
range and feature of the operating parts.
5.2.1 Start the engine
1. Position of key switch:
The key switch position is shown in the right
figure:
OFF - to stop
ON - to switch on
START - to start
HEAT - to heat (standby)

Notice
2. Starting sequence: a. Turn all the hydraulic control
a. Turn on the main power switch levers to the middle position.
b. Rotate the key switch clockwise to ON to b. Close all the roof gates when
turn on the power supply and carry out electronic the engine is running.
monitor pre-check. No warning symbol will blink c. In the event of warning, check
except the charge indication and oil pressure and solve all the faults before
indication (under normal condition); starting.
c. Turn the safety lever to ON position
d. Press the horn button to warn and ensure
no one is in the equipment or in the vicinity of it
e. Continue to rotate the key switch clockwise
to START position. After the engine starts, reset
the switch to ON (the starting time should not
exceed15s). The interval of two start attempts
107
should be more than 2 minutes. Notice

a. Do not shut down the engine
5.2.2 Shutdown
directly at high speed (except for
1. The equipment parked or garaged on a emergency), as the surge voltage of the
solid, flat ground generator may damage the circuit and
2 Mast in the vertical position impair the cooling of high speed
3 would drill into the lowest hanging loads moving parts for a long time.
into the ground b. The incorrect shut down
4 Adjust the car and the track in a straight line procedures will damage the
5 Put the drive rotary to the lowest position supercharger.
6 All of the control buttons and brakes are off c. Pull out the key to prevent
location battery discharging after shut down
7 Pulling operation the dead man's handle to the engine!
the vertical position. d. The starting time should not
8 Push the engine adjusting handle forward exceed 15 s and the interval of two
slowly, so that engine gradually slow down and start attempts must be more than 2
idling for 5 minutes, turn the key switch inverse minutes.
clockwise to the "OFF" position to cut off the e. Control the hand throttle slowly
power,and the handle should be in the lowest and maintain the engine speed below
position. 2100 rpm. The interval of two start
9 Turn off the power switch attempts should be more than 2
10. Lock the doors and windows of the cab minutes.
f. Do not shut down (stall) the engine at
high speed directly unless necessary
108
Chapter5 Operation
Notice
5.3 Traveling
a. Close all the side doors and
roof cover, set the door locking
bar to fasten the opened cab door
or close it.
b. Start the diesel engine as
required, run it at idle speed for 3
- 5 minutes and then set it to the
5.3.1 Traveling method
working speed. The warming up
1. The travel control valve is in the front
time should be longer (but not
lower of the cab seat. The different traveling
exceeding 30 minutes) if the
modes can be achieved through manual control or
temperature is below 0℃
foot control, that is, advance, reverse, left turn,
c. Set the safety lever
right turn and pivot steering.
d. Press the horn switch to
2. Turn the travel locking rocker switch of the
remind the persons around
left armrest box to the position shown in the right
figure before traveling.
Notice
After the traveling finishes, restore this button to prevent the incorrect
operation causing unnecessary loss during the drilling operation.
109
Below figure shows the travel control valve control direction and the corresponding action.
5.3.2 Precautions of traveling
1. Insure the crawler driving sprocket wheel is behind the cab before traveling.
2. Release the travel pedal and it will reset to brake the machine. When driving downslope, take
care tocontrol the speed though the speed limiting valve can restrict the speed and prevent coasting.
3. When traveling,; place the drive rotary and drill bit to the lowest position ， make the drill bit
above the ground 0.5m and control the mast backward rake around 45°approximately.
4. Choose flat road as much as possible when travelling, try best to select straight way for
traveling, take large steering radius for turning and control slowly in the case of pivot steering in the
narrow place.
5. Reduce the traveling speed to relieve the shock when traveling on the waste or rough gravel
road.
6. When traveling on the slope or getting in or off the rolling car, arrange someone to guide. In
such cases, operate slowly, lift the derricking mechanism slightly and ensure the mast angle is not more
than 15°.
7. Try best to avoid reverse driving to prevent the undue breakage of crawler attachments.
8. The continuous traveling time should be less than 2 h. Where it is necessary to travel at a high
speed over 2 h continuously, stop for 10 minutes or more to allow the machine members to cool down
110
Chapter5 Operation
and then continue to travel.
5.4 Slewing
1. Slewing method:
a. Remove the fixing pin roll for slewing
b. Press the left lever button C and turn it side
to side to achieve the clockwise or
counterclockwise slewing of rotary drilling rig, as
shown in the right figure.
2. Precautions of slewing:
a. Control the horn to warn the persons
around before slewing.
b. To start slewing, press button C first and
then move the lever slowly; to stop slewing,
restore the lever to the middle position and then
release button C.
c. Check the obstacles in the site and travel
for one loop slowly to ensure safety before
slewing.
d. The slewing brake is normally closed and

the brake is applied when the control lever returns
to the middle position. As the lever has certain
inertia slewing after the lever returns to the middle
position, pay special attention to the equipment
stop position, leave sufficient braking allowance
and do not apply compulsory braking by operating

the lever conversely.
111
e. Do not start slewing with the kelly bar in
the hole or carry out extra operation with the rotary

force (push or impact some object with the kelly
bar or mast); otherwise the drilling rig breakage
may occur.
f. When driving on a slope, pay more
attention to the slewing operation to prevent
tilting.
5.5 Main winch

The main winch is always connected to the
kelly bar and drill bit through the kelly bar during
operation. The operation is quite frequently and
the procedures are as follows:
Lifting and lowering of main winch wire rope
a. Place main winch and auxiliary winch
rocker switch of front control panel on the position
as shown in figure on the right.
b. The corresponding operation is shown in
the right figure: move the left lever up and down to

achieve the main winch lifting and lowering.
112
Chapter5 Operation
c. To lower the drill bit quickly, press button
A of the left lever while performing the above

operation.
2. Main winch floating function
During drilling, the drill bit should always
maintain the slip-free drilling in the soil layers
under the gravity of the kelly bar. Therefore, the
main winch wire rope should be freely released to
meet the demand of the kelly bar actual position.
This function can be achieved through button E of
the right control box, as shown in the above figure.
警告
Danger
During the main winch lifting,
do not press button E; in no case
should button A and E be pressed at
the same time while operating the
left lever up and down; otherwise the
kelly bar will fall quickly and
damage the hydraulic elements!
113
5.6 Mast
1. Operating method
a. The mast operating lever is in the right

front of the cab, as shown in the right figure.
b. Push the lever downward while turning it
forward (direction 1 in the right figure) and the

mast will lift. Turn the lever backward (direction 2
in the right figure) and the mast will lower. Turn
the lever leftward (direction 3 in the right figure)

and the mast will tilt leftward. Turn the lever
rightward (direction 4 in the right figure) and the
mast will tilt rightward.
2. Precautions of mast operation:
a. Lift the derricking mechanism first during
mast lifting and lowering to ensure the mast
bottom is above the cab roof and protect the cab
against deflection or squeezing.
b. The mast operation must be slow. The
simultaneous mast lifting and lowering requires
another person to monitor and command the entire
operating procedure in addition to the master
operator to prevent the collision of equipment or
with the objects around.
c. In the actual mast operation, the mast may
deflect leftward or rightward due to many factors.
In such cases, correct the mast according to the Caution

dynamic display of data (the column icon).
During mast operation, the
d. Where the mast deflects during
display page should be maintained
construction, operate the lever in the single
in Mast Action page.
direction (forward/backward or leftward/rightward)
to correct the vertical angular deviation in a certain
direction (X or Y).
114
Chapter5 Operation
5.7 Rotary drive

The rotary drive operation is the most
frequent and important during the drilling

operation and it has direct influence on the drilling
efficiency. The operating procedures are as
follows:
1. Operate the left and right lever directly to
achieve the rotary drive positive rotation (drill bit
rotary excavating) and negative rotation.

2. To rotate the rotary drive quickly to
increase the drilling rate, press button H on the
lever back while performing the above operation
(Optional function).
3. Each time when the drilling operation is
finished and the main winch should be lifted,
rotate the rotary drive reversely by 2 - 5 loops to
facilitate the drill bit pulling up and avoid rod
smash. In particular for the mechanical locking rod,
the negative rotation loops should be more.
115
5.8 Crowd cylinder

When the hard formation is encountered and
the normal drilling cannot be ensured under the

gravity of the rod and drill bit, enhance the drilling
rate with the help of crowd cylinder.
The detailed procedures are as follows:

1. Turn the boosting/derricking rocker switch
of the left armrest box to the position shown in the
right figure.
2. The corresponding operation is shown in
below figure: push the right lever forward or
backward to retract (lift the rotary) or stretch
(lower the rotary) the crowd cylinder.
3. In the case of mechanical locking kelly
bar,rotate the rotary drive slowly while the
cylinder is stretching. When the rotary drive is in a
proper position, the rotary drive interior teeth
panel will enter the boosting groove of the kelly
bar automatically to make the boosting effect

better.
4. Where the mechanical locking kelly bar is

used, to make the rod pulling smooth, stop the
rotary drive and rotate it reversely to ensure the
boosting key exits the boosting groove completely.
5. To lift the rotary drive, stop the rotary
drive driving and carry out appropriate negative

rotation.
116
Chapter5 Operation
5.9 Auxiliary winch
1.The "Main Winch / Auxiliary Winch"
rocker switch on the front panel is shown in the

figure on the right, and keep pressing the downside
of the rocker switch with your hand.
2. Push the left control box pilot lever
forward to lower the auxiliary winch wire rope.
3. Push the pilot lever backward to lift the

auxiliary winch wire rope.
117
Memo
118
Chapter5 Operation
Memo
119
Chapter 6 Installation, Removal and Transportation
6.1 Unloading the Drilling rig in jobsite

In general, the drilling rig is transported to the site with rolling transport vehicle.When arrived,
choose a solid, level and open place to unload, lower the gang board the angle between the gang board
and the ground should within15°, operate the drilling rig carefully and drive it off the rolling truck.
During the unloading process, adjust the angle between derricking mechanism and mast as needed to
avoid the drilling rig from falling or component breakage due to unbalance .
Warning
a. The operator must possess the skills of operating the drilling rig and be
familiar with the usage and function of each component.
b. The size of site for mast connecting should not less than 20×8m2 and it
must keep distance from the high voltage power line (cable,etc.).
c. Before the drilling rig is ready to work, each operation should be
cooperated by 3 personnel and at least 2 of whom are familiar with the
equipment using and operating; the operation must under unified command.
d. He who operates the drilling rig for the first time must read the operation
instruction carefully, learn about the functions of each operating lever and
button to have full confidence of operating it.
e. Use the necessary sling when handling and moving the related parts.
120
6.2 Installation of drilling rig

6.2.1 Installing (connecting) mast
1. Take out the fixing and connecting bolts of
mast II and III;

2. Push the （masthead）and mast III with
auxiliary equipment to rotate anticlockwise around
the hinge pin roll between the two masts by 165°
or so, in order to make the machining planes of
two masts (mastⅡ and Ⅲ) end plate contact with
each other.Then mount the connecting bolts
between the end plates and tighten them (intwo
steps, tighten the bolts to 480 and 600 N.m

No. Name
respectively), tighten the check nut (thin nut) to 1 Fixed connecting bolt
480 N.m and apply proper amount of grease to the 2 Mast III
3 Mast II
screw threads.
4 Cathead
3.Support the cathead assembly with
necessary tools or equipments, remove the tie bar
between the masthead and mast Ⅲ , lift the
cathead and make the cathead assembly bottom

No. Name
board perfectly contact with the end plate of mast
1 Cathead
Ⅲ.
2 Tie bar
3 Mast III
4 Connecting bolt
121
4．Install the connecting bolt between the
two plates, tighten it in two steps to 480 N.m and

600 N.m respectively, tighten the check nut thin
nut to 480 N.m and apply proper amount of grease
to the screw threads.
No. Name
1 Cathead
2 Connecting bolt
5.Control the mast lifting cylinder through the
electric joystick in the cab to lift and lower the
mast. Turn this joystick to left or right to adjust the
leftward and rightward rake of the mast at
necessary situation .
6．Operate the mast lifting cylinder slowly to
lift mast II.
122
No. Name
1 Mast I
2 Small tie rod
3 Mast II
4 Mast lifting cylinder
7．Stop the lifting operation on the instant

the end face of mast I contacts with the end face of
mast II. Mount the connecting bolts between the
two plates, tighten them in two steps to 480 N.m

and 600 N.m respectively, tighten the check nut
(thin nut) to 480 N.m and apply proper amount of
grease to the screw threads.
NO. Name
1 mastI
2 Binding bolt
3 Drag bar
4 Lifting cylinder
8．When the mast assembly is well connected,
adjust the mast lifting cylinder slightly to make the
tie rod between mastⅠand the triangular frame the
"small tie rod" for short free of stress, take out the
small tie rod's fixing pin, remove the rod and keep
it properly.
9.Extend the crowd cylinder through handing
the knob of the crowd cylinder, installing the
123
connecting pin and locking it when the mounting
hole of the crowd cylinder and rotary drive is

concentricity.
No. Name
1 Bolt
2 Buffer jacket
3 Check nut
Notice
The connecting of mast I and mast II, mast II and mast III, mast III and
cathead connecting bolt should be assembled according to the sequence shown in
the right figure.
Caution
1.Do not operate the mast lifting cylinder lever before the derricking
cylinder completely stretched; otherwise may cause unnecessary injuries.
2.Carry out fine adjustment leftward or rightward according to the prompt
of the commander during the mast lifting.
3.The operator should concentrate and operate slowly throughout the mast
lifting process.
4.When the front ends of mastⅠandⅡnearly coincide, reduce the lifting
speed of mastⅡ and stop lifting immediately when the front ends coincide, so as
to avoid structural breakage caused by the excessive forward tilt.
124
6.2.2 Installing the wire rope

1 2 3 4 5
1. Installing the main winch wire rope

a. Operate the lever of lifting cylinder to
make the mast assembly horizontal and keep its
lower end on the mast supporter properly.

b. Pass the wire rope's free end neither
extruded nor provided with rope clip through the
interior cotter of the cathead bracket's upper end

according to the direction shown by the arrow in The sequence for the free end of the wire rope
passing through the gooseneck boom pulley
the below figure, then run it along the main winch
1 Drill mast 2 Steel wire rope 3 Gooseneck boom
pulley groove and cross another pulley at the lower
landing leg 4 Pulley 5 Spacer pin
end. When crossing the pulley groove, keep clear
of the wire rope limiting pin near the pulley to
ensure the wire rope contacts the groove during
operating.
1 2 3 4
c. Release the retainer spring of main winch
wire rope to ensure the wire rope can pass the
clearance between the rope holder and drum freely.
d.Keep pulling the wire rope to run along the

pulley groove, until its free end passes from the
drum mounting flange's inside to the pressure

Fixation of free end of the wire rope 1 Wire
plate's inside via the through-hole. Apply Loctite rope 2 Fastening bolt 3 Pressing plate 4
262 sealant to the screw threads.Mount the rope Winding drum
holder and bind the bolt and tighten the
symmetrical two bolts clockwise/counterclockwise.
Tighten the bolts in two steps.
e. Adjust the tensile force of main winch wire
125
rope retainer spring to ensure the pressing force
applied to the rope is within the appropriate range.

f. Operate the main winch lever to make the
drum rotate toward rope winding direction (to
enwind the rope). At this point, observe the rope

winding angle, position and drum rotary speed to
prevent rope disorder until the number of turns of
rope on the drum complies with the requirement.
2. Auxiliary winch wire rope
The installation process and method are
almost the same as those of the main winch wire

Vice winch switch button
rope, except that the wire rope crosses the cathead
auxiliary winch pulleyinstead, and when fixing
the rope's free end to the auxiliary winch drum
flange's outer end, tighten the bolts of the pressure
plate to 60 N.m and 95 N.m in two steps
respectively
6.2.3 Installing the kelly bar
Notice
Choose the solid, level and open side and keep away from the high voltage
power line.
Operate with care, have 3 persons to participate in and at least one person is
familiar with the use and operating method of the equipment; the operation must
be under the unified command.
1. Make the kelly bar assembly elevator's end facing the frontside of the drilling rig, as shown in
the below figure.Maintain the two guides the slide assembly of the kelly bar supported by the ground,
and keep the elevator connecting wire rope and the towing lug pin roll which connects the kelly bar
horizontal.
126
1 2 3 4
No. Name No. Name

1 Kelly bar guide 3 Fixing pin roll
2 Kelly bar carriage 4 Elevator
127
1 2
5 4 3
2. As shown in Figure1 , set the mast vertical, adjust the verticality, lower the main winch wire
rope, adjust the derricking mechanism in the maximum working scope, move the rotary drive to the
lowest position and drive the drilling rig to the kelly bar's front;
3. As shown in Figure 2, tilt the mast forward, connect the wire rope and kelly bar rotary joint
and fix them.

4. As shown in Figure3 , drive forward while lifting the main winch wire rope to ensure the wire
rope's suspension end vertical, and avoid the impact caused by the kelly bar lower end sliding.
128
Warning
While winding the wire rope

(before the kelly bar's lower end off the
ground), the elevator and kelly bar correct
towing lug is only allowed to withstand

tensile load and avoid bending. If the
situation shown in the lower of right
figure occurred, stop operating
immediately and carry out necessary
adjustment to ensure the load complies
with the requirement, then the rope
winding could be continued.
5. As shown in Figure4 , lift the kelly bar to a
position higher than the rotary drive and the kelly
bar carriage guide lower end higher than the guide
rail's top.
6. As shown in Figure5, reduce the mast
forward rake slowly until the front end is vertical.
Press the main winch height limiting button while
unwinding the main winch wire rope. While the
kelly bar square shaft entering the inner space of

rotary shock absorber, send someone to observe
the conditions on the rotary drive, adjust the
position of the rotary driving sleeve's internal
key in time to ensure the mounting position with
the kelly bar's external key is correct.
7. Continue unwinding the main winch wire
rope, release the main winch height limiting button
while liftting the rotary drive to finish the kelly bar
installation.
129
6.2.4 Installing the drill bit
1. Place the appropriate drill bit near the
drilling rig and make the rotary excavating center

line vertical to the ground as much as possible.
2. Increase the rotary ground clearance
properly, move the drilling rig and adjust the

relative position of the kelly bar square shaft and
square hole in time to place the shaft in the hole.
3. Lower the kelly bar properly and have the

auxiliary person to insert the locking pin and take
measures to prevent the pin falling when the kelly
bar square shaft and pin hole of square hole
achieves certain coaxiality.
130
6.3 Drilling rig shift

Each time when the drilling rig finishes the
rotary excavating operation of one filling pile hole,

shift it to the next hole site to carry out the same
operation immediately. It is common as well that
the drilling rig shift among the hole sites.

1. Move the rotary drive and drill bit to the
lowest position.
2. Operate the mast to tilt backward by 45°

approximately and then retreat the drilling rig to 1.The operation should be slow
the proper position slowly. and in order. Watch out and observe
3. Adjust the position of drill bit and the command!
undercarriage properly to complete the drilling rig 2.Warning! Do not drive or turn
shift among hole sites and new hole site thr drilling rig on any slope
operation preperation.. laterally.When pass the road

including o slope g on any slope
(the slope ≤15°)from the front,the
mast should be in transportation
state.The slewing platform (slewing
tabel)should not slew while the
drilling rig is transferred.
3.In case that the drilling
machine needs to drive on abrupt
slope (the gradient is more than
5°),please remove the drill pipe an
lay dowm the drilling mast in order
to prevent dangers cause by the drop
of the pipe.
131
6.4 Disassembly of drilling rig

6.4.1 Removal of drill bit
1.Remove the drill bit components first if the bit should be changed during construction or after
long-distance transfer.Operate as follows:

1.Remove the mud in the drill bit and close the bucker gate .Remove the attachment (for
example,the clay)on the external wall of excavator bucket if necessary.
2. Drive the drilling rig onto an open, level and solid space, keeping away from high voltage
cable. Rotate the slewing platform clockwise by 90°, lower the main winch until the drill bit is rest on
the ground, and make sure the wire rope is complete relaxed. If it is necessary, rotate the power head to
make the part of bucket tooth be buried properly or use skids to pad its bottom (ensuring no wounding
when the drilling bit is out of the kelly bar).
3. Lift the main winch (the kelly bar) slowly and adjust the height in time to ensure the pin roll
connecting the drill bit and kelly bar does not bear the load.
4. Remove the thrust pin of the connecting pin roll and pull out the pin roll at the same time.
5. Continue to lift the kelly bar to make the lower square shaft completely leaves the square
mounting hole of the drill bit and then rotate the slewing platform counterclockwise to make the cab
face the front of drilling rig .
132
6.4.2 Removal of kelly bar
After finishing the above operation, remove the kelly bar.
1 2 3
6 5 4
1. As shown in Figure1 , set the rotary drive to the lowest position (contacting with the mast
lower end stopper), turn the front left pilot lever backward to wind the main winch wire rope slowly
(press the height limiting release button on the right lever when the height limits the motion) and stop
the rope winding when the kelly bar top carriage guide (the slide assembly) lower end leaves the mast
guide rail top end.
2. As shown in Figure2 , operate the mast slowly to make the forward rake about 5°.
3. As shown in Figure3 , unwind the main winch wire rope until the kelly bar square end touches
the ground.
4. As shown in Figure 4, unwind the main winch wire rope and retreat the drilling rig to ensure
the wire rope suspension end remains vertical to avoid impact caused by the sliding of kelly bar lower
end
133
5. Keep operating until the kelly bar carriage guides completely rest on the ground, as shown in
Figure5.
6. As shown in Figure6 , remove the connecting pin roll of the wire rope and kelly bar rotary
joint, place the wire rope bushing (passing through the connecting pin end) in the rotary driving sleeve
and make the bushing expose from the lower end of rotary bump-resistant body. Reduce the mast
forward rake slowly until the front end is vertical to the horizontal plane and then the kelly bar removal
is finished.
6.4.3 Mast folding
Fold the mast before the long-distance transfer of drilling rig or climbing to the flatbed truck.
Operate as follows:
1. Maintain the mast vertical to the ground and connect the (transportation) tie rod connecting the
mastⅠ and triangular frame.
2. Push the front right pilot lever forward and operate the pull-down cylinder stretching to rest
the rotary on the stopper of mastⅠ lower end.
3. Adjust the crowd cylinder piston rod stretching length, ensure the connecting pin roll of
thispiston rod and rotary carriage does not bear load and take out the pin roll.
4. Retract the crowd cylinder piston rod to the minimum size.
5. Remove the connecting bolt of mast sectionⅠandⅡ, operate the mast control lever to set the
mast sectionⅡ,Ⅲand cathead horizontal and make the mast seat the mast bracket center correctly to
ensure the derricking mechanism is in the lowest position.
6. Support the cathead with necessary equipments and tools, remove the connecting bolt of
mast Ⅲ and cathead and lower the cathead slowly.
7. Connect the tie bar of mastⅢ and cathead while removing the cathead supporting device.
8. Remove the connecting bolt of mast sectionⅡandⅢ, push the mast Ⅲ and cathead to rotate
clockwise around the hinge pin of mast sectionⅡandⅢ by 165°or so and connect the mast Ⅱ and
Ⅲ through the transportation journal and bolt.
9. Operate the main and auxiliary winch to enwind the slack wire rope.
134
6.5 Transportation of drilling rig

Prepare the transportation of driling rig ,after removing the kelly bar and rotary drive:
1. Lock the upper structure slewing

2. Pull down the safety lever to the vertical close position
3. Shut down the engine
4. Take out the ignition key,and lock the door and window of the cab
After the necessary hand over procedures are handled, the freight company should be responsible
for the full transportation process
Information to be confirmed by the freight company:

1. Transportation size and weight
2. Transportation route: origin and destination
Transportation weight: 47 t
Transportation width: 2960 mm(Excluding drill pipe, drill)
Crawler width: 700 mm
135
6.5.1 Precautions of hoisting, loading and transportation
1. All the components loaded to the transport vehicle should be securely tied up and fixed. Ensure
no component motion or out-of-position will occur to result in vehicle tipping or parts breakage when
the vehicle is running on the rugged road, turning or braking.
2. The driver must check whether the parts move and whether these are securely fixed to the
flatbed of the vehicle before driving each time.

3. Check whether the anchorage and safety devices of the vehicle side board and backboard are
normal and check the tensioning chain is reliable.
4. Do not carry any person in the compartment during transportation.

5. Ensure the height and angle of the skew bridges for both crawlers are consistent and the rest
persons are out of the dangerous zone during the equipment handling.
6. Do not use the side board of the vehicle as the skew bridge. Prevent the bearing bridge sliding
when it is used.
7. Ensure the shackle is safe and reliable when the handling is made by the crane.
Caution
注意
During lifting, the wire rope hook must be vertical; otherwise the heavy
object will slide, rotate or tilt! If the heavy object slides or rotates during lifting,
stop operation immediately and adjust the hook again.
8. Properly keep the small parts that are easy to ignore and do not miss any during transportation.
9. Take proper protective measures for the parts with sharp corner or edge during transportation.
6.5.2 Disassembly for transportation
If the transportation weight exceeds the limit tonnage of the road, the equipment must be
disassembled for long-distance transfer.
1.Removal of balance weight

a. Lift the rear section of mast and remove the mast bracket on the balance weight.
b. Remove the bolt of balance weight and slewing table connection and move the balance weight
away.
c. Assemble the bolts to connect the transportation bracket and slewing table and tighten the nuts.
d. Assemble the bolts to connect the transportation bracket and mast bracket and tighten the nuts.
e. Place the mast on the bracket gently.
136
Counterweight weight: 8.5t; see the figure above for overall dimension.
2.. Removal of rotary drive

a.Remove the hose at the valve block of the rotary dive and transport the hose with the rotary
drive.
b.Seal the hose with proper joint and end cap (VSK28L; VSK30S)
c.Seal the oil port of valve block with plate and end cap (VDT30S/N; VDT28L/N)
d.Use an auxiliary hoist to lift and dismount the rotary drive
Weight of rotary drive assembly: 4.7t; see the right figure for overall dimension.
3.Removal of left/right longitudinal beams and crawler assembly
a.Remove retractable cylinder of crawler and connecting pin roll of left/right longitudinal beams;
b.Remove hoses at left/right traveling motors and transport the hoses with main unit;
c.Lift and remove the left/right longitudinal beams and crawler assembly by using an auxiliary
crane.
137
Weight of longitudinal beams and crawlers: 7.3t. See the figure above for overall dimension
Main unit after removal of the kelly bar, drilling bit, counterweight, rotary drive, left and right
longitudinal beams and crawler assembly: overall dimension is shown in the figure above; weight: 31t.
4.Lift the dismounted parts and upper structure onto the trailer and fix them firmly.
when the rotary of drilling rig is

disassembly for transportation , you
should make sure the components of the
drill are strongly binding in the vehicle.
138
Memo
139
Memo
140
Chapter 7 Repair and Maintenance
7.1 Safety measures

Observe the following safety codes before or during equipment repair and maintenance.
1. The repair and maintenance must be made by the authorized and skilled maintenance staff who
is familiar with the equipment and understands the related contents of the instruction.
2. Carry out repair at the prescribed interval.

3. For the maintenance and repair of the specific component, refer to the maintenance and service
instruction.
Measures:
a. Park the drilling rig on the ground.
b. Pull the safety lever to close position, shut down the engine and take out the key.
c. Affix maintenance signs on the equipment and components under maintenance to prevent
accident.
d. Strictly observe the safe operation codes, wear the necessary protective articles and take the
protective measures such as wearing the safety glasses and safety helmet etc.
e. The cleaning staff using the compressed air must wear the work clothes and safety glasses; the
maximum pressure of the compressed air should not exceed 2 bar.
f. Smoking or lighting fires are strictly forbidden near the battery.
g. Be careful of hot component and lubricant.
h. Strictly prohibit welding on the hydraulic oil tank and oil circuit pipeline.
i. Do not service the equipment with the engine running, equipment operating or traveling.
j. Do not maintain the hydraulic system before the pressure is released.
k. Prepare a large enough container when change the hydraulic oil and handle the waste oil
properly to prevent environmentpollution.
l. Filtrate the added or changed hydraulic oil first before filling it in the tank.
m. Ensure the tools and equipment used for maintenance are safe and reliable.
141
7.2 Interval of repair and service

Depending on the operating conditions and wear conditions of the components, the following
repair and service intervals are specified:
a. Every 10 working hours or every day.
b. Every 50 working hours or every week.

c. Every 100 working hours or every two weeks.
d. Every 250 working hours or every month.
e. Every 500 working hours or every three months.
f. Every 1000h or half a year.
g. Every 2000 working hours or every year.
h. Every 3000 working hours or every two years.
The customer must implement the corresponding maintenance strictly at the stated interval for
the sake of own benefit.
The interval is cumulated. For example, when the interval of 100 working hours reaches, the
maintenance of 10 working hours and 50 working hours must be completed as well.
The maintenance interval should be shortened in the high humidity or dusty operating conditions.
All the maintenance records should be documented in the Maintenance and Repair Record Sheet,
which should be kept by the special person and signed by the repair man.
Safety requirements:
a. The tools and working space must be clean.
b. Use the regular (genuine) parts.
c. Use the recommended (allowed) lubricating oil and grease.
d. Use the lubricating oil and grease carried in the tank with cover.
e. Check the nozzle tip carefully and remove the dust, grease and oil sludge before service
lubrication.
f. Open the filter cap only when filling oil.

g. Do not open the protective cap or shield unless necessary to prevent the dust admission. Take
dustproof measures for the exposed hydraulic line, joints and electrical connectors.
h. The engine maintenance and service should comply with the requirements of the Operation
Instruction of the engine.
142
7.3 Schedule of repair and service

1. Service schedule
Service
contents Required interval
2000h
10h 50h 250h 500h 1000h 1000h
Every Every
Every Every 150h 3 6 Every Every Remark
month two
Item day week months months year year
years
Left and right longitudinal member sliding rail
Lubrication ●
Crawler
Adjust
Check the according
tensioning ● to the
condition tensioning
condition
Crawler telescopic cylinder
Lubrication √
Main/auxiliary winch shaft end support
Lubrication ●
Rotary gear box
Check the oil
●
level
Change the
●
lubricating
oil ★
Remove the
scrap
iron on the ●
bar
magnet
Rotary gear box
Check the oil
●
level
Change the
●
lubricating
oil ★
Main/auxiliary winch gear box
Check the oil
●
level
Change the
●
lubricating
oil ★
Rotary speed gear box
Check the oil
● 1
level
Change the
●
lubricating
oil ★
143
Required interval
Service 2000h
10h 50h 250h 500h 1000h 1000h
contents Every Every 150h
Every
3 6 Every Every
Every
Remark
month two
Item day week months months year year
years
Slewing gear box
Check the oil
●
level
Change the
lubricating oil
Traveling gear box
Check the oil
●
level
Change the
lubricating oil
Hydraulic oil
Check the oil
●
level
Change the
lubricating oil
Connecting bolts of important parts (the gear box connecting bolt, slewing bearing connecting bolt,
engine connecting bolt and mast connecting bolt)
Pre-tightening ●
Fuel
Check the oil
●
level
Engine
Drain the oil
●
-water separator
Check the belt ●
Check the
lubricating oil ●
level
Coolant level ●
Check the fan ●
Change the
lubricating oil
Replace the oil
filter
●
Replace the fuel
filter
●
Refer to the
Check the air
intake system
● operationin
struction of
Check the air the engine
filter restriction
●
Inspection and
cleaning charge ●
air cooler
Change the
lubricating oil
●
Replace the oil
filter
●
Replace the fuel
filter
●
Check the air
intake system
●
Check the
antifreeze level
●
144
Service Required interval

contents 2000h
10h 50h 250h 500h 1000h 1000h
Every Every
Item Every Every 150h 3 6 Every Every Remark
month two
day week months months year year
years
Check the
belt
tensioner
●
bearing
Check the
belt tension
●
Check the
coolant or
anti-freeze
●
liquid level
Change the
lubricating oil
●
Replace the
lubricating oil ●
filter
Replace the
fuel filter
●
Adjust the
valve ●
clearance
Check the fan
shaft ●
housing
Check the
belt
tightener
●
bearing
Check the
belt tension
●
Check the
shock ●
absorber
Check the
belt
tightener
●
bearing
Check the
belt tension
●
Change the
coolant
or anti-freeze
●
liquid
Check the
boosting
air cooler for
●
leak
Notice
●★means the initial change.

2. Sketch of lubrication and service
145
2. Sketch of lubrication and service
146
XR220D 旋挖钻机润滑示意图 XR220D Rotary Drilling Rig Lubrication Chart

工作前 Before working
10 小时/每天 10 hours / day
50 小时/每周 50 hours / weekly
鹅头轴承 Gooseneck boom bearings
钻杆回转支承 Kelly bar slewing bearing
背轮与钻桅铰接处 Hinge points of back gear and drill mast
钻杆提升器 Elevator of kelly bar
钢丝绳 Steel wire rope
动力头及钻杆托架滑块 Rotary dive and kelly bar bracket sliding block
Hinge points of the pressurized cylinder and the rotary
加压油缸与动力头铰接处
dive
背轮销轴油杯 Back gear pin roll oil cup
傾缸与钻桅铰接处 Hinge points of tilt cylinder and drill mast
动力头减速机油位 Oil level of rotary dive speed gear box
减速箱油位 Oil level of reduction gearbox
动力头过渡接盘油杯 Rotary dive transition flange oil cup
臂架与变幅油缸铰接处 Hinge joints of arm rest and luffing oil cylinder
卷扬轴端支承 Winch shaft end bearing
大圆盘 Large disc
臂架、支撑架各铰接点 Hinge points of the arm rest and the support frames
转台与变幅机构连接处 Junction of rotary table and luffing mechanism
回转支承 Slewing bearing
履带伸缩油缸 Track telescopic oil cylinder
左右纵架滑轮 Left and right vertical frame pulley
履带下垂度、涨紧油缸 Track sag and the tensioned oil cylinder
标志说明 Mark description
加润滑脂 Add grease
定期检查 Regular inspection
定期更换油品 Regular replacement of oil products
定期更换 Regular replacement
首次更换油品 First replacement of the oil products
集中润滑覆盖点 Covering points of centralization lubrication
备注 Remarks
1. 发动机相关事项详见发动机使用手册和说明 1. See Engine Manual and Instruction for details of
书 the engine-related matters
2. See specific lubrication and maintenance in the
2. 具体润滑保养参见旋挖钻机使用说明书
Operation Instruction of Rotary Drilling Rig
3. The covering points of centralization lubrication
3. 集中润滑覆盖点由集中润滑系统自动润滑，但 are automatically lubricated by the centralization lubrication
需要按照润滑时间间隔定期检查 system, but it requires regular inspection in accordance with
the interval of lubrication time
工作前 Before working
50 小时 50hours
150 小时 150 hours
1500 小时/每年 1500 hours /each year
147
钻桅各段铰接处 Hinge joints of each segment of drill mast

支腿油缸铰接处（选装） Hinge joints of support oil cylinder
动力头齿轮箱齿轮油 Rotary dive gearbox gear oil
动力头减速机 Rotary dive speed gear box
回转减速机 Rotary speed gear box
主副卷扬减速机 Main and auxiliary winch decelerator
机油滤芯、柴油滤芯 Oil filter, diesel filter
空气滤清器滤芯 Air cleaner element
液压油箱油位及液压油 Oil level and hydraulic oil of hydraulic oil tank
机油油位、燃油油位 Oil level of engine oil, fuel oil
冷却液液位 Coolant liquid level
行走减速机 Walking decelerator
148
7.4 Service of electrical system

7.4.1 Replacement of fuse
Replacement of fuse:
a. Open the front left door and remove the
cover plate of fuse box
b. Hold the fuse box by hand and pull it up to

remove it
c. Nip the fuse box cover with the right hand
thumb and forefinger in the direction shown by the

arrow and remove it outward
The specification for the fuse is listed in below table:
Name Function Remark Name Function Remark

K1 Air conditioning Relay F1 Headlight Fuse
K2 Emergency stop Relay F2 Engine Fuse
K3 Horn Relay F3 Top headlight Fuse
K4 reservation Relay F4 Main winch confluence Fuse
Rotary dive
K5 Relay F5 Pressurized confluence Fuse
confluence
Main winch
K6 Relay F6 Self sucking pump Fuse
confluence
Rotating warning
K7 Relay F7 Monitor Fuse
lamps
F8 Luffing Fuse
F9 controller Fuse
149
7.4.3 Electrical system
1. Cleaning and replacement of battery and recovery of waste battery

a. Cleaning of battery
Wipe the battery surface with the clean cloth and maintain the terminal post clean. Apply vaseline
to the terminal post and then fit the cap.

b. Recovery of battery
In general, return the waste battery to one of the following:
1) The supplier of battery;

2) The authorized battery recovery site;
3) The recovery plant.
c. Tightening of battery retaining clip
Tighten the battery retaining clip to prevent
the battery moving during machine running. The
incorrect connection of battery pack polarity will

Warning
result in the breakage of alternator rectifier.
d. Replacement of battery, battery cable or

The battery vapor or explosion of
battery trip switch
battery may cause severe injury. The
1) Turn the engine ignition switch key and
flammable vapor discharged by the
all the switches to OFF position;
battery may trigger an explosion. The
2) Turn the battery trip switch to OFF
electrolyte is an strong acid and will cause
position and remove the key;
personal injury if it contacts the skin or
3) Disconnect the battery negative cable;
eyes. Do not allow the spark to approach
4) Disconnect the battery positive cable;
the battery as the spark may trigger vapor
5) Disconnect the trip switch battery cable
explosion. Do not allow the jumper cable
and carry out the necessary service or replace the
ends to contact each other or contact the
battery (the trip switch is mounted to the machine
engine. The incorrect jumper cable
frame);
connection will trigger an explosion. Wear
6) Connect the battery cable to the trip
the safety goggles when operating the
switch;
battery.
7) Connect the battery positive cable;
150
8) Connect the battery negative cable;

9) Insert the trip switch key and turn it to ON
position.
2. Replacement of fuse
a. The electrical system must always be in
intact state and the blown or corroded fuse and
bulb must be replaced immediately. Check the

related circuits for short circuit or overload before
replacing the fuse. To allow the battery to supply
power normally, always keep the battery clean, in

particular, clean the electrodes and wire chucks
periodically and apply acid-proof grease.
b. The fuse box is provided on the fuse panel
behind the cab. Open the fuse viewing cap and
check each fuse. The fuse protects the circuit
against breakage cause by overload. The fuse
should be replaced if blown. If the new fuse is
blown again, check the circuit and/or repair the
circuit.
Notice
Below are the fuses for each circuit and each The type and capacity of the new
circuit bears the ampere value of the fuse. fuse must be the same as those of the
1) F1 starting circuit 20A old one; otherwise the circuit may be
2) F2 charging circuit 5A damaged.
3) F3 horn circuit 5A The circuit may have faults if the
4) F4 working lamp 15A fuse is blown frequently.
5) F5 wiper and cleaner 5A
6) F6 stereo set 10A
7) F7 cab lamp 10A
8) F8 A/C fuse 20A
9) F9 service lamp 5A
151
7.5 Service of hydraulic syste

7.5.1 Use and keeping and hydraulic
hose
The hose should be kept in the dry and
dustless place under free state, out of sunshine or
direct radiation of ultraviolet.
The hoses still will age and should be
replaced after a period of time even these are

correctly stored and used. Where the
manufacturer's recommendation is not available,
refer to the below table. The hoses must be
replaced if the storage period or service period is
exceeded. The sufficiently experienced customer
may determine the service life of hose according to
the specific conditions.
·Name Storage period Service period

Hose
The service life of hose also depends on the 2years 6years
assembly
operating environment and operating conditions.
The extreme operating conditions (for
example, high temperature and high pressure of

operating environment or excessively frequent
hose transfer) will shorten the service life. The
customer must communicate and consult the
manufacturer upon purchase if this special
requirement is practical.
Reuse of hose:
The hoses cannot be used any more after a
period of time if they not comply with the safety
standards; to recycle the hoses, replace and adjust

the hose ends and unions for the sake of safety.
152
The reused hoses must be provided with the

following marks on the union: letters RP indicating
repair, repair date and maximum allowable
working pressure etc.

Carry out safety testing before putting the
reused hoses into service.
The customer must solely bear the

responsibility when reusing the hoses.
Check and replacement criteria of hoses:
The hose or hose assembly must be replaced

if any of the following defects occurs:
1. The hose breakage has reached to the
inner layer (for example, abrasion, notch or crack).
2. The hose surface layer is crisp (for
example, crack on the surface).
3. The hose deforms and it cannot resume
the original shape regardless of pressure of
bending (for example, burst, layers isolation and
foaming).
4. The hose leaks or the connection is loose.
5. The union breaks or deforms and cannot
be sealed.
6. The hose head falls from the buckle.
7. The union corrosion reduces the leak
tightness or strength of materials.
8. The assembly of hose and union is bad.
9. The storage period or service life is
exceeded.
7.5.2 Maintenance of hydraulic cylinder
1. Repair of hydraulic cylinder
153
a. The hydraulic cylinder with seal damaged

Caution
must be immediately repaired or replaced.
b. The hydraulic cylinder repair must be Clean the piston rod with
made by the skilled technician who has received hydraulic oil and do not use the water
certain training (do not repair the cylinder in the jet, vapor, alkaline cleaning solution
dusty construction site). (containing soda) or swab with the
c. The pipeline and cylinder must be abrasive substance or hard tools so as
connected without pressure. to avoid unnecessary breakage.
d. The open union, hose and hydraulic
cylinder must be plugged immediately.

2. Service of hydraulic cylinder
a. Clean all the hydraulic cylinders and
check them for leak every day or at least every 10

Warning
working hours or before site transfer or if the
cylinders are out of operation for a long time. In the case of severe leak of
The cylinder will require particular service if hydraulic cylinder during rig
it will be out of operation for a long time installation and removal, ensure the
b. Lubricate all the cylinder pin holes every safety by the auxiliary hoist!
250 working hours or every month. Otherwise, it will result in serious
c. Wipe the extended piston rod section with damage of equipment and may cause
the hydraulic oil once or twice every week or personal injury.
move the piston rod for several times.
d. Apply corrosion resistant grease to the
piston rod surface if it will be exposed for a long

Caution
time.
3. Storage of cylinder
The cylinder, in particular the
Pay attention to the following items during
pull-down cylinder, exposed to the
cylinder storage:
direct sunshine has extremely high
a. Seal all the oil ports with the plastic cover
pressure inside. In such cases, take
or plug.
special care to open the joint so as to
b. Fill the cylinder with the operating
avoid accidents.
hydraulic oil.
154
c. Apply grease to the exposed piston rod

and lubricate the connecting pin hole if the
cylinder will be out of use for a long time.
d. The place for cylinder indoor storage must

maintain good ventilation, dry and corrosion-free
environment with temperature about 14 - 20 ℃; in
the case of outdoor storage, take the necessary

measures to prevent sunshine and raining.
e. Rinse the exposed machining faces with
the clean preventive oil every half a year in the

case of long-term storage. In general, replace the
static seal and check the sealing property of
dynamic seal elements if the storage period
exceeds one year.
155
7.5.3 Service of winch gear box
For more detailed maintenance and service

of winch gear box, refer to the Operation
Instruction of Gear box.
1. Check the oil level of main and auxiliary

winch gear box every week or before the gear boxs
are put in service after long term storage.
2. Change the gear box gear oil after the first

250 working hours or one month; change the oil
every 1000 working hours or every half a year
later.
Check the oil level of winch gear box:
1. Remove the oil level screw plug of gear

Check the oil level only after
box
the winch
2. Check whether the oil spills from the oil
Gear boxhas stopped for 3-5
level hole.
minutes.
3. If no oil spills, remove the oil filler screw
plug and fill gear oil until the oil spills from the oil
level hole.
4. Wipe the sealing face, check the oil seal
for breakage or abrasion and replace it where
necessary.
5. Mount the screw plug and tighten.
7.5.4 Slewing gear box
Observe the gear box oil level scale every

day before working. When the oil level is below
the lowest level indicated by the scale, fill the oil

2
to the gear box in time.
156
1.The oil should be changed after the first

working for about 150 hours and should be
changed every 1500 hours or every year later.
2.Replacement measure
NO Name
Twist off the choke plug of the oil outlet，
1 Oil filler
outfall the oil and then screw up it again. Twist off
2 Oil outlet
the plug screw, fillling-up the grease oil for about
5.5L by oil filler.
7.5.5 Service of traveling gear box
Measures of oil filling or changing of
traveling gear box: (as shown in the right figure)
1.Rotate the upper platform by 90° and
support the crawler of one side off the ground by
the working unit
2.Run the supported crawler idling for a few
loops and stop it in the position as shown in the

NO Name
right figure (the oil testing port and oil drain outlet
1 Oil filler
in the same line).
2 Oil level observation port
3. Remove the testing port screw plug and
3 Oil discharge outlet
observe the oil level. The level is normal if the oil
can be seen; if not, fill oil in the following way.

Notice
4. Remove the oil filler screw plug and fill
oil to the gear box housing until the oil flows from
1. After removing the screw plug,
the testing port.
clean it and check the O-ring for
5. Mount the two screw plugs in position.
breakage; replace the O-ring if any
To change the oil, remove all the three screw
breakage is detected.
plugs to drain off the oil; then mount the oil drain
2. Check the drained oil for metal
outlet screw plug and fill oil to the required level;
chipping or particles and carry out
mount the rest two screw plugs.
further service if necessary.
157
7.5.6 Service of hydraulic oil tank
1.Return oil filter(as shown in the right

figure)
a.Dismount the aerofilter cap to release the
tank pressure.
b. Screw off the mounting bolt of cover
plate , take out the cover plate and bring the bar
magnet out.
c. Wipe the magnetic bar with clean cotton
cloth or clean it with kerosene.
d. Take the retainer spring and gland out and
pull up the element carefully (without removing
the filter cartridge).
e. Clean the element internal and external
surface with the clean kerosene and compressed air
with pressure < 0.2MPa and check whether the
bypass valve is intact.
f. Check whether the O-ring is intact and Notice

reinstall the element. a. No matter return oil element or oil
suction element, they both should be
replaced if
2. pollution discharge of hydraulic oil tank severe breakage occurs or the pollution
The blowing down port of hydraulic oil tank cannot be removed!
is behind the drain valve of diesel oil tank and the b. Do not scratch the O-ring during
blowing down method is the same as that of diesel reinstallation!
oil tank. When changing the hydraulic oil, remove
the water trap, clean it thoroughly and clean the
hydraulic oil tank inside with the clean kerosene as
well.
158
7.6 Maintenance of wire rope

The normal maintenance can prolong the
service life of wire rope.
7.6.1 Lubrication of wire rope
Apply grease to the new wire rope to resist
corrosion in addition to anti-attrition and
enhancing the fatigue resistance.
The grease of the wire rope under tension or
passing through the drum and pulley will reduce
along with use. In general, the grease content is 12
~ 15% for a new wire rope, 8 ~ 12% for the used
rope and 2 ~ 3% at the maximum breakage part
upon discard, however, the grease content at the
end of same rope not passing through the pulley
still can be 12 14%. The service life of the rope
will be increased if the grease is applied to the rope
surface periodically (the grease will permeate to
the rope core) to maintain the certain grease
content.
The fatigue property will differ by 1~2 times
and even more depending on the grease applied to
the rope.
As the above stated, it is necessary to
maintain the proper lubrication of rope to ensure
the rope safety.
7.6.2 Cleaning of wire rope
The wire rope surface should be cleaned
when it is very dirty, in particular when the wire
rope presents chemical reaction materials or strong
abrasive operating conditions.
159
7.6.3 Reject the broken wire rope
The wire rope may present broken wires

after operation of a period of time due to various
reasons. In such case, to continue to use the wire
rope, the broken wires must be handled in time.

To save time and avoid trouble, clamp the
head of broken wires with wire clamp and bend
them repeatedly until these wires are severed. In

this way, the wire end will be clamped between the
strands and will not endanger the wire rope use,as
shown in below figure:
7.6.4 Cropping, transposition and

reverse
The service life of wire rope subjected to
high stress and dense wearing still can be
prolonged in the following way:
Notice
The wire rope of the drum must not be
wrapped from the first layer to the second layer
while the stress is high, crop the wire rope shorter Do not cut off the broken wire end
to distribute the stress to different sections of the with the wirerope vice in any case!
rope.
If the wire rope abrasion is severe as the
wire rope line contacts with the adjacent rope and
is pressed to one side, carry out wire rope
transposition for several times to stagger the

abrasion and stress concentration section.
If each half of the wire rope is subjected to
different stress and abrasion, prolong the service

life by reversing the rope.
160
7.6.5 Check of wire rope
1. Check the wire rope and fixed rope end for potential breakage and deformation every day, in
particular the related equipment contacting the wire rope.
2. For the sake of operational safety, the wire rope must be periodically checked by the
experienced specialists.
3. Frequently check the rope for potential breakage and the interval of testing in the first week
after installation and after the broken wire is detected for the first time should be shorter than usual.
4. Where the abrasion or stress is abnormal, the rope is questionable while no breakage can be
seen, check the rope more frequently.
5. After long time rest (more than 3 months), when the equipment is put in service in the new site
for the first time, if the devices related to the wire rope gearing present fault or breakage, check the
rope immediately.
6. When checking the wire rope, pay special attention to the parts frequently contacting the
pulley, near the anchorage and fixing point. The routine check contributes to due detection of potential
broken wire.
7. The check interval should be shorter where the plastic or metal pulley with plastic bushing is
used.
8. Pay special attention to the parts of no lubrication or poor lubrication.
9. Check the pulley, drum and back gear once every year at least or after the rope is replaced.
10. All the test results should be documented to maintain the complete inspection record within
the prescribed interval.
Notice
The wire rope is expendable with a limited service life. As the properties and
features within the service life will change, it is necessary to observe the following
regulations.
161
7.6.6 Criteria of wire rope replacement
The wire rope replacement is determined by

ISO 4309 and the criteria for safe operation should
be as follows:
a. Type and number of broken wires

b. Wire rope end broken wire
c. Broken wire position
d. Wire breaking interval

e. Strand breaking
Notice
f. Reduction of rope diameter (necked-in)
g. Reduction of rope elasticity For the sake of safety, discard the wire
h. Abrasion of inner and outer layer rope reaching one or more of the
i. Corrosion of inner and outer layer following replacement criteria.
j. Wire rope deformation Failing to replace the defective wire
k. Deformation caused by heat rope may cause serious breakage or even
L. Percentage of elongation of rope within severe or fatal accident.
certain time
According to the above criteria, the skilled
professional should determine the use condition of
the rope
Most defects of the rope are caused by
several above factors
It is necessary to check whether the rope

defects are caused by the related defective devices.
If so, repair the devices before installing the new
rope.
1. Type and number of broken wires
a. The wire breaking of 6-strand and
8-strand rope normally occurs on the surface.

b. Most wire breakings of multi-strand occur
inside the rope and are difficult to detect.
c. The replacement criteria of
162
slewing-resistant wire rope is determined by the

construction of wire rope, installation date and
application category etc.
table 2.Conditions of rope replacement because of wire breaking and rope abrasion
Number of Number of visible broken wires upon replacement due to abrasion
outer layer Category of driving unite Category of driving unite

strand wire M1,M2,M3,M4 M5,M6,M7,M8
rope Cross lay Long lay Cross lay Long lay
bearing
Length range Length range Length range Length range
load①
N② 6d 30d 6d 30d 6d 30d 6d 30d
50 2 4 1 2 4 8 2 4
51 to 75 3 6 2 3 6 12 3 6
76 to 100 4 8 2 4 8 16 4 8
101 to 120 5 10 2 5 10 19 5 10
121 to 140 6 11 3 6 11 22 6 11
141 to 160 6 13 3 6 13 26 6 13
161 to 180 7 14 4 7 14 29 7 14
181 to 200 8 16 4 8 16 32 8 16
201 to 220 9 18 4 9 18 35 9 18
221 to 240 10 19 5 10 19 38 10 19
241 to 260 10 21 5 10 21 42 10 21
261 to 280 11 22 6 11 22 45 11 22
281 to 300 12 24 6 12 24 48 12 24
大于 300 0.04*n 0.08*n 0.02*n 0.04*n 0.08*n 0.16*n 0.04*n 0.08*n
Notice
1. The filler wires are not used as the load bearing wires
Only the outermost layer strand of the multilayer strand wire rope is
regarded as the outer layer strand.
For the wire rope with reinforced core, the steel core is regarded as inner
strand.
163
2. The values should be calculated by the customer:

For the highly dense outer layer strand cover wire construction of wire rope,
for example: 6×19 core corresponding to DIN 3058 and 8×19 core round strand
wire rope corresponding to DIN 3062, the abrasion replacement criteria is 2
visible broken wires, lower than the value shown in the above table.
table 2.Number of visible broken wires of torsion resistant wire rope on the pulley
Number of visible broken wires
Category of driving unit Category of driving unit
M1, M2, M3, M4 M5, M6, M7, M8
Length range Length range
6d 30d 6d 30d
2 4 4 8
2.Broken wire of the wire rope
a. The end broken wires are resulted by the high stress and incorrect installation.
b. If the wire rope has been used for a long time, the end should be cut off and replaced.
3. Broken wire position
a. The wire rope should be discarded in the case of clustering broken wires.
b. If the length of broken cluster is less than 6 times of rope diameter or the cluster breaking
occurs in the same strand, the rope should be discarded even if the number of broken wires is less than
that listed in Table 1 and 2.
3. Position of the broken wire
In general, the wire breaking requires certain time, however it may increase soon in some cases.
In the event of wire breaking, check the rope carefully, observe the breaking development and
determine when to replace the rope.
5. Strand breaking
Discard the wire rope in the case of strand breaking.
6. Necked-in caused by rope core variation
a. The rope core variation causes wire rope necked-in for some reasons:
1) Inside abrasion and notch
2) Inside abrasion caused by friction and inflection
3) Transformation of core fiber structure
4) Damage of steel core
5) Breakage of multi-layer structure wire rope inner layer
164
b. The slewing resistant wire rope should be discarded if the normal diameter is reduced by 3%
because of the above reasons; for the ropes of other structure, it should be replaced if the diameter is
reduced by 10%.
The wire rope should be discarded even no broken wire is seen.

7. Reduction of elasticity
a. The reduction of rope elasticity is difficult to detect and should be determined by the
experienced and specialized technician.

b. For the sake of safety, the wire rope must be discarded if the elasticity is reduced due to any of
the following cases
1)Neck-in of wire rope

2) Wire rope elongation
3) Less clearance between the wire and strand caused by compression
4) Fine and brown powder occurs between twostrands
5) Though no wire breakage is detected, the wire rope evidently stiffens while the rope diameter
is much less than the prospective normal wear.
8. Abrasion of inner and outer layer
a. The abrasion is caused by: contact of rope and strand under pressure, rope curve, motion in the
pulley and dragging on the ground.
b. Lack of lubrication, no lubrication, too dirty or texture or large sand grain and so on, they are
all will aggravate the abrasion.
c. The rated winding capacity will reduce if the abrasion causes necked-in
d. The wire rope should be discarded if the necked-in of outside diameter caused by abrasion
reaches 7% even if no broken wire is detected.
9. Corrosion of inner and outer layer
a. The operation in the corrosive environment conditions will aggravate the corrosion.
b. The metal profile reduction caused by corrosion will reduce the wire rope tensile force.
c. The corrosion also may result in wire rope surface irregularity and cause fracture when the
rope is loaded.
1) Corrosion of outer layer
The corrosion of outer layer can be observed from the surface
2) Corrosion of inner layer
The corrosion of inner layer is difficult to check, however it can be determined by the following
features.
165
Variation in the rope diameter

The diameter of wire rope passing through the pulley may reduce.
The rust attached to the inertia wire rope may cause the rope diameter larger.
The smaller clearance of outer layer strands may be related to the strand wire breaking.
3) Have the experienced technician to check the rope if the internal corrosion is suspected. The
wire rope must be discarded or replaced if the corrosion is confirmed.
10. Wire rope deformation

The deformation of wire rope structure caused by excessive tension or breakage can be observed
from the surface. The deformation is classified as follows depending on the different shapes:
Deformation
Description Picture description
category
The direct-axis of wire rope is in
helical line shape. Such deformation does
not always result in any strength loss,
however, the severe deformation will
Wave shape
generate run-out, cause irregular driving and
even result in abrasion and wire breaking
over long time.
When the core is twisted, the outer

layer wire rope will protrude because of
Cage shape
stress to make the outside diameter larger. In
such cases, the rope must be discarded.
Strand The twisting imbalance may cause the

strand to protrude from the rope structure. In
emergence such cases, the rope must be discarded..
The vibration load may cause the single

Wire or a set of wire to emerge from the rope
structure and form links. The rope should be
emergence discarded if there is wire emergence on the
rope surface.
Rope When the core is twisted, the outer

layer wire rope will protrude because of
diameter stress to make the outside diameter larger. In
such cases, the rope must be discarded
becomes
larger
166
When the wire rope core fractures, the

Rope outer layer strand will slide in the point of
diameter fracture and result in necked-in.
Pay special attention to the wire rope
becomes near the fixed end.
smaller Discard the rope if evident necked-in is
detected.
Deformation
Description Picture description
category
When the wire rope is squeezed, it will
become flat, which will aggravate the wire
breaking. This will occur as well when the
wire rope winding on the drum is incorrect.
Flat rope
The wire rope of serious collapsing
should be discarded.
The kinking will occur when the wire
rope loop is stretched.
Knot will be produced while the kinky

Kinking is stretched.The kinky rope must be
discarded.
Folding The folding mark is generally caused

mark by the external force.
11. Deformation caused by heating
The tensile strength of the rope will evidently reduce when the rope is exposed to the
environment condition with temperature exceeding 300℃. The dull wire rope indicates the rope is
overheated.
12. Service life
The experienced worker can determine when the rope should be replaced.
7.6.7 Determination of rope diameter
To calculate the allowable value and the
future necked-in, measure the wire rope for several
167
times after it arrives at the site. Measure the

hypersurface of wire rope to obtain the exact
diameter, for example: the distance of extremity of
two wire ropes (as shown in the right figure).

If the measured distance of wire rope
opposite notches is used as the diameter, the result
will be wrong (as shown in the right figure)

Measure with the conventional vernier
calipers if the outer layer strands of wire rope are
even number (4, 6, 8……).

Wide face vernier calipers is recommended
for measurement if the outer layer strands of wire
rope are odd number (3, 5, 7……) as the strand
extremity is opposite to the notch.
To check the ovality of wire rope, after
finishing the measurement at one point, rotate the
vernier calipers by 90° to check at another point.
7.6.8 Check up structure strength of

the wire rope
Insert the screwdriver between two outer
layer strands of the wire rope to check the structure
strength.
If the wire rope does not resist and the
screwdriver can even pass through the gap of two
strands, it means the rope structure is too loose.
The structure strength of outer layer wire
rope strands can be checked in the same way.
7.6.9 Storage of wire rope
The wire rope should be stored in the clean,
cool,dry and ventilated room. Protect the ropes
againstdirect sunshine or hot air and avoid rolling
168
or placing the wire rope in any material harmful to

the steel products such as the slurry, dust or slag.
Where the dust or sand attaches to the wire
rope surface, remove it with a brush.

Do not place the wire rope on the ground
directly; place it on the wood rack stand (as shown
in the right figure).

If the rope must be stored outdoor, place it
on the dry ground with wood plate under it and
cover it with the oilskin with good venting quality

(as shown in the right figure).
7.6.10 Check up the terminal of the

wire rope
Check the wire rope terminal periodically. If
any problem is detected, cut (crop) it in time and
fabricate it again:
Check the fixed rope end, lifting point hole

and terminal jacket periodically to ensure the rope
is firm, reliable and safe.
Check the wire rope end for corrosion and
check the wire rope near the terminal jacket for
wire breaking, falling and corrosion.
169
7.6.11 Guide pulley of the wire rope
Before installing the new rope, check the

pulley first and check it once 250 working hours or
every month later.
Apply bearing grease every 250 working

hours.
Check whether the pulley rotation is flexible;
if the pulley rotation is not flexible or the pulley is
seized, it will result in malfunction and too soon
rope abrasion.
Check the pulley center pin roll.

Check whether the pulley groove matches
the rope diameter; the pulley groove should be
replaced if it is too large or deformed.
Check whether the pulley groove is smooth.
If there is burr, repair or replace the pulley.
Check whether the pulley scrapes or rubs the
wire rope roller.
The pulley must be replaced in the case of
excessive abrasion.
170
7.7 Maintenance of rotary joint

The wire rope rotary joint can withstand
tensile load and have the function of free rotation
to eliminate the twist force generated by the rope.
Apply grease to the rotary joint and check

the working conditions every 10 working hours or
every day.
Perform the required operation for the rotary
joint used in the kelly bar in time.
1. Apply grease to it until the grease spills
from the housing connection, as shown in the
figure.
2. Check whether the rotary joint can rotate
freely when under zero load, for example, rotate it
by hand.
3. If the joint cannot rotate freely after the
grease is applied, repair or replace it.
4. For the sake of safety, the replaced parts
and new joint should be the same specification as
the original.
5. Check whether the joint upper and lower Notice

pin rolls are correctly installed (the upper connects Change the oil of the power
the wire rope and the lower connects the kelly bar) control box if the oil becomes turbid
while applying the grease. or bears water: rinse the box with
The joint must be replaced if the fit clean and new oil carefully and
clearance is too large or the pin roll and bolt repeatedly before filling oil!
present breakage.
7.8 Maintenance of rotary drive

7.8.1 Routine maintenance
1. Clean the rotary drive with clean water
171
every day after operation and the water can be

under certain pressure; otherwise, the dust or slurry
will cumulate on the rotary drive and will be
difficult to remove along with time; the slurry will

penetrate to the box of rotary drive along with the
rotation of the rotary drive and such impair the
service life of rotary drive.

2. Check the rotary drive assembly for
breakage and check the bolt and pin roll for loose.
7.8.2 Check the box of rotary drive oil

level
1. Make sure the mass is in the state of
upright before checking.
2. On the box of rotary drive,an oil level
checking window is fixed, so that it will
convenient for people to the oli level in the box.
3. Make sure checking the oil level
everyday.
4. It should ensure the oil level in the rotary
drill box is located on the top of the intermediate
position of the oil level checking window.
7.8.3 Oil change
Precautions
1. For the new equipment, change the rotary
gear oil for the first time after 200 working hours;
change the oil later every 1000 working hours or
every year whichever occurs the first.
2. The gear oil grade must be that

recommended in this instruction. If the gear oil of
another grade is used, the compatibility test must
be made for both oil.
172
3. It will be better to change the oil after the

rotary has operated and certain temperature is
maintained. If the outdoor temperature is low
during oil change, it is recommended to heat the

new oil (to 50 ℃) of certain volume to rinse the
rotary and remove the impurity and mineral
substances left in the rotary.

4. If the operating temperature of rotary Notice
exceeds 100℃, the color of discharged oil will be The heated oil may result in serious
dull or dark, the oil age will be aggravated and the personal injury!
lubricating function will lose. In such cases, the oil
change interval should be shortened.
5. Check the oil for impurity and mineral
substance (the abrasive); the maximum allowable
allowance upon oil change is 0.15% of total oil
volume.
6. The maximum size of particle in the oil
should not exceed 5μ m; otherwise, the rotary
must be removed and check it carefully regardless
of the number of particles.
7. Rinse the rotary drive with benzene or
flushing oil and do not use the gasoline, petroleum
or diesel oil in any case.
8. Fill the new oil only after the flushing oil in
the rotary drive is completely drained.
173
Oil change
1. Unscrew the air filter on the upper cover plate (see below figure)
2. Prepare a proper container to accept the waste oil
3. Place the container under the oil drain screw plug and unscrew the oil drain screw plug on the
lower end cap to drain the oil off
4. Remove the lower end cap and check whether the slewing bearing connecting bolt is firm and
reliable. In general, do not turn this bolt; otherwise the bolt sealant will be broken. Where this bolt is
loose, tighten it to 900 N.m.
5. Mount the lower end cap
6. Check or replace the screw plug seal and tighten the oil drain screw plug
7. Fill oil recommended in this instruction to the filter seat until it reaches the upper part of the
oil gauge(around 55 L)
8. Tighten the air filter
174
7.8.4 Oil change of rotary drive gear

box
Observe the gear box oil level every day
before working. When the oil gauge indicates no
oil or the oil cup indicates no oil, fill the oil to the
gear box in time.
1. Filling oil:
Unscrew the breather cap and fill oil via the
oil cup until the oil level can be observed through
the oil level sight glass.
2. Change the oil:
The oil should be changed after the first 150
working hours and should be changed every 1500
hours or every year later.
3. Changing oil:
NO Name
a. Place the rotary in a horizontal position;
1 Breather cap
b. Unscrew the screw plug on the bottom of Rotary gear box oil level
2
gear box meter
c. Drain the oil to a proper container;
d. Tighten the screw plug;
e. Place the rotary drive in a vertical
position;
f. Unscrew the oil cup breather cap and fill
the oil recommended in this instruction to the cup
until the oil level reaches the middle position of

the scale;
g. Tighten the cap;
7.8.5 Check the key of the driving sleeve
Check the key of the driving sleeve for
abrasion every 50 working hours or every week.

Replace this key in the case of severe abrasion.
175
7.8.6 Check the nylon block in the slide
Check the nylon slide for abrasion every 50

working hours or every week.
1. Check the 3 nylon slides in the bracket.
2. As shown in the right figure, if the

distance of left and right stopper from the guide
rail is more than 6 mm, adjust it through regulating
the slide position in the following way:
a. Loosen the binding bolt;
b.Change the side to side position of bracket
through adjusting the bolt;

c. Tighten the binding bolt.
3. The slide must be replaced if it protrudes
from the structural member surface less than 3 代号名称

mm. 1 carriage
4. Replacement of slide: 2 Binding bolt
a. Remove the bolt of slide to be replaced
b. Take out the old slide and mount the new
one
c. Screw in the adjusting screw to move the
slide to the proper position
d. Tighten the bolt again
176
7.9 Maintenance of traveling mechanism

The routine check includes:
a. Check the carrying wheel, thrust wheel
and guide wheel for leak;
b. Check the abrasion degree of carrying

wheel, thrust wheel, guide wheel rolling surface,
creeper tread and driving sprocket wheel
c. Check the connecting bolt for loose
d. Drive slowly on the open and wide
ground to listen for abnormal noise and repair in
time if any unfavorable condition is detected.
7.9.1 Check the tightness of crawler
The crawler is too loose and too tight crawler
both will shorten the service life of crawler and
driving parts and it is necessary to check the
crawler sag frequently. As shown in right figure

a. Place a long enough ruler between the
guide wheel and carrying wheel;
b. Measure the maximum size from the
creeper tread to the lower edge of ruler;
c. The appropriate sag should be 30 mm ~
50 mm (the crawler should be loose for operation
in the clay).
7.9.2 Tensioning or loosening the

crawler
1. Tensioning the crawler

If the crawler is too loose, apply grease to
the tensioning cylinder via the grease gun from the
service hole at the crawler bracket side (as shown

in the right figure) to tension the crawler. Caution:
177
do not tension it too tight.

2. Loosening the crawler (as shown in the
right figure)
Unscrew the filler valve slowly until the

grease spills. Where the grease spill rate is too low,
rotate the platform by 90°, support the crawler
with the operating device, run the crawler idling

for several loops and then fasten the filler valve.
1. Do not peep the service hole;

otherwise the high pressure grease
jet may injure the persons!
2. To prevent the part bursting out
and causing injury, do not fasten the
filler valve too loose!
7.10 Service when out of

service
To maintain the proper functions of
equipment if it will be out of service for a long

time, implement the following service items
carefully:
1.When shutting down the equipment,
retract all the cylinder piston rods requiring no
extension and apply grease to the exposed piston
rod for corrosion protection.

2.Clean the complete machine and pay
special attention to the traveling section.
3. Apply grease to each hinge point and

rusting easy part, in particular the sliding rail.
178
4.Every 2 ~ 3 weeks, start the engine, turn

on A/C in the cab and run the engine at moderate
speed for about 1 hour.
5.In case the engine should not be started,

while the engine repair and maintenance must be
made, refer to the Operation Instruction of the
engine.
7.11 Maintenance and service of kelly bar and drilling bit
7.11.1 Check and service of kelly bar
The regular and correct service will prevent undue abrasion of kelly bar, prolong the service life
and enhance the working efficiency.
The regular and correct check and service will help to find problems in the early stage of kelly
bar breakage and will greatly reduce the failure rate of kelly bar and maintenance load.
The check and maintenance should be made in a wide and smooth site and sufficient sleepers
should be prepared. When removing and installing the kelly bar, operate slowly to make all sections of
kelly bar are in the same line. The large range swing will result in the rod bending, interior teeth section
crack or even fracture.
Service interval
The service should be made according to the below table depending on the kelly bar category,
working time and formation condition.
1. Friction type Unit: working hours

Commonr
Working Condition Good Poor
(sand bed and
Interval (soft soil layer) (pebble bed)
gravelly layer)
First use 100 80 50
Normal use 500 300 200
2. Mechanical locking type

Common
Working Condition Good Poor
(sand bed and
Interval (soft soil layer) (pebble bed)
gravelly layer)
First use 80 60 40
Normal use 300 200 150
179
Where any of the following situations is detected during operation, lower the kelly bar in time
and disassemble it to check and repair.
a. The rod cannot telescope freely and there is rod slip or seizing.
b. The crowd is abnormal and the rod slipping occurs.
c. The eye ring deforms
d. Crack is detected in the rod

e. Other abnormal conditions
180
7.11.2 Removal and installation
1 2 slewing joint
3
apron backstop
direction of
down upon
drilling rod
1. Removal (with 4-section kelly bar as an example)
a. Remove the bolt indicated by code number 1 in the above figure and take out the kelly bar
casing and carriage.
b. Remove the pin roll indicated by code number 2 in the above figure and take out the rotary
joint.
c. Remove the bolt indicated by code number 3 in the above figure and take out the two baffles
and notch ring.

d. Pull the innermost section of kelly bar (the fourth section kelly bar) out along the kelly bar
lower.
e. Pull the third section kelly bar out along the kelly bar upper.
f. Pull the second section kelly bar out along the kelly bar upper.
2. Installation of kelly bar
a. Fit the second section kelly bar from the top of the first section kelly bar (when inserting the
second section in the interior teeth section of the first section rod, align the exterior teeth of the second
section with the interior teeth groove of the first section). After completely fitting, pin the first and
second section kelly bar at the kelly bar drain hole with pin roll to prevent the second section kelly bar
being carried over when the third section is installed.
b. Fit the third section kelly bar from the top of the second section kelly bar. After completely
fitting, pin the first, second and third section kelly bar at the kelly bar drain hole with pin roll to prevent
the second and third section kelly bar being carried over when the fourth section is installed.
181
c. Fit the fourth section kelly bar from bottom of the third section kelly bar and do not forget to
keep the spring and water proof disc with notch side facing upward.
d. Mount the baffle and bolt indicated by code number 3 in the above figure. Note the baffle
direction and back and front side (with marks).

e. Mount the pin roll and elevator indicated by code number 2 in the above figure.
f. Mount the bolt indicated by code number1 in the above figure and connect the kelly bar
carriage.
7.11.3 content of check and service
To service and check the kelly bar correctly, pull out each section to check it carefully
Breakage
No. Component Sketch
condition
Compression
1 Tube deformation
of tube Cut off this tube and replace a new
section.
This should be made by the professional
Flanging of
Internal and
2 internal and
external key
external key
The maximum protrusion should be 1 -3
mm. The protrusion section should be grinded
in time.
Abrasion of
Internal and
3 internal
external key Maximum abrasion loss: 8 mm for the external
andexternal key
key and 10 mm for the internal key. In the case
of abrasion, perform overlay welding with the
wear resistant electrode and grind the weld
level. Replace the key in the case of severe
abrasion.
182
Abrasion of Abrasion of
4
boosting key boosting key
Maximum abrasion loss: 20 mm. In the
case of abrasion, perform overlay welding with
the wear resistant electrode and grind the weld
level. Replace the key in the case of severe
abrasion.
No. Component Breakage condition Sketch

5 Bracket flange Deformation and crack Weld or replace
6 Rod slip -prevention flange Deformation, screw loose or fracture Replace or tighten
7 Spring Breakage Replace
8 Spring seat Abrasion Repair
9 Bolt Breakage Replace
10 Upper cushionblocking Breakage Replace
11 Spring pin Breakage Replace
12 Pin roll Breakage Replace
13 Kelly bar joint Deformation and crack Repair or replace
14 Kelly bar squareend Deformation and crack Repair or replace
7.11.4 Precautions of repair

No. Precautions Sketch
Fracture of flange from the kelly bar

Weld the tube and flange until
1
welding through and weld radius is
5 mm
Crack at key joint

Grind out the crater shown in the
figure at the crack with angle grinder
2
and grind it level after welding (to
avoid damaging the kelly bar, do not
cut it with flame directly)
183
Do not keep the welding interfaces of

3 keys in the same plane; leave spacing
about 100 mm between them
The total length of key should be

4
more than 1500 mm in general
Crack at the kelly bar interface

Grind out the crater shown in the
figure at the crack with angle grinder
5
and grind it level after welding (to
avoid damaging the kelly bar, do not
cut it with flame directly)
Do not assemble the kelly bar with

6
tubes less than 200 mm
Do not approach the tube interface to

7
the boosting plane
7.12 Description of engine service

As the necessary data, the Operation and Service Manual of B Series Diesel Engine prepared by
Cummins will be available when XR series rotary drilling rig is sold. This manual details the engine
operation and service and specifies the selection of fuel, coolant and oil. The operator and management
184
stall of the drilling rig should read and comprehend the contents of this manual and strictly observe the
regulations.
Below is the description of service of periphery equipment of the engine

.
185
7.12.1 Service of cooling system
1. Clean the fly net, A/C condenser, oil
radiator and water tank
As shown in below figure, in the dusty site or
if there is too much impurity, clean the fly net and
condenser surface every day with the soft hair
brush or clear water or compressed air with a
pressure ≤0.2 MPa.
NO Name
1 Radiator
2. Precautions:
a. Replace the fly net if damaged to prevent

2 Engine
shortening the service life of oil radiator and water
tank.
b. The operating staff must wear the
protective articles according to the safety
regulations in particular those for eye, mouth and
nose protection and urge the unrelated persons to
leave.
c. Replenish the A/C refrigerant in the case of
leak.
NO Name
1 Fly net
To avoid overheating of engine, do

not place fuel 1
drum or other
impurity in the space in front of the
oil cooler!
186
7.12.2 Service of fuel system
1.Drain the water from the oil by separator

and replace the fuel filter
As shown in the right figure, open the rear

right door and the separator will be seen; it is
mounted to the diesel engine block.
a. Draining of measures NO Name

1) Loosen the water drain screw plug of the 1 Oil water separator
separator, rotate it for several loops by hand and 2 Fuel pump
then the water will flows out from the bottom; 3 Water proof valve
2) Fasten the screw plug immediately after
draining water;
b. Replace the fuel filter

For the replacement measures, refer to
Operation and Service Manual of B Series Diesel
Engine
c. Precautions:
1) Oil water separator is provided to facilitate
the service made by the customer. If too much
water is drained every day, the draining cycle of oil
water separator should be shortened;
2) The service of oil water separator and
replacement of fuel filter should be made NO Name

Ball valve at the drain
according to Operation and Service Manual of B 1
outlet
Series Diesel Engine and the oil filling and
bleeding should be made as required; do not start
the engine forcedly;
2.Blowing down of fuel tank (as shown in the

right figure)
a. Method:
1) Loosen the screw plug with sleeve and then
187
unscrew it for several loops (without falling) to

drain the water;
2) Fasten the screw plug after draining water.
b. Precautions:
Perform the following operation if the drain
hole is plugged by the settlement:
1) Remove the inlet pipe of oil water

separator
to discharge the fuel tank;
2) Remove the screw plug or water trap to

rinse;
3) Install the trap of screw plug again (do not
damage the sealing element);
4) Install the inlet pipe.
7.12.3 Service of intake system
The service of intake system mainly includes
two items: one is to check whether the intake
pipeline is intact and whether the hoop is loose
every day and the otherone is to blow down and
clean the air filter element as required. (as shown
in the right figure)
1. Service procedures
a. Loosen the 6 wing nuts (without removing)
to take out the filter cap;
b.Shaking the filter element softly and
remove this filter element by both hands slowly

NO Name
c. Clean the element surface with compressed
1 Air filter end cover
air of pressure < 0.2 MPa;
2 Hasp
d. Install filter element in the procedures
3 Air filter clogging alarm apparatus
reverse to the above after cleaning the filter inside
4 Dust setting pockets
188
2. Precautions
a. In the case of filter breakage, replace it
immediately together with stage Ⅰ and Ⅱ
elements. Clean the filter inside before removing

stage Ⅱ element;
b. Wear protective articles and protect the
mouth, nose and eyes while cleaning;

c. Clean stage Ⅰ element immediately if the
color of indicating instrument turns red from green
or the arrow indicates 6.2 during routine check.
NO Name
1 Air filter end cover
Main filter element +safty
2
filter element
189
7.13 Lubrication and service of

drilling rig
7.13.1 Handling of waste oil,

filter-element and additive
Observe the following regulations when
handling the waste oil,filter element and additive: Use the oil (grease) of grade
The following waste oil should be stored recommended in the table only; any
solely breakage of equipment parts caused by
a. The useful oil the use of oil not recommended will not
b. The oil can burn in the special site enjoy the warranty.
c. The oil should be treated as dangerous Before changing the oil (grease) grade,
material confirm the new oil (grease) property
matches that of the previous one. Do not
In no case should the waste oil of different mix the synthesized oil (grease) with the
grades be mixed! mineral base oil (grease)! The oil (grease)
a. The waste oil must be handled by the to be used must be fresh and clean!
authorized company to handling
b. Handle the waste oil in the way allowed by
the state and do not mix the waste oil to burn at

Use the appropriate container when
will.
changing the oil!
c. Refer to the instructions supplied by the
related manufacturers when replacing the engine or
gear box element and waste oil.
Biologically dissolvable oil (grease)
If the oil (grease) leak may endanger the
environment, for example, during the construction

in the protected zoned, the biologically dissolvable
oil (grease) is strongly recommended.
Observe the following requirements when using the environment-friendly oil (grease):
190
In no case should the synthesized liquid and mineral-free or vegetable oil-free oil (grease) be
mixed with the mineral-bearing oil (grease).
Before changing to use the biologically dissolvable oil (grease), obtain the description of
manufacturer of related parts on the relevant oil (grease), seal ring, hose, filter system and related
container inside paint compatibility.
7.13.2 List of recommended lubricating oil (grease) and anti-freeze liquid
Oil (grease), diesel oil, hydraulic oil and anti-freeze liquid recommended by XCMG
Table 1
Component Code and grade Volume, L Name Maker Remark
Subject to oil gauge
Approx15
CH-4 scale (ambient
Engine oil pan Diesel oil Caltex
SAE15W/40 temperature
- 15℃~ +40℃)
Fuel tank 0 or -10# Approx280 Diesel oil
Anti-wear 2/3 of oil gauge

Hydraulic system Rando HD46 Approx400 Caltex
hydraulic oil window height
Subject to oil
Traveling gear box Approx55 Caltex
cup scale
Slewing gear box Approx5.7×2 Caltex Subject to oil

flowing from the
Main winch gear box Meropa 220 Approx3.4 Caltex
inspection hole.
Auxiliary winch Approx6.5 Caltex
(ambient
gear box Approx3 Caltex
Gear oil temperature -
Rotary gear box Approx3×2 Caltex 15℃~ +40℃)
Extreme
pressure
Wire rope 1# Approx2000g Kunlun
lithium base
grease
Slewing bearing (the
slewing table and 2# Approx550g Gear oil Kunlun GB 7323
kelly bar)
Extreme
pressure
Elevator 2# Approx30g Kunlun
lithium base
grease
Extreme
pressure
Component hinged
2# Approx1500g lithium base Kunlun GB 7323
point and guide rail
grease
Gear oil
55/45 Approx31 Fleetguard CC8958 or Fleetguard CC8959

Engine water tank
191
Recommended oil grade for drilling rig in cold area (with ambient temperature being -30 ℃~
+40 ℃)
Table 2:
Component Code and grade Volume, L Name Maker Remark
CH-4 Subject to oil

Engine oil pan Approx15 Diesel oil Caltex
SAE10W/30 gauge scale
Fuel tank －35# Approx280 Diesel oil
Anti-wear 2/3 of oil

Hydraulic system Rando HDZ46 Approx400 Caltex gauge window
hydraulic oil
height
Subject to oil
Rotary case Approx55 Diesel oil Caltex
cup scale
Traveling gear box Meropa Synthetic Approx5.7×2 Diesel oil Caltex
Slewing gear box EP 220 Approx3.4 Diesel oil Caltex Subject to oil
Main winch flowing from
Approx6.5 Diesel oil Caltex the inspection
gear box
Auxiliary hole.
Approx3 Diesel oil Caltex
winch gear box
Subject to oil
Rotary gear box Approx3×2 Diesel oil Caltex
gauge scale
7.13.3 Lubricating part and service schedule of rotary drilling rig operating
mechanism
50h or every 1500h or

Service part 10h/every day 150h 250h 500h
week every year
Check and apply
Kelly bar elevator
grease
Kelly bar slewing bearing
Back gear Apply grease

rack and
mast hinge
Check and apply
Wire rope
grease
Rotary and kelly bar
slide
Apply grease
Mast lifting cylinder
and mast hinge
Pull-down cylinder and
Apply grease
towing carriage hinge
Rotary case and gear box Check the oil level
Oil cup of rotary

Check the oil level Fill oil
gear box
192
Rotary case Check the oil level Fill oil
Large disc
Apply grease
Triangular frame hinges
Derricking mechanism
Apply grease
hinges
Main/auxiliary winch
Apply grease
shaft end support
Derricking mechanism
Apply grease
slewing table hinges
Slewing bearing grease Fill and apply
Crawler telescopic
Apply grease
cylinder pin roll
10h/every 50h or every 1500h or

Service part 150h 250h 500h
day week every year
Guide wheel sliding
Apply grease
rail
Crawler slack Check Fill oil

according to the
Tensioning cylinder slack degree
Check the oil Initial Periodic

Traveling gear box
level replacement replacement
Diesel oil and
coolant Check
level
Diesel oil, coolant Periodic
and Check replacemen
air filter element t
Hydraulic oil tank Initial
Periodic
oil Check replacemen
replacement
level t
Periodic
Hydraulic oil filter Initial
Check replacemen
element replacement
t
Periodic
Pilot oil source valve Initial
Check replacemen
block element replacement
t
Initial
By-pass filter Periodic
Check replacemen
element replacement
t
Main/auxiliary
winch
gear box
193

Slewing gear box
Rotary case
Rotary gear box
Mast hinges
Apply
Outrigger cylinder grease
Note: optional
hinge
7.14 Operation and Maintenance of Centralkized Lubrication System

7.14.1 Composition of lubrication syetem
The SLE progressive centralized lubrication system is composed of SLE electric oil pump,JPQ
progressive parent distributor,JPQ progressive sub-distributor,main oil pipe,distribution
pipe,displancement sensor,pipe fittings and controlle.
7.14.2 Description for working principle of lubrication system
Controller gives instructions to lubrication pump unit based on the set operation time and offtime;
lubrication pump motor drives cam, cam drives piston to work, convey pressure oil to distributor
through main pipeline, separate oil at distributor and inject oil into lubrication point of friction pair
through oil pipeline. After the displacement sensor installed in the master distributor reaches the
predetermined position, it will issue a displacement signal to the controller. After receiving the
displacement signal, the controller determines the normal operation of the lubrication system, and
carries out the self-controlled operation.
7.14.3 Parameters of SLE Electric Oil Pump

Rat
Applied grease (extreme
Item Applied Nominal Oil tank Rated ed
pressure lithium based
lubrication pressure capacity voltage po
lubricating grease)
Type points n MPa L V wer
NLGI
W
SLE10-24 1.2 24DC 20

00、0、1、2；When the
environment temperature
SLE10-220 ≤60 20 1.2 220AC 6
is less than -10 ℃, the
SLE25-24 2.5 antifreeze grease is 24DC 20
194
recommend to use (not

mix the grease with
SLE25-220 2.5 220AC 6
different brands and
different levels)
7.14.4 JPQ progressive distributor
JPQ progressive is a component that can continuously conduct progressive distribution of
lubricating grease . The pressure lubrication grease provided by the lubrication pump enter into the
master distributor through the master oil pipe, and be discharged out of several pipes after the oil
distribution by the oil distribution valve element, and then enter into the sub-distributor, then be
discharged to the lubrication points after the oil distribution by the sub-distributor. If the pumps
continuously work, the sub-distributor will distribute the oil in cycles according to the order of
progressive oil distribution.
7.14.5 Instructions of SL-ECU13-EJ Controller
Turn on the ignition switch (key), the controller will display the factory set offtime after the
initialization of 2-3 seconds .
1、Unlock
Click the "Settings" button, and then continuously press the "▲" button twice within two seconds,
relieving the lock of the setting function.
2、Offtime settings
In the condition of unlocking of the setting function, the "Setting" character will display on the
upward side of the display, while the "resting" character flashing. Press "▲" key or "▼" key to change
the offtime, changing 30 minutes for each time, the range of variation: from 30 minutes to 24 hours.
3、Set the number of cycles
In the condition of unlocking of the setting function, by pressing the "Setting" button to bring up
the number of cycles setting function; the "Setting" character will display on the upward side of the
display, while the "resting"Character flashing. Press "▲" key or "▼" key to change the offtime,
changing 1 time for each time, the range of variation: 1 time to 10 times. After setting, press the
"Setting" key to exit the setup mode, and self-locking.

4、Working state of debug system
Press "▼" key for more than 3 seconds and release it, then the system will enter into the manual
working state. The "Manual Operation" character will display on the top left of the display, and the "○
195
M" and work instructions "○X" appears on the lower right of the display. Start timing from the number
one, and the "Second" displays on the right side.
5、Alarm for working overtime
After continuous working (manual operation or automatic) for eight minutes, number of work
cycles does not reach to the setting value, determine that pressure does not meet the requirements,
disconnect the electric motor, controller gives a alarm at the same time, display Err1, pressure switch
symbol blinking displays(PS2 below).

6、Open circuit alarm of electric motor
Under this circumstance of the electric motor being in open circuit, the electric motor stops
working (with 3 seconds delay), and gives a alarm at the same time, display Err2, the symbol "○M"
blinks. Press the "Reset" key to clear the alarm.
7、Short circuit alarm of electric motor
Electric motor large current occurs when the electric motor is working, the electric motor stops
working (with 3 seconds delay), and gives a alarm at the same time, display Err4, the symbol "○M"
blinks.
8、Alarm for lowest oil level
Connecting line of liquid level sensor is connected with ground line (i.e., oil level is too low), or
determine the oil level exception, disconnect the electric motor, controller gives a alarm at the same
time, display Err3, oil level switch symbol is in blinking (below PS1).
9、Stop working
After the system starting to work (whether start to work due to the offtime reaches to setting
value or press "▼" button for more than 3 seconds to conduct debugging operations work), if requested
to immediately stop, press "Reset" key, the system will stop working, and return to dormant state.
10、Eliminate alarm reset
In the event of system alarm, press "Reset" key to stop the alarm, system is shifted into dormant
state (but it should be noted that faults in system have not been eliminated)
11、Queries of state, number of times
The controller is in dormant state, press "▲" key, the display shows the last fault message, press
"▲" key again to display the total number of cumulative working of system, press "▲" key again,
return to the dormant state (automatically back to the original dormant state after 10 seconds).
Comparison Table of Controller Alarm Condition:

alarm display
alarm description alarm reason solutions
characters
196
1、check and repair the

Action of 1、piping break
pipeline
displacement sensor
2、displacement sensor
Err1 is not detected within 2、check and repair the
damage
eight minutes of displacement transducer
working time 3、run out of oil
3、refuel
1、electric motor line is

1、check and repair wirings
disconnected
of electric motor
Electric motor occurs
2、the electric motor is
open circuit or its 2、replace electric motor
damaged
Err2 current is too small
3、disconnect the connection
(current is less than 3、negative wire of electric
between negative wire of
0.1a) motor and ground line of
electric motor and ground
power supply is in short
line of power supply
circuit
1、run out of oil

Alarm for the too low 1、refuel
Err3 2、oil level sensor is
oil level 2、check oil level sensor
damaged
1、the electric motor is

1、replace electric motor
damaged
Operating current of
2、check and repair wirings
electric motor is too 2、access terminal of
of electric motor
Err4 large or short circuit electric motor is
(12v for 5a, 24v for short-circuit
3a) 3、check the oil line and
3、the oil line is blocked
dredge the blockage point
off, load is overcharge
7.14.6 Manuals for SJP50 Oil Pump Nozzle
197
1. 1. Hand grip 2. Handle 3. Pump body 4. Foot-pressing plate

5. Connection of oil filling pipe 6. Dust plug
Steps:： 1.Unscrew Handle, insert Pump Body into the oil drum, screw down Handle ;
2.Unscrew Dust Plug , screw on Connection of Oil Filling Pipe into the refueling end and screw
down;
3.Use feet to press Foot-pressing Plate , use hands to slowly pull oil-taking Handle to take oil;
then, slowly press down Handle to inject the oil into the oil tube of the pump, repeat the process till the
oil tube of the pump is full;
4.Take down Connection of Oil Filling Pipe , screw on Dust Plug
7.14.7 Precautions for use
1、Oiliness for lubrication system must be clean, fresh lubricating grease, strictly prohibit
recycling, filter screen inside of the oil port should be replaced or cleaned once a year.
2、When the lubricating grease of lubrication pump is used to below oil level of oil tank,
lubricating grease should be replenished promptly when the lowest oil level of controller giving alarm.
198
3、To avoid debris entering into the oil tank, lubricating grease must be filled from oil port of oil
lubrication pump.
4、When using the oiler to fill grease into oil tank, identification of oil level upper limit of oil tank
in lubrication oil pump should be strictly enforced, otherwise it would damage oil tank structure.
5、Strictly prohibit great pressure and soaking on controller, otherwise it would damage electronic
components.
6、Strictly prohibit bumping against lubrication pump and distributor, otherwise it would damage
machine elements.
7、Strictly prohibit pulling lubricating oil pipeline.
8、Pay attention to routine maintenance to ensure that system works properly.
199
Memo
200
Memo
201
Chapter 8 Hydraulic Pressure System
8.1 Hydraulic Schematic Diagram
202
Chapter 8 Hydraulic Pressure
System
203
204
8.2 List of hydraulic parts

Operatin
Rated
Identification g Manufact
No. Code Name pressure
number pressure urer
(MPa)
(MPa)
A8VO107+A10VO45+AZPF- Main
1 0P1 35 35
1X-019 pump
Main
2 1M1 A2FE160 winch 30 40
motor
Rotary
3 1M4（5） A6VM160HA2 dive 33 40
motor
Rotary
4 2M1 A2FE45/61W-VZL100 28 40
motors
Walking
5 1M2（3） TM60VC-A-195/120-2 32 40
motor
Main
6 1V1 M8-1364-00/7M8-22 35 42
valve
Balance
7 1V2 08.44.89-03-03-35 valve 30 35
(luffing)
Luffing
8 1A1（2） XR180D-YG01 30 32
cylinder
Return oil
9 0Z1 E700-156 3.5 10
filter
Bypass
10 0Z2 SDU-H8 0.5 6
filter
Deputy
11 2V1 M4-4358-20/7M4-15 28 42
valve
Balance
valve
12 2V2 08.45.88-13-04-35 10 35
(pressuriza
tion)
205
Balance
13 2V3 05.71.46-03-04-35 valve 28 35
(rotary)
Balance
14 2V4（5） 08.48.12-03-03-35 valve(tiltin Hydraulic
35 Pressure
35 System 163
g cylinder)
Pressurizat
15 2A1 XR200-YG03 ion oil 10 32
cylinder
Track
telescopic
16 2A2 TDP55-YG04 28 28
oil
cylinder
Tilt
17 2A3（4） XR180D-YG02 35 35
cylinder
Pilot oil
18 3V1 XRFZ-003-DN source 3.5 5
block
Servo
19 4TH6NRC70-20/M01 3.5 5
pedal
Servo
20 12-00528 3.5 5
pedal
Servo
21 12-00529 3.5 5
handle
206
Memo
207
Memo
208
Chapter 9 Electrical System
9.1 Electrical System Program
209
210
211
212
213
9.2 List of electric parts

No. Code Name Position Ratings Manufacturer
1 +D-F01 Fuse 1.A3 80A LITTLEFUSE
2 +D-F02 Fuse 1.A4 100A LITTLEFUSE
3 +P1-F03 Fuse 2.B1 30A LITTLEFUSE
4 +P1-F11 Fuse 1.A2 20A LITTLEFUSE
16 +P-K1 Relay 1.D5/B2 LITTLEFUSE
17 +P-K2 Relay 3.D4/1.C8 LITTLEFUSE
18 +P-K5 Relay 4.C4/2.B3 LITTLEFUSE
21 +P-K8 Relay 3.D5/C3 LITTLEFUSE
23 +D-K25 Relay 1.D4/C3 Cummins
24 +D-K24 Relay 2.E3/1.C4 Cummins
25 +P3-S1 Key switch 1.C5 Hella
26 +P2-S15 Emergency stop switch 4.B4 Schneider
27 +P2-S14 switch 1.C6 Schneider
32 +P2-S3 switch 4.B5 Schneider
214

38 +P-S2 Button switch 3.C4 Rexroth belt
42 +P-S3 Button switch 5.B2 Rexroth belt
43 +P-S9 Pedal switch 5.B2 Schmersal
44 +D-ST5 Pressure switch 3.D2 SUCO
45 +D-ST2 Pressure switch 4.B4 SUCO
46 +D-ST1 Pressure switch 5.B7 SUCO
47 +A-S21 Travel switch 5.B6 Pizzato
48 +A-S34 Proximity switch 5.B4 Pepperl Fuchs
49 +D-S3 Proximity switch 5.B6 Pepperl Fuchs
50 +D-S4 Proximity switch 5.B7 Pepperl Fuchs
51 +D-S0 ower main switch 1.D1 Zhejiang Chint
52 +D-E1 Headlight 1.E6 Hella
53 +D-E2 Headlight 1.E6 Hella
54 +D-E31 Top headlight 2.D6 Hella
55 +D-E32 Top headlight 2.D6 Hella
56 +D-E33 Back up lamps 2.D6 Hella
57 +P-B1 Monitor 3.D7 Autoequips
58 +P-B1 Monitor 3.D7 Autoequips
59 +A-E5 Rotary alarm light 3.D5 Jinyunda
60 +P-S4 Dead-man’s handle 5.C3 Maneuvering box belt
61 +P-B2 Horn 1.E8 Hella
62 +P-M3 Wiper 1.D7 Cab
Wiper water spraying
63 +D-M3 1.D7 Cab
motor
64 +D-M1 Self sucking pump 3.D6 Tianzhengtong
65 +D-G1/G2 Storage battery 1.D1 12V Varta
66 +D-G3 Generator 1.D2 Cummins belt
67 +D-M2 Starter 1.D3 Cummins belt
68 +D-B3 Heater plug 1.D4 Cab
215
0.58~3.5
69 +P3-S3 Accelerator knob 2.E4 Star New
KΩ
70 +P1-X20 9-pin connector 2.B4 Cummins engine belt
71 +D-J2 50-pin connector 2.D4 Cummins engine belt
-pin
72 +D-J3 4-pin connector Cummins engine belt
connector
73 +P-SB Electric control handle 5.D4 Kidsmania
74 +A-A1 Tilt angel sensor 4.B8 Jhirmack
75 +D-A1 Encoder 4.B3 Rexroth
76 +D-B1 Oil temperature sensor 5.D6 Danfoss
77 +D-B2 Fuel oil level sensor 5.E2 Compro
78 +P1-A5 Controller 4.C2/5.C2 Pal-fin
79 +P-A1 Display 5.B8 Pal-fin
80 +D-S41 Pressure sensor 5.E3 Pal-fin
83 +D-Y11 Solenoid valve 2.D5 Yage
89 +D-Y15 Solenoid valve 3.E3 Yage
90 +D-Y16 Solenoid valve 3.E3 Yage
216

217
Memo
218
Memo
219
Annexed table :Recommended torques of bolts (screws) N.m

Strength Grade 8.8 10.9 12.9
Thread
Min Max Min Max Min Max
Specification
M6 10 12 14 17 17 20
M8 25 30 34 41 41 48
M10 49 59 68 81 81 98
M10×1 55 66 76 90 90 106
M12 86 103 119 141 141 167
M12×1.5 90 108 124 147 147 174
M14 137 164 189 224 224 265
M14×1.5 149 179 206 243 243 289
M16 214 256 295 350 358 414
M16×1.5 228 273 314 372 372 441
M18 294 353 406 481 481 570
M18×1.5 331 397 457 541 541 641
M20 417 500 576 683 683 808
M20×1.5 463 555 640 753 758 897
M22 568 680 786 941 918 1099
M22×1.5 624 747 863 1034 1009 1208
M24 722 864 998 1195 1167 1397
M24×2 785 940 1086 1300 1269 1520
M27 1056 1264 1461 1749 1707 2044
M27×2 1141 1366 1578 1890 1845 2208
M30 1434 1717 1984 2375 2318 2775
M30×2 1587 1900 2196 2629 2566 3072
M36 2506 3000 3466 4150 4051 4850
M36×3 2653 3176 3670 4394 4189 5135
M42 4008 5798 5544 6637 6479 7757
M42×3 4312 5162 5969 7141 6921 8345
M48 6020 7207 8327 9969 9732 11651
M48×3 6556 7848 9069 10357 10598 12688
220
Accompanied Spare Details

序
代号名称规格数量备注
号
Code Name Specification Q’ty Remark
No
主卷背轮
819949483 主卷背轮
1 YHH907-390A 1 Main Winch
Main Winch pulley
pulley
主卷滑轮
焊接滑轮
2 420701456 YH308-495 2 Winch
Winch pulley
pulley
滑块
3 420101385 8 动力头滑块
Nylon Shoe
Nylon Shoe
滑块
4 420101387 4 For Rotary
Nylon Shoe
钻杆滑块
滑块 Nylon Shoe
5 420900396 6
Nylon Shoe k For Kelly
Bar
发动机柴油滤芯
6 860113205 （精滤） FF5612 1
Engine diesel oil
filter
发动机柴油预滤
7 800107871 器滤芯 FS19732
1
Engine diesel oil 3973233
filter
发动机机油滤芯
8 800105264 LF3970 1
Engine lube filter
发动机空气滤芯
9 803374120 AA90139 1
engine air filter
燃油预滤器
FH23604M
滤芯
10 800107884 FS19728 1 For Fuel
Filter
Filter
FH23604M
油杯
11 801100336 M10X1 3
Grease cup
保险丝
12 803679964 0297005（5A） 10
Fuse
保险丝
13 803679962 0297010（10A） 10
Fuse
保险丝
14 803679965 0297020（20A） 10
Fuse
保险丝
15 803669937 049860（60A） 1
Fuse
保险丝
16 803645742 0498100（100A） 1
Fuse
保险丝
17 803680537 153.5631.520(20A) 3
Fuse
221
预热继电器
18 803611790 SB2008 1
Warm-up relay
液压油箱
滤芯 For
19 803190074 E700-156 1
Filter Hydraulic
Tank
先导阀块
滤芯
20 803172728 0060D010BN4HC 1 For Pilot
Filter
Valve
旁通过滤器
SDU-H8
滤芯
21 803374232 SDFC 1 For Bypass
Filter
Filter
SDU-H8
油缸罩I 倾缸
22 819949531 Cylinder piston-rod φ230—2000 2 For Mast
cover Cylinder
变幅油缸
油缸罩II
23 819949532 φ230—1250 2 For
Cylinder piston-rod
Derricking
cover
cylinder
销
24 420100233 RD18.19-18 2
Pin 钻杆用
挡圈 For Kelly
25 420100486 RD22.19-12 4
Spacer Bar
开口销 10X100
26 805600149 GB/T91-2000 2
Pin
减震圈动力头
27 420700816 1
Shock absorber For Rotary
脚踏
28 420100274 RD18.04.12 2
foot plate
液压密封包见附表 3
29 803377324 MF01-ZXD 1
Seal box Table 3
继电器
30 803677657 303-1AH-C-R1 2
Relay
继电器
31 803679963 898H-1CH-C-R1 2
Relay
继电器
32 803668891 301-1C-C-R1 2
Relay
螺钉 M12X25 动力头减震
33 805138264 GB/T70.1 18
Bolt 圈用
For Rotary
垫圈 12
34 805300018 GB/T93 18 Shock
Washer
absorber
电磁阀先导切换电
35 803076596 RPE3-062X11/02400E1K1 1
Electro valve 磁阀
For Polit
电磁阀
36 803076597 RPE3-063Y11/02400E1K1 1 Solenoid
Electro valve
valve
222
螺栓
37 805047608 GB/T5782 10
M20X140-10.9
38 805238385 螺母 M20-10 GB/T6184 10 钻桅连接

螺栓
螺母 M20 10（达 For Mast
39 805238375 GB/T6170 10
克罗）
40 420100833 钢套 steel bushing XR280.17-1 10
高压聚酯管
41 801969323 FQHC-4600 2
Hose assembly
高压聚酯管集中润滑用
42 801970706 FQLC-7000 2
Hose assembly For
860133271 接头 lubrication
43 GPDHFB6 10 system
Fittings
860133272 接头
44 GPDB6 10
Fittings
803683453 德驰两芯插头
45 DT04-2P-CE03 20
Two-pin plug
德驰两芯插座
46 803683454 DT06-2S-CE05 20
Two-pin socket
822537783 柴机油
47 CH-4 15W/40 2 加德士 36L
Lubrication oil
223
Memo
224
Memo
225
Conclusion
Dear users: Hello!
Because of the time, data and component selection, and a lot of other reasons, error and mistakes
are inevitable in the compilation of the instructions. In order to guarantee that users can make
themselves familiar with the structure of the equipment within a short time, correctly operate and use
the drilling rig, and give full play to the potential of the equipment, and you are welcome to make your
comments. We appreciate your comment very much.
In order to guarantee that your drilling rig can work properly and get better and more timely care
and maintenance and that you can find more reasonable operation and maintenance methods during the
construction and adopt new construction tools and processes, and we earnestly welcome you to keep
direct contact with us. In order to timely amend and improve contents of this manual, so that benefit for
more users.
The description in this manual may differ from the real object along with the technical progress
andproductimprovement. No further notice will made upon any modification.
Sincerely thank you for your cooperation and help!
XCMG XCMG, Solutions for Your Success
Tel: 0516-87738161
DECLARATION OF CONFORMITY
EG-KONFORMITÄTSERKLÄRUNG
Business name of the manufacturer: Xuzhou Construction Machinery Group Co., Ltd.
Firmenbezeichnung des Herstellers:
Full address of the manufacturer: No. 1, Industry Area, Xuzhou Economic Development Zone, Xuzhou, Jiangsu,
221004, P. R. China
Vollständige Adresse des Herstellers:
Name and address of the person (established in the Community) compiled the technical file:
Name und Adresse der Person (innerhalb der Gemeinschaft), die das technische Datenblatt erstellt hat
XCMG Europe 99-416 Nieborow, Kompina, Poland Mr. Michak Myczkowski, 008-222-111-201,
Michielens Trading NV Bisschoppenhoflaan 275 B-2100 Deurne, Antwerp, Belgium Mr. Yvon Michielsens,
0032-332-440-00
We declare that the machinery

Wir erklären hiermit, dass die Maschine
product name: Rotary Drilling Rig

Produktbezeichnung:
commercial name:
Handelsbezeichnung:
function:
Funktion:
model: XR220D, XR220D II

Modell:
type:
Typ:
serial number:
Seriennummer:
fulfills all the relevant provisions of Directives

entspricht allen relevanten Anforderungen folgender Richtlinien
2006/42/EC
tested in accordance with below standards

wurde gemäß folgender Normen geprüft
EN 16228-1
EN 16228-4
place and date of the declaration:

Ausstellungsort und Datum der Erklärung
signature of the person:

Unterschrift des Ausstellers
徐州工程机械集团有限公司
XUZHOU CONSTRUCTION MACHINERY GROUP Co.,Ltd.
Xuzhou Xugong Foundation Construction Machinery Co.,Ltd.
Add：No.1 Industrial Zone, Jinshanqiao Economic Developing zone,Xuzhou JiangSu, China
National unified customer service hotline：（Tel）：+86 400-110-9999
：+86 0516-87738167 8773816987892612
Telephone of sales department（Tel）
Fax：+86 0516-87892627-103、104、109
：+86 0516-87892690 87738150
Telephone of service center（Tel）
Fax：+86 0516-87738173
Postcode：221004
website：http：//www.xcmgjc.com
April,2015

Mesin Bor XR220D Operating Instructions

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XR220D Rotary Drilling Rig

Xuzhou Construction Machinery Group Co;Ltd

hydraulic system and some other precautions.

service this machine correctly and safely.

repair and maintenance for your machine.

1. Equipment refitting without permission.

2. Operating in mode not complying with the normal use.

3. Exceeding the prescribed range of equipment use.

2. Undue and insufficient maintenance.

3. Use of fuel or lubricant which are not recommended.

may not reflect those changes.

4.6 Left Operation Box ..........................................................................................................87

7.13 Lubrication and service of drilling rig .........................................................................190

Use of This Instruction

6. Installation, Removal and Transportation

8. Hydraulic Pressure System

be used as lifting appliance.

5. No untrained or unauthorized person is allowed to operate this rig.

the ring,watch, necklace or clothing not buckled.

avoid incorrect operation, please do not pull them.

11. Always keep an emergency kit in the cab.

the other one.

repairing or maintaining the devices.

the exhaust gas entering the working area to ensure safety.

and flat ground; otherwise, there will be a danger of tip-over.

Sales and Services

Address: No. 36 Tuolanshan Road, Economic development Zone, Xuzhou

Fax: (+86) - 0516 - 87892627-103 (for sales), 87738150 (for service)

Post code: 221004

1.1 Features of products

parts are readily available.

drilling accuracy and achieve transportation of 3-section folding type.

ergonomics principle to make the internal layout more reasonable.

efficiency hydraulic system ensures the strong power output.

consumption, meeting the requirements of economy.

1.2 Construction range of equipment

port, railway bridge and high-rise building.

XR220D Rotary Drilling Rig

1.3 Name of main components

Chapter 2 Safety Precautions

Prevention can effectively reduce the hazards!

The safety information involved in this instruction is classified as follows:

This symbol is to remind you that ignoring or failing to observe the

2.1 Equipment safety

2.2 Main hazards

As the equipment is provided with slewing

ensure the personnel safety, otherwise, it might

result in mortal injury.

2. Safety device and limit switch

Do not move these safety installations and do

not use any faulty safety installation or part.

Do not endanger the equipment stability. If

the equipment capacity is exceeded or the

equipment is operated by the damaged lifting limit

switch, it will result in equipment tilting and cause

With the mast being lifted, before the

4. Leak of hydraulic oil

a. Check the leak of hydraulic system oil

causes and fix it.

b. Where there is no pressure release, check

the pipe with a thin slab or paperboard as the

liquid ejected under high pressure may penetrate

the skin and cause severe injury.

Ensure the equipment is shut down in the