Sr305s Manual de Oper y Mtto

Quality Changes the World
Rotary Drilling Rig
SR305R
Operation & Maintenance Manual

SR305RS10Rotary Drilling Rig
SR305RS10
Rotary Drilling Rig
Operation & Maintenance Manual
WARNING
Risk of personal injury or even death!
Before operating the machine, be sure to read and follow the safety precautions and instruc-
tions in this manual and on the machine nameplate. Failure to comply could result in severe
personal injury or death.
• Carefully read and follow the safety precautions and use instructions in this manual and on
the machine nameplate. Keep this manual with the machine for future reference.
Operation & Maintenance Manual-October 10, 2023 1

Sany Group
Sany Heavy Industry Co., Ltd,
Beijing Sany Intelligent Technology Co., Ltd,
Sany Industry Park,
Nanyan Road, Nankou,
Changping District, Beijing, China, Zip code:102202
Service hotline (complaint/enquiry): 0086 4006098318
Email: crd@sany.com.cn
http://www.sanygroup.com
© 2023 by Sany Group. All rights reserved. No part of this publication may be reproduced,
used, distributed or disclosed except during normal operation of the machine as de-
scribed herein. All information included within this publication was accurate at the time of
publication. Product improvements, revisions, etc., may result in differences between
your machine and what is presented here. Sany Group assumes no liability. For more in-
formation, contact Sany Group.
Operation & Maintenance Manual-October 10, 2023

Exemption Clauses
Specified Declaration
Rotary drilling rig is a foundation machine used for drilling piles. Any other use or any operation
more than the specified work range is not approved operation. Sany expressly bears no liability for
any consequence due to any not approved operation.
Information on this manual is used to guide approved operators to operate and maintain rotary
drilling rigs correctly. Sany expressly bears no liability for any consequence due to any use not
obeying the information on this manual.
It is not permitted to change the rotary drilling rig without authorization. Sany expressly bears no li-
ability for any consequence. When crack or electrical malfunction on the rotary drilling rig occurs,
contact the supplier, and don’t conduct welding or make changes without permission, or else, for
any consequence due to such contravention, Sany shall not bear any liability.
Use genuine spare parts from Sany. Sany expressly bears no liability for any machine damage or
accident due to the use of untested or unauthorized spare parts or tools.
Obey the rules on the manual when you operate or do maintenance.
Sany expressly bears no liability for any machine failure or damage due to force majeure of natural
disasters (earthquake, typhoon) and wars.
Sany cannot predict every circumstance that might involve a possible dangerous in operation or
maintenance. Operators and owners must highly attach importance to safety. Local specified
safety rules of the countries may be stricter. If they are different from the regulations on this man-
ual, obey the stricter one.
Duty of Sany
• Be responsible for supplying approved products and correct documents.

• Obey their promises on after-sales service, and document all maintenance and repair working
done by after-sales service personnel.
• Train the operation and maintenance personnel based on their needs.
Duty of Owners or Other Approved Personnel
• Only after each person involved in the product operation, maintenance and repair is trained and
fully understands the Parts Book and Operation and Maintenance Manual, can they operate and
maintain the rotary drilling rig.
• Make sure the operation and maintenance personnel are qualified and know their related
responsibilities.
Operation & Maintenance Manual-October 10, 2023 1

• Check related personnel safety consciousness during working at regular interval.

• If any fault which will lead to unsafety occurs, stop the rotary drilling rig immediately.
• If necessary Sany service personnel have the right to check the rotary drilling rig for safety.
• Besides check items regulated by Sany, obey local laws and regulations to check the rotary drill-
ing rig.
• Make sure timely maintenance and repair on the rotary drilling rig.
• Carefully plan the use of the rotary drilling rig.
Duty of All Personnel
• If there is any abnormal symptom which may cause abnormal working of the rotary drilling rig or
potential hazard, report to your leader. If possible, correct fault in time.
• All personnel working around the rotary drilling rig must observe all warning signals and take
care of their own and others’ safety.
• All personnel should know their working tasks and procedures.
• Monitor something like high voltage wire, unrelated personnel and defective ground for possible
risk, and report to the operators and signalmen.
Duty of Managers
• Make sure the operators are trained and fully understand the Operation and Maintenance Man-
ual supplied by Sany. Make sure they are in physical fitness and have the certification of opera-
tion. Otherwise, it is not permitted to operate the rotary drilling rig.
• Make sure the operators have good judgment ability, teamwork consciousness and psychologi-
cal quality. Otherwise, it is not permitted to operate or repair the rotary drilling rig.
• Make sure the signalmen have good vision and acoustic judgment, master standard command
signals. At the same time, they must have sufficient experience in recognizing danger factors
correctly, and tell the operators of danger factors to avoid them in time.
• Make sure assistant workers can identify the model and working condition to choose a proper ro-
tary drilling rig.
• Publicize safety consciousness to personnel, and make them aware of safety precautions and
their related responsibilities.
2 Operation & Maintenance Manual-October 10, 2023

SR305RS10Rotary Drilling Rig Table of Contents
Table of Contents
1 Foreword..............................................................................................................................1-1
1.1 Overview.................................................................................................................................1-3
1.2 Legal and Regulatory Requirements..................................................................................1-4
1.3 Safety Information.................................................................................................................1-5
1.4 Reading Instruction...............................................................................................................1-7
1.5 Introduction ............................................................................................................................1-7
1.5.1 Intended use of the machine.......................................................................................1-7
1.5.2 Machine directions .......................................................................................................1-8
1.5.3 Breaking-in of new machine........................................................................................1-8
1.6 Product Information ..............................................................................................................1-9
1.6.1 Special tips ....................................................................................................................1-9
1.6.2 Product nameplate .................................................................................................... 1-10
1.7 Your Documentation Package...........................................................................................1-11
1.7.1 Suggestions on the use of the documents..............................................................1-11
1.7.2 Document storage recommendations .....................................................................1-11
1.8 Accessory Box.................................................................................................................... 1-12
1.9 Glossary .............................................................................................................................. 1-13
1.10 Abbreviations.................................................................................................................... 1-14
1.11 Contact Information ......................................................................................................... 1-14
2 Safety.....................................................................................................................................2-1
2.1 Safety Decals.........................................................................................................................2-3
2.1.1 Overview........................................................................................................................2-3
2.1.2 Decal locations..............................................................................................................2-4
2.1.3 Safety decals.................................................................................................................2-7
2.2 Safety Equipment............................................................................................................... 2-17
2.2.1 Safety lock lever ........................................................................................................ 2-17
2.2.2 Fire extinguisher ........................................................................................................ 2-17
2.2.3 Emergency exit .......................................................................................................... 2-18
2.2.4 Seat belt...................................................................................................................... 2-18
2.2.5 Emergency stop switch............................................................................................. 2-19
2.2.6 Guards ........................................................................................................................ 2-19
2.2.7 Alarm lamp ................................................................................................................. 2-20
2.2.8 Chassis level .............................................................................................................. 2-21
2.3 Safety Precautions............................................................................................................. 2-21
2.3.1 Safety rules................................................................................................................. 2-21
2.3.2 Handling of abnormalities......................................................................................... 2-22
Operation & Maintenance Manual-October 10, 2023 I

Table of Contents SR305RS10Rotary Drilling Rig
2.3.3 Mechanical injury....................................................................................................... 2-22

2.3.4 Battery hazards.......................................................................................................... 2-24
2.3.5 Fire prevention ........................................................................................................... 2-26
2.3.5.1 Away from fire ..................................................................................................... 2-26
2.3.5.2 Daily checks........................................................................................................ 2-27
2.3.5.3 If a fire should occur........................................................................................... 2-28
2.3.5.4 First aid for burns ............................................................................................... 2-28
2.3.6 Scald prevention ....................................................................................................... 2-29
2.3.7 Safety information of hose ....................................................................................... 2-30
2.3.8 Fluid leakage.............................................................................................................. 2-31
2.3.9 Be cautious of high pressure fluid ........................................................................... 2-32
2.3.10 Crawler safety information .................................................................................... 2-33
2.3.11 Lightning and strong wind precautions ................................................................ 2-33
2.3.12 Do not tow the machine.......................................................................................... 2-35
2.3.13 Falling protection ..................................................................................................... 2-36
2.3.14 Dust hazard ............................................................................................................. 2-36
2.3.15 Noise protection ...................................................................................................... 2-37
2.3.16 Unauthorized modification ..................................................................................... 2-37
2.3.17 Wire rope safety information.................................................................................. 2-37
2.3.18 Climbing on/off drilling rig....................................................................................... 2-38
2.3.19 Kelly bar and drilling tools ...................................................................................... 2-39
2.3.20 Accumulator ............................................................................................................. 2-40
2.3.21 Working at areas with underground pipelines..................................................... 2-40
2.3.22 Working at aera with high-voltage lines ............................................................... 2-41
2.3.22.1 Electrical accident............................................................................................ 2-41
2.3.22.2 First aid in case of shock................................................................................. 2-42
2.4 Safety during Operation .................................................................................................... 2-43
2.4.1 Staff ............................................................................................................................. 2-43
2.4.2 Protective tools .......................................................................................................... 2-45
2.4.3 Prohibited operation.................................................................................................. 2-45
2.4.4 Keeping the rig in good service condition .............................................................. 2-46
2.4.5 Safety on construction site ....................................................................................... 2-47
2.4.6 Signals to control operation .................................................................................... 2-48
2.4.7 Danger areas of drilling rig ....................................................................................... 2-54
2.4.8 Avoiding tipping over................................................................................................. 2-55
2.4.9 Before entering the cab ............................................................................................ 2-56
2.4.10 Before starting the engine ..................................................................................... 2-57
2.4.11 Before operating the machine ............................................................................... 2-58
2.4.12 Drilling rig operation ................................................................................................ 2-59
2.4.13 Construction of drilling rig ...................................................................................... 2-60
II Operation & Maintenance Manual-October 10, 2023

2.4.14 Winch operation ...................................................................................................... 2-61

2.4.15 Parking safety ......................................................................................................... 2-62
2.4.16 Safety when cleaning the machine....................................................................... 2-63
2.4.17 Drilling rig dismantling ........................................................................................... 2-64
2.4.18 Safety guidelines for transport............................................................................... 2-64
2.4.19 Machine maintenance ............................................................................................ 2-65
2.5 Environment Protection..................................................................................................... 2-66
2.5.1 Proper waste disposal ............................................................................................. 2-66
2.5.2 Mud pollution.............................................................................................................. 2-66
2.5.3 Fuel discharge .......................................................................................................... 2-67
3 Technical Specifications.............................................................................................3-1
3.1 Overall Dimensions...............................................................................................................3-3
3.2 Performance Parameters.....................................................................................................3-4
3.3 Wire Rope Specifications.....................................................................................................3-5
4 System Function .............................................................................................................4-1

4.1 General Structure .................................................................................................................4-3
4.2 Machine Description .............................................................................................................4-5
4.2.1 Traveling mechanism...................................................................................................4-5
4.2.2 Upper carriage ..............................................................................................................4-5
4.2.3 Main winch.....................................................................................................................4-6
4.2.4 Auxiliary winch ..............................................................................................................4-7
4.2.5 Boom mechanism.........................................................................................................4-8
4.2.6 Mast assembly ..............................................................................................................4-8
4.2.7 Rotary drive ...................................................................................................................4-9
4.2.8 Kelly bar ...................................................................................................................... 4-10
4.2.9 Drilling bucket..............................................................................................................4-11
4.3 General View of the Operator’s Cab ............................................................................... 4-12
4.4 E-pad.................................................................................................................................... 4-13
4.5 Operation Control Panel.................................................................................................... 4-15
4.6 Engine Ignition Switch and Engine Speed Control Dial................................................ 4-17
4.7 Operation Instruction of Freefall Pedal ........................................................................... 4-18
4.8 Safety Lock Lever .............................................................................................................. 4-19
4.9 Traveling Lever/Pedal........................................................................................................ 4-20
4.10 Left and Right Operation Handle ................................................................................... 4-20
4.10.1 Left operation handle .............................................................................................. 4-20
4.10.2 Right operation handle ........................................................................................... 4-21
4.10.3 Directional function of operation handle .............................................................. 4-21
4.11 Mast Lever......................................................................................................................... 4-23
4.12 Air Conditioning System.................................................................................................. 4-25
Operation & Maintenance Manual-October 10, 2023 III

4.12.1 Control panel............................................................................................................ 4-25

4.12.2 Operation method ................................................................................................... 4-25
4.13 Radio.................................................................................................................................. 4-28
4.14 Display............................................................................................................................... 4-31
4.14.1 Start-up interface..................................................................................................... 4-31
4.14.2 Drilling operation interface ..................................................................................... 4-32
4.14.3 Menu interface ......................................................................................................... 4-36
4.14.4 Common function-function..................................................................................... 4-38
4.14.5 Common function-switch........................................................................................ 4-41
4.14.6 Common function-operation .................................................................................. 4-43
4.14.7 Common function-calibration................................................................................. 4-46
4.14.8 Parameter calibration interface ............................................................................. 4-48
4.14.9 Parameter calibration interface I ........................................................................... 4-50
4.14.10 Parameter calibration interface II........................................................................ 4-52
4.14.11 Locking device parameter calibration interface ................................................ 4-54
4.14.12 Construction method interface ............................................................................ 4-56
4.14.13 Central lubrication interface................................................................................. 4-59
4.14.14 User settings interface.......................................................................................... 4-60
4.14.15 User setting-language .......................................................................................... 4-61
4.14.16 User setting-time setting ...................................................................................... 4-62
4.14.17 User setting-brightness ........................................................................................ 4-63
4.14.18 User setting-handle interface .............................................................................. 4-64
4.14.19 Service assistant interface................................................................................... 4-66
4.14.20 Machine configuration interface.......................................................................... 4-67
4.14.21 Maintenance interface.......................................................................................... 4-68
4.14.22 GPS information interface.................................................................................... 4-70
4.14.23 History query interface ......................................................................................... 4-71
4.14.24 Running information interface ............................................................................. 4-72
4.15 Electric Cabinet ................................................................................................................ 4-73
4.16 Fuse ................................................................................................................................... 4-74
4.17 Limit Switches................................................................................................................... 4-76
5 Operation.............................................................................................................................5-1
5.1 Basic Operation.....................................................................................................................5-5
5.1.1 Initial use of the machine.............................................................................................5-5
5.1.2 Before starting the engine ...........................................................................................5-5
5.1.2.1 Visual checks.........................................................................................................5-5
5.1.2.2 Adjustment before operation ...............................................................................5-7
5.1.2.3 Checks before starting the engine................................................................... 5-10
5.1.2.4 Confirmation before starting the engine...........................................................5-11
IV Operation & Maintenance Manual-October 10, 2023

5.1.3 Starting the engine .....................................................................................................5-11

5.1.3.1 Normal start-up....................................................................................................5-11
5.1.3.2 Starting the engine in cold weather ................................................................. 5-13
5.1.4 After starting the engine ........................................................................................... 5-13
5.1.4.1 Breaking-in a new machine .............................................................................. 5-13
5.1.4.2 Warming-up operation....................................................................................... 5-14
5.1.5 Shutting down the engine......................................................................................... 5-15
5.1.6 Checks after each workday...................................................................................... 5-17
5.1.7 Traveling ..................................................................................................................... 5-18
5.1.7.1 Traveling operation ............................................................................................ 5-18
5.1.7.2 Traveling on slopes............................................................................................ 5-23
5.1.8 Upper carriage swing ................................................................................................ 5-24
5.1.9 Adjusting drilling center distance............................................................................. 5-25
5.1.10 Raising and lowering the mast .............................................................................. 5-27
5.1.11 Lowering the mast with Kelly bar........................................................................... 5-31
5.1.12 Raising the mast with Kelly bar ............................................................................. 5-37
5.1.13 Adjusting mast to verticality ................................................................................... 5-39
5.1.14 Crowding control ..................................................................................................... 5-41
5.1.15 Main winch operation.............................................................................................. 5-43
5.1.16 Auxiliary winch operation ....................................................................................... 5-45
5.1.17 Rotary drive control................................................................................................. 5-46
5.1.18 Depth measurement ............................................................................................... 5-48
5.1.19 Calibration operation............................................................................................... 5-48
5.1.20 Crawler extending and retracting.......................................................................... 5-49
5.1.21 Parking the drilling rig ............................................................................................. 5-50
5.1.21.1 Regular parking................................................................................................ 5-50
5.1.21.2 Checks during parking .................................................................................... 5-51
5.1.21.3 Lockable areas ................................................................................................. 5-52
5.1.21.4 Long-term storage ........................................................................................... 5-53
5.1.22 Operation in cold weather ...................................................................................... 5-53
5.1.22.1 Checks in cold weather ................................................................................... 5-53
5.1.22.2 Operation tips in cold weather........................................................................ 5-55
5.1.22.3 After daily operation......................................................................................... 5-57
5.1.22.4 After cold season ............................................................................................. 5-57
5.2 Drilling Rig Construction.................................................................................................... 5-57
5.2.1 Operation requirements in construction and disassembly mode ....................... 5-57
5.2.2 Construction preparation.......................................................................................... 5-58
5.2.2.1 Drilling rig checks .............................................................................................. 5-58
5.2.2.2 Drilling tool selection.......................................................................................... 5-60
5.2.3 Drilling rig in place ..................................................................................................... 5-60
Operation & Maintenance Manual-October 10, 2023 V

5.2.4 Drilling ......................................................................................................................... 5-61

5.2.4.1 Drilling in clay layer ............................................................................................ 5-61
5.2.4.2 Drilling in sand layer........................................................................................... 5-61
5.2.4.3 Drilling in pebble layer ....................................................................................... 5-61
5.2.4.4 Drilling in shale layer.......................................................................................... 5-62
5.2.4.5 Drilling in sandstone layer................................................................................. 5-62
5.2.4.6 Drilling in limestone layer .................................................................................. 5-63
5.2.4.7 Drilling in granite layer ....................................................................................... 5-63
5.3 Rigging & Derigging........................................................................................................... 5-64
5.3.1 Requirements for rigging and derigging................................................................. 5-64
5.3.1.1 Guidelines for rigging and derigging................................................................ 5-64
5.3.1.2 Notes on rigging and derigging ........................................................................ 5-65
5.3.1.3 Precautions for rigging and derigging ............................................................. 5-65
5.3.1.4 Preparation for rigging and derigging.............................................................. 5-66
5.3.2 Rigging drilling rig ...................................................................................................... 5-67
5.3.2.1 Removing locking bar ........................................................................................ 5-67
5.3.2.2 Extending the crawlers ...................................................................................... 5-67
5.3.2.3 Mounting counterweight.................................................................................... 5-68
5.3.2.4 Connecting upper mast and middle mast ....................................................... 5-69
5.3.2.5 Connecting masthead ....................................................................................... 5-71
5.3.2.6 Installing lower mast .......................................................................................... 5-73
5.3.2.7 Installing rotary drive.......................................................................................... 5-74
5.3.2.8 Connecting rotary drive electrical harness ..................................................... 5-75
5.3.2.9 Connecting hoses .............................................................................................. 5-76
5.3.2.10 Connecting middle mast and lower mast ..................................................... 5-77
5.3.2.11 Installing wire ropes ......................................................................................... 5-78
5.3.2.12 Drilling rig test run ............................................................................................ 5-81
5.3.3 Installing drilling tool.................................................................................................. 5-82
5.3.3.1 Connecting Kelly guide to Kelly bar................................................................. 5-82
5.3.3.2 Connecting rope swivel to Kelly bar ................................................................ 5-83
5.3.3.3 Aligning drilling rig with Kelly bar upper end................................................... 5-84
5.3.3.4 Connecting wire rope and rope swivel ............................................................ 5-84
5.3.3.5 Installing Kelly bar .............................................................................................. 5-85
5.3.3.6 Installing drilling bucket ..................................................................................... 5-88
5.3.4 Disassembling drilling tool........................................................................................ 5-88
5.3.4.1 Disassembling drilling bucket........................................................................... 5-88
5.3.4.2 Removing Kelly bar............................................................................................ 5-89
5.3.5 Disassembling drilling rig.......................................................................................... 5-91
5.3.5.1 Removing rotary drive and crowd cylinder .................................................... 5-91
VI Operation & Maintenance Manual-October 10, 2023

5.3.5.2 Disconnecting middle mast and lower mast................................................... 5-92

5.3.5.3 Removing rotary drive ....................................................................................... 5-93
5.3.5.4 Removing lower mast ........................................................................................ 5-94
5.3.5.5 Disconnecting masthead and upper mast ...................................................... 5-95
5.3.5.6 Disconnecting upper and middle mast ........................................................... 5-95
5.3.5.7 Removing counterweight .................................................................................. 5-97
5.4 Drilling Rig Transport ......................................................................................................... 5-98
5.4.1 Safety guidelines for transport................................................................................. 5-98
5.4.2 Transport requirements ............................................................................................ 5-98
5.4.3 Transport parameters ............................................................................................... 5-99
5.4.4 Loading and unloading the machine..................................................................... 5-103
5.4.4.1 Requirement for loading and unloading........................................................ 5-103
5.4.4.2 Loading the machine ....................................................................................... 5-103
5.4.4.3 Fastening method ............................................................................................ 5-104
5.4.4.4 Unloading the machine.................................................................................... 5-104
5.4.5 Requirements for sea transportation .................................................................... 5-105
6 Maintenance.......................................................................................................................6-1
6.1 Maintenance Guideline ........................................................................................................6-5
6.1.1 Overview........................................................................................................................6-5
6.1.2 Maintenance information.............................................................................................6-6
6.1.2.1 Maintenance personnel........................................................................................6-6
6.1.2.2 Risks during maintenance ...................................................................................6-6
6.1.2.3 Before maintenance..............................................................................................6-9
6.1.2.4 During maintenance..............................................................................................6-9
6.2 Treatment of Oil, Fuel and Coolant...................................................................................6-11
6.2.1 Oil..................................................................................................................................6-11
6.2.2 Fuel...............................................................................................................................6-11
6.2.3 Coolant........................................................................................................................ 6-12
6.2.4 Grease ........................................................................................................................ 6-12
6.2.5 Storage of engine oil and fuel .................................................................................. 6-13
6.2.6 Filter element ............................................................................................................. 6-13
6.3 Electrical System Maintenance........................................................................................ 6-13
6.4 Wear Parts .......................................................................................................................... 6-14
6.5 Recommended Fuel, Coolant and Lubricating Oil ........................................................ 6-15
6.6 Drilling Rig Oil ..................................................................................................................... 6-18
6.7 Lubrication Points............................................................................................................... 6-22
6.8 Tightening Torque .............................................................................................................. 6-26
6.9 Regular Inspection ............................................................................................................. 6-28
6.10 Maintenance Schedule ................................................................................................... 6-29
Operation & Maintenance Manual-October 10, 2023 VII

6.11 Maintenance Procedures ................................................................................................ 6-32

6.11.1 Every 10 service hours ........................................................................................... 6-32
6.11.1.1 Crawler tension - check and adjust ............................................................... 6-32
6.11.1.2 Hydraulic cylinders- check .............................................................................. 6-34
6.11.1.3 Shock absorbing device of rotary drive - check and replace ..................... 6-36
6.11.1.4 Rotary drive bolts - check................................................................................ 6-38
6.11.1.5 Crawler track - inspect .................................................................................... 6-41
6.11.1.6 Wire rope - inspect .......................................................................................... 6-42
6.11.1.7 Wire rope - maintain ........................................................................................ 6-43
6.11.1.8 Wire rope - discard........................................................................................... 6-44
6.11.1.9 Rope swivel flexibility - check ......................................................................... 6-45
6.11.1.10 Rope swivel - check and lubricate ............................................................... 6-46
6.11.1.11 Engine oil level - check.................................................................................. 6-47
6.11.1.12 Fuel amount - check and refuel ................................................................... 6-48
6.11.1.13 Water and sediment in fuel tank - drain ...................................................... 6-49
6.11.1.14 Coolant level - check and refill ..................................................................... 6-50
6.11.1.15 Hydraulic oil level - check and refuel........................................................... 6-51
6.11.1.16 Switches, buttons and operation handles - check..................................... 6-53
6.11.1.17 Kelly guide swing bearing - lubricate........................................................... 6-54
6.11.1.18 Kelly guide swing bearing - check and replace ......................................... 6-54
6.11.2 Initial 50 service hours ............................................................................................ 6-55
6.11.2.1 Engine oil and filter - change and replace .................................................... 6-55
6.11.2.2 Fuel tank strainer - clean................................................................................. 6-58
6.11.3 Every 50 service hours ........................................................................................... 6-58
6.11.3.1 Winch reducers oil level - check..................................................................... 6-58
6.11.3.2 Rope hold-down rollers - check...................................................................... 6-59
6.11.3.3 Rotary drive sliding strip - check and replace ............................................. 6-60
6.11.3.4 Shock absorber - check................................................................................... 6-61
6.11.3.5 Air intake and exhaust system - check.......................................................... 6-61
6.11.3.6 Window wiper - check...................................................................................... 6-61
6.11.3.7 Window washer - check .................................................................................. 6-62
6.11.3.8 Impact ring - check and replace ..................................................................... 6-62
6.11.3.9 Track shoe bolts - check ................................................................................. 6-63
6.11.3.10 Spring of Kelly bar- check and replace ....................................................... 6-64
6.11.3.11 Hydraulic hose - check and replace ............................................................ 6-64
6.11.3.12 Other maintenance item................................................................................ 6-65
6.11.4 Initial 250 service hours .......................................................................................... 6-66
6.11.4.1 Winch reducer oil - change ............................................................................. 6-66
6.11.4.2 Rotary drive reducer gear oil - change.......................................................... 6-66
VIII Operation & Maintenance Manual-October 10, 2023

6.11.4.3 Bolts connecting swing bearing - check........................................................ 6-68

6.11.5 Every 250 service hours ......................................................................................... 6-68
6.11.5.1 Rotary drive gear oil level - check.................................................................. 6-68
6.11.5.2 Rotary drive gear oil - sample and test ......................................................... 6-69
6.11.5.3 Driver strip - check and change ..................................................................... 6-70
6.11.5.4 Air conditioner circulation filter - clean .......................................................... 6-70
6.11.5.5 Air recirculation filter - inspect and replace ................................................. 6-72
6.11.5.6 Filter of water oil separator - replace ............................................................. 6-72
6.11.5.7 Fuel filter - check and replace ........................................................................ 6-74
6.11.5.8 Hoses - check and replace ............................................................................. 6-75
6.11.5.9 Kelly guide sliding strip - check and replace ................................................ 6-76
6.11.5.10 Kelly bar locking recesses - check .............................................................. 6-76
6.11.5.11 Kelly bar tube - check .................................................................................... 6-76
6.11.5.12 Kelly bar drive gibs - check........................................................................... 6-78
6.11.5.13 Kelly bar baffle - check .................................................................................. 6-78
6.11.5.14 Wire rope sheaves - check ........................................................................... 6-79
6.11.5.15 Hydraulic system cleanliness - control........................................................ 6-79
6.11.5.16 Generator belt - check and adjust ............................................................... 6-80
6.11.5.17 Fan belt - check and adjust........................................................................... 6-80
6.11.6 Initial 500 service hours .......................................................................................... 6-80
6.11.6.1 Rotary drive gearbox gear oil - change ......................................................... 6-80
6.11.6.2 Travel reducer oil - change ............................................................................. 6-81
6.11.7 Every 500 service hours ......................................................................................... 6-83
6.11.7.1 Air recirculation filter - replace ....................................................................... 6-83
6.11.7.2 Gear oil for swing reducer - change .............................................................. 6-83
6.11.7.3 Other maintenance items................................................................................ 6-85
6.11.8 Initial 1000 service hours........................................................................................ 6-86
6.11.8.1 Hydraulic oil - change ...................................................................................... 6-86
6.11.8.2 Oil suction filter - replace................................................................................. 6-89
6.11.9 Every 1000 service hours....................................................................................... 6-90
6.11.9.1 Pilot filter element - replace ............................................................................ 6-90
6.11.9.2 Return filter - replace ....................................................................................... 6-91
6.11.9.3 Auxiliary pump filter element - replace .......................................................... 6-93
6.11.9.4 Breather valve - check and replace ............................................................... 6-94
6.11.9.5 Battery - clean and recycle ............................................................................. 6-94
6.11.9.6 Other maintenance items................................................................................ 6-95
6.11.10 Every 2000 service hours..................................................................................... 6-96
6.11.10.1 Other maintenance items.............................................................................. 6-96
6.11.11 Every 3000 service hours..................................................................................... 6-96
Operation & Maintenance Manual-October 10, 2023 IX

6.11.11.1 Generator belt - replace ................................................................................ 6-96

6.11.11.2 Fan belt - replace（if equipment）.............................................................. 6-96
6.12 Storage of Drilling Rig ..................................................................................................... 6-96
6.12.1 Preparations before storage .................................................................................. 6-96
6.12.2 Maintenance during storage .................................................................................. 6-96
6.12.3 Routine maintenance of drilling rig ....................................................................... 6-97
6.12.4 Maintenance for removal of drilling rig from garage........................................... 6-98
6.12.5 Maintenance for long-term storage....................................................................... 6-99
7 Troubleshooting ..............................................................................................................7-1
7.1 Special Instructions...............................................................................................................7-3
7.2 Precautions during Troubleshooting ..................................................................................7-3
7.3 Common Troubleshooting and Solutions ..........................................................................7-4
7.4 Solutions to Common Non-quality Problems ..................................................................7-11
7.5 When Battery Feed Fails to Start Up............................................................................... 7-14
7.6 When Battery Feed Needs to Be Charged..................................................................... 7-17
7.7 When Engine Coolant Temperature Too High ............................................................... 7-19
7.8 When Engine Oil Pressure (Low Pressure) Abnormal ................................................ 7-19
8 Accessories and Options ...........................................................................................8-1

8.1 Safety Precautions................................................................................................................8-3
8.2 Options ...................................................................................................................................8-4
8.2.1 Overview........................................................................................................................8-4
8.2.2 Kelly bar configuration .................................................................................................8-4
8.2.3 Kelly bar - check ...........................................................................................................8-5
8.3 Kelly Bar .................................................................................................................................8-7
8.3.1 Instructions ....................................................................................................................8-7
8.3.2 Welding ..........................................................................................................................8-8
8.3.3 Transport and storage............................................................................................... 8-13
8.4 Drilling Tool.......................................................................................................................... 8-15
8.4.1 Overview..................................................................................................................... 8-15
8.4.2 Kelly box ..................................................................................................................... 8-15
8.4.3 Drilling tool categories .............................................................................................. 8-15
8.4.3.1 Drilling bucket double cut.................................................................................. 8-15
8.4.3.2 Cone auger ......................................................................................................... 8-18
8.4.3.3 Straight auger ..................................................................................................... 8-20
8.4.3.4 Core barrel .......................................................................................................... 8-21
8.4.3.5 Double-layer core barrel.................................................................................... 8-23
8.4.3.6 Underreamer bit ................................................................................................. 8-24
8.4.3.7 Casing drive adapter.......................................................................................... 8-24
X Operation & Maintenance Manual-October 10, 2023

8.4.3.8 Easily worn parts of drilling rig.......................................................................... 8-25

8.4.4 Drilling tool operation ................................................................................................ 8-25
8.4.4.1 Drilling bucket ..................................................................................................... 8-25
8.4.4.2 Auger.................................................................................................................... 8-26
8.4.4.3 Core barrel .......................................................................................................... 8-27
8.4.4.4 Belling tool........................................................................................................... 8-28
8.5 Wire Rope ........................................................................................................................... 8-29
8.5.1 Installing wire rope .................................................................................................... 8-29
8.5.2 Unloading and storing wire rope.............................................................................. 8-35
8.5.3 Discarding wire rope ................................................................................................. 8-35
8.6 Central lubrication system ................................................................................................ 8-37
8.6.1 Central lubrication parameter setting ..................................................................... 8-37
8.6.2 Adding grease to lubrication pump ......................................................................... 8-44
8.6.2.1 Recommended grease...................................................................................... 8-44
8.6.2.2 Instructions on adding grease .......................................................................... 8-44
8.6.2.3 Operation instructions on manual grease charger ........................................ 8-45
8.6.2.4 Operation instructions on quick connector ..................................................... 8-48
8.6.3 Troubleshooting methods......................................................................................... 8-48
8.6.3.1 Common troubleshooting methods ................................................................. 8-48
8.6.3.2 Fault code troubleshooting method ................................................................. 8-49
8.6.3.3 Air exhausting methods of lubrication pump .................................................. 8-50
8.6.3.4 Air exhausting methods of distributor.............................................................. 8-52
8.6.4 Maintenance on central lubrication system ........................................................... 8-53
8.7 Maintenance Chart............................................................................................................. 8-55
8.8 Common Misoperation ...................................................................................................... 8-67
9 Warranty Information....................................................................................................9-1
9.1 Warranty Information ............................................................................................................9-3
9.2 References.............................................................................................................................9-3
9.3 Disposal of the Old Machine................................................................................................9-3
Operation & Maintenance Manual-October 10, 2023 XI

XII Operation & Maintenance Manual-October 10, 2023

SR305RS10Rotary Drilling Rig Foreword
Foreword
1.1 Overview.................................................................................................................................1-3
1.2 Legal and Regulatory Requirements..................................................................................1-4
1.3 Safety Information.................................................................................................................1-5
1.4 Reading Instruction...............................................................................................................1-7
1.5 Introduction ............................................................................................................................1-7
1.5.1 Intended use of the machine .....................................................................................1-7
1.5.2 Machine directions ......................................................................................................1-8
1.5.3 Breaking-in of new machine ......................................................................................1-8
1.6 Product Information ..............................................................................................................1-9
1.6.1 Special tips...................................................................................................................1-9
1.6.2 Product nameplate................................................................................................... 1-10
1.7 Your Documentation Package...........................................................................................1-11
1.7.1 Suggestions on the use of the documents ............................................................1-11
1.7.2 Document storage recommendations....................................................................1-11
1.8 Accessory Box.................................................................................................................... 1-12
1.9 Glossary .............................................................................................................................. 1-13
1.10 Abbreviations.................................................................................................................... 1-14
1.11 Contact Information ......................................................................................................... 1-14
Operation & Maintenance Manual-October 10, 2023 1-1

Foreword SR305RS10Rotary Drilling Rig
1-2 Operation & Maintenance Manual-October 10, 2023

1.Foreword
1.1 Overview
Before operation and maintenance, the operators and maintenance personnel must do the
following:
• Be sure to read through and understand this manual.
• Read and fully understand the safety notices in the manual and safety labels on the machine.
• Shall in no circumstances use the machine for applications or operations forbidden in the
manual.
• If fuel amount, particulate size or latitude exceeds the upper limit specified for the model and ap-
plication setting, it may result in injuries and can not be covered by the quality guarantee.
• Always keep the manual in the cab for reference at anytime.
• Immediately contact our authorized dealer for reissuing or replacement if this manual is lost or
stained and thus unreadable.
• This manual shall be deemed as a permanent part of the machine, so be sure to hand it over to
a new user together with the machine if you resell it.
• Machines that provided by Sany to the country of purchase meet all applicable regulations and
standards. Purchasing from another country or a person of another country may deprive you of
some safety devices and specifications necessary for using in your country. If you have any
questions about machine’s compliance with national standards and regulations for using, con-
tact the authorized agent of Sany before using it.
This manual is a guide for correct use of the

machine and mainly provides technical and
safety information required in operation. Be
sure to read each part of it carefully.
Only qualified and experienced operators with

an official license (according to local laws)
can operate the machine.
Fig 1-1
Make sure that the relevant laws and regulations of the state ,a province, an autonomous region or
a municipality are always observed in operation of the machine, and the operation safety informa-
tion and instructions contained herein are only provided as suggestions and cautions.
We cannot foresee all situations in operation and maintenance that may pose risks. Therefore, the
safety information in this manual and on the machine do not contain all the possible safety meas-
ures. When methods or actions other than those specifically recommended or allowed in this

manual are used or taken, you are obliged to take necessary in this manual are used or taken, you
are obliged to take necessary measures to ensure safety.
Unauthorized modification or abuse of the machine may influence the performance or even cause
greater safety hazard, for instance, settings more than the specified fuel quantity may overload the
machine. Drive and use the machine carefully, as faulty operation and misuse may also cause
damage, and we do not accept any responsibility for the loss thus caused.
The machine referred to in this manual is used for various operations under normal conditions; do
not use it in an inflammable and explosive place or an area with asbestos dust.
When the machine is used in the areas over 2000 m above sea level, the controller automatically
adjusts the power of engine and main pump to adapt to high altitude conditions.
This machine is subject to the electromagnetism and capacitance test according to EN13309-
2000. Therefore, all the unapproved electronic auxiliary devices such as communication apparatus
shall be tested before installation and use to ensure that they will not produce electromagnetic in-
terference to the machine.
All data, charts and specifications in this manual are the latest product information available at the
time of publication. We reserve the right to alter the above information without notice. Please con-
tact us or our authorized dealer for the latest product information or the problems related to the in-
formation covered in this manual.
Standard SANY rotary drilling rig application range: below 2000 m above the sea level. -20°
C～40°C ambient temperature
1.2 Legal and Regulatory Requirements

Environmental protection legal and regulatory requirements
In order to implement the Environmental Protection Law of the People's Republic of China and the
Law of the People's Republic of China on the Prevention and Control of Air Pollution, prevent and
control the environmental pollution caused by non-road diesel mobile machinery exhaust pollu-
tants, and improve environmental air quality, the GB20891-2014 standard is formulated. This
standard is interpreted by the Ministry of Ecology and Environment. Since April 1, 2016, all the
manufactured, imported, and sold non-road mobile machinery (except agricultural machinery)
should not be equipped with diesel engine that does not meet the phase 3 requirements in the
"Non-road Standards".
Laws and regulations on unauthorized equipment modification
Beijing Sany Intelligent Technology Co., Ltd. will not be responsible for any damage to the equip-
ment or legal liability due to any unauthorized dismantling, destruction, or tampering with engine
facilities.

1.3 Safety Information

For safe use of the machine, this manual contains and explains the safety precautions and labels
attached to the machine, to provide a description of potential hazards involved and methods to
avoid them.
Before operation and maintenance, users and after-sales service personnel must get familiar with
the warning signs and symbols on the machine, strictly observe the safety rules and recommenda-
tions in this manual, and actively take safety precautions and countermeasures to minimize the
risks of personal injuries, machine damage due to improper repair or the risks due to unsafe
factors.
1. Safety warning
A safety warning is comprised of an attention symbol and signal words, used as a reminder of po-
tential hazards that may cause personal injuries or damage. Safety warnings can be classified by
signal words according to the severity of hazardous situations.
Four types of signal words are used in this manual: DANGER, WARNING, CAUTION and NO-
TICE, each representing the following:
DANGER
It indicates a critically dangerous situation which might lead to death or serious injury if not
avoided.
WARNING
It indicates a potentially dangerous situation which may lead to death or serious injury if
not avoided.
CAUTION
It indicates a potential dangerous situation which may lead to low-or-moderate-level injury
if not avoided.
NOTICE
It indicates a potential dangerous situation which may lead to damage to the machine or
environment if not avoided.
Examples of safety warnings

CAUTION
Risk of personal injury!
Before entering and leaving the cab, before starting the engine, and before working, the safety
lock lever is not at the locked position, can cause personal injury.
• Before entering and leaving the cab, before starting the engine, and before working, set the
safety lock lever to the locked position.
2. Safety decals
Safety decals are attached to the machine to remind the operators or maintenance personnel of
potential hazards during operation or maintenance.
The “literal safety decals” and “graphic safety decals” are used on the machine to represent safety
measures.
a. Examples of literal safety decals 履带松紧调节警示牌
警告 WARNING
卸压时只允许拧松一圈。
如果将阀拧得太松，阀内
的高压脂会使阀喷出。
To release pressure,loos -
en only one turn.If the
valve is loosened too
much,grease under high
pressure may squirt out.
Fig 1-2

b. Examples of graphic safety decals
Safety icons are graphic representations of

the severity of hazards, equivalent to the liter-
al statement. Graphic symbols are used in
these safety icons to keep operators or main-
tenance personnel informed of the type and
severity of hazards.
In the graphic symbols at right side, the safety

icon above represents the type of hazard and
the icon below indicates the method to avoid
it.
Fig 1-3
1.4 Reading Instruction
Description of page
For the purpose of this manual, the page is numbered by chapter. Example: 3-20
Example: 3-20
Page 20 in Chapter 3
Chapter 3
Description of callout
The callout in the illustrations corresponds to the number in the related text, For example: 1 →(1).
Description of unit
In this manual, the units are expressed in international standard units (SI).
1.5 Introduction
1.5.1 Intended use of the machine
Sany rotary drilling rig is designed for the following operations:
1. Piling construction;
2. Engaged pile construction;
3. Diaphragm wall grab pile construction.

1.5.2 Machine directions
All views are taken from the seat (1) facing A

forward. In the manual, front side (A), rear
side (C), left side (B), and right side (D) means
the traveling direction seen from the cabin 1
when the cabin faces forward.
B D
Fig 1-4 Machine Directions
1. Seat B. Left side

2. Drive wheel C. Rear side
A. Front side D. Right side
1.5.3 Breaking-in of new machine
The machine of Sany is fully commissioned and tested before delivery. However, keeping machine
at full load before breaking-in process will seriously affect the performance and shorten the useful
life.
Be sure to carry out breaking-in within the initial 100 h (according to the indication of working hours
on the display).
Be sure that you are fully aware of the content of this manual and note the following during the
breaking-in process.
After start-up, keeping the machine idling for 3 min~5 min. During this period, do not operate the
control lever or fuel control knob, and then slowly set the engine knob to L gear until the coolant
temperature reaches about 60°C (140°F).
Avoid sudden acceleration, fast movement or stop during operation.

1.6 Product Information

1.6.1 Special tips
Read this manual carefully. Sany will take no responsibility, if you do not obey the following
provisions:
• Change or repair the machine without the permission of the company.
• Disassemble, weld, or add parts on the machine without the permission of the company.
• Use drilling tools or other accessories which are not supplied or recognized by the company
without the permission of the company.
• Fail to install, operate, and park the machine refer to the requirements in the manual.
• Use fuel, lubrication oil, and grease which do not obey the requirements in the manual, or the lu-
brication oil and grease dosage is not sufficient.
• Do not have correct maintenance and servicing refer to the requirements in the manual.
The guarantee period of the equipment is 2,000 h or 12 months, whichever comes first.
Take note of the use in details so that we can offer high-quality services for your equipment in time.

1.6.2 Product nameplate
The product nameplate is positioned on the

front of the machine, close to the operator
cab.
Fig 1-5 Location of Nameplate
Fig 1-6 Product Nameplate

1.7 Your Documentation Package

1.7.1 Suggestions on the use of the documents
The documentation for this machine includes the following items:

• Operation and Maintenance Manual-a copy of this operation and maintenance manual must al-
ways remain in the cab at all times.
• Parts Manual-this publication has parts lists and drawings for ordering spare parts as-needed. If
it was not shipped with your machine, the parts book for your machine is available directly from
Sany.
• Repair log-it lists regularly scheduled maintenance to be performed by the operator or mainte-
nance personnel. It should also record all maintenance did on the machine.
All the documents are placed in the document box together with the machine. If any or several
manuals are not delivered with the machine, contact Beijing Sany Intelligent Technology Co., Ltd.
or the authorized dealers to obtain them.
Recommendations on using the documentation

• This documentation applies only to this machine and must not be used with any other machines.
• To make sure that the documentation is always complete and up to date.
• Keep all pages inside its binder (if shipped loose leaf).
• Insert Sany replacement pages immediately into the appropriate book. Destroy old versions of
those pages.
1.7.2 Document storage recommendations
The Operation and Maintenance Manual must always be kept within reach (in the tool compart-
ment or the specially provided container) at the area where the equipment is deployed.
The Parts Manual is best left either shelved in the workshop area or office. It should always be
available to the maintenance and servicing personnel as required.

1.8 Accessory Box

The accessory boxes delivered with the ma-
chine include the accessories box and the tool
box.
• Accessories box: Includes the spare parts
drawings, the operation and maintenance
manual, and the engine use instructions.
• Tool box: Includes common installation
tools and filter elements.
Fig 1-7

1.9 Glossary
Table 1–1 Common terms
Glossary Description
Basic functional drilling rig that uses rotary buckets, short auger
buckets or other operating devices for dry and wet drilling, and uses
Rotary drilling rig
rotary digging to take soil one by one and repeatedly circulate to form
holes.
A key component on rotary drilling rig. Used to provide torque for
Rotary drive
Kelly bar.
Drive stub A part used to connect Kelly bar and drilling tool.
Flat tooth Drilling tooth type. Used for soft layers.
Drilling tooth type. Used for hard layers, such as high weathered
Round chisel
rocks or mud rock.
Drilling tooth type. Used for super hard layers, such as granite, ba-
Roller bit
salt and gneiss.
State that the rotary drilling rig meets the railway and highway trans-
Transport status
port requirements.
When the center of the mast coincides with the travel axis, the speci-
Swing angle fied swinging angle is 0°. When the slewing head is rotated to the left
or right by a certain angle, the angle is known as the swinging angle.
Main part of the rotary drilling rig except the rotary drive and its sup-
Base machine porting and guiding devices (mast and its accessories), drill rod and
drill tools.
Distance from the center of the drill rod to the swinging center of the
Working radius
slewing head when the rotary drilling rig is in the working status.
Mass of the rotary drilling rig in the transport status, which should be
Transport weight
the sum of the specified mass of liquid that can be injected.

1.10 Abbreviations
Table 1–2 Abbreviations
Abbreviations Description
FOPS Falling object protective structure
GPS Global position system
MIN Minimum
MAX Maximum
A/C Air conditioner
LCD Liquid crystal display
FM/AM Frequency modulation/Amplitude modulation
VOL Volume
BAS Bass
TRE Treble
BAL Balance
ECU Engine Control Unit
EGR Exhaust Gas Recirculation
LED Light Emitting Diode
OBD On-Board Diagnostics
1.11 Contact Information

Thank you for choosing Sany. In case of any problem, please contact by:
Beijing Sany Intelligent Technology Co., Ltd.
Address: Sany Industry Park, Nanyan Road, Nankou Town, Changping District, Beijing, China
Postal code: 102202
Service hotline: 0086 - 4006098318
Email: crd@sany.com.cn
Website: www.sanygroup.com

SR305RS10Rotary Drilling Rig Safety
Safety
2 Safety.....................................................................................................................................2-1
2.1 Safety Decals.........................................................................................................................2-3
2.1.1 Overview.......................................................................................................................2-3
2.1.2 Decal locations ............................................................................................................2-4
2.1.3 Safety decals ...............................................................................................................2-7
2.2 Safety Equipment............................................................................................................... 2-17
2.2.1 Safety lock lever ....................................................................................................... 2-17
2.2.2 Fire extinguisher....................................................................................................... 2-17
2.2.3 Emergency exit......................................................................................................... 2-18
2.2.4 Seat belt..................................................................................................................... 2-18
2.2.5 Emergency stop switch ........................................................................................... 2-19
2.2.6 Guards ....................................................................................................................... 2-19
2.2.7 Alarm lamp ................................................................................................................ 2-20
2.2.8 Chassis level............................................................................................................. 2-21
2.3 Safety Precautions............................................................................................................. 2-21
2.3.1 Safety rules ............................................................................................................... 2-21
2.3.2 Handling of abnormalities ....................................................................................... 2-22
2.3.3 Mechanical injury ..................................................................................................... 2-22
2.3.4 Battery hazards ........................................................................................................ 2-24
2.3.5 Fire prevention.......................................................................................................... 2-26
2.3.5.1 Away from fire.................................................................................................... 2-26
2.3.5.2 Daily checks....................................................................................................... 2-27
2.3.5.3 If a fire should occur ......................................................................................... 2-28
2.3.5.4 First aid for burns .............................................................................................. 2-28
2.3.6 Scald prevention ...................................................................................................... 2-29
2.3.7 Safety information of hose ...................................................................................... 2-30
2.3.8 Fluid leakage............................................................................................................. 2-31
2.3.9 Be cautious of high pressure fluid.......................................................................... 2-32
2.3.10 Crawler safety information ................................................................................... 2-33
Safety SR305RS10Rotary Drilling Rig
2.3.11 Lightning and strong wind precautions .............................................................. 2-33

2.3.12 Do not tow the machine ........................................................................................ 2-35
2.3.13 Falling protection.................................................................................................... 2-36
2.3.14 Dust hazard ............................................................................................................ 2-36
2.3.15 Noise protection .................................................................................................... 2-37
2.3.16 Unauthorized modification.................................................................................... 2-37
2.3.17 Wire rope safety information ................................................................................ 2-37
2.3.18 Climbing on/off drilling rig ..................................................................................... 2-38
2.3.19 Kelly bar and drilling tools..................................................................................... 2-39
2.3.20 Accumulator............................................................................................................ 2-40
2.3.21 Working at areas with underground pipelines ................................................... 2-40
2.3.22 Working at aera with high-voltage lines.............................................................. 2-41
2.3.22.1 Electrical accident........................................................................................... 2-41
2.3.22.2 First aid in case of shock ............................................................................... 2-42
2.4 Safety during Operation .................................................................................................... 2-43
2.4.1 Staff ............................................................................................................................ 2-43
2.4.2 Protective tools ......................................................................................................... 2-45
2.4.3 Prohibited operation................................................................................................. 2-45
2.4.4 Keeping the rig in good service condition............................................................. 2-46
2.4.5 Safety on construction site...................................................................................... 2-47
2.4.6 Signals to control operation ................................................................................... 2-48
2.4.7 Danger areas of drilling rig...................................................................................... 2-54
2.4.8 Avoiding tipping over ............................................................................................... 2-55
2.4.9 Before entering the cab ........................................................................................... 2-56
2.4.10 Before starting the engine .................................................................................... 2-57
2.4.11 Before operating the machine .............................................................................. 2-58
2.4.12 Drilling rig operation............................................................................................... 2-59
2.4.13 Construction of drilling rig .................................................................................... 2-60
2.4.14 Winch operation .................................................................................................... 2-61
2.4.15 Parking safety ........................................................................................................ 2-62
2.4.16 Safety when cleaning the machine...................................................................... 2-63
2.4.17 Drilling rig dismantling .......................................................................................... 2-64
2.4.18 Safety guidelines for transport ............................................................................. 2-64
2.4.19 Machine maintenance ........................................................................................... 2-65
2.5 Environment Protection..................................................................................................... 2-66
2.5.1 Proper waste disposal ............................................................................................ 2-66
2.5.2 Mud pollution............................................................................................................. 2-66
2.5.3 Fuel discharge ......................................................................................................... 2-67

2.Safety
2.1 Safety Decals

2.1.1 Overview
It is important that all safety and informational decals are in place, not damaged, covered up or re-
moved. It is also important for the operator and all personnel involved are aware of the decal con-
tent and locations on the machine.
• When replacing damaged or missing decals, be sure they are placed in the proper locations.
• Additional safety or informational decals may be added to your machine if necessary.
• The call-out numbers in the illustrations on this page and the next two pages match the num-
bered decal descriptions on the following pages.

2.1.2 Decal locations
8
4
Warning
6
5
7
9 10 11
12
13-10
Fig 2-1 Decals Location Diagram I
1. Wire safety decal 5. Boom safety warning decal 9. Fire prevention decal
2. Mast folding warning decal 6. Hard hat decal 10. Maintenance warning
decal
3. Rotary drive rotation warn- 7. Manual decal 11. Swing warning decal
ing decal
4. Winch system warning 8. Auxiliary winch parameters 12. Lifting point decal
decal decal

13
14
15
19 18
16
17
Fig 2-2 Decals Location Diagram II
13. Torque values decal 17. High pressure oil warning decal
14. Pin connecting decal 18. Main winch parameters decal
15. Safe distance warning decal 19. Hydraulic oil level decal
16. Operation prohibition decal

21
22
23
20
Fig 2-3 Decals Location Diagram III
20. Avoid getting crushed decal 22. Belt warning decal

21. Spurting medium warning decal 23. Fan warning decal
27
26
25
24
Fig 2-4 Decals Location Diagram Ⅳ
24. Crawler extending decal 26. Load capacity decal

25. Safety operation decal 27. Power supply warning decal

2.1.3 Safety decals
1. Warning decal: When connecting upper

mast and middle mast, pay attention to the 注意 CAUTION
wire.
在折合上桅杆与中桅杆时，请注意穿过
桅杆的导线，防止因折合桅杆过程使导线受
挤压或折断的危险。
When connecting upper mast with middle

mast, pay attention to the wire which
crosses the mast to avoid breaking or
squeezing the wire.
Fig 2-5
2. Warning decal: Tightening the bolts. Keep

away from mast folding area. 警告 WARNING
Fig 2-6
3. Warning decal: Keep away from the rotary

drive when it is rotating. 警告 WARNING
在动力头旋转和升降过程中，请远离动力
头装置。
动力头工作一段时间后，请不要用手摸动
力头箱，以免烫伤！
Keep away from rotary drive when it is rotating,

lowering and raising.Never touch it to avoid
being scalded.
Fig 2-7
4. Warning decal: Stay clear of the winch

system while the winch is in operation. 警告 WARNING
卷扬机在工作时，严禁人工排绳，严禁使用
报废的钢丝绳排绳，防止挤压。
When the winch is working,it is not allowed to help

the wire rope with steel bar. Strictly avoid using
discarded wire rope to protect from being
squeezed.
Fig 2-8

5. Warning decal: Keep clear of personnel

and objects underneath the boom. 警告 WARNING
在钻机变幅过程中，请不要站在动臂的
下面，动臂下面不得有异物。平行四边形在
变幅中请注意安全！
When the rig is luffing, it is not allowed stand

beneath the boom. Nothing should be allowed
to be placed under the boom.
Fig 2-9
6. Mandatory decal: Wear hard hat.
Fig 2-10
7. Mandatory decal: Carefully read the man-

ual before operating the machine.
Fig 2-11

8. Informational decal: Functional parame-

ters of auxiliary winch.
副卷扬 Auxiliary Winch
承载能力
Load Capacity
1.最大单绳拉力
90 kN
Maximum Line Pulling Force
2.钢丝绳直径
20 mm
Diameter of Rope
3.最大速度
Maximum Speed 70 m/min
Fig 2-12
9. Warning decal: No smoking anywhere

near the fuel tank while refueling the machine. 警告 WARNING
Fig 2-13
10. Mandatory decal: Before maintenance,

first removing the key.
Fig 2-14

11. Warning decal: Keep a safe distance dur-

ing the swinging of the drilling rig.
Fig 2-15
12. Functional decal: Lifting point on ma-

chine; not for towing.
Fig 2-16
13. Warning decal: Torque values for bolts of

Kelly bar and Kelly guide. 注意 CAUTION
T
随动架与钻杆安装连接，螺栓预紧请确保使用扭
力扳手，扭矩达到274N·m-323N· m；每工作50小时
需进行松动检查，否则螺栓松动将引起严重后果。
Make sure fasten the bolts by using torque
spanner, when assemble the Kelly with Kelly guide.
Fasten torque up to 274N.m-323N.m. Do check it after
working every 50 Hrs, Otherwise would cause serious
accident.
11341471
Fig 2-17
14. Warning decal: Make sure pins of rope

swivel and Kelly bar are reliably connected. 注意 CAUTION
在吊起钻杆时，请确保销轴插入提引器，
并且安全联接完成后，才允许起吊钻杆，否
则会出现严重的事故！
When hoising the drill stem, do make

sure insert the stud in the thumb bustar and
complete the connection before hosing the
drill stem. Otherwise it would result in serious
accident.
Fig 2-18

15. Warning decal: Safe clearance distance

is at least 10 m (33 ft).
注意 CAUTION
10m 33ft
Fig 2-19
16. Warning decal: Do not go near machine

during operation.
Fig 2-20
17. Warning decal: To release pressure,

loosen only one turn.
Fig 2-21

18. Informational decal: Functional parame-

ters of main winch.
Fig 2-22
19. Warning decal: hydraulic oil level decal.

注意 CAUTION
最高刻度，油液面在最
加注液压油时，请遵循以下条件：
高刻度线±5mm内。 1、油管、油缸内空气全部排出；
The highest level，the
2、设备所有油缸处于收回状态；
oil level should be at ± 5
3、环境温度下，液压油加至液位计最高刻度处。
mm of the highest level.
To add hydraulic oil,follow the belowing notes:
1.Expel the air in the hose and cylinder;
2.Retract all the cylinder;
3.Add the hydraulic oil to the highest level in the
ambient temperature.
Fig 2-23

20. Warning decal: Avoid getting crushed.
Fig 2-24
21. Warning decal: High pressure and tem-

perature. Serious injury could result if not
handled properly.
Fig 2-25
20. Warning decal: Rotating parts. Serious

injury may result if you contact rotating parts.
Fig 2-26

23. Warning decal: Rotating parts. Serious

injury may result if you contact rotating parts.
Fig 2-27
24. Warning decal: Crawler extending decal.
警告 WARNING
仅在运输时履带处于缩回状态，行走、回转、
施工、立桅、倒桅时必须伸展开，否则可能导
致主机重心不稳，剧烈晃动。甚至倾翻。
Only if the machine was on transportation, the
crawler need to be retracted. The crawler must
extend when travelling/ swing/ working/
erecting/ lowering.
Otherwise it may cause instability in the center
of gravity, shaking, and even rollover.
Fig 2-28

25. Functional decal: Operation instructions decal in operator cab.
安全操作说明 Safety Operation Instructions

1.上车右回转 Uppercarriage Swing Right 25.收音机面板 Radio Control Panel
16. 15. 48. 2.主（副）卷扬降 Main(Auxiliary) Winch Down 26.备用按钮 Backup Button
17. 14. 3.上车左回转 Uppercarriage Swing Left 27.备用按钮 Backup Button
18. 4.主（副）卷扬升 Main(Auxiliary) Winch Up 28.备用按钮 Backup Button
5.调桅有效 Mast InclineEffective 29.备用按钮 Backup Button
47.
6.桅杆左倾 Mast Incline Leftward 30.前窗洗涤开关 WindshieldWasher Switch
7.桅杆后倾 Mast Incline Backward 31.前窗雨刮器开关 Windshield Wiper Switch
46.
8.桅杆右倾 Mast Incline Rightward 32.主卷扬照明灯开关 Main Winch Lamp Switch
19. 45.
2. 13. 9.桅杆前倾 Mast Incline Forward 33.后视灯开关 Back Lamp Switch
3. 1. 10. 12. 44. 10. 动力头正转 Rotary Drive Rotate Clockwise
20. 34.前车灯开关 Front Lamp Switch
5. 9.
4. 11. 43. 11.起拔/变幅升 Crowd/Boom Up 35.引擎点火开/关 Engine Ignition SwitchON/OFF
21.
6. 8. 42. 12.动力头反转 Rotary Drive Rotate Counter Clockwise 36. 调档旋钮 Engine Speed Control
Dial
41. 13.加压/变幅降 Crowd/Boom Down
22. 37.空调面板 Air-condition Panel
7.
40. 14.右履带后行 Right Track Backward 38.调垂手柄 Mast Adjusting Lever
23. 39. 15.右履带前行 Right Track Forward 39.自动甩土(下推) Auto Throwing(push downward)
24. 38. 16.左履带前行 Left Track Forward ( upward)
40.浮动(上推) Freewheel push
37. 17.左履带后行 Left Track Backward
I
L E H P
41.手柄记忆 Handle Memory
座椅 rpm
36.
25. Seat ON
35. 18.水平仪 Gradienter 42.加压/变幅切换 Crowd/Boom Switchover

STA
OFF
RT
34. 19.喇叭 Horn 43.备用按钮 Backup Button

26. 33. 20.主/副卷切换 Main/Auxiliary Winch Switchover
32. 44.急停按钮 Emergency Stop Switch
31. 21.自动回转 Auto Swing 45.点烟器 Cigarette Lighter
30. 22.先导开/关 Hydraulic Lock Lever 46.功能键盘 E-Pad
29.
28. 23.手动回转有效(上推) Manual Swing Effective( pushupward) 47.显示器 Display
27. 24.主卷快速下放 Main Rope Fast Speed Down 48. 脚踏浮动开关 Foot Freewheel Switch
面板有效动力头S档动力头R档动力头E档变幅操作 The operation of boom：
Keyboard Rotary Drive Rotary Drive Rotary Drive P1
Effective S Gear R Gear E Gear
P1:动臂最高位置
The highest location of boom
C
调垂有效自动立桅自动倒桅自动调垂 P2:动臂最低位置 B
Mast Adjusting Auto Erecting Auto Lowering Auto Vertical The lowerest
AUTO Effective AUTO AUTO AUTO Adjusting location of boom
P2
A O
行驶解锁变幅/加压辅卷扬解锁主/辅卷扬切换 O: 机架 Shelf
Travel Unlock Boom/ Crowd Auxiliary Winch Main/ Auxiliary
钻机变幅机构动作时注意以下几点：
AUX
Unlock MAIN AUX
Winch Switchover
1、变幅范围分为A、B、C三个区域。
履带伸展折桅伸展张紧伸出支腿伸出
Crawler Extend Mast Folding
*
Tensioning Outrigger Cylinder
2、当且仅当动臂位于B区域时，方可进行倒立桅。
3、当且仅当动臂位于C区域时，方可进行钻进施工。
Cylinder Extend Cylinder Extend Extend
The following points should be noted when operating:
履带收缩
Crawler Retract
折桅收缩
Mast Folding
* 张紧缩回
Tensioning
支腿缩回 1.Boom mechanism is divided into A, B and C areas .
Outrigger Cylinder 2.Only if boom is in B zone, mast erecting and lowering
Cylinder Retract Cylinder Retract Retract operation is enabled.
3.Only if boom is in C zone, drilling operation is enabled.
注意 NOTES: 表示配置加压卷扬时有效be effective withwinch crowd; 表示选配功能 optional.
* P1 P3
倒立桅操作 The operation of mast： A P2
A: 桅杆油缸铰点 Mast cylinder pivot B

B: 三角形铰点 Triangle connectionpivot C
C: 桅杆支座 Mast pedestal
钻机进行倒桅和立桅操作前强烈建议注意以下几点： The following notes are strongly recommended during lowering or raising the mast:
1、钻机进行倒桅或立桅过程中：请使随动架处于A点位置附近；使动力头处于B点位置 1. In the process of lowering or raising the mast: Make Kelly guide near position A; place rotary
以下，见P1。 drive nearpositionB. Refer to P1.
2、钻机进行倒桅的过程中：首先请保证变幅机构不变的前提下将桅杆绕B点缓慢放平， 2. In the process of lowering mast: Firstly ensure that the mast lies slowly around position B with
the boom mechanism unmovable. Refer to P2. Then lower the boom mechanism slowly to lower
见P2；其次使桅杆随变幅机构进行缓慢下降以实现倒桅，特别是当桅杆即将落在桅
the mast. Especially when the mast is close to the pedestal, you should control the joystick to
杆支座上时要控制好手柄以保证好缓慢下降，见P3。 lower the mast slowly. Refer to P3.
3、钻机进行立桅，过程与倒桅相逆。 3. The process of raising mast is a reverse of lowering it.
4、桅杆进行倒桅和立桅的过程中请务必缓慢进行，以防止将机器损坏。 4. Make sure that raising or lowering mast slowly to avoid damage to the machine.
Fig 2-29 Safety Operation Instructions

26. Functional decal: Load capacity decal in

operator cab. SR305R 载荷表 ( Load Capacity )
警告：必须遵守下列条件以保证钻机 WARNING:Must obey the followings to ensure the
的稳定性，否则钻机有倾倒的危险！ machine's stability, or the turnover may happen!
仅对以下装置有效： Valid only for:

- 钻杆：摩擦钻杆 Φ508-6×18 m 16.6 t - Kelly Φ508-6×18 m 16.6 t
- 钻斗：土层双底捞砂斗 Φ2500 mm 5.6 t - Bucket Φ2500 mm 5.6 t
工作条件： Conditions for operation:

- 设备必须停放在坚实平整的地面上， - Machine is on firm, horizontal and even ground,
且履带伸展。 and crawler is extended.
- 钻进工作时上车不能回转。 - Uppercarriage held stationary when working.
- 辅卷扬钢丝绳带负载时上车回转应缓慢。 - Slow swing of uppercarriage with load on auxiliary rope.
- No diagonal pull.
- 不能斜拉负载。
- Do not exceed specified maximum values in the table.
- 不能超过下表中的角度和载荷，其均为最大值。
最大钻孔中心距（Max drill distance ）：4534 mm 最大允许负载 [吨] Max allowable load [ t ]
主钢丝绳 33
Main rope
副钢丝绳
Auxiliary rope 9
β γ
α β
α＝2°
副钢丝绳 β＝3°
δ
Auxiliary γ＝0° 8
rope δ＝120°
δ
γ β
β α
副钢丝绳 α＝2°
Auxiliary β＝3° 3
rope γ＝0°
行走条件： Conditions for onsite travelling:

- Uppercarriage in line with crawler.
- 上车与履带保持平行。
- Work attachments and movable loads kept
- 工作装置与运动负载尽量接近地面。 as close to the ground as possible.
- 导向轮在前。 - In front of the guide wheel.
- 不能剧烈动作。 - No abrupt movements.
Fig 2-30
27. Warning decal: Stay away from power

supply.
Fig 2-31
Remark:

The operation methods and parameters shown here are indicative only. If there is inconsistency,
the contents of actual decal and following sections shall govern.
2.2 Safety Equipment

2.2.1 Safety lock lever
CAUTION
Risk of accident! 1
The uncontrolled movements of the
equipment could cause accident.
• Before leaving the cab, switch off the
equipment safety lock lever.
2
When the safety lock lever is in the unlocked
position (1), the unlocking of the hydraulic pi-
lot system is unlocked and connected, and
the hydraulic system of the entire equipment Fig 2-32 Safety Lock Lever
can work normally. When the safety lock lever
1. Unlocked position 2. Locked position
is in the locked position (2), the hydraulic pilot
system is disconnected and all hydraulic com-
ponents do not function.
2.2.2 Fire extinguisher
The fire extinguisher is put at the rear part of

the operator cab. Read the instructions on the
fire extinguisher at regular intervals, to make
sure that you can operate it correctly if fire
occurs.
Fig 2-33 Fire Extinguisher

2.2.3 Emergency exit
CAUTION
Risk of injury!
Broken glass could cause body injury.
• Protect body parts from broken glass
when you use the emergency hammer.
The emergency hammer (1) is located in the

rear right part of the cab. If it is not possible to
leave the cab, shit the edge of the window
with the emergency hammer. Leave the cab
from the emergency exit (2). 1 2
Fig 2-34
1. Emergency hammer 2. Emergency exit
2.2.4 Seat belt
If there is a rollover accident, operator may be

injured or thrown from the cab resulting in
serious fatal accident.
• Be sure to fasten seat belt when you oper-
ate the machine.
• Before operating the machine, be sure to
check condition of the seat belt, buckle, and
connecting pieces.
• If any wear or cracks are found, replace the
seat belt, buckle, and connecting pieces. Fig 2-35
The seat belt should be replaced for every
three years.

2.2.5 Emergency stop switch
NOTICE
Risk of causing damage to components!
Components of the equipment could be
damaged by heavy loads.
• The emergency stop switch may only be
used in emergencies.
The emergency stop switch is located on the

right side of operator’s seat.
In case of an emergency:
Fig 2-36 Emergency Stop Switch
Press the switch. Diesel engine shuts down
and all of the equipment's functions are shut
down.
Unlock the button before restarting the

diesel engine:
Pull the switch upward. All of the equipment's

functions are unlocked.
2.2.6 Guards
The front guard and top guard are installed on

the cab to protect the operator from the falling
objects.
Inspect the guards on a daily basis in order to

check for structures that are bent, cracked or
loose. Never operate a machine with a dam-
aged structure.
Fig 2-37 Guards

2.2.7 Alarm lamp
The alarm lamp is located on the rear part of

the upper carriage.
Fig 2-38

2.2.8 Chassis level
The chassis level is located at the top left of

traveling pedal.
If the air bubble is in the central position, it

shows that the undercarriage is in level
position.
3
2
1
3 2 1 1 2 3
1
2
3
Fig 2-39 Chassis Level
2.3 Safety Precautions

2.3.1 Safety rules
Only trained workers can be assigned to operate and maintain the machine.
Abide by all safety rules, precautions and instructions when operating and maintaining the
machine.
Alcohol and medicine will severely reduce and weaken workers’ ability to operate or maintain the
machine in a safe manner, endangering himself or herself and other people on the site.

When working with another operator or a commander, keep all informed of all adopted hand
signals.
2.3.2 Handling of abnormalities
When any abnormalities (noise, vibration, odor, incorrect instrument display, smoke, oil leakage
and etc. or any abnormal display in the warning device or monitor) are discovered in the process
of operation and maintenance, report to the supervisor and take necessary measures. Do not op-
erate the machine before removing all faults.
2.3.3 Mechanical injury
WARNING
Risk of entanglement!
Rotating components can cause crushing or entanglement of body parts. This can result in seri-
ous or fatal injuries to persons.
• Do not put any body parts between moving components.
NOTICE
Risk of causing damage to the equipment!
Since the machine is not equipped with an FOPS protection device, if no additional protective
measures are taken when it is used under a risk of falling objects, such as near a building under
construction, on a slope down which stones may roll, and in a deep pit where construction is
underway, the machine can be damaged.
• Take effective protection measures for the areas where there is a risk of falling objects near the
machine.
When you work around turning components,

do not let hands, feet, clothes, and hair be
caught in or crushed by turning components.
Do not let objects fall into turning area of mov-

ing components.
Fig 2-40

Guard against falling objects above the cab.
Do not walk or stay in the space below

hanged load.
Do not make adjustment to the components

when the engine is started.
Fig 2-41
Start the engine with the method of jumper

motor solenoid terminal can cause unex-
pected move for the machine.
Fig 2-42
If you will be working below the machine, al-

ways use approved jack supports that will
support the weight of the machine.
Install the disassembled protective device to

its initial position after maintenance
procedure.
Fig 2-43

WARNING
When a pin is disassembled or hammered
with a hammer, can caused serious personal
injury or death.
• When workers remove or hit pins with a
hammer, be sure to wear work clothes,
anti-smashing shoes, and protective
goggles. Fig 2-44
• Make sure there is no one in the direction
where the pin may fly out.
If you hit hard metal parts for example pins

with a hammer, always wear safety glasses
and gloves when you do these operations,
and make sure all personnel are clear of your
work area.
2.3.4 Battery hazards
WARNING
When in contact with open flame, the battery gas can explode, could result in severe injury or
death.
• Do not use open flames near the battery.
Working around batteries always poses a hazard, especially if the battery has been in service for a
long period of time. Listed below are some basic precautions to be aware of when servicing or
working around batteries.
Battery gasses are extremely explosive.

When opening a battery compartment, always
let ample time for the gasses to release before
servicing the battery.
Fig 2-45

Always wear personal protective equipment

when working around batteries.
Fig 2-46
When working with batteries, always work in a

well-ventilated area. If the battery is corroded,
flush the area with a baking soda and warm
water mix. Do not use starting aids to start the
engine. Starting aids are explosive and will
damage the engine.
Fig 2-47

If battery acid should get on your skin or in

your eyes, flush the area immediately with
fresh water and seek medical attention.
NOTE：
If the electrolyte is sprayed to your body,
do the following:
• Neutralize the acidity using soda or
limewash.
• Then, flush for 10 min~15 min using
clean water, and seek medical advice Fig 2-48
immediately.
Fig 2-49
2.3.5 Fire prevention
2.3.5.1 Away from fire
WARNING
Risk of fire!
Welding, torch cutting, and grinding tasks on the equipment can cause fire or explosions. This
could result in serious or fatal injuries to persons.
• Do not let the flammable liquid contact fire or leak it on hot surface or electrical systems.

Do not smoke when refuelling or maintaining

the machine. Also do not smoke in the area
where there may be coolant.
Stop the engine when you refuel. When diesel

oil or hydraulic contacts a hot surface, it may
cause fire.
Do not operate or maintain the machine near

a fire.
Fig 2-50
Do not weld or cut on the pipe or tank body

which contain flammable liquid. Do not heat or
welding beside the hydraulic pipeline.
Before welding or weld-cutting the pipe or

tank body, clean them with flame retardant or
flame retarding solution and solvent.
When heat paint will produce poisonous gas.

Remove before welding or heating.
Fig 2-51
2.3.5.2 Daily checks
Clean up flammable substances from the machine, such as fuel, lubricating oil, rags, and scraps.
Damage or loss of thermal protection shield may cause a fire. If any unusual situation is discov-
ered, repair it or equip with new thermal protection shield before operating the machine.
Check oil leakage, and check whether the pipeline is damaged, or whether the clamp and bolts are
loose, etc.
Check all the cable and wiring daily for loose, disconnected, or damaged.
Before starting electrical equipment, tighten

all the loose wire and repair damaged wires.
Clean and tighten all the electrical
connectors.
Fig 2-52
2.3.5.3 If a fire should occur
• Never attempt to move or continue operat-

ing the machine.
• Immediately shut down the engine.
• Exit the machine in a calm manner, using
all handrails and steps.
• Immediately call for help.
• If time allows, shift all the control devices in-
to neutral position.
• If you will be using a fire extinguisher, al- Fig 2-53
ways aim the extinguisher at the base of
the fire.
• Remain clear of the machine until the fire
department gives you permission to come
near the machine.
2.3.5.4 First aid for burns
Basic principle of first aid at the burn scene: Immediately flush the burnt area with cold water. Wrap
antibiotic bandage on the burnt area and go for medical treatment.
Burn type:
• Burnt by flame: Immediately take off the

clothes on fire, and extinguish the fire with
water or by lying down or rolling on the
ground. Do not run and shout to prevent in-
jury to the head, face, and the respiratory
tract.
• Burnt by hydrothermal solution: Take off
the clothes that are soaked with the hot Fig 2-54
liquid. (Avoid stripping of the blister skin.
You can remove the heat with cold water
before cutting the soaked clothes.)
• Burnt by chemicals: Take off the clothes soaked by the causative factor of injury, and quickly
rinse with a large amount of water to remove the chemicals on the surface of the wound.
• Burnt by electricity: Immediately cut off the power before contacting the patient. In case of a
cardiac arrest or respiratory arrest, immediately carry out external cardiac compression and arti-
ficial respiration. Send the patient to a nearby hospital when the breath and cardiac restore. In
case of burns by arc, treat the burns based on the procedure for burns after cutting off the
power.

Onsite handling:
• The most effective and economic treatments of burns at the early stage include rinsing, soaking
or wet compress with cold water.
• No special treatment is needed for the surface of the wound on site. Keep the integrity of the
blisters whenever possible. Do not remove the rotten skin. Meanwhile, simply bandage with a
wound dressing or a clean coverlet or cloth.
• Shock may occur if the burn area reaches a certain level. Beverages containing salt are recom-
mended for patients with mild symptoms, while intravenous transfusion is necessary for patients
with serious symptoms. Avoid drinking a lot of water, especially boiled water. Generally, the
water volume should not be greater than 50 ml each time for oral administration, to prevent
vomiting.
• Treat the patient locally, or send the patient to a qualified hospital.
2.3.6 Scald prevention
WARNING
Opening the radiator cover before the engine has cooled down could result in serious personal in-
jury or death.
• When opening the cover after the engine is cooled down, slowly rotate the cover, and remove it
after the pressure is fully released.
When operation is started, the cooling system of the engine is hot and has pressure. Hot water or
steam from the engine, radiator will cause serious burns.
During operation, engine oil, gear oil, and hydraulic oil will become hot. The engine, hose, pipes,
and other parts will also become hot. Maintenance work shall be started only after the oil and parts
cool down.
Temperature of all the work components of drilling rig such as rotary drive tank body and pin axles
will be higher because of friction. Direct skin contact may result in serious burns.

Antirust agent in cooling system contains

strong alkaline materials, may result in per-
sonal injury. Do not contact with skin, eyes,
and mouth.
Fig 2-55
Before adding fluids, shut the machine down

and let the systems to cool down to the out-
door ambient temperature before removing
caps.
Always be aware that hydraulic systems are

under high pressure and are hot.
Fig 2-56
2.3.7 Safety information of hose
Damage will cause hydraulic oil leakage and a sudden move of work devices, which may result in
unexpected accident.
• Do not bend hit the pipes supplying high pressure fluid. Do not install bent, twisted, or damaged
pipes.
• Repair or replace, loose, or damaged pipes. Leaking fuel and oil may cause a fire.
• Because of aging, fatigue, and wear, the hose containing flammable fluid may crack under
pressure.
• The aging hose must be replaced at regular interval.
• Make sure all the pipe clamps are correctly installed.

• When servicing or disassembling hydraulic

elements such as hose and valve block,
plug all connecting port to avoid foreign
matter entering hydraulic oil and causing
pollution.
For any of the following situation, it must be

replaced as soon as possible:
• End connector is damaged or leak.
• Hose outer surface is scratched or cut.
Fig 2-57
• External protective layer is scratched or
pierced by steel wire or electrical wire.
• External protective layer is partially
expanded.
• The hose has crack and distortion marks.
• Internal frame damages the external protec-
tive layer.
2.3.8 Fluid leakage
NOTICE
Risk of environmental pollution!
Industrial fluid, especially waste oil, can cause environmental pollution.
• Oil used in the water source protection zone or the natural protection zone must meet the rele-
vant requirements.
Periodically check the hydraulic pipeline. Carefully check all the hoses, and do not check leakage
by hand. The leaked fluid should be cleaned promptly.
Carefully check all the connecting and parts of the hose whether they are loose. Tighten all the
joints and connecting pieces with recommended torque.
When installing or dismantling hydraulic com-

ponents, or during oil changing and mainte-
nance, use a container with sufficient capacity
to hold the fluid. Never discharge oil onto the
ground.
Fig 2-58

2.3.9 Be cautious of high pressure fluid
WARNING
Risk of injury or possibly death!
High pressure fluid can cause injury.
• Do not remove any hydraulic parts before
releasing the pressure.
The maximum air pressure cannot be higher

than 205 Kpa (29.73 psi), and maximum water
pressure cannot be higher than 275 Kpa Fig 2-59
(39.89 psi).
When examining leakage, use a thin slab or

carton board to avoid the fluid penetrating
your skin.
Pay special attention to protect hands and

body against high pressure fluid. Wear mask
or safety glasses to protect eyes.
If the fluids come into contact with the skin or

eyes, take appropriate countermeasures and
visit the medical specialist without delay. Fig 2-60
After the engine has stopped for a long time,

the pressure is still in hydraulic system. When
releasing the pressure, it may cause sudden
move for the machine or accessories. Be cau-
tious when disconnecting the hydraulic pipe
or joints. High pressure oil will make the hose
whip. The released high pressure oil may
cause hydraulic elements (such as pipe plug)
to sprout rapidly.
Fig 2-61
When the fluid in tank is heated, the pressure
will go up. When opening the cap, the fluid will
sprout.

2.3.10 Crawler safety information
WARNING
Risk of getting crush or hit!
The crawlers are extendable. Person in the risk area during extending the crawlers can get injury.
• Leave the danger area before extending or retracting the crawlers.
Apply high pressure lubricating grease to

crawler adjusting system to keep the crawler
tensioned.
Grease in crawler tension cylinder has high

pressure. If the high pressure grease is
spewed onto body, it can cause serious or
fatal injury.
Buffer spring has high pressure, incorrect dis-

assembling may cause sudden fly off of the Fig 2-62
spring and then result in personal injury.
NOTE：
Pins and bushings on track shoe are very hot after working for a long period of time. Direct
contact with these hot components can lead to burning or scalding of body parts.
2.3.11 Lightning and strong wind precautions
WARNING
Risk of lightning strikes!
Lightning strikes can result in serious injury or death.
• Do not leave the cab if there is an imminent risk of a lightning strike.
• Persons in the vicinity of the equipment must leave the danger area immediately.

When there is lightning near the drilling rig, do

not climb up or down the drilling rig. During
lightning strike, if the operator is in the cab, he
should stay inside. If the operator stands on
the ground, keep a distance from the drilling
rig.
If the wind force scale reaches force eight,

stop drilling operation and lay the mast in hori-
zontal position.
Fig 2-63 Lightning and Strong Wind
Fig 2-64 Horizontal State of the Mast
Permissible wind speed: Wind speed less than 17.2 m/s to 20.7 m/s (62 km/h to 74 km/h) or
677.17 in/s to 814.96 in/s (38.53 mph to 45.98 mph).
NOTE：
• The equipment can tilt and fall over during storms with high wind speeds. This could re-
sult in serious or fatal injuries to persons in the vicinity of the equipment.
• If the maximum permissible values are exceeded, shut-down the equipment immediately
and secure it.

2.3.12 Do not tow the machine
WARNING
Risk of personal injury or death!
Machine towing not following the regulations will cause the drilling rig to tip over, which can lead
to personal injury or death.
• Avoid towing the drilling rig with another machine.
NOTICE
Risk of damaging the equipment!
Towing the machine will cause the equip-
ment tipping over, which can lead to machine
damage.
• Do not tow the machine.
The operator shall prohibit machine towing

when using or transferring the machine. This
can prevent machine tip-over due to out of
balance, causing damage or personal injury.
Fig 2-65

2.3.13 Falling protection
WARNING
Rotation of drilling rig and crawler can cause
serious damage to person.
• During traveling, construction and drilling,
never stand on the crawler or upper
carriage.
When performing maintenance, repair, or in-

stallation work, there is potential falling haz-
ard. Protection methods must be taken, for
example, wear safety belt or use special fall-
Fig 2-66
ing protection devices.
Fig 2-67
2.3.14 Dust hazard
If there is possibly asbestos in the air, be sure

to operate the machine at upwind location.
Personnel should use dust mask.
Inhaled unknown dust may cause damage to

respiratory system.
Make sure the construction site is well venti-

lated. Adopt necessary measures, such as
spraying water.
Fig 2-68

2.3.15 Noise protection
Wear correct hearing protector so as to avoid

hazardous or uncomfortable loud noise.
NOTE：
Noise for operator in the cab of the ma-
chine is ≤80 dB.
Fig 2-69
2.3.16 Unauthorized modification
Unauthorized machine modification may lead to safety issues and personal injury. It will have se-
vere influence on the strength and view of the machine. Before any modification, contact the au-
thorized agent of Sany. For any accident, malfunction or damage caused by unauthorized
modification, Sany will take no responsibility.
2.3.17 Wire rope safety information
Wire rope is one of the crucial parts for rotary drilling rig and also a quick-wear part. Correct selec-
tion and reasonable utilization and maintenance could extend service life of the wire rope and
avoid accidents.
• Connection between wire rope, hook, and wire rope connector, and inspection, maintenance,
and discarding of wire rope must strictly comply with relevant laws and regulations for crane in-
dustry in the country.
• Newly replaced wire rope should usually share the same model and specifications with the for-
mer installed wire rope. If adopting a different model, the user should make sure the new wire
rope is not inferior to the original wire rope.
• Do not use wire rope with potential safety hazard, such as kinking, broken wire, deformation,
and so on.
• Wear protective gloves when dealing with wire ropes.
Replace as soon as possible, if any of the following situation happens:

• Broken wire appears at the rope end or nearby.
• Strand cracks.
• Resilience decreases, rope diameter is undersized, and lay length extends.
• Exterior and interior side of the wire rope is severely corroded.
• Wire rope wear.
• Wire rope deformation.

• Rope diameter undersized.
2.3.18 Climbing on/off drilling rig
CAUTION
Risk of accident!
Climb on or jump from the machine when it is traveling could cause damage to person.
• Only climb on or off the machine from areas with steps and/or handrails when the machine is
stable.
Before using steps, platforms or handrails, make sure that they are complete and in correct work
order.
When climbing on or off the machine, point the machine and hold three-point contact with handrails
and steps. Three-point contact can be the two feet and one hand or one foot and the two hands.
Fig 2-70

Do not use the machine controls or non-speci-

fied points to get on or off the machine.
Do not climb on or off the machine with tools

or similar objects in your hands.
Never get on or off the machine when it is run-

ning or rotating, and you can't jump off the
machine.
Before you get on the machine, be sure your

Fig 2-71
shoes are free of mud, oil, grease or similar
material that could cause you to slip and fall.
Fig 2-72
2.3.19 Kelly bar and drilling tools
WARNING
Risk of equipment tipping over!
The toppling drilling tool and Kelly bar can result in injury or possibly death.
• Take effective safety measures during transportation.
Choose proper location to store Kelly bar and

drilling tools to avoid tipping over.
Fig 2-73

2.3.20 Accumulator
The accumulator is filled with high-pressure

nitrogen, thus improper operation to the accu-
mulator may cause an explosion, which may
lead to serious accidents. Therefore please
comply with the following precautions:
• Do not disassemble the accumulator.
• Keep the accumulator off fire source or do
not expose it to fire.
• Do not punch, weld or cut by torch the
accumulator.
• Do not collide with or roll the accumulator,
or make it suffer any impact. Fig 2-74
• Deflation is required for handling of the ac-
cumulator. Contact the authorized agent of
Sany to conduct this operation.
2.3.21 Working at areas with underground pipelines
It is important to study the area for hazards involved with the work operation before putting the ma-
chine on a work site or starting any work operations.
• Before starting any drilling operations, contact all utility departments in your area and have them
identify and mark any underground systems locations, gas lines, water lines, electrical lines,
sewer lines, etc.
• If there is underground utilities, develop a reasonable construction scheme to guarantee safety
of utilities and working personnel.
Operator must be clear about specified posi-

tion of the pipeline, and use correct measures,
and work with caution.
If pipeline or its protection is damaged acci-

dentally, the operator must stop operation and
report to responsible person.
Fig 2-75

2.3.22 Working at aera with high-voltage lines
2.3.22.1 Electrical accident
WARNING
Risk of electric shock!
If the equipment comes into contact with overhead or underground voltage lines, a current trans-
fer to the equipment occurs. Persons in the immediate vicinity receive an electric shock as well
as burns, which can cause serious or fatal injuries.
• Before starting work, ask an authorized person about the prescribed safety distance. Always
observe the required safety distance.
• Before starting work, inform the company responsible for the power supply.
If work near overhead power lines, it is important to be aware of the risks involved with these sys-
tems. The hazard exists even if you are not near or touching power lines. High humidity may in-
crease the hazard. Always use more caution when working near power lines and follow the
precautions listed below.
Operating a rig near high frequency towers

can also pose an electrical hazard. Ask the
company to shut this system down or remove
the lines down until your work is finished.
Do not trust the word of a coworker or work

site personnel that power lines are de-ener-
gized. Always contact a representative of the
power company in your area for correct au-
thorization and be sure power lines are de-
energized.
Always be aware of the dangers when work-

ing around overhead electrical lines. High hu-
midity can pose an electrical hazard even if
your equipment seems to be safely clear of
the overhead power lines. See the table below Fig 2-76
for minimum machine-to-cable distances.
Table 2–1 Minimum distance
Minimum Distance Between Machine and

Power Line Voltage
Cables
u≤1 kV ≥4 m or 13.12 ft
1 kV<u≤10 kV ≥6 m or 19.69 ft
35 kV<u≤110 kV ≥8 m or 26.25 ft

Table 2–1 Minimum distance (continue)
110 kV<u≤220 kV ≥10 m or 32.81 ft

220 kV<u≤500 kV ≥15 m or 49.21 ft
If your machine touches overhead electrical

lines, stop the machine, stay in the operator
seat, do not touch any controls until the power
company clears the lines.
If the drilling rig comes in contact with electri-

cal lines, operator must disconnect the drilling
rig from electrical lines, tell workers nearby to
keep clear of the drilling rig, and ask techni-
cian to cut off the power.
Fig 2-77
If accident, cut off the power immediately, call

a doctor, and do first aid under the guidance
of doctor or rush the injured to hospital.
All operators should know first aid about elec-

trical accidents.
Fig 2-78
If the drilling rig comes in contact with electric lines, operator should follow the procedures below:
• Be sure the high voltage power line is cut off.
• The best manner is to jump down instead of climbing off.
• Jump away from the drilling rig with both feet together.
• Do not touch any parts of the drilling rig with body after hitting the ground.
• When hitting the ground, hop or jump with both feet together away from the drilling rig.
2.3.22.2 First aid in case of shock
The electric shock may cause mechanical injuries such as high-altitude fall. Follow the steps listed
below after an electric shock:
• Turn off the power immediately. Do not touch the patient who suffered the electric shock.

• You can push the power cable with a bamboo pole or wood stick. You can also wear a pair of in-
sulation gloves or wrap your hands with dry clothes, or stand on an insulation mat or a dry wood
board, and then pull the patient away from the electric object. Do not touch any metal object or
the exposed part of the patient's body.
• The first-aid personnel should not use metal or other wet materials as the first-aid tools.
• Before taking insulation measures, the first-aid staff should not directly touch the skin or wet
clothes of the patient.
• When the patient is at a high position, take measures to prevent the patient from falling to the
ground, which may cause injury or even death after he or she is away from the power source.
• In case of a shock at night, consider temporary lighting after power-off to ensure easy medical
treatment.
• If the patient suffering a shock is unconscious, but has normal breath and heartbeat, make sure
the patient lies comfortably, and keep proper ventilation. Unbutton the collar for proper breath-
ing. Keep warm in cold weather.
• If the patient is difficult in breathing or cardiac arhythmia, quickly perform artificial respiration or
chest compression (CPR). In addition, send the patient to the hospital as soon as possible. Do
not stop the first aid on the way.
Principles for the treatment of electrical injuries:

• For the trauma, you can flush with aseptic natural saline, and then bandage using an antiseptic
gauze.
• In case of a massive bleeding from the wound, the quickest hemostatic therapy is compression,
followed by bandaging using an antiseptic gauze.
• For the patient suffering bone fracture after falling off due to the shock, stop bleeding and band-
age. Then, use a wood board, a bamboo pole or a wood stick to temporarily fix the body with the
broken bone, and send the patient to the hospital immediately.
2.4 Safety during Operation

2.4.1 Staff
WARNING
Negligence of onsite workers can result in serious personal injury or death.
• The equipment is equipped with safety protection measures and onsite safety personnel during
work and maintenance.
Before working, the working personnel must carefully read the manual and the safety information.
They must be fully familiar with the safety instructions. Relevant personnel, for example, the as-
sembly personnel and maintenance personnel, must be familiar with the information related to the
equipment and safety.

The operator must study to learn and master the composition and performance of the machine,
and get familiar with the operating methods, maintenance procedures, various commanding sig-
nals, and basic knowledge of drilling. The operator is not allowed to operate the machine unless
he or she has passed examinations. Non-operators are not allowed to operate the drilling rig.
The operator must be fully concentrated on

the operation, and must not carry out any ac-
tivities that distract his or her attention (for ex-
ample, chat or make calls during operation).
The workers should understand the informa-

tion about the use of the relevant safety devi-
ces, and understand the measures needed
after a harm.
Fig 2-79
The workers should also be familiar with the equipment sizes like the height, width and swinging
range of the equipment, so as to keep a safety distance between the equipment and the obstacle
nearby during operation.
The operator shall not have long hair, wear loose clothes, or wear a necklace, bracelet or ring to
prevent the protruded portion from being drawn into the machine.
The operator must have the operating capability. Operations when he or she is fatigue, sick or after
drinking alcohol may result in serious accidents.
When operating, the worker must wear the re-

quired safety equipment, such as the safety
helmet, safety shoes, protective goggles,
gloves, masks, overalls and other required
kits.
The operator is responsible for the operations

directly under his or her control. Therefore,
the operator has the right to reject operations
requested by others that may result in hazard-
Fig 2-80
ous accidents or that violate the
requirements.
Personnel who are being trained should not operate the equipment unless under the supervision
and guidance by an experienced operator.
Only professionals familiar with hydraulic, electrical, welding and commissioning knowledge are al-
lowed to maintain the machine.
If the operator has any question about the machine safety, he or she must suspend operations im-
mediately, and report to the person in charge.

The employer or the authorized personnel should regularly check the operations, and the safety
awareness of the maintenance personnel during the work.
2.4.2 Protective tools
Wearing proper safety equipment, as required

for site conditions, helps avoidable harms.
• Safety helmet: Wearing a helmet can pro-
tect the head and reduce injuries.
• Protective goggles: Protective goggles can
protect the eyes against injury.
• Earplug: If the noise level will exceed 90
dB, wear earplugs.
• Face shield: Face shield protects workers
Fig 2-81
against dust hazards.
• Protective gloves: Hands may be injured
when using the crane, wear gloves.
• Safety shoes: Safety shoes reduce the risk
of hitting, walking on a heavy object, or the
risk of being hit by a falling heavy object.
• Reflective protective clothing: Wear these
clothes if you need to be easily identified.
• Special protective clothing: They can effec-
tively prevent the dangers caused by burn- Fig 2-82
ing, overcooling, corrosion, puncturing or
scratching.
The staff have the responsibility to:

• Wear the required personal protective equipment.
• Regularly clean and maintain the machine.
• Replace damaged or unserviceable protective kits immediately.
• The staff must be aware that the safety equipment cannot provide 100% protection. The helmet
protects a person from small falling objects, but it can do nothing against heavy ones. Therefore,
always be vigilant and have safety consciousness.
2.4.3 Prohibited operation
This drilling rig can only be used for general pile scene construction operations, especially the fol-
lowing behaviors are prohibited:
• Use equipment for personnel transfer;
• Use the device as a working platform;
• Use as a transport vehicle and crane;

• Use machine for leveling;

• Use device to move goods;
• Use the equipment in an explosion hazard area.
NOTE：
If the above prohibited operation occurs, any consequences arising therefrom shall be
borne by the customer, and the Company shall not assume any responsibility.
2.4.4 Keeping the rig in good service condition
NOTICE
When the machine is being cleaned, water can enter the machine and damage the control
elements.
• During drilling rig washing, protect the control elements. Do not flush them directly.
Making sure the rig is in a good operation status can decrease the occurrence of accidents, and
improve construction efficiency and equipment service life.
• Keep the cab clean and neat. The operator should make sure his or her personal items will not
affect operation.
• All relevant staff should get familiar with the location and meaning of the safety and warning
signs, and keep the signs intact and clear.
• Keep the machine clean. Remove all debris from the machine.
• Make sure all safety, alert, warning and informational decals are in place, not damaged, covered
up or removed.
• Make sure alarms and horns in good condition.
• Be careful of protecting control units when

cleaning the drilling rig.
• Without the written consent by the manufac-
turer, the user shall not do any modification
or accessory addition which affects the
safety of the machine, including installation
and modification of safety devices or pres-
sure adjusting valve.
• Make sure that all the protective equipment
are installed correctly on the required loca-
tion of the machine.
Fig 2-83

2.4.5 Safety on construction site
WARNING
People may fall into the grooves where the machine works in the process of construction, which
can cause serious personal injury or death.
• On the grooves of machinery and equipment construction, cover plates of sufficient strength
when construction is not started.
• During construction, ensure a safety distance between the machine and the groove, for exam-
ple, the machine is 1 m (3.28 ft) to 2 m (6.56 ft) from the groove, to prevent groove collapse,
and the falling of persons or objects into the groove.
• Secure your work area with safety fencing,

security markings or designated safety
personnel.
• Cover the bore hole with a cover plate with
enough load-bearing capacity. Set warning
decals near the cover plate to indicate the
danger.
• The power supplies and electric circuits on
the construction site shall conform to the
current industry standards.
Fig 2-84
• The construction site shall be equipped with

good surrounding illumination.
• Fully examine the area for any unusual con-
ditions that could be dangerous before
starting any operations.
• Before starting any work operations, or
maintenance and repair procedures, make
sure all personnel are at a safe distance
away from any point on the machine.
• If they must go near, signal them to stop
where they are, lower all work equipment to
the ground, set the work equipment hy-
draulic lock lever in the locked position and
shut the engine down.
Fig 2-85

• Before moving the machine, make sure there is nothing in the procedure of travel. Make sure
the Kelly bar is out of the ground and secured before moving.
• Before raising the mast, make sure it is clear of tools or objects that could fall. Make sure hy-
draulic hoses are not entangled with other parts.
• When leaving the job site, always lower all work equipment to a safe position, set controls to
neutral position and lock.
• Always park the equipment in a stable, level area, lower work equipment to a safe position, lock
the controls and stop the engine before leaving the cab.
• Use extra caution when working near banks

or on grades to avoid rolling over.
Fig 2-86
2.4.6 Signals to control operation
When working with another person on a work site, make sure that all personnel involved under-
stand all hand signals that are to be used. The operator shall respond to operating signals from on-
ly the proper signal person. But, the operator must obey a stop signal from anybody at any time.
The flagman shall stand in a safe location,

where he can view all the operation sites.
Fig 2-87

Attention: One arm stretches up and keep

hand opening.
Fig 2-88
Stop in emergency: The two arms stretch

out and keep waving.
Fig 2-89
Start moving: One arm stretches up and

keep waving.
Fig 2-90

Show more room for moving: Put the two

hands at level near the chest, showing there
is still some horizontal distance before stop-
ping moving.
Fig 2-91
Stop moving: Arms stretch out horizontally
Fig 2-92
Move forward slowly: Keep arms at level

with palms rearward and wave slowly.
Fig 2-93

Retreat slowly: Keep arms at level with palm

center forward and wave slowly.
Fig 2-94
Show more room for moving: Put the two

hands at level near the chest, showing there
is still some horizontal distance before stop-
ping moving.
Fig 2-95
Move in the right direction: Keep the back

of left hand up, with the thumb showing the di-
rection for moving
Fig 2-96

Move in the left direction: Keep the back of

right hand up, with the thumb showing the di-
rection for moving.
Fig 2-97
Turn in the right direction: Right thumb

shows turning direction with left hand circling.
Fig 2-98
Turn in the left direction: Left thumb shows

turning direction with right hand circling.
Fig 2-99

Lift the load: Right up, left hand moves up

and down before the chest.
Fig 2-100
Lower the load: Right palm down, left hand

moves up and down before the chest.
Fig 2-101
Crawler extends: Lift the arms, with fists

clenched slightly and the two thumbs pointing
out.
Fig 2-102

Crawler retracts: Lift the arms, with fists

clenched slightly and the two thumbs pointing
inwards.
Fig 2-103
2.4.7 Danger areas of drilling rig
WARNING
Abrupt swinging or rollover due to instability can cause severe personal injury or death.
• Set a warning sign if required to prevent unwanted persons from approaching the dangerous
areas.
• The drilling rig operator shall warn others to keep out of the dangerous areas.
The danger areas are defined as follows.
Danger area within which the drilling rig

does swing movement.
A B
Fig 2-104
A. 5 m (16.4 ft) B. 3 m (9.84 ft)

Danger area within which the drilling rig

moves. E
C D
Fig 2-105
C. 5 m (16.4 ft) E. 1 m (3.28 ft)

D. 5 m (16.4 ft) F. 1 m (3.28 ft)
2.4.8 Avoiding tipping over
WARNING
If there is insufficient stability, the equipment can tilt and fall over. This can result in serious or fatal
injuries to persons in the vicinity of the equipment.
• Always ensure the stability of the equipment. If there are any doubts as to the stability of the
equipment, stop work immediately.
Tipping over may occur in the following

conditions:
• The drilling rig is traveling on unstable or
sloping grounds, including backfill, slope,
suspended land, ravines, drainage, land-
slides, embankment.
Fig 2-106

• The winch is overloaded.

• Sudden acceleration or deceleration in
moving, sudden upper carriage swing and
whole vehicle rotation.
Fig 2-107
When the drilling rig is at its normal traveling position, the operator shall look towards the uphill di-
rection when traveling up a slope. He shall look towards the downhill direction when traveling down
a slope. Such requirement is aimed to keep the rig's centre of gravity as far back as possible to en-
sure that sudden movement of centre of gravity does not lead to the rig's instability.
Before traveling up or down a slope, adjust the mast’s inclination angle. Avoid change of direction
and motion on a slope. Do not stop the vehicle or perform swing operation when traveling up or
down a slope. Pay attention to the mast’s inclination angle when traveling up a slope. Over inclina-
tion may make the drilling rig tilt backwards.
Before driving the drilling rig, put work unit, Kelly bar, drilling tool to a lower location.
When the drilling rig is operating on a work site with slopes extend the crawler to its utmost width
(for rigs with this function). At this moment, the maximum grade of slope on the ground is 2°, only
suitable for solid and rigid ground.
Do not reduce the speed suddenly when traveling down a slope. Before passing dangerous
ground, be sure to check the grade of slope and whether the ground is solid enough. Make judg-
ment and selection on the routes and ground in advance, try your best to avoid dangerous ground.
Level sloping and sinkable ground in advance. Ensure the drilling rig’s requirements for inclination
angle are met and the ground is rigid enough to bear the drilling rig.
When working or traveling on the frozen ground, pay attention to the effects of temperature and
pressure on the ground.
2.4.9 Before entering the cab
CAUTION
Risk of accident!
If the cab door is in unlocked position, it could move automatically, leading to the operator’s dis-
traction or even causing injury.
• Always keep the cab door in locked position.

Before entering the cab, be sure to remove mud and grease from shoes.
Examine the rear view mirrors. If it is damaged, replace it with a new mirror. Clean the surface of
the mirror and adjust the angle so that the view to the rear of the machine can be seen by the oper-
ator clearly from the operators seat.
Adjust the seat and console so you can easily

access all controls from the seat position.
Examine the seat belt for correct operation,

damage, wear and age condition. Examine
the seat belt mounting points for damage or
looseness. If damaged or loose, have it re-
paired immediately.
Fig 2-108
2.4.10 Before starting the engine
• Examine the meters. Set all the control lev-

ers in neutral position. Examine the work
conditions of the lights on the machine.
• Examine the adjacent area of the machine.
Examine for blockage, looseness, leakage,
and damaged or worn parts.
• Do not start the engine if the ignition switch
DANGER
or lever is attached with warning tags.
Fig 2-109 Warning Tag

• Before starting the engine, set all the levers

to the neutral position.
• Set the Safety lock lever (hydraulic lock lev- 1
er) to locked position (2).

• Operate the engine in the well-ventilated
environment to avoid breathing the exhaust
gas.
2
• Heat the engine in cold weather. If the elec-
trolyte is frozen, melt it before recharging
and starting the engine.
Fig 2-110 Safety Lock Lever
2.4.11 Before operating the machine
• Clear all obstacles.

• Make sure that all persons not involved in operation keep clear off the dangerous areas.
• Be familiar with dangerous terrains near the machine, for example cable trench and backfill.
• Lock the door and window open or closed.
• Adjust the rear-view mirror to enhance the visibility.
• Make sure that horn and all alarms on the machine are in good work condition.
• Before moving the machine, examine the relative positions of upper carriage.
• Connect the seat belt.
• The right traveling direction: front idlers (1)

are in the front under the cab, while travel-
ing drives (2) are at the rear.
• When the cab is in its normal traveling posi-
tion, move the machine forward by pushing
the pedals forward and move it rearward by
pushing the pedals rearward. Push the left
pedal, the left track moves and the machine
turns in the right direction. Push the right 1 2
pedal, the right track moves and the ma-
Fig 2-111
chine turns in the left direction.
1. Front idler 2. Traveling drive
• When the guide wheels are behind the cab, all pedal movements and corresponding machine
movements reverse the movements at the normal traveling position.

2.4.12 Drilling rig operation
• The operator must sit on the cab seat to operate the machine.
• When the drilling rig is traveling, especially on uneven or rocky ground, the mast may sway verti-
cally or horizontally. Make sure that the mast’s swaying range does not exceed the specified
value.
• Make sure that there is no one staying within the operation radius before operation.
• Do not do any operation before the job site is clear.
• Do not drive the machine near objects, cliff or hole edges. Keep a safe distance to areas with
risks of landslide.
• Do not operate the machine in bad weather.
• Do not move the mast while moving the drilling rig.
• Do not turn the equipment quickly.
• Before turning the swing system, check if there are obstacles within the reach of drilling tool and
mast, if they are high enough off the ground. Make sure that ropes and mast do not hit other
items.
• When the drilling rig is traveling and before turning upper carriage, tilt the mast rearward to a
certain angle in order to increase stability.
• Do not change the movements suddenly.

• For the minimum distance to obstacles, ad-
here to national and local construction
safety laws and regulations.
• Place wooden or iron plates under the
tracks if the ground is soft or tends to sink.
• Supply sufficient illumination if the drilling
rig has to be operated at night.
Fig 2-112

2.4.13 Construction of drilling rig
WARNING
Attempts to tilt the mast, swing or move the machine before getting out of the groove or hole can
result in serious personal injury or death.
• It is forbidden to tilt the mast, swing or move the machine before getting out of the groove or
hole.
• If the ground is soft, consolidate and level

the ground in advance before construction.
Set thick steel plates if necessary. Thick-
ness of steel plate should be no less than
20 mm (7.87 inch), the length and width
should be 1 m (3.28 ft) longer than those of
the crawlers.
• If construction is necessary on a slope,
make sure that inclination angle is within Fig 2-113
the allowed range.
• Keep the machine at the travel lock status during drilling.

• Before mast movement, make sure that the boom is higher than the cab to avoid the cab being
crushed.
• During operation, upper carriage and undercarriage must be kept in parallel.
• Do not dump soil by pulling drilling tools up and down quickly or hitting the bucket upon other
objects.
• When turning and dumping soil, pay attention to the bucket and boom height avoid collision.
• Stop operation at once if the drilling rig tilts.
• When the machine is down for mainte-

nance, pull the drill bucket out the hole to
avoid being buried.
• When the inclination angle of chassis does
not exceed 2°, construction on uneven
ground can be done by adjusting mast
verticality.
• Always examine the wire ropes on the main
winch drum and rewind them if they get
twisted. Fig 2-114

• Always examine Kelly bar working condition. If it can not extend or retract normally, or other ab-
normal conditions occur, report it at once and Do not handle at will.
• Always examine the working condition of rope swivel. If wire ropes are twisted, examine the rope
swivel, and replace it when necessary.
• When driving the machine in the job site, keep a safe distance from the complete holes and blind
holes.
• Keep safety distance between the rig and the bore hole to avoid hole collapse and machine
turnover.
• Do not try to raise or lower mast, move upper carriage or move the rig when the Kelly bar is still
in the hole.
2.4.14 Winch operation
WARNING
Improper loading/unloading can lead to tipping over of the machine. Persons in the vicinity of the
equipment could be hit and receive serious or fatal injuries.
• When lifting the load, ensure that it is placed ahead of the mast and the angle between wire
rope and mast does not exceed 15°. When the load is placed at the offside front of the mast, ro-
tate the drilling rig to move the load to the extension line of vertical axle of the drilling rig.
• The winch is equipped on the drilling rig to perform hole-drilling operation and shall not be used
other than such purpose.
• Winching operation shall comply with relevant laws and regulations where the drilling rig
operates.
• The maximum lifting capacity of the winch shall be made clear. Overloading must be prohibited.
• The lifted load shall be tied up firmly. Do not lift items slantwise. Do not lift items that are ex-
truded together or buried in the soil or has odd accessories.
• When the load is about to depart from the ground, make sure that the hoisting wire rope and load
are perpendicular to the ground. It can avoid vibration when lifting the load from the ground.

2.4.15 Parking safety
1. Always park the machine in a flat, stable

N
level location away from moving equipment,
pedestrians or traffic.
2. Put the left and right travel levers to neutral

position (N) before parking your machine. N
Fig 2-115 Natural Position
N. Neutral position
3. Move the safety lock lever to locked 1

4
position.
2
4. Stop the engine.
5.Turn the engine start switch to the OFF posi-

tion (1) and remove the key.
3
Fig 2-116 Engine Start Switch
1. OFF position 3. START position

2. ON position 4. HEAT position

6. Turn the battery disconnect switch to the

OFF position (5). 6
Fig 2-117 Battery Disconnect Switch
5. OFF position 6. ON position
2.4.16 Safety when cleaning the machine
• If cleaning the machine, do not use flamma-

ble or caustic cleaning agents. Use only ap-
proved non-flammable cleaning solvents to
clean the machine or parts.
• Do not use high-pressure steam cleaners to
clean the machine. Steam cleaners will
damage the paint, hoses or electrical sys-
tem. Always use high-pressure hot water
and mild grease cutting soaps to clean the
machine. Fig 2-118
• Do not pressure-wash or flood the operator cab of the machine.

• Always lubricate the machine thoroughly after cleaning to push out any water or soap residue.
• After cleaning, examine for leakage of all the fuel pipeline, engine oil line, and hydraulic oil line.
Examine the joints for looseness, cracks, or damage.

2.4.17 Drilling rig dismantling
WARNING
Failure to disassemble and assemble the machine according to the manual could cause severe
personal injury or death.
• Strictly comply with the requirements of the operation manual regarding the machine. Other-
wise, serious losses and injury may occur.
• Use proper tools and allocate adequate staff and support accessories. Crane and sling shall
have enough load-bearing capacity.
• All the grounds should be even, solid and open. There should not be obstacles like high-voltage
lines overhead.
• Be sure to seal the hydraulic pipes well and avoid oil leakage. Pay attention to the oil pipe’s mini-
mum bending radius. Do not bend oil pipes.
• The dismantled components should not be placed on the ground. Put crosstie or plank on the
ground in the first place. Dismantled small parts and pieces shall be placed in a designated
location.
2.4.18 Safety guidelines for transport
WARNING
Risk of accident!
When loading the machine to the trailer or unloading it from the trailer, if the gravity center of the
drilling rig strays, moving or rollover can cause personnel injury.
• Do not adjust the rig’s direction or continue traveling after the drilling rig strays from the axle. In
this case, drive the drilling rig to its initial position, and load it to or unload it from the trailer
again after changing the direction.
• Select a vehicle with sufficient load-bearing capacity for transport, which must meet related
transportation standards on special vehicles.
• Disassemble the machine on solid and level ground.
• The platform must be wide enough and the

inclination angle (1) must not exceed 15°.
The ramp must be clean, free of snow and
oil. 1
Fig 2-119
1. Inclination angle

• When driving the machine on or off the trailer, a signalman should provide support.
• When driving the machine on or off the trailer, pay attention to the location of mast to avoid colli-
sion. Make sure that the machine and trailer are in the same line, and tracks have the largest
contact area. The front idlers must be near the end of the trailer. Travel slowly onto the trailer at
a constant speed.
• Install the locking bar to avoid upper carriage swing.
• When going through bridges and tunnels, make sure the maximum load of bridge and the size of
tunnel meet requirements.
• When transporting the drilling rig on a highway, connect it tightly and follow the requirements of
transportation laws and regulations. Avoid sudden stop or sharp turn.
• Only use lifting equipment and lifting slings that have sufficient bearing capacity.
• If the machine required to be shipped by sea, anticorrosion treatment is necessary.
2.4.19 Machine maintenance
• All maintenance to be performed on this machine must be by trained and authorized personnel.
It is important to follow all maintenance procedures and safety information.
• Always be aware of the hazards when performing maintenance on this machine.
• For maintenance work, the equipment's danger area must be made safe by closing off a suffi-
ciently ample area. Any fittings, components, or tools which are left down must not impede the
traffic routes and must be secured by appropriate means against sliding, rolling, falling over, or
falling down.
• Maintenance work must always be performed on horizontal and level ground with a sufficiently
stable surface.
• Before performing any maintenance, service or repair on the machine, be sure to remove the
ignition key and hang warning decals reading "DO NOT OPERATE" signs on the drilling rig's
key switch, levers or control panel, in order to avoid injury incurred by wrong operation.
• When performing maintenance and service, choose the adequate device to ensure good
operation.
• When handling lubricants, grease, or other chemical substances, abide by safety regulations for
corresponding products.
• Before welding on the machine, the positive and negative electrodes of the battery must be dis-
connected, otherwise it will cause serious accidents such as wire harness burning, battery ex-
plosion, and may also burn down the electrical components of the machine.
• When performing repairs and maintenance, the correct tools and devices required should be
fully prepared and ensure good use.

2.5 Environment Protection

2.5.1 Proper waste disposal
NOTICE
Incorrect handling of used oil can cause environmental pollution.
• Do not spill any oil on the ground.
• Put your used oil in a clean plastic container with a tight lid. Do not keep used oil in a container
that once held chemicals, food, or beverages.
• Do not mix the oil with anything else, for example antifreeze, solvent, or paint.
• Take used oil to a servicing station or other location that collects used oil for recycling.
• Incorrect waste disposal will do harm to the

environment and the ecosystem.
• Potentially dangerous materials include hy-
draulic oil, fuel, coolant, brake fluid, filter
and so on.
• Environment protection laws and regula-
tions can be different from region to region.
For correct waste disposal process, refer to
local environment protection or recycling
center or your designated dealer.
Fig 2-120
2.5.2 Mud pollution
• Prepare the mud pit and the discharging

system based on the construction situation.
• Clean the work site after construction is
completed. Handle the mud by the local
regulations.
Fig 2-121

2.5.3 Fuel discharge
• Stop the engine or lower its power at work

intervals in order to decrease the discharge
of waste gas or noise.
• The defective fuel not only does harm to the
machine, but also discharges large amount
of harmful gas and dust, causing pollution
to the environment.
Fig 2-122


SR305RS10Rotary Drilling Rig Technical Specifications
Technical Specifications
3 Technical Specifications.............................................................................................3-1
3.1 Overall Dimensions...............................................................................................................3-3
3.2 Performance Parameters.....................................................................................................3-4
3.3 Wire Rope Specifications.....................................................................................................3-5

Technical Specifications SR305RS10Rotary Drilling Rig

3.Technical Specifications
3.1 Overall Dimensions
F F
D
A B C
Fig 3-1 Overall Dimension Diagram (mm)

Item Unit Data

A. Swing Radius mm 4465
B. Drilling Tool Working Range mm 3835~4535
C. Crawler Extending mm 3460~4760
D. Crawler Width mm 800
E. Rig Height mm 26395
F. Left/Right Inclination Angle ° 3
G. Rotary Drive Working Range mm 6000
3.2 Performance Parameters

1. Base machine
Item Data
Max. Output Torque 360 kN·m
Max. Borehole Diameter 2500 mm
Max. Drilling Depth 100 m/65 m
Drilling Distance (Distance from swing center) 3835 mm~4535 mm
Max. Pulling Force 335 kN
Max. Crowding Force 275 kN
Working Weight (with standard drilling tools) 105 ton
2. Chassis
Item Data
Chassis Model SY360RE
Engine Model 6WG1
Engine Power 300 kW/1800 rpm
Width of Track Shoes 800 mm
3. Rotary drive
Item Data
Max. Output Torque 360 kN·m
Drilling Rev 6 rpm~29 rpm
4. Main winch
Item Data
Pulling Force (first layer) 330 kN
Rope diameter 36 m/min
Max. Pulling Speed 72 m/min

5. Auxiliary winch
Item Data
Pulling Force (first layer) 90 kN
Rope diameter 20 m/min
Max. Pulling Speed 70 m/min
6. Crowd cylinder
Item Data
Max. Crowding Force 275 kN
Stroke of Crowd System 6000 mm
7. Mast inclination
Item Data
to Left 3°
to Right 3°
Forward 5°
Backward 90°
3.3 Wire Rope Specifications

1. Main winch wire rope
Item Data
Standard Length 107 m
Nominal Diameter 36 mm
Nominal Tensile Strength 1960 MPa
Min. Breaking Force 1185 kN
Surface Condition Ungalvanize
Structure Classification Rotation resistant - 35W×K7
Lay and Direction ZZ
Weight 6.614 kg/m
Operative Norm EN12385
2. Auxiliary winch wire rope
Item Data
Standard Length 55 m
Nominal Diameter 20 mm
Nominal Tensile Strength 1770 MPa
Min. Breaking Force 252 kN

Item Data
Surface Condition Ungalvanized
Structure Classification Non rotation resistant–6×29Fi
Rope Core IWR
Lay and Direction SZ
Weight 1.67 kg/m
Operative Norm GB8918
NOTE：
• The main rope length is only suitable for the Kelly bar of standard configuration.
• When you have to change the main rope, auxiliary rope or the crowd rope, ensure that
the rope model must be the Sany designated one. Failure to do so, Sany will bear no li-
ability for any consequence caused by rope accident.

SR305RS10Rotary Drilling Rig System Function
System Function
4 System Function .............................................................................................................4-1

4.1 General Structure .................................................................................................................4-3
4.2 Machine Description .............................................................................................................4-5
4.2.1 Traveling mechanism .................................................................................................4-5
4.2.2 Upper carriage.............................................................................................................4-5
4.2.3 Main winch ...................................................................................................................4-6
4.2.4 Auxiliary winch.............................................................................................................4-7
4.2.5 Boom mechanism .......................................................................................................4-8
4.2.6 Mast assembly.............................................................................................................4-8
4.2.7 Rotary drive..................................................................................................................4-9
4.2.8 Kelly bar..................................................................................................................... 4-10
4.2.9 Drilling bucket ............................................................................................................4-11
4.3 General View of the Operator’s Cab ............................................................................... 4-12
4.4 E-pad.................................................................................................................................... 4-13
4.5 Operation Control Panel.................................................................................................... 4-15
4.6 Engine Ignition Switch and Engine Speed Control Dial................................................ 4-17
4.7 Operation Instruction of Freefall Pedal ........................................................................... 4-18
4.8 Safety Lock Lever .............................................................................................................. 4-19
4.9 Traveling Lever/Pedal........................................................................................................ 4-20
4.10 Left and Right Operation Handle ................................................................................... 4-20
4.10.1 Left operation handle............................................................................................. 4-20
4.10.2 Right operation handle .......................................................................................... 4-21
4.10.3 Directional function of operation handle ............................................................. 4-21
4.11 Mast Lever......................................................................................................................... 4-23
4.12 Air Conditioning System.................................................................................................. 4-25
4.12.1 Control panel .......................................................................................................... 4-25
4.12.2 Operation method .................................................................................................. 4-25
4.13 Radio.................................................................................................................................. 4-28
4.14 Display............................................................................................................................... 4-31
System Function SR305RS10Rotary Drilling Rig
4.14.1 Start-up interface ................................................................................................... 4-31

4.14.2 Drilling operation interface.................................................................................... 4-32
4.14.3 Menu interface........................................................................................................ 4-36
4.14.4 Common function-function ................................................................................... 4-38
4.14.5 Common function-switch ...................................................................................... 4-41
4.14.6 Common function-operation................................................................................. 4-43
4.14.7 Common function-calibration ............................................................................... 4-46
4.14.8 Parameter calibration interface............................................................................ 4-48
4.14.9 Parameter calibration interface I.......................................................................... 4-50
4.14.10 Parameter calibration interface II ...................................................................... 4-52
4.14.11 Locking device parameter calibration interface ............................................... 4-54
4.14.12 Construction method interface........................................................................... 4-56
4.14.13 Central lubrication interface ............................................................................... 4-59
4.14.14 User settings interface ........................................................................................ 4-60
4.14.15 User setting-language......................................................................................... 4-61
4.14.16 User setting-time setting..................................................................................... 4-62
4.14.17 User setting-brightness....................................................................................... 4-63
4.14.18 User setting-handle interface............................................................................. 4-64
4.14.19 Service assistant interface ................................................................................. 4-66
4.14.20 Machine configuration interface ........................................................................ 4-67
4.14.21 Maintenance interface......................................................................................... 4-68
4.14.22 GPS information interface .................................................................................. 4-70
4.14.23 History query interface ........................................................................................ 4-71
4.14.24 Running information interface............................................................................ 4-72
4.15 Electric Cabinet ................................................................................................................ 4-73
4.16 Fuse ................................................................................................................................... 4-74
4.17 Limit Switches................................................................................................................... 4-76

4.System Function
4.1 General Structure
17
18
16
19
15
14
13
20
12
11
10
9
8
7
21
6
5
3 4 22
2 23
24
Fig 4-1 General Structure

Table 4–1 Function descriptions
Sn Name Function
Travelling Controlled by hydraulic system, could achieve forward traveling,
1
Mechanism backward traveling, left steering, right steering.
2 Counterweight Enhance the stability of the drilling rig.
3 Main Winch Used for lifting and lowering Kelly bar.
4 Upper Carriage House the engine, hydraulic system, control system, and the cab.
A moveable link between the triangle and the upper carriage. Ad-
5 Boom
just the distance between the mast and the upper carriage.
6 Boom Cylinder Control the movement of boom.
Rotate synchronously with the boom to keep the triangle parallel
7 Support Rod
with the upper carriage.
8 Triangle Used to place the auxiliary winch.
9 Auxiliary Winch Auxiliary lifting appliance used for load handling.
10 Backstay Cylinder Support the mast and allow its inclination to be adjusted.
Main Winch Wire
11 Used to lift and lower the Kelly bar.
Rope
12 Guide Pulley Guide for main rope from drum to pulley yoke.
Auxiliary Winch
13 Used for rigging operations and load handling.
Wire Rope
14 Middle Mast Guide for Kelly bar and rotary drive.
15 Upper Mast Guide for Kelly bar.
16 Pulley Yoke Wire rope sheave, support and divert wire ropes.
17 Rope Swivel Connect main winch wire rope and Kelly bar to prevent rope twist.
18 Kelly Guide Guide Kelly bar and mount bearing.
It transmits torque and rotary movement from rotary drive to the drill
19 Kelly Bar bucket. It is telescopic tubular shape drilling bar. The maximum
hole depth depends on the whole length of Kelly bar.
Provide downward pushing and upward pulling force for the rotary
20 Crowd Cylinder
drive.
Provide rotary movement and torque for Kelly bar and drilling
21 Rotary Drive
bucket.
22 Mast Pivot A swivel link between mast and triangle.
23 Lower Mast Used to guide rotary drive
24 Drilling Bucket Erode and convey soil.

4.2 Machine Description

4.2.1 Traveling mechanism
Traveling mechanism carries the upper car-

riage and moves it from one drilling spot to the
next. The traveling mechanism is mainly com-
posed of track roller bracket, hydraulic motor,
reducer, sprockets and tensioning device,
tracks, track wheel and idlers. Traveling
mechanism is controlled by hydraulic system.
It can achieve forward traveling, backward
traveling, left steering and right steering.
Fig 4-2 Traveling Mechanism
4.2.2 Upper carriage
Upper carriage is mainly composed of swing

unit, hydraulic pump assembly, operator’s
cab, engine, counterweight, hydraulic oil tank,
and fuel tank.
Fig 4-3 Upper Carriage

4.2.3 Main winch
Through the winding/unwinding of the related

rope (1), the main winch (2) controls the up/
down movements of the Kelly bar (3) and the
drilling tool connected to the bar.
Fig 4-4 Main Winch
1. Wire rope 3. Kelly bar

2. Main winch

4.2.4 Auxiliary winch
Through the winding/unwinding of the related

wire rope (1), the auxiliary winch (2) is used to
lift and handle objects.
Fig 4-5 Auxiliary Winch
1. Wire rope 2. Auxiliary winch

4.2.5 Boom mechanism
Boom mechanism is mainly composed of

boom (1), triangle (2), support rod (3) and
boom cylinder (4).
1 2
4 3
Fig 4-6
1. Boom 3. Support rod

2. Triangle 4. Boom cylinder
4.2.6 Mast assembly
Main feature of the mast is to guide the crowd sledge and the attached components of the process
equipment. It mainly consists of the following parts:
1 2 3 4 5
Fig 4-7 Mast Assembly
1. Lower mast 3. Middle mast 5. Pulley yoke

2. Guide pulley yoke 4. Upper mast 6. Crowd cylinder

4.2.7 Rotary drive
Rotary drive is a very important component of

drilling rig. It provides rotary movement and
torque for Kelly bar and drilling bucket. It is
composed of hydraulic motor, reducer, reduc-
er box, buffer unit, crowd sledge, connecting
plate, flange or casing driver.
Fig 4-8 Rotary Drive

4.2.8 Kelly bar
Two kinds of bars:

1
• Friction bar
• Interlocking bar 2
The difference between the two types is that

the internal elements of the friction bars trans-
mit the thrust force each other by friction,
while those of the locking bars transmit this
force through special locking recesses.
4
5
Fig 4-9 Kelly Bar
1. Kelly eye 4. Spring seat

2. Kelly bar flange 5. Kelly bar spring
3. Outer key 6. Drive stub

4.2.9 Drilling bucket
The main function of the drilling bucket is to

drill and convey the soil.
Fig 4-10 Drilling Bucket

4.3 General View of the Operator’s Cab
1 2 5 6 7 8
3 4
14
13
12
11 10
Fig 4-11 Internal Structure of the Operator's Cab
1. Display 6. Engine speed control 11. Safety lock lever (Hydraulic lock lever)
dial
2. E-pad 7. Engine Ignition Switch 12. Chassis level
3. Cigarette lighter 8. Operation control 13. Traveling pedal
panel
4. Emergency stop 9. Air–condition panel 14. Freefall pedal
switch
5. Mast lever 10. Radio control panel

4.4 E-pad
E-pad is located beneath the display. It can
realize the controls of key components such
as rotary drive, mast and crawlers.
Fig 4-12 E-pad
Table 4–2 Button function
Button Name Function
E-pad activation Activate the function of E-pad.
Standard gear (Ro- Default gear (suitable for all common

tary drive) formations).
Rock gear (Rotary Press this button to enter rock drilling mode
drive) (suitable for rock formations).
Press this button to enter self-adaptation

Self-adaption gear mode (suitable for complicated
(Rotary drive) formations).
Note: Not used in this model.
Press this button to unlock the functions of

Mast adjusting
auto erecting/auto lowering/auto
activation
adjusting.

Table 4–2 Button function (continue)
Auto erecting
Press the button to realize mast auto erect-
ing and lowering, see: Chapter 5 Opera-
tion, “Raising and lowering the mast”.
Auto lowering
Press this button to realize mast auto ad-

justing, see: Chapter 5 Operation,
Auto adjusting
“Adjusting mast to verticality” on page 5-
39.
Default to locked mode. Press it to switch
Travel unlock/lock to unlocked mode.
switchover Note: Only unlock this function during
travelling.
Derricking/crowding Default to derricking mode. Press it to

switchover switch to crowding mode.
Auxiliary winch Defaults to auxiliary winch locked mode;

unlocked press to unlocked.
Main/auxiliary winch Default to main winch mode. Press to

switchover switch to auxiliary winch mode.
Press the button and hold to extend or re-

Crawler extension/
tract the crawlers. Release it to block this
retraction
function.
Press the button and hold to extend or re-

Masthead cylinder
tract the masthead cylinder. Release it to
extension/retraction
block this function.


Press the button and hold until the tension-
Tensioning cylinder ing cylinder extends/ retracts to the desired
retract/ extend position; release the button, the movement
stops.
Press the button and hold until the outrig-
Outrigger cylinder ger cylinder extends/ retracts to the desired
retract/ extend position; release the button, the movement
stops.
4.5 Operation Control Panel

Operation control panel is on the right side of cab’s seat. See “General View of the Operator’s
Cab” on page 4-12
1 2 3 4 5 6 7 8
Fig 4-13 Operation Control Panel
1. Front lamp switch 4. Front wiper switch 7. Backup switch

2. Rear lamp switch 5. Front washer switch 8. Backup switch
3. Main winch lamp switch 6. Backup switch
Table 4–3 Button function
No. Button Name Function
Front lamp Used to control the toplight. Push upward, the light
ON
1
switch lights up. Push downwards, the light goes out.
OFF
Rear lamp Used to control the rear lamp. Push upward, the lamp
ON
2
switch lights up. Push downwards, the lamp goes out.
OFF

No. Button Name Function
Main winch Used to control the main winch lamp. Push upward, the
ON
3
lamp switch lamp lights up. Push downwards, the lamp goes out.
OFF
Used to control front wiper. Push downward to slow

down the movement. Push upward to speed up the
movement. Reset the button to original position, the
Front wiper ON
4 movement stops.
switch OFF
Note: If the window wiper does not operate with the

switch in the ON position, turn the switch off
immediately.
ON
Front washer Used to control washer fluid. Press the switch, the
5
switch OFF washer fluid will spray from the nozzle.
6 Backup switch Not used in this model.
ON

OFF

4.6 Engine Ignition Switch and Engine Speed Control Dial
WARNING
During traveling, if change the engine speed suddenly, machine stability could be adversely af-
fected which could cause personal injury or possibly death.
• Never change the travel speed during machine traveling.
Engine speed control dial and engine ignition switch are located on the right panel in the cab. See
“General View of the Operator’s Cab” on page 4-12.
Name Operation procedure

Decrease: Turn the dial counterclockwise to decrease the en-
gine speed.
Increase: Turn the dial clockwise to increase the engine speed.
Gear selection:
Engine • I (idle): Travel on rough surfaces or on soft surfaces or during
speed control loading or unloading the machine
dial
• L (Light): Small diameter and soil layer construction
• E (Economic): Standard working conditions
• H (Heavy): Rock drilling working conditions
• P (Powerful): Complex working conditions
Before start, turn the engine speed control dial to I position.
HEAT: When start in low temperature, first turn the switch to
heat position to preheat the machine for 30 min.
OFF: Insert or remove the engine start switch only while the
engine start switch is in OFF position. Turn the start switch to
Engine igni-
OFF position to shut down the engine.
tion switch
ON: Turn the engine start switch to ON position to activate all
circuits.
START: Turn the engine start switch to START position to start
the engine. Release the key after engine starts. The start
switch will return to ON position.

4.7 Operation Instruction of Freefall Pedal

The freefall pedal is located on the right side
of the travelling pedal in the cab.
Fig 4-14 Freefall Pedal
Operation instructions:
1. Lower main rope, until the “rope slack pre-

vention” function is activated.
2. When this function is activated, the main

Fig 4-15 Freefall Pedal Operation
winch rotates counterclockwise automatically
and stops until the pre-tensioning force is
reached.
3. Step the pedal downward, main winch free-

fall function is activated.
4. Release the pedal, this function is

deactivated.
NOTE：
• Check if the main winch line pull compensation value on parameter calibration interface
is normal; if not, reset and recalibrate, see “Parameter calibration interface” on page 4-48.
• Check if the main rope load on parameter calibration interface set by the operator is nor-
mal (the standard value is 4500 kg), see “Parameter calibration interface” on page 4-48.
• When the “rope slack prevention” function fails, press “rope slack prevention” deacti-
vated switch only in very urgent circumstances. In this case, freefall function can be only
used for temporary operation.
• Before performing crowd drilling operation, first step down freefall pedal, start drilling
only when this function is activated.

4.8 Safety Lock Lever
NOTICE
Risk of damage to the equipment.
When you enter and exit the control room, if the safety lock lever is not swung to the locked posi-
tion (2), it is easy to touch the handle by mistake, causing the machine to operate, which can re-
sult in damage to the equipment.
• Be sure to swing the safety lock lever to the locked position (2) when entering or exiting the
control room.
The safety lock lever ( hydraulic lock lever)

is a safety lock device that prevents mi-
1
soperation during non-working hours by
locking the hydraulic system.
• Push forward the handle of the safety lock

lever (the red shift lever rises). The hydraul-
ic system is unlocked at this time. The hy- 2
draulic system of the whole machine can
work properly.
• Pull backward the handle (the red shift lever
falls) to lock the hydraulic system. At this
time, drilling rig operations are disabled. 1. Unlocked position 2. Locked position

4.9 Traveling Lever/Pedal

The travel lever and pedal is an integrated de-
vice. Press the pedals and push or pull the
levers can achieve the traveling and steering
operation. For detailed operation, see: Chap-
ter 5 Operation, “Traveling operation”.
Fig 4-17 Traveling Lever/Pedal
4.10 Left and Right Operation Handle

4.10.1 Left operation handle
A button (PWM): Push up to make manual

A
swing effective and pull down for main rope B D
fast speed down C
B button: Main/auxiliary winch switchover
C button: Auto swing button
D button: Horn
Fig 4-18 Left Handle Diagram
A. Manual swing ef- C. Auto swing

fective/Main rope fast
speed down
B. Main/auxiliary D. Horn button
winch switchover
button

4.10.2 Right operation handle
E button (PWM): Push upward to activate

freefall. Pull downward to activate auto F
throwing. E G H
F button: Crowding/derricking switchover.
G button: Handle memory.
H button: Backup.
Fig 4-19 Right Handle Diagram
E. Freefall/auto G. Handle memory

throwing
F. Crowding/derrick- H. Backup
ing switchover
4.10.3 Directional function of operation handle
Table 4–4 Directional function of left operation handle
Left operation handle Process
Main winch mode: unwind the rope on the main

winch
Main winch mode: wind in the rope on the main

winch
Auxiliary winch mode: unwind the rope on the

auxiliary winch
Auxiliary winch mode: wind in the rope on the

auxiliary winch

Table 4–4 Directional function of left operation handle (continue)
Push up button A and push the handle left to

make the upper carriage move left
Push up button A and push the handle right to

make the upper carriage move right
Table 4–5 Directional function of right operation handle
Right operation handle Process
Crowd mode: move the crowd sledge down
Crowd mode: move the crowd sledge up
Derricking mode: lower boom mechanism
Derricking mode: lift boom mechanism
Turn rotary drive clockwise
Turn rotary drive counter clockwise

4.11 Mast Lever

Mast adjusting lever is on the right side of op-
erator’s seat.
Push the top button and move the lever to

start mast movement.
Fig 4-20 Mast Adjusting Lever
Table 4–6 Directional function of mast lever
Direction Process
Move the mast forward
Move the mast rearward
Move the mast leftward
Move the mast rightward
Move the mast to the left front
Move the mast to the right front

Table 4–6 Directional function of mast lever (continue)
Move the mast to the left back
Move the mast to the right back

4.12 Air Conditioning System

4.12.1 Control panel
C
8
1 2 3 4 5
6 7 9
Fig 4-21 Control Panel
1. OFF 5. AUTO 9. A/C

2. Fan speed 6. Recirculation air A. Present temperature
3. TEMP 7. Fresh air B. Air delivery level
4. MODE 8. LCD C. Air outlet mode
4.12.2 Operation method
1. OFF
Use this switch to switch off the fan and air conditioner.
Press this switch, the temperature and air delivery shown on the LCD display (a, b, c) disappear,
the indicator lights above the AUTO (5) and A/C (9) are off, and the air conditioner stops operation.
2. Fan speed
Use this switch to adjust the air.
Six air delivery levels are available for selection.
Air delivery level (b) is shown on the LCD (8).
• Press to increase.
• Press to decrease.

• Air delivery level is selected automatically under AUTO control.

Table 4–7 LCD display and air delivery
LCD display (b) Air delivery level
Low flow
Moderate flow -1
Moderate flow - 2
Moderate flow - 3
Moderate flow - 4
High flow
3. TEMP
Use this switch to control the temperature in the operator cab.
The temperature can be set between 18°C (64.4°F) and 32°C (89.6°F).
• Press to increase the temperature.
• Press to decrease the temperature.
• The temperature is usually set at 25°C (77°F).
Table 4–8 LCD display and function
LCD display (a) Present temperature

18.0°C Maximum cooling
18.5°C – 31.5°C Adjust temperature inside operator cab to the preset temperature
32.0°C Maximum heating
4. MODE
Use this switch to select air outlet mode.
• When the switch is pushed, the LCD will show the mode selected. The air will come out of the
outlets showed.
• The air outlet mode changes automatically under AUTO control.
Table 4–9 LCD display and air outlet mode
Air outlet mode

LCD dis- Air out- Air outlet
Air outlet mode Air outlet Air outlet Note
play (c) let for for de-
for face for feet
back frosting
Front outlet for Disabled in
⃝
face auto mode
Front and back
⃝ ⃝
outlets for face

Table 4–9 LCD display and air outlet mode (continue)
Air outlet mode

LCD dis- Air out- Air outlet
Air outlet mode Air outlet Air outlet Note
play (c) let for for de-
for face for feet
back frosting
Front and back
outlets for face ⃝ ⃝ ⃝
and feet
Air outlet for feet ⃝
Air outlet for feet Disabled in

⃝
and defroster auto mode
Air outlet for Disabled in
⃝
defroster auto mode
5. AUTO
This switch can be used to set air delivery level, outlets and fresh air or recirculation air automati-
cally according to the preset temperature.
• Pressing the switch, the indicator light above the switch comes on.
• Usually, pressing this switch and setting with the switch of TEMP (3) to a suitable temperature,
the air conditioner will operate automatically.
• Changing from AUTO control to manual control requires only setting the air delivery level, air
outlet mode and fresh air/recirculation air mode. The indicator light above the switch goes out.
• Air delivery level is selected automatically under AUTO control.
6. Recirculation air
• Press to select recirculation air.

The air inlet is closed. The air will recirculate in the operator cab.
Recirculation air It is suitable for fast cooling or heating of the operator cab. It is also used
when the external air is contaminated.
7. Fresh air
The default mode is fresh air.

• Press to select fresh air.
Fresh air is taken into the operator cab.

Fresh air
It is used to take in fresh air and defog.

8. LCD
LCD display shows the present temperature (a), air delivery level (b) and air outlet mode (c) during
operation.
Press OFF (1), LCD (8) disappears, and the operation stops.
9. A/C
This switch is used to switch on/off the air conditioner.
• When the fan is working (the LCD displays (b)), press the switch A/C (9) to start the air condi-
tioner. The indicator above the switch is on. Press this switch again to stop the air conditioner.
The indicator goes out.
• The air conditioner is disabled when the fan is switched off (air delivery mode disappears from
the LCD display).
4.13 Radio
1 2 3 4 5 6
7 8 9 10
Fig 4-22 Radio Control Panel
1. USB 5. TIME 9. VOL

2. AS/PS 6. LCD 10. POWER
3. FM/AM 7. PRESET STATION
4. SRC 8. TUNING

Table 4–12 Operation Description
No. Name Function

1 USB /
Press this button to start auto scan and preset stations.
• Auto scan:
When tuning in the radio, press this button to scan each preset
station.
2 AS/PS
• Preset stations:
When tuning in the radio, press this button to start the auto scan-
ning of current stations. Six radio stations that have the stron-
gest signal will be kept.
3 FM/AM Press this button to toggle the bands between FM and AM.
Press this button to toggle the sound effects in the order of VOL→
4 SRC
BAS → TRE→ BAL.
5 TIME Press time button to show current time.
6 LCD Show the band, radio frequency and current time.
PRESET In radio mode, 12 stations can be preset. Press one button and
7
STATION hold to keep the station on the related button.
• In radio mode, press tuning buttons to change channels.

8 TUNING • In time mode, press tuning buttons to reset time (hour and
minute).
9 VOL Press volume button to increase or decrease the sound volume.
10 POWER Press this button to turn on the radio.
Antenna
1
Follow the steps below to turn the antenna to
the lower position: A
1. Loosen the bolt (1) in order to put the anten-

na in position (A).
2. Tighten the bolt (1).
Fig 4-23
1. Bolt A. Position
Operation precautions
• Keep the volume at a level that you can hear the outer sound during operation.
• The penetration of water into the loudspeaker or radio can lead to unexpected trouble.

• Do not use benzol, diluent or other solvent to clean the control panel or push buttons. Soft dry
cloth shall be used for cleaning. If the device is too dirty, clean it with alcohol.
• When disconnecting or replacing the battery, the preset stations and the clock will be cleared.
Table 4–13 Radio Parameters
Name Parameters
Voltage 24 V negative ground
Output power 2×15 W
Impedance 8 Ohm
FM: 87.5 MHz to 108.0 MHz (step: 50 KHz)
Radio band
AM: 522 KHz to 1620 KHz (step: 9 KHz)
Tuning method ETR
Oscillation type Superheterodyne
FM: 10.7 MHz
Medium frequency
AM: 450 KHz
Dark current ≤ 5 mA
NOTE：
• Parameters of the internal circuit are subject to change, without prior notice, due to performance
improvement.
• Please power off before installing or removing the audio device.
• Before maintenance, be sure to cut off the power to prevent losses.
• Never remove the cover of the machine when it is powered, to prevent damages to the machine
due to presence of high voltage inside.
• Please adjust the volume in such a way that you can clearly hear the traffic signals (horn, whis-
tle) to ensure your safety.
• Keep the machine body from water or corrosion. Be sure to wipe the machine using a dry cloth.

4.14 Display
4.14.1 Start-up interface
Temperature conditions:
The display system can be guaranteed to operate at cab temperature ranging between -20 ℃ and
+65 ℃.
Fig 4-24 Start-up Interface

4.14.2 Drilling operation interface
13 14 15 16 17 18 19 20
1 21
2 22
23
3
24
4 25 26
27
10
11
12 28
29
Fig 4-25

Function descriptions:
No. Function description

Time and date
1 /
display
Locking recess posi- The value shows the distance between the inner key and the
2
tion display 1 nearest locking recess above.
Rotary drive position
3 The value shows the position of the rotary drive.
display
Locking recess posi- The value shows the distance between the inner key and the
4
tion display 2 nearest locking recess below
The default state is red. Press it, the color will turn green.
Calibrating lock recess position: Lock inner key with locking
Locking recess posi-
5 recess. Press locking recess position calibration button, the
tion calibration
button changes from red to green, and the value of -0.2 (-0.1)
will display .
Kelly bar specifica- Press this key to select corresponding specification from
6
tion selection pull-down menu.
Display the hole depth difference between two consecutive
7 Depth of per bucket
drills.
Display the position of the drilling bucket. The value is posi-
Depth display in real
8 tive when bucket is below the hole , and the value is negative
time
when bucket is above the hole.
9 Hole depth Display the current hole depth.
The default color is red. Press it, the color will turn green.
Hole depth
10 The value of depth per bucket, real-time bucket depth and
calibration
hole depth are all zero.
11 Hole depth setting Press this key to select hole depth from pull-down menu.
Display warning information in real time. Press it to switch to
12 Warning information
Alarm Interface.
The default state is gray. When the electricity index reaches
13 GPS signal
1023, it will turn green.
The default state is main/auxiliary winch deactivated. Press it
Main/auxiliary winch to switch to main winch state (M). When the auxiliary winch is
14
switchover in unlocked state, press this key to switchover between main
(M) and auxiliary (A) winch.
Derricking/crowding The default state is derricking state. Press it to switch to
15
switchover crowding state.
The default state is travelling locked state and the icon is red.
16 Travelling state Unlock the hydraulic lock lever, then press this icon, the color
turns green. It is switched to unlocked state.


It is red by default. Red stands for limit function activated.
17 Limit switch icon Press this icon, it turns to green and the limit function is
deactivated.
Display rotary drive gear in real time. S stands for standard
18 Rotary drive gear
gear. R stands for rock gear and E stands for roller bit.
Red stands for central lubrication is not in working state.
19 Central lubrication
Green stands for it is in working state.
20 Engine oil pressure Backup
Display working hours, engine speed and gear.
Rig working
21
information
a: Working hours
b: Oil consumption
c: Engine gear
Display the mast angle in real time. When the absolute value
of the swing angle is less than 15 °, it switches to near-view
display automatically. When mast inclines to a certain angle,
it will automatically switch to the wide-angle display.
22 Mast positioning
: deflection angle along X axis.
: deflection angle along Y axis.
: swing angle.
: display fuel amount in real time. When the

Fuel amount/coolant amount is less than 30%, it shows yellow. Less than 10%, it
23 temperature/hydraul- shows red and the warning “fuel level low” is on the display.
ic oil temperature : display current coolant temperature.
: display current hydraulic oil temperature.
P1 stands for main pump 1 pressure, P2 stands for main
pump 2 pressure, P3 stands for auxiliary pump pressure, and
24 Pressure display P4 stands for pressurizing pressure. The bar graph displays
each pressure in real time, and the value is displayed above
the bar graph.

(Mn): main winch speed, the value ranges from 0 m/min

to 100 m/min.
Main winch speed (MT): main winch pull, the value ranges from 0 t to 60 t.
25
and pull force The display of speed and pull force can be read directly
through the dial value, or it can be read through the dial
filling.
(n): rotary drive speed, the value ranges from 0 rpm to

Rotary drive speed 40 rpm.
26
and torque
(T): the rotary drive torque percentage, and the value
ranges from 0% to 100%
The default camera is main winch camera. Click to switch the
27 Camera
monitoring screen of each camera.
Display the current working state information in real time,
28 Working state
and click to jump to the state prompt interface.
29 Main menu Click the main menu button to return to the main interface.
The auto drilling function is designed to meet the operator's
judgment based on geology, drilling bucket, depth and other
factors, and to select the drilling method by himself. It is
/ Automatic drilling
mainly based on the setting of rotary drive speed and crowd
pressure to meet the drilling function under different working
conditions.
The intelligent drilling function is to reduce the inconvenience
/ Smart drilling of repeatedly adjusting parameters and to intelligently match
the best drilling method for the operator.
Automatic dumping soil function is developed to reduce
/ Auto soil dumping
working intensity and increase working efficiency.
Automatic freefall function is developed to reduce the prob-
lem that the operator needs to continuously push the freefall
/ Auto freefall switch in the rock drilling process. This function can auto-
matically turn on the freefall function during the drilling
process.
The handle memory function is developed to reduce the
problem that the driver needs to continuously push the han-
/ Handle memory dle to perform rotary drive forward rotation during rock drilling
process. This function can lock the output state of the rotary
drive in the current position of the handle.
There are two ways to unlock swing operation: manual swing
/ Auto swing
and auto swing. The default state is manual swing unlock.

4.14.3 Menu interface
Press to enter menu interface.
Fig 4-26

Function description:
Icon Name Function description

Click the icon to jump to the common function interface.
Common
It contains four sub-interfaces: function, switch, opera-
Function
tion, and calibration.
Click the icon to jump to the parameter calibration inter-
Parameter face. Click on the parameter calibration interface
calibration to jump to the locking recess parameter calibration
interface.
System Click the icon to jump to the system selection interface,

selection this interface currently only has one system: roller bit.
Click the icon to jump to the central lubrication inter-

Central
face, which contains two sub-interfaces of operation in-
lubrication
formation and parameter settings.
Click the icon to jump to the GPS interface, which con-

GPS inquire
tains two sub-interfaces: GPS state and GPS unlock.
Click this icon to jump to the status interface, which

Status contains two sub-interfaces: input signal and output
signal.
Maintenance Click the icon to jump to the maintenance interface.
Historical
Click the icon to jump to the historical query interface.
query
Click the icon to jump to the user setting interface, this

User setting interface contains four function options: language se-
lection, time setting, brightness and handle setting.
Click the icon to jump to the service assistant interface,
Service this interface contains four function options: machine
assistant configuration calibration, machine configuration query,
operation instruction and software upgrade.
Click the icon to jump to the local information interface,
Local
which contains two sub-interfaces: component registra-
information
tion and rig configuration.
Click the icon to return to the main working interface of

Back icon
the rig.

4.14.4 Common function-function
Click the common function icon on the menu interface to jump to the common function inter-
face, and click function to enter the function interface.
Fig 4-27


Standard gear (S): The default mode is standard gear. In this
mode, the output current is adjusted according to the torque
pressure of the rotary drive.
Rock-drilling gear (R): Click the icon to switch to rock-drilling
Rotary drive gear
gear. Rotary drive works at low speed and high torque mode.
switchover
Roller bit gear (E): Click the icon again to switch to roller bit
gear.
Return to standard gear: Click the icon again in roller bit mode
to return to standard mode.
The default is valid state. At this time, the main rope lowering
movement is stopped after the main rope pull force is less than
the set value. Click this icon, this function is switched to invalid
Slack-rope
state and the restriction of main rope lowering movement is
switch-off acti-
deactivated.
vated/deactivated
note：During the construction process, it is forbidden to switch
switchover
the Rope slack prevention function to an invalid state, other-
wise the main wire rope will be damaged during the construc-
tion process.
The default state is valid state. In this state, main winch upper
limit, crowd upper limit and auxiliary winch upper limit are all in
Limit activated/
activated state.
deactivated
Press this icon, it is switched to deactivated state. In this state,
switchover
main winch upper limit, crowd upper limit and auxiliary winch
upper limit are all in deactivated state.
The default mode is the standard mode. At this time, the icon is
Engine standard blue, and the engine is working at 100% capacity. Click the icon
mode/fuel saving to switch to the fuel saving mode. At this time, the color turns
switchover gray, and the engine output torque is reduced to 80% of the
standard mode.
Derricking/crowd- The default state is derricking state. Click the icon to switch to
ing switchover crowding state.
Auxiliary winch The default state is invalid and the icon is gray. In this state, it
unlock activated/ cannot be switched to auxiliary winch state. Click the icon to
deactivated switch to valid state and the color turns blue. In this state, press
switchover this icon to switch the state between main/auxiliary winch.
By default, the main and auxiliary winches are invalid. At this
Main winch/auxili- time, the icon is gray. Click the icon to switch to main winch
ary winch state. At this time, the icon turns blue. When auxiliary winch un-
switchover lock is in activated state, press this icon to switch to auxiliary
winch state.


By default, the main winch is in low speed state, and the icon is
Main winch
blue. Click this icon to switch to high speed state, the icon color
speed adjustment
turns green, and the main winch is in the converging fast mode.
With power-down memory function, the state before power-off
is displayed after power-on.
Operation/as-
Operation mode: In this state, only when boom front limit is val-
sembly
id, it can switch to assembly mode.
switchover
Assembly mode: In this state, only when mast Y-axis angle is
less than 10°, it can switch to operation mode.
The default state is idle state. Click the icon to switch to full-
Idle/full-speed speed state.
switchover The engine speed will not automatically decrease When the
machine is no action, speed-up is decided by the current gear.
By default, it is in deactivated state and the icon is blue. Set the
Travelling acti- safety lock lever to horizontal state (unlock), click the icon to
vated/ deacti- switch to travelling activated state, at this time, the color turns
vated switchover green. Then press this icon or set the lever to vertical state to
switch to travelling deactivated state.
Swing locked/un- The default state is swing locked. Click this icon to switch to
locked switchover swing unlocked state.
Manual/auto free- The default state is manual freefall. Press this icon to auto
fall switchover freefall.
Backup ——
Supporting trestle
alignment acti- The default state is deactivated state and the icon is gray. Click
vated/deactivated this icon to switch to activated state and the color turns blue.
switchover
Back Press this icon to return to main interface.

4.14.5 Common function-switch
Click the switch icon on the common function interface to jump to the switch interface.
Fig 4-28


Manual/auto
The default state is manual swing. Click this icon to switch to
swing
auto mode.
switchover
This function is in deactivated state by default, and the icon is
gray. Click the icon to activate this function and the color turns
blue. After the adjusting operation is finished, it automatically
Auto vertical-
switches to deactivated state.
ity activated/
Note: The automatic adjustment function can only be per-
deactivated
formed when the absolute values of the X-axis angle and Y-ax-
switchover
is angle of the mast are less than 5° and left and right limits are
all in deactivated state. This movement stops when the abso-
lute values of X-axis angle and Y-axis angle are less than 0.1°.
Backup ——
Collision pro-
tection acti-
It is in activated state by default and the icon is blue, press this
vated/deacti-
icon, the color turns gray and switch to deactivated state.
vated
switchover
Low speed
Press the icon to activate this function.
radiating
Standard rig Press the icon to switch to standard rig.
Mast cylinder
movement Press the icon to control mast cylinder movement.
slow
Fuel pump The default state is off.
Back Press this icon to go to menu interface.

4.14.6 Common function-operation
Click operation icon on common function interface to jump to the operation interface.
Fig 4-29


It is in deactivated state by default. At this time, the icon is
blue. Hold it down, this icon turns yellow and cylinder ex-
Mast left cylinder tension movement is actuated. Release it to deactivate
extend this function.
Note: It cannot be operated simultaneously with other
icons.
blue. Press this icon and hold, the cylinder is extended
Mast right cylin- and the icon color turns yellow. Release the icon, the
der extend movement stops.
icons.
blue. Press this icon and hold, the cylinder is retracted
Mast left cylinder and the color turns yellow. Release the icon, the move-
retract ment stops.
icons.
blue. Press this icon and hold, the cylinder is retracted
Mast right cylin- and the icon color turns yellow. Release the icon, the
der retract movement stops.
icons.
blue. Press this icon and hold, the crawler is extended and
Crawler extend
the icon color turns yellow. When you release the icon, the
movement stops.
blue. Press this icon and hold, the crawler is retracted and
Crawler retract
the icon color turns yellow. Release the icon, the move-
ment stops.
blue. Press this icon and hold, the outrigger is extended
Outrigger extend
and the icon color turns yellow. Release the icon, the
movement stops.
blue. Press this icon and hold, the outrigger is retracted
Outrigger retract
and the icon color turns yellow. Release the icon, the
movement stops.


Tensioning cylin- blue. Press this icon and hold, the cylinder is extended
der extend and the icon color turns yellow. Release the icon, the
movement stops.
Tensioning cylin- blue. Press this icon and hold, the cylinder is retracted
der retract and the icon color turns yellow. Release the icon, the
movement stops.
Main winch fast

Press this icon to activate this function.
lift
Back Press this icon to go back to menu interface.

4.14.7 Common function-calibration
Click the calibration icon on common function interface to jump to the calibration interface.
Fig 4-30


blue. Click the icon, the icon color turns yellow, and the val-
Depth reset
ue of single bucket depth, real-time bucket depth and hole
depth on the main interface are all reset to zero.
Swing reset blue. Click the icon, the color turns yellow, and the value of
swing angle on the main interface will be reset to zero.
blue. Click the icon, the icon color will turn yellow, and the
Main pull reset
value of main winch pull on the main interface will be reset
to zero.
Rotary drive blue. Click the icon, the icon color will turn yellow, and the
position value of rotary drive position on the main interface will be re-
set to zero.
blue.
Locking recess
Calibration method: lock the inner key and locking recess.
calibration
Click this icon, the color turns yellow and the value -0.2 is
on main interface.
It is in deactivated state by default and the icon is blue.
Locking recess Press this icon, it turns yellow and the value in locking re-
calibration reset cess area in drilling operation interface is reset to original
value.
Back Press this icon to go back to menu interface.

4.14.8 Parameter calibration interface
Click on menu interface to jump to parameter calibration interface, as shown below:
Fig 4-31

Icon Function description
Press to go into parameter calibration I interface.
Press to go into parameter calibration II interface.
Press to go into locking device calibration interface.
Press to go back to previous interface.

4.14.9 Parameter calibration interface I
Click parameter calibration icon on menu interface to jump to parameter calibration interface, as
shown below:
Fig 4-32

Function description
Main winch pull/ Operate the main winch to lift a heavy object with the weight of X and ob-
main winch pull serve whether the value displayed is X. If not, click this icon to enter the
compensation compensation value until the value is X.
Swing angle / swing Operate the rig for one turn and observe whether the value displayed is 0.
angle If not, click this icon to enter the compensation value of the swivel angle
compensation until the value is 0.
Operate the crowd winch to lift heavy object with the weight of Y and ob-
Crowd force/crowd
serve whether the value displayed is Y. If not, click this icon to enter the
force compensation
compensation value until the value is Y.
Current depth Display current depth.
The standard value is 4500 kg. This parameter is divided by 1000 as the
Slack rope protec-
pull force judgment condition for the main winch lowering action when the
tion pull force
ground contact protection is effective.
Lift Kelly bar upwards for 10 m and observe if the value on the display is
Main winch depth
10 m. If not, press this icon to enter the compensation value until the value
compensation
is 10 m.
Mast angle/mast Mast X angle calibration: Click the icon, the value will become 0.
angle calibration Mast Y angle calibration: Click the icon, the value will become 0.
The crowd force can be set between 0% and 100%, and the default is
100%.
Crowd setting
Note: The larger the coefficient, the greater the force. If the value is 0%,
there will be no pressure. Do not set the value to 0%.
Click this icon, a numeric keyboard will pop up. Set the extension and re-
Mast current setting
traction current values of the left and right masts in this keyboard.

4.14.10 Parameter calibration interface II
Click on parameter calibration interface to jump to parameter calibration interface II, as shown
below:
Fig 4-33

Rotary drive posi-
Compensation method: Lift rotary drive upwards for 10 m and observe if
tion/rotary drive po-
the value on the display is 10 m. If not, press this icon to enter the com-
sition
pensation value until the value is 10 m.
compensation
Rotary drive stroke Display rotary drive stroke in real time.
Rotary drive speed When rotary drive mode is in E gear, the speed is adjustable within range.
Compensation method: Set rotary drive speed as 18 r/min and observe if
Rotary drive speed
the value on the display is 18 r/min. If not, press this icon to enter the com-
compensation
pensation value until the value is 18 r/min.
Rotary drive motor
Press the icon to select motor type.
selection
Hole diameter Click this icon to input the diameter value.
Depth per bucket Click this icon to input the preset depth value.
Mast current setting Adjust the current compensation value based on the mast folding speed.
Swing positioning Input the compensation value based on the real angle and displayed
coefficient angle.
Click this icon to refresh the interface.
Back to menu interface.

4.14.11 Locking device parameter calibration interface
Click on the parameter calibration interface to enter locking device parameter calibration inter-
face. Click to return to the menu interface.
Fig 4-34
Click to enter next interface of locking device parameter calibration interface. Click to re-
turn to the menu interface.

Fig 4-35
Calibration method:
1. Select the Kelly bar model by clicking pull-down icon, the distance between locking device and
the weight of each Kelly bar will be displayed.
2. Select custom icon in pull-down icon, you can manually enter the corresponding locking device
distance and Kelly bar weight information.
3. Click OK to save.

4.14.12 Construction method interface
Click on menu interface to access to construction method interface.
Click to go back to previous interface.
Fig 4-36

Click to access to the next interface of construction method interface.
Click to go back to previous interface.
Fig 4-37

Old and new
selection Click to select between old roller bit and new roller bit.
Machine model Click to select machine model.

Rotary drive weight Click to input rotary drive weight.
Kelly bar model Click to select the corresponding Kelly bar model.
Interlocking bar
Display the corresponding interlocking bar model.
model
Kelly bar weight Display the corresponding Kelly bar weight.
Bucket model Press to select the corresponding bucket model.

Bucket
Display the corresponding bucket specification.
specification
Diameter Display the corresponding bucket diameter.
Weight Display the corresponding bucket weight.
Roller bit number Display the corresponding roller bit number.

4.14.13 Central lubrication interface
On the menu interface, click to enter lubrication operation info interface. Click to return to
the menu interface.
Fig 4-38
On this interface, you can check the oil pressure, temperature, lubrication times, lubrication posi-
tive timing, and lubrication countdown. stands for on and stands for off.

4.14.14 User settings interface
On the menu interface, click to enter the user settings interface, as shown in the figure below.
Click to return to the menu interface.
Fig 4-39
This interface contains language selection, interval, display brightness, handle setting, and SIM
card setting.

4.14.15 User setting-language
Click language on the user settings interface to enter the language selection interface, as shown
in the figure below. Click to return to the menu interface.
Fig 4-40

4.14.16 User setting-time setting
Click interval on the user setting interface to enter the time interface, as shown in the figure below.
Click to return to the menu interface.
Fig 4-41
On this interface, RED stands for cancellation and GREEN stands for selection. When setting the
time zone, click the pull-down icon to select the time zone. The time selection area below shows
the year, month, day, hour, minute, and second from left to right. You can slide to select a value,
and then click the icon to confirm.

4.14.17 User setting-brightness
Click the brightness on the user settings interface to enter the display and brightness interface,
as shown in the figure below. Click to return to the menu interface. In this interface, drag the
button left and right to adjust the screen brightness.
Fig 4-42

4.14.18 User setting-handle interface
Press on user setting interface to enter handle interface.
Fig 4-43

Press to enter handle setting interface.
Fig 4-44

4.14.19 Service assistant interface
Press service assistant icon on menu interface to go into service assistant interface.
Fig 4-45 Service Assistant Interface

4.14.20 Machine configuration interface
Press machine configuration calibration on service assistant interface to go into machine con-
figuration calibration interface.
Fig 4-46 Machine Configuration Calibration Interface
Press to go back to main interface. Press to go back to service assistant interface.

4.14.21 Maintenance interface
Two ways to enter maintenance interface:

• Click on menu interface to enter maintenance interface.
• If the warning information is displayed at the lower left area on drilling operation interface, click it
to enter maintenance interface.
Fig 4-47
Maintenance procedures:
On maintenance interface, if the number icon turns red, which means that the corresponding item
should be maintained.

1. Press the number icon, a keypad will pop up. Enter the password 12318 to check the corre-
sponding maintenance information.
2. Perform maintenance procedures according to the maintenance information displayed on the

screen.
3. After maintenance, press , a keypad will pop up. Enter 12318 to confirm.
Note: Press to check the details of maintenance information, as shown in the figure below.
Fig 4-48

4.14.22 GPS information interface
Click to enter GPS information interface.
Fig 4-49
This interface displays the GPS status information, including longitude, latitude, altitude, speed,
number of satellites, communication instructions, signal-to-noise ratio, and remaining time of ma-
chine lock. The communication index increases from 0, and it is normal for any value to jump to 0
and restart the increase before reaching 1023. When the communication index is not equal to
1023, the longitude, latitude, altitude, speed, and signal-to-noise ratio are 0, and the remaining
lock-up time represents the time when there is no signal in the surroundings that can operate
normally.

4.14.23 History query interface
Click to enter history query interface.
Fig 4-50

Click this icon to enter historical fault interface. Informa-
Historical fault tion such as occurrence time, fault code, fault name
and total working hours are on the display.
Click this icon to enter overload record interface. Infor-
Overload record mation such as overload percentage, value, occurrence
time and total working hours are on the display.

4.14.24 Running information interface
Press on menu interface to go into running information interface.
Fig 4-51 Running Information Interface

4.15 Electric Cabinet

Non-professionals prohibit open the electric
cabinet. 注意 CAUTION
非专业人员，禁止打开电控箱!
启机前，确保电控箱门关闭!
维修后，确保电控箱门关闭！
Non-professionals, Prohibit open!

Before start up, Ensure electrical control box close!
After repair, Ensure electrical control box close!
Fig 4-52
1 5
3 7
Fig 4-53 Electric Cabinet

1. Controller 4. Start-up relay 7. Fuse

2. Intermediate relay 5. Barometric pressure sensor
3. Integrated box 6. Preheat relay
4.16 Fuse
NOTICE
Risk of causing damage to the electrical
wiring!
When you replace the fuse, the capacity of
the new fuse must be the same as that of the
existing fuse. Otherwise, the electrical wiring
could be damaged.
• Only the fuse of the same capacity can be
used for the replacement.
Fig 4-54 Fuse Box
The fuse box is located in the electric control cabinet. The following table lists the load capacity
and functions of the fuses.
Table 4–14 Function of fuse
Fuse/relay No. Load capacity Function

F0 30 A Fuse for ECM power supply
F1 30 A Fuse for automatic circuit
F2 10 A Fuse for the charging line
F3 10 A Horn fuse
F4 10 A Fuse for rear lamp switch
F5 10 A Fuse for platform lamp switch
F6 5A Fuse for main winch lamp switch
F7 5A Fuse for front windshield wiper/cleaner
F8 20 A Fuse for air conditioner
F9 5A Fuse for audio device
F10 5A Fuse for cab lamp
F11 20 A Fuse for service light
F12 20 A Fuse for fuel pump
F13 15 A Fuse for cigar lighter
F14 10 A Fuse for the engine oil discharge pump

Table 4–14 Function of fuse (continue)
F15 5A Buzzer fuse

F16 5A Fuse for the alarm lamp
F17 5A Fuse for fan power supply of electric control cabinet
F18 5A Fuse for GPS power supply
F19 10 A Fuse for the display power supply
F20 5A Fuse for monitoring system power supply
F21 20 A Fuse for controller power supply
F22 5A Fuse for main winch pulling
F23 5A Fuse for rotary drive position
F24 5A Fuse for rotary drive speed 1
F25 5A Fuse for the swinging phase A/B
F26 5A Fuse for depth measurement phase A/B
F27 5A Fuse for leveling handle switch
F28 5A Fuse for winch limit
F29 5A Fuse for mast limit
F30 5A Fuse for mast inclination sensor
F31 20 A Fuse for expansion module
K4 24 V/20 A Start protection relay
K7 24 V/20 A Horn relay
K8 24 V/20 A Power supply relay
K9 24 V/20 A Main winch relay
K10 24 V/20 A Platform lamp relay
K11 24 V/20 A Buzzer relay
K12 24 V/20 A Light alarm relay
K13 24 V/20 A Flameout delay relay

4.17 Limit Switches

The limit switch is used to limit the movement of the winch, mast, and boom. It is essential guaran-
tee for safe operation.
Table 4–15 Limit switches
SN Name Function Position
Stops the auxiliary winch

Auxiliary
1 lifting any further before the
winch limit
load hits the limit switch.
Stops the main winch lifting 1

Main winch
2 any further before the Kelly
limit
guide hits the limit switch. 2
Limits mast
Limits mast inclination to
3 inclination to
right.
right
Limits mast 3 4
Limits mast inclination to
4 inclination to
left.
left
From the highest position to

the lowest position, the der-
ricking range can be divided 5
Derricking
into three areas: working
5 position mon-
area, non working area
itoring device
(mast lowering and erecting
area) and the mast lowest
area.

SR305RS10Rotary Drilling Rig Operation
Operation
5 Operation.............................................................................................................................5-1
5.1 Basic Operation.....................................................................................................................5-5
5.1.1 Initial use of the machine ...........................................................................................5-5
5.1.2 Before starting the engine..........................................................................................5-5
5.1.2.1 Visual checks........................................................................................................5-5
5.1.2.2 Adjustment before operation..............................................................................5-7
5.1.2.3 Checks before starting the engine.................................................................. 5-10
5.1.2.4 Confirmation before starting the engine .........................................................5-11
5.1.3 Starting the engine....................................................................................................5-11
5.1.3.1 Normal start-up ..................................................................................................5-11
5.1.3.2 Starting the engine in cold weather................................................................ 5-13
5.1.4 After starting the engine .......................................................................................... 5-13
5.1.4.1 Breaking-in a new machine ............................................................................. 5-13
5.1.4.2 Warming-up operation...................................................................................... 5-14
5.1.5 Shutting down the engine ....................................................................................... 5-15
5.1.6 Checks after each workday .................................................................................... 5-17
5.1.7 Traveling.................................................................................................................... 5-18
5.1.7.1 Traveling operation........................................................................................... 5-18
5.1.7.2 Traveling on slopes........................................................................................... 5-23
5.1.8 Upper carriage swing............................................................................................... 5-24
5.1.9 Adjusting drilling center distance ........................................................................... 5-25
5.1.10 Raising and lowering the mast............................................................................. 5-27
5.1.11 Lowering the mast with Kelly bar ......................................................................... 5-31
5.1.12 Raising the mast with Kelly bar............................................................................ 5-37
5.1.13 Adjusting mast to verticality.................................................................................. 5-39
5.1.14 Crowding control .................................................................................................... 5-41
5.1.15 Main winch operation ............................................................................................ 5-43
5.1.16 Auxiliary winch operation ...................................................................................... 5-45

Operation SR305RS10Rotary Drilling Rig
5.1.17 Rotary drive control................................................................................................ 5-46

5.1.18 Depth measurement.............................................................................................. 5-48
5.1.19 Calibration operation ............................................................................................. 5-48
5.1.20 Crawler extending and retracting......................................................................... 5-49
5.1.21 Parking the drilling rig............................................................................................ 5-50
5.1.21.1 Regular parking............................................................................................... 5-50
5.1.21.2 Checks during parking ................................................................................... 5-51
5.1.21.3 Lockable areas................................................................................................ 5-52
5.1.21.4 Long-term storage .......................................................................................... 5-53
5.1.22 Operation in cold weather..................................................................................... 5-53
5.1.22.1 Checks in cold weather.................................................................................. 5-53
5.1.22.2 Operation tips in cold weather ...................................................................... 5-55
5.1.22.3 After daily operation ....................................................................................... 5-57
5.1.22.4 After cold season ............................................................................................ 5-57
5.2 Drilling Rig Construction.................................................................................................... 5-57
5.2.1 Operation requirements in construction and disassembly mode ...................... 5-57
5.2.2 Construction preparation......................................................................................... 5-58
5.2.2.1 Drilling rig checks ............................................................................................. 5-58
5.2.2.2 Drilling tool selection ........................................................................................ 5-60
5.2.3 Drilling rig in place.................................................................................................... 5-60
5.2.4 Drilling ........................................................................................................................ 5-61
5.2.4.1 Drilling in clay layer........................................................................................... 5-61
5.2.4.2 Drilling in sand layer ......................................................................................... 5-61
5.2.4.3 Drilling in pebble layer...................................................................................... 5-61
5.2.4.4 Drilling in shale layer ........................................................................................ 5-62
5.2.4.5 Drilling in sandstone layer ............................................................................... 5-62
5.2.4.6 Drilling in limestone layer................................................................................. 5-63
5.2.4.7 Drilling in granite layer...................................................................................... 5-63
5.3 Rigging & Derigging........................................................................................................... 5-64
5.3.1 Requirements for rigging and derigging................................................................ 5-64
5.3.1.1 Guidelines for rigging and derigging .............................................................. 5-64
5.3.1.2 Notes on rigging and derigging....................................................................... 5-65
5.3.1.3 Precautions for rigging and derigging ............................................................ 5-65
5.3.1.4 Preparation for rigging and derigging ............................................................ 5-66
5.3.2 Rigging drilling rig..................................................................................................... 5-67
5.3.2.1 Removing locking bar....................................................................................... 5-67
5.3.2.2 Extending the crawlers..................................................................................... 5-67
5.3.2.3 Mounting counterweight................................................................................... 5-68
5.3.2.4 Connecting upper mast and middle mast...................................................... 5-69
5.3.2.5 Connecting masthead ...................................................................................... 5-71
5.3.2.6 Installing lower mast......................................................................................... 5-73
5.3.2.7 Installing rotary drive ........................................................................................ 5-74

5.3.2.8 Connecting rotary drive electrical harness.................................................... 5-75
5.3.2.9 Connecting hoses ............................................................................................. 5-76
5.3.2.10 Connecting middle mast and lower mast .................................................... 5-77
5.3.2.11 Installing wire ropes........................................................................................ 5-78
5.3.2.12 Drilling rig test run........................................................................................... 5-81
5.3.3 Installing drilling tool ................................................................................................ 5-82
5.3.3.1 Connecting Kelly guide to Kelly bar ............................................................... 5-82
5.3.3.2 Connecting rope swivel to Kelly bar ............................................................... 5-83
5.3.3.3 Aligning drilling rig with Kelly bar upper end ................................................. 5-84
5.3.3.4 Connecting wire rope and rope swivel........................................................... 5-84
5.3.3.5 Installing Kelly bar............................................................................................. 5-85
5.3.3.6 Installing drilling bucket.................................................................................... 5-88
5.3.4 Disassembling drilling tool ...................................................................................... 5-88
5.3.4.1 Disassembling drilling bucket.......................................................................... 5-88
5.3.4.2 Removing Kelly bar .......................................................................................... 5-89
5.3.5 Disassembling drilling rig ........................................................................................ 5-91
5.3.5.1 Removing rotary drive and crowd cylinder ................................................... 5-91
5.3.5.2 Disconnecting middle mast and lower mast ................................................. 5-92
5.3.5.3 Removing rotary drive ...................................................................................... 5-93
5.3.5.4 Removing lower mast....................................................................................... 5-94
5.3.5.5 Disconnecting masthead and upper mast..................................................... 5-95
5.3.5.6 Disconnecting upper and middle mast ......................................................... 5-95
5.3.5.7 Removing counterweight ................................................................................. 5-97
5.4 Drilling Rig Transport ......................................................................................................... 5-98
5.4.1 Safety guidelines for transport ............................................................................... 5-98
5.4.2 Transport requirements........................................................................................... 5-98
5.4.3 Transport parameters .............................................................................................. 5-99
5.4.4 Loading and unloading the machine ................................................................... 5-103
5.4.4.1 Requirement for loading and unloading ...................................................... 5-103
5.4.4.2 Loading the machine ...................................................................................... 5-103
5.4.4.3 Fastening method ........................................................................................... 5-104
5.4.4.4 Unloading the machine .................................................................................. 5-104
5.4.5 Requirements for sea transportation................................................................... 5-105


5.Operation
5.1 Basic Operation

5.1.1 Initial use of the machine
Although the machine has been completely commissioned before delivery, make sure only low
load is used during the work (within the initial 100 h) because that breaking-in of the drive system
and other mechanisms have not been done. Full-load work from the beginning may result in lower
performance and shorter service life. Therefore, please note the following:
1. When the machine is used for the first time, carefully check the assembly of the components to
be connected/assembled on site to ensure proper assembly.
2. Avoid high-speed rotation, sudden startup, acceleration, sudden braking, rotation, sudden turn-
ing, and sudden stop.
3. Start the engine and run it at a low idle speed for 5 min.
4. The engine shall run economically, and the engine shall be operated with a load that is not great-
er than 80% of the full load.
5. Avoid no load for a long time while the engine is operating.
5.1.2 Before starting the engine
5.1.2.1 Visual checks
Before starting your machine, it is important to

be sure your equipment is safe to operate. Be-
low is a list of basic items to examine before
any work is to begin. If any problems are
found during your pre-operational checks,
have them repaired immediately.
• Examine the whole equipment for loose

connections and missing pins or bolts.
• Look for any obviously damaged items and
immediately replace or repair them.
• Examine all components for wear.
• Examine all electric lines for damage.
• Look for leaks and fluid spills. Fig 5-1 Pre-operational Checks
• Be sure all safety decals are in place and are not damaged. Be sure they are clean and visible
to all personnel.

• Remove the dirt and contamination around the engine, battery and radiator.
• Examine the hydraulic unit, hydraulic tank, hoses and joints for any leaks of oil.
• Examine the undercarriage (track, front idlers, traveling drives and guards) for damage, wear,
loose bolts or roller leakage.
• Examine the handrail and step for any problem like loose bolts. Be sure the steps, walkways
and other areas are clean and not covered with mud, concrete or debris.
• Examine the gauges and monitor in operator compartment. Change the parts or components if
any problem appears. Clean their surfaces.
• Clean and examine the rear mirrors for any damage. Repair it in case of any damage. Clean the
mirrors and adjust their positions so that the area behind the machine could be seen clearly from
the seat.
• Examine the safety belt and holds for damage or wear. Replace it with a new one if any damage
appears.

5.1.2.2 Adjustment before operation
Driver Seat D
Before operation starts or after the driver
changes, adjust the seat position so that the
driver can operate the joysticks, the pedals
and the switches.
1. Front and rear adjustment of the seat (A)

• Pull up the link (1) to move the seat to the E
desired position, and then release the link.

Adjustment distance: 200 mm (10 mm per A
stage). C
2. Overall front and rear adjustment of the

seat (B)
• Pull up the link (2), move the seat to the de-
sired position, and then release the link. In
1
this case, the driver's seat, left and right
armrest boxes, and pilot lock lever slide 3 2 4
together. B
3. Suspension adjustment (C) (if equipped) Fig 5-2

• Rotate the lever (3) to the left to make the
1. Lever B. Overall front and
suspension harder for heavier drivers; ro-
rear adjustment of
tate the lever (3) to the right to soften the the seat
suspension for drivers with lighter weight.
2. Link C. Suspension
adjustment
NOTE：
To achieve the best adjustment, adjust the 3. Lever D. Rear backrest
reading (kg) of the dial (4) to match the weight adjustment
of the driver. 4. Dial E. Armrest angle
adjustment
A. Front and rear
seat adjustment

4. Rear backrest adjustment (D)

• Pull up the handle (5), place the backrest in
the best position for easy operation, and
then release the handle.
NOTE：
When adjusting the inclination of the backrest, 5
do not let the backrest touch the rear air con-
ditioner cover, and do not let the armrests
touch the operation handle.
Fig 5-3
5. Handle
5. Armrest angle adjustment (E) 6
1) Turn the adjusting turntable (7) at the bot-

tom of the armrest (6) to adjust the angle of
the armrest to the desired position.
2)The armrest can be lifted to a vertical posi- 7
tion so that the driver can leave the seat. Ad-

justable angle range of the armrest: 40°.
Fig 5-4
6. Armrest 7. Turntable
6. Rearview mirror
9
Adjust the position of the rearview mirror, so
that you can see the people behind the left
side of the machine.
1) Install the rearview mirror at the position 8

shown in the right figure.
2)Rotate the fixing rod (8) around the armrest 10

to a proper position, and fix the fixing rod (8).
Fig 5-5
3) If you cannot move the mirror smoothly
when adjusting the angle, loosen the fixing 8. Fixing rod 10. Bolt
bolts (9) and the fastening rod bolts (10) of the 9. Bolt
mirror. Tightening torque of fixing bolt (9): 4.0
N·m to 5.4 N·m (0.41 kgf·m to 0.55 kgf·m).

When you adjust the angle of the rearview

mirror, it is a standard to take the side of the
machine into the line-of-sight of the mirror, as
shown in the right figure.
Fig 5-6
7. Seat belt
Fasten the seat belt.

14 13 12 11
1)Hold the seat belt clip (12) and pull the seat
belt out of the winding device (11). Make sure
that the seat belt is not twisted, and then insert
SS
PRE
the lock latch (13) into the buckle (14).
2)Pull the seat belt gently to confirm that it is

buckled up securely. Fig 5-7
NOTE： 11. Winding device 13. Lock latch

• Be sure to buckle up the seat belt during 12. Seat belt clip 14. Buckle
operation.
• The seat belt comes with a winding device,
so you do not need to adjust the length.
Loosen the seat belt.
1) Press the red part on the buckle (14). The lock latch (13) will pop out automatically from the
buckle (14).
2)The seat belt will be drawn into the winding device (11) automatically. Hold the seat belt clip (12)
and slowly wind the seat belt into the winding device (11).

5.1.2.3 Checks before starting the engine
WARNING
After the engine is shut down, there could be personal burns if you detect the coolant level
immediately.
• Before you detect the coolant level, shut down the engine, wait for the coolant to cool down,
and slowly rotate the radiator cap.
Before starting the engine, perform the checks listed below.
Table 5–1 Checks list
No. Item Method

1 Check coolant level “Coolant level - check and refill” on page 6-50
2 Check engine oil level “Engine oil level - check” on page 6-47
Drain water and sediment
3 “Water and sediment in fuel tank - drain” on page 6-49
in fuel tank
Check fuel amount and
4 “Fuel amount - check and refuel” on page 6-48
refuel
5 Check hydraulic oil level “Hydraulic oil level - check and refuel” on page 6-51
• Check the fuse and replace defective fuses with new

ones.
• Check the electrical circuit of battery, starter motor, and
alternator.
6 Check electric circuit
• Upper surface of the battery should be kept clean. Check
the vent hole on the battery cover. If the vent hole is
plugged by dirt or dust, flush the battery cover and clear
up the vent hole.
Press horn switch and make sure it sounds immediately. If
7 Check horn function
the horn fails to sound, contact service department to repair.
Turn the start switch to the ON position. The indicator goes
8 Check the indicator
up.

5.1.2.4 Confirmation before starting the engine
1. Confirm that the safety lock lever is in the

locked position (2). 1
2. Confirm that all the operation handle are in

the neutral position.
3. Check the light bulb of the indicator: When

you press the one-click start switch, the
2
charging indicator turns on.
4. Adjust the seat until you can push the pedal Fig 5-8 Safety Lock Lever
and the control lever to their limit positions
even if you lean back against the seat back,
then fasten the seat belt properly.
NOTE：
• To avoid damaging the surface of the dashboard, only use a wet cotton cloth that is wrung out
sufficiently to wipe the monitor or the switch panel.
• Because the switches have rubber parts, be sure not to damage their rubber parts with sharp
tools like screwdrivers.
• Before standing up from the seat, put the safety lock lever in the locked position, regardless of
whether the engine is running.
5.1.3 Starting the engine
5.1.3.1 Normal start-up
WARNING
Exhaust gas contains carbon monoxide, which by itself has no color or odor. Carbon monoxide is
a dangerous gas. It can cause unconsciousness and can be lethal.
• Do not run the engine in confined areas. If at any time you think exhaust fumes are entering the
cab, have the cause determined and corrected as soon as possible. If you must drive under
these conditions, drive only with all windows fully open.

NOTICE
Risk of causing damage to the electrical system!
During running the engine, turning the battery switch to OFF position could cause severe damage
to electrical system.
• Do not turn battery switch while the engine is running.
1. Set the safety lock lever to unlocked posi-

tion (1). 1
2. Turn the battery switch to ON position. Bat-

tery switch is in the left access door behind
the cab.
3. Turn the engine start switch to ON position

(2) to start the monitoring system.
2
4. Operate the horn to alert personnel nearby.
5. Turn the engine start switch to START posi- 1

4
tion (3). Release the key, the switch will go to
2
ON position (2).
NOTE：
• If the engine start switch is kept in ON
position for more than two seconds, the 3
pre-start check for monitoring system
will be enabled.
• If the fluid level is low, the warning infor-
mation will be on the display. Add fluid
before starting the engine.

5.1.3.2 Starting the engine in cold weather
WARNING
It can result in personal injury or death If the engine is started in cold weather by using the auxili-
ary start fluid.
• Check whether there are persons or obstacles in the surrounding area before starting the en-
gine. Then, whistle and start the engine.
• Do not use the auxiliary start fluid when starting the engine.
• If the temperature is below 0℃, run the en-

gine at idle speed to preheat for at least 5
min.
• If the temperature is below -18℃ or hy-
draulic system is malfunctioning, longer
pre-heating time will be needed.
Fig 5-11 Engine Speed Dial
5.1.4 After starting the engine
5.1.4.1 Breaking-in a new machine
In case of any problems or faults, press the engine startup switch to shut down the engine.
Your machine has been fully adjusted and tested before shipment. But, operating the machine
under dangerous conditions at the beginning can affect the performance of the machine or de-
crease the machine life.
Machine breaking-in must be done for the initial 100 h (as indicated on the hour counter). During
breaking-in, observe the precautions as described in this manual.
During the breaking-in period:

• After starting the engine, run the machine at idle speed for 5 min.
• Do not sudden starts or fast movements or stops.
• The engine shall run economically, and the engine shall be operated with a load that is not great-
er than 80% of the full load.
• Always let the system cool down at the end of the work day.

NOTE：
Avoid no load for a long time while the engine is operating.
5.1.4.2 Warming-up operation
CAUTION
Risk of accident!
Under low ambient temperature, if operate the machine without warm-up, there could be no reac-
tion or sudden fast movements phenomenon during operation which could result in accident.
• Do not operate the machine without warm-up under low temperature.
Do not immediately start operation after the engine is started. First do the following operations and
checks:
1. After starting the engine, adjust the engine speed dial and run the engine without load at low
speed (about 900 rpm) for about 5 min.
2. Adjust the engine speed control dial and operate the engine at moderate speed (1700 rpm) for 5
min.
3. Adjust the engine speed control dial and operate the engine at high speed for 5 min to 10 min.
4. After pre-heating, check if the instruments are normal.
5. Check the exhaust color, noise, and vibration. If any abnormality is found, immediately repair it.
NOTE：
• Use antifreeze recommended by SANY. Do not add tap water or coolant of other brands.
The highest applicable hydraulic oil temperature for chassis is above 50℃.
• In cold weather, the hydraulic oil temperature is very low, and there may be transient
pause phenomenon when it is started, which is normal. After warming-up, the oil temper-
ature will go up, and this phenomenon will disappear automatically.
• When the hydraulic oil temperature is low, never operate or suddenly move the lever. Be-
fore warming-up operation is completed, do not suddenly increase the engine. Do not
run the engine at low speed or high speed continuously for above 20 min, which will
cause oil leakage at oil supply pipeline of the turbocharger.
• If the machine is operated without completing a warming operation when the ambient
temperature is extremely low, there may be no response or a sudden rapid movement,
which may lead to serious accidents.

5.1.5 Shutting down the engine
NOTICE
Risk of damaging the engine!
If the engine is stopped before cooling down,
it could shorten the engine life.
• Run the engine at medium speed to make
it cool down gradually, and then shut down
the engine. Never stop it suddenly espe-
cially when the engine is over-heated.
1. Drive the machine on solid and level

ground. Lower the work equipment on the
ground.
Fig 5-12
2.Turn the engine speed dial to low idle posi-

tion. Operate the engine for 5 min to cool the
engine down.

3. Turn the key to OFF position (1). Remove

4 1
the key from the engine start switch.
2

4. Set the safety lock lever to locked position

1
(2).
In case of an emergency:
Push down the emergency stop Switch. Die-

sel engine stops and all of the equipment's
functions are stopped.
Unlock the button before restarting the

diesel engine:
Pull the Switch up. All of the functions are

unlocked.
Fig 5-16 Emergency Stop Switch

If the engine still cannot stop, turn the fuel shutoff valve (located under the fuel tank) clockwise to
cut off fuel supply. When the residual fuel in the fuel pipe is used up, the engine will stop running.
5.1.6 Checks after each workday
1. Examine the work components, machine exterior and undercarriage, check for oil leakage or
water leakage. If any abnormality is found, repair it immediately.
2. Check if there is paper and scraps in the engine compartment, and remove the paper and
scraps to avoid fire hazard.
3. After operation in water or mud, remove the water on the undercarriage.
4. Park your machine on a hard and level ground.
5. If the ambient temperature is below -35°C or -31°F, make sure to drain the cooling water of radi-
ator and engine.
6. Open the drain valve to discharge accumulated water of the fuel system so as to prevent it from
freezing.
7. Refuel the tank to maximum level. In this way when ambient temperature drops, the condensate
in the tank could be minimized.

5.1.7 Traveling
5.1.7.1 Traveling operation
NOTICE
Risk of causing damage to the crawlers!
The machine’s installed crawlers are designed for standard operations. Traveling for long distan-
ces could damage the crawler components.
• Do not travel long distances. To move the equipment over longer distances, use a suitable
transporting vehicle.
Basic principles during traveling:
• When traveling with machine, make sure it is safe around the machine, and sound the horn be-
fore moving.
• Designate a person who gives signals during traveling. See: Chapter 2 Safety, “Signals to
control operation ” on page 2-48.
• Adjust the upper carriage in line with the undercarriage.
• Lower the working attachments and movable loads as close to the ground as possible.
• Before traveling, confirm the bearing capacity of the bridge and road. Choose route as required.
• Do not allow the machine to contact with electric wire and bridge edge.
• Choose level ground as far as possible, and remove all the obstacles from the traveling route.
Drive the machine in a straight line as far as possible, and change directions slightly and
gradually.
• When traveling on uneven ground, reduce the engine speed, and choose low traveling speed.
Low speed will reduce possibilities to damage the machine.
• When traveling in working state, allow the mast to tilt backward 20° and then travel.
• Avoid making abrupt movements during traveling.

NOTICE A
Risk of causing damage to the crawlers!
The machine’s installed crawlers are de- 1
signed for standard operations. Traveling
for long distances could damage the
crawler components.
• Do not travel long distances. To move B D
the equipment over longer distances,
use a suitable transporting vehicle.
Standard traveling position:

2
The guide wheel is in the front of the machine,
and the drive wheel (travelling motor) is at the
C
rear of the machine. If the drive wheel (travel-
Fig 5-17 Standard Traveling Position
ling motor) is in the front of the machine, the
control direction of the travelling lever/pedal is 1. Seat in cab B. Left
opposite to the travelling direction of the
2. Drive wheel C. Back
machine.
A. Front D. Right
Traveling control description:
Unlock traveling mode before traveling operation: Press on operation control panel to unlock
travelling mode.

NOTE：
4
• For stable operation, the traveling pedal
(3) and traveling lever (4) are equipped
with damper. During cold weather, oper-
ating force of traveling lever/pedal will A
increase. To facilitate operation, first set B
the safety lock lever in locked position,
then operate the traveling lever (4) back
C
and forth for several times.
• When the traveling lever/pedal is re- 3
leased from forward position (A) or re-
verse position (C), it will automatically
return to the neutral position (B), and the
machine will be in braking mode Fig 5-18 Lever Sudden Shifting
automatically.
3. Traveling pedal B. Neutral position
4. Traveling lever C. Reverse position
A. Forward position
1. Forward travel
4
• Method 1: Step downward the front side of
two traveling pedals (3).
• Method 2: Push forward the two traveling
levers (4).
Fig 5-19 Forward Travel
3. Traveling pedal 4. Traveling lever
2. Reverse travel
• Method 1: Step downward the rear side of 4
two pedals (3).
• Method 2: Push backward the two traveling
levers (4).
Fig 5-20 Reverse Travel
3. Traveling pedal 4. Traveling lever

3. Pivot left turn (forward)

• Method: Push forward the right traveling
lever, or step downward the front side of
right pedal.
Fig 5-21 Pivot Left Turn (Forward)
4. Pivot left turn (reverse)

• Method: Push backward the left traveling
lever, or step downward the rear side of left
pedal.
Fig 5-22 Pivot Left Turn (Reverse)
5. Counter rotate turn (left)

right pedal and the rear side of left pedal at
the meantime.
• Method 2: Push forward right traveling lever
and push backward left traveling lever at
the meantime.
Fig 5-23 Counter Rotate Turn (Left)

6. Pivot right turn (forward)

• Method: Push forward left traveling lever or
step downward the front side of left pedal.
Fig 5-24 Pivot Right Turn (Forward)
7. Pivot right turn (reverse)

• Method: Push backward right traveling lever
or step downward the rear side of right
pedal.
Fig 5-25 Pivot Right Turn (Reverse)
8. Counter rotate turn (right)

left pedal and the rear side of right pedal at
the meantime.
• Method 2: Push forward left traveling lever
and push backward right traveling lever at
the meantime.
Fig 5-26 Counter Rotate Turn (Right)

5.1.7.2 Traveling on slopes
WARNING
Risk of personnel injury!
If there is insufficient stability, the equipment can tilt and fall over. This could result in serious or
fatal injuries to persons in the vicinity of the equipment.
• When driving on slopes or inclines, reduce engine speed and never exceed the maximum per-
missible tilt angle (15°).
When driving on slopes or inclines:

• Reduce the engine speed.
• Turning and swinging will cause loss of bal-
ance. If you have to operate the machine,
pile up a solid platform with soil on the slope
so as to keep balance during operation.
• During traveling and turning movements,
keep the center of gravity as low as
possible. Fig 5-27 Adjusting the Direction before Driving
• Driving the equipment crosswise or diago- on a Slope
nally on slopes is prohibited.
• Do not drive up or down the steep slope.
Otherwise, it may cause the tip-over of the
machine. The maximum allowable gradient
is 15°.
• If mast angle (Y) is greater than 4.5° or the
lowering depth is equal to or greater than
0.5 m, it is forbidden to travel on the slope.
Fig 5-28 Keeping Balance of the Drilling Rig on
the Slope
When traveling with Kelly bar, first raise boom mechanism to mast lowering and rising area. At this
time, MAST NOT IN THE WORKSPACE is indicated on the display. Then raise the mast until the
angle (1) between the mast and the ground is larger than 10°. In this condition, travelling on slope
is allowed.

Fig 5-29 Travelling on Slopes with Kelly Bar
1. Angle
5.1.8 Upper carriage swing
WARNING
Risk of getting crushed or hit!
During swing operation, personnel within the swinging area could get crushed or hit.
• Before swinging the upper carriage, check whether the danger area is free. The rearview mirror
must be clean at all times.
Upper carriage swing to left:

A
Push button A of left operation handle upward
to activate upper carriage swing. Simultane-
ously push the handle in left direction to make
the upper carriage swing to left.
Fig 5-30 Upper Carriage Swing to Left
A. Swing

Upper carriage swing to right:
Push button A of left operation handle upward A
to operate upper carriage. Simultaneously

push the handle to the right direction to make
the upper carriage swing to right.
Fig 5-31 Upper Carriage Swing to Right
A. Swing
NOTE：
• Release button A, the machine will be in swing braking state automatically.
• Released at any position, the handle will return to neutral position automatically, and the
machine stops swing.
• The speed changes with the amount of handle movement. Avoid violent operation. Avoid
sudden shifting for the operation handle direction.
5.1.9 Adjusting drilling center distance
NOTICE
Risk of component deformation and damage!
In case of mast lowering with the drill rod, during luffing up and down, if the wire rope is too tight,
it will squeeze the components such as the counterweight, cover plate, and triangle, which can
cause deformation and damage to the components.
• During luffing up and down, loosen the main winch wire rope properly to keep it in a slack state.
Select derricking mode: F
• Press button F on right handle to switch to

derricking mode.
• Press derricking/crowding switchover icon
on common function-function interface to
select derricking mode .
Fig 5-32 Crowding/Derricking Switchover
F. Crowding/derricking button

Increasing machine's distance to the bore:
Push forward the right operation handle
Fig 5-33 Increasing Machine's Distance to the

Bore
Reducing machine's distance to the bore:
Push backward the right operation handle
NOTE：
• Be sure there is no obstruction within
the moving range of the boom mecha-
nism before derricking operation.
• Released at any position, the handle will
return to neutral position automatically,
and the derricking operation stops.
• The speed changes with the amount of
handle movement. Avoid violent
Fig 5-34 Reducing Machine's Distance to the
operation.
Bore
• During boom operation, the sensor will
detect the position of boom. For detail
operation.
• During boom operation with Kelly bar
equipped, operate main winch to release
main rope until the rope is slack. Or the
tensioned wire rope will squeeze rope
guard pins, counterweight, engine cover
and will cause damage and deformation
to the relevant parts.

5.1.10 Raising and lowering the mast
WARNING
Risk of accident!
Violent or sudden operation in manual mode could cause severe accident and personal injury or
possibly death.
• Avoid violent and sudden operation in manual mode. Before operating the mast, make sure
that the maximum height of the machine and the length space are free of any obstacles.
Two ways to achieve raising and lowering

mast:
• manual mode by the mast adjustment

handle
• auto mode by E-PAD
Mast inclination is displayed on the screen in

real time.
When the absolute value of the swing angle is

less than 15 °, the camera is switched to near-
view state. When Kelly bar rotates to a certain
angle, it will automatically switch to the wide-
angle state. : deflection angle along
X axis. : deflection angle along Y
axis.
Fig 5-35 Drilling Operation Interface

NOTE：
P1
• When mast left/right limit is activated,
mast adjusting is not allowed. When
C
main winch upper limit is activated, mast
erecting is not allowed.
• When the boom is in mast erecting/low-
B
ering area (B area), the operation of mast
erecting/lowering is allowed.
• When mast Y value is within the range of A
-58° to -90° , and mast is in lowering and P2
O
erecting area (B area) . Mast erecting
and lowering operation can be per-
Fig 5-36 B Area
formed. At this time, “BOOM NOT IN
THE WORKSPACE” is indicated on the A. Mast lower area O. Shelf
display. B. Mast lowering and P1. The highest posi-
erecting area tion of boom
C. Mast high area P2. The lowest posi-
tion of boom
Manual mode:
Raising the mast manually:
1. Press the top button and hold.
2. Move the lever forward.
NOTE：
Observe the mast movement track area
and mast inclination value at the “Drilling
operation interface” of the display, and
keep the mast from tilting left and right un-
til the mast is vertical, that is, close to the
Fig 5-37 Mast Lever
origin in the mast movement trajectory
area, which is " X "and" Y "values are
close to zero.
Lowering the mast manually:
1. Press the top button and hold.
2. Move the lever backward.

NOTE：
• Observe the mast movement track area and mast inclination value at the “Drilling opera-
tion interface” of the display, and keep the mast from tilting left and right until the mast is
level.
• In manual mode, first adjust mast on X axis, then adjust mast on Y axis.
• Release the top button on mast adjusting lever, the mast cylinder will be deactivated au-
tomatically. In this state, the function of mast adjusting lever cannot be used.
• Release the lever at any position, the lever will be back to the neutral position automati-
cally and the movement of mast will stop.
Auto mode:
Raising the mast: On E-pad
1. Press panel activated button.
2. Press mast adjusting activated button (A).
3. Press auto erecting (B).
When “ BOOM NOT IN THE WORKSPACE ”

is indicated on the display or cab anti-collision
function is deactivated, auto erecting can be Fig 5-38 Automatic Mast Raising Operation
activated. When cab anti-collision function is
A. Mast adjusting C. Auto lowering
activated, and boom is in workspace or mast
activated
Y angle is less than -58° (refer to the right fig),
B. Auto erecting
It is prohibited to erect the mast.

Lowering the mast: On E-pad
1. Press panel activated button. 1
2. Press mast adjusting activated button (A).
3. Press auto lowering (C).
When mast Y angle is -58° (refer to the right

fig),check if the mast is in lowering and erect-
ing area (B area), or deactivate cab anti-colli-
sion function, mast lowering can be
performed and stop when mast Y angle is
-85°. When cab anti-collision function is acti-
vated, and mast is in workspace, it is prohib-
ited to lower the mast when mast angle is less
than -58°.
Fig 5-39
1. Mast Y angle
NOTICE
Risk of causing damage to the equipment！
During lowering mast, failure to confirm the rotary drive and Kelly guide position could cause
damage to the machine.
• During lowering mast operation, first confirm the position of the rotary drive to ensure that the
rotary drive crowd sledge is near the mast pivot shaft and not above the mast pivot shaft, other-
wise the cab and the mast will be crushed. When lowering the mast with Kelly bar, confirm the
position of the Kelly guide. The Kelly guide must be located within the middle mast above the
crowd cylinder, otherwise the mast and chassis cover will be crushed.
During lowering mast or lowering mast with Kelly bar, Always observe the rotary drive crowd
sledge and Kelly guide position to avoid causing damage to the machine

2
1
Fig 5-40
1. Kelly guide within the mid-mast above the 2. Rotary drive crowd sledge lower than the
crowd cylinder mast pivot shaft
5.1.11 Lowering the mast with Kelly bar
WARNING
Risk of serious injuries to persons!
Incorrect operation during lowering the mast could cause personal injuries.
• The operator must obey the requirements of safety operation instructions when you operate
the machine.
• Do not stand in the danger area of the machine.
• There must be one person giving directions to examine the overall condition of the machine at
all times, and give warnings if an emergency occurs.
Before lowering the mast:
1. Visually do a check around the machine

and make sure that there are no person and
obstacles in the dangerous area of the
machine.
2. Make sure that the wire rope is not en- 1

tangled with other parts.
3. Adjust the position of the rotary drive. Stop

A
until the crowd sledge is near but not higher
than the mast pivot (position 1 in right figure).
Fig 5-41 Before Lowering the Mast
1. Position 1 A. Square stub

4. Operate the main rope to keep the square

stub (A) at a safe distance of 0.5 m to 1.0 m
from the ground.
NOTICE
Risk of machine damage!
During mast lowering operation, after the mast lowered to approximately 75°, if continue to lift the
Kelly bar, the gravity center of the Kelly bar could be not stable or the mast cylinder and pivot
could be damaged because of the sudden force. The damage of mast cylinder and pivot could
cause mast deformation or falling down on the chassis.
• In this process, do not operate crowd system and when the mast inclination is approximately
75°, do not lift Kelly bar.
Operation procedures:
1. Lift the boom mechanism. At this time, see

the drilling operation interface, stop until
“Boom not in the working area” is shown on
the display.
Fig 5-42 Lowering the Mast I

2. Slowly retract the main rope and make sure

the distance between the square stub (A) and
ground is in the range of 0.5 m to 1.0 m.
Fig 5-43 Lowering the Mast II
A. Square stub
3. Lower the mast. When the distance (B) be-

tween the square stub and the pressure plate
of the rotary drive is approximately 5 m, con-
tinue lowering the mast and at the same time
adjust the main winch to keep the distance (B)
at 5 m.
B
Fig 5-44 Lowering the Mast III
B. Distance
4. See the drilling operation interface. When

2
the mast inclination angle (2) is approximately
75° on the display, stop retracting the main
rope and continue lowering the mast.
Fig 5-45 Lowering the Mast IV

NOTICE
During mast lowering operation, after the mast is lowered to approximately 75°, if continue to lift
the Kelly bar, the gravity center of the Kelly bar can be not stable or the mast cylinder and pivot
can be damaged because of the sudden force. The damage of mast cylinder and pivot could
cause mast deformation or falling down on the chassis.
• In this process, do not operate crowd system and when the mast inclination is approximately
After mast lowering operation:
1. Slowly retract the main rope. Stop until the lowest point of the wire rope is away from the ground
for approximately 2 m.
Fig 5-46

2. Lower boom mechanism. See the display

screen to make sure that the wire rope and
the main winch lever are always in a loose
condition.
Fig 5-47 Wire Rope and the Main Winch Lever
3. At the same time, the person outside the

cab should check and make sure that the wire
rope is always in a loose condition.
Fig 5-48 Wire Rope and the Rope Retainer

4. Make sure that the wire rope falls on the

counterweight (3) between two mast supports
(4), and is always in loose condition.
Fig 5-49 Wire Rope and the Counterweight
Fig 5-50 Wire Rope between Two Mast

Supports
3. Counterweight 4. Mast supports
NOTICE
Risk of damaging the components!
After lowering the mast, if over-winding the wire rope, wire rope could be entangled with main
winch lever, counterweight and guide pulley frame rope retainer, which could cause serious dam-
ages to the parts.
• Do not over-wind the wire rope.
5. Stop lowering until the mast falls on the mast support. At this time, the lowest point of the wire
rope is approximately 1 m from the ground.

Fig 5-51
5.1.12 Raising the mast with Kelly bar
WARNING
Risk of serious injuries to persons!
Incorrect operation during lowering the mast could cause personal injuries.
• The operator must obey the requirements of safety operation instructions when you operate
the machine.
• Do not stay in the danger area of the machine.
• There must be one person giving directions to examine the overall condition of the machine at
all times, and give warnings if an emergency occurs.
Before raising the mast:
NOTICE
When raising the mast, the tensioned rope could be entangled with the related components. It
could also pull the Kelly bar and Kelly guide to move rearward, which could cause damage to
mast cylinder and mast pivot. The damage of cylinder and pivot could cause mast deformation or
even falling down on the chassis.
• After the mast is in horizontal condition, make sure that the wire rope is always in a relaxed
condition.
• Visually examine around the machine and make sure that there is no person and obstacles in
the dangerous area of the machine.
• Make sure that the wire rope (A) is not entangled with other parts.
• Make sure the crowd sledge is near but not higher than the mast pivot (B).
• Make sure that the distance (C) between the square stub and the rotary drive pressure plate is
approximately 5 m.

Fig 5-52
A. Wire rope B. Mast pivot C. Distance
Raising the mast:
NOTICE
Risk of causing severe damage to equipment!
During raising the mast, before the mast inclination is approximately 75°, if continue to lift the
Kelly bar, the gravity center of the Kelly bar could be not stable or the mast cylinder and pivot
could be damaged because of the sudden force. The damaged mast cylinder or pivot could cause
mast deformation or falling down on the chassis.
• In this process, do not operate crowd system and before the mast inclination is approximately
1. Lift the boom mechanism. Stop until the

boom mechanism is above the cab.
Fig 5-53 Raising the Mast I
2. Push the mast lever forward to raise mast.
3. During raising the mast, see the drilling op-

2
eration interface. When the mast inclination
angle is approximately 75 °, slowly operate
the main winch to tighten the wire rope.
Fig 5-54 Raising the Mast II

4. Slowly adjust the main rope to make the

distance (D) between the square stub and the
lower pressure plate of the rotary drive is ap-
proximately 5 m, and keep this distance at 5
m.
Fig 5-55 Raising the Mast III
D. Distance
NOTICE
During raising the mast, the square stub or
the bottom of the bucket could touch the
ground, which can cause damage to the
square stub.
• During this operation, make sure there is
always a safe distance between square
stub and the ground.
Fig 5-56 Raising the Mast IV
5. Continue to raise the mast. When the square stub is approximately 0.5 m to 1.0 m away from
the ground, slowly retract the main rope and lift the Kelly bar to make sure that the safety distance
between square stub and the ground is always between 0.5 m to 1.0 m.
6. Stop raising the mast until the it is vertical.
5.1.13 Adjusting mast to verticality
Adjusting the mast to vertical could guarantee the borehole verticality.
Two ways for adjusting:
Inching mode and auto mode.

1. Inching mode:
Click on menu interface to jump to func-

tion interface. Click operation to jump to oper-
ation interface.
Note:
The inching mode can be only used as the

slight verticality adjusting function. Pro-
hibit to use it directly for raising or lower-
ing the mast.
Click , , and to adjust the

mast in single direction.
: mast left cylinder extend.
: mast left cylinder retract.
: mast right cylinder extend.

Fig 5-57
: mast right cylinder retract.
2. Auto mode:
Operation procedure:
1. Press panel activated button .
2. Press mast adjusting activated button .
3. Press auto adjusting.

Fig 5-58
NOTE：
Only when mast X angle absolute value
≤3°, Y angle absolute value ≤5° and left/
right/front limiter is deactivated, auto ad-
justing operation can be performed.

5.1.14 Crowding control
Press button F of right operation handle to F

switch between crowding and derricking, or
press derricking/crowding button on E-pad.
Fig 5-59 Crowding/Derricking Switchover
F. Crowding/derricking switchover button
Fig 5-60 Derricking/Crowding
Moving the crowd sledge down:

• Push forward the right operation handle.
Fig 5-61

Moving the crowd sledge up:

• Pull backward the right operation handle.
Fig 5-62
Moving the crowd sledge up with fast

speed: E
• Pull backward the right operation handle
and push upward button E.
NOTE：
• The speed changes with the stroke of
handle. Avoid violent operation.
• Released at any position, the handle will
return to neutral position automatically,
and the movement stops.
Fig 5-63
E. Freefall (upward)

5.1.15 Main winch operation
WARNING
Risk of crushing, cutting and entanglement!
If a rope is being moved by a rope drum or rope pulley, persons in the area of the rope drum/rope
pulley can be seriously or fatally injured, caught or entangled.
• Do not put a hand in the winch moving area.
• Do not touch between winch and rope.
• Do not seize a rope in movement.
Push button B on left operation handle or

push main/auxiliary winch switchover button B
on E-pad to set between main and auxiliary
winch.
WARNING
Risk of serious injury hazard!
If there is not sufficient rope on the rope
drum, the rope can become detached from
the rope drum. Persons can be hit by falling Fig 5-64 Main Winch/Auxiliary Winch
loads and thus seriously or fatally injured. Switchover
• The rope drum of a rope winch must al-
B. Main winch/auxiliary winch switchover
ways contain at least three windings of
button
rope.
Lowering:
Push forward the left operation handle to ex-

tend main winch rope and lower the Kelly bar.
Fig 5-65 Main Winch/Auxiliary Winch Switch-

over Button on E-pad

Fig 5-66 Lowering Main Winch Rope I
Lifting:
Pull rearward the left operation handle to retract main winch rope and lift the Kelly bar.
Fig 5-67 Lifting Main Winch Rope
Freefall:
During drilling operation, push forward the

E
button E on right handle, the main winch will
automatically extend wire rope with the in-
crease of drilling depth.
Fig 5-68 Main Winch Freefall
E. Freefall (upward)
Slack rope switch-off:

When the drilling tool touches the ground or the borehole bottom, if continue releasing main rope,
it will be in slack condition. With the slack rope switch-off function enabled, if the rope pulling force
is smaller than the set value (standard value: 2 t), the main rope stops lowering to avoid main rope
twisting. This function does not work in freefall state.
NOTE：
• When you release the handle in any position, the handle will automatically return to the
middle position and the moving stops.
• The stroke of the handle controls the speed. Avoid violent movements.
• In the process of lifting Kelly bar, the main winch limit will be activated. At this time, main
rope can not be lifted any more. Derricking mechanism and mast lowering movements
are also limited.
• Main winch freefall function can only be used under drilling conditions.
• When main winch limit is activated, there are four ways to continue the lifting operation:
deactivate limit function on display, reset depth on display, lower main rope larger than
0.5 m and then continue the operation, and restart the engine.
5.1.16 Auxiliary winch operation
WARNING
If a rope is being moved by a rope drum or rope pulley, persons in the area of the rope drum/rope
pulley can be seriously or fatally injured, caught or entangled.
• Do not put a hand in the winch moving area.
• Do not reach between winch and rope.
• Do not seize a rope in movement.
Push down button B of left operation handle

or push main/auxiliary winch switchover but- B
ton on E-pad to set between main and auxili-
ary winch and the icon is shown on the
screen.
Fig 5-69 Main Winch/Auxiliary Winch

Switchover
B. Main winch/auxiliary winch switchover

Lowering:
Push forward the left operation handle to ex-

tend auxiliary winch wire rope and lower the
load.
Fig 5-70 Lowering Auxiliary Winch Rope
Lifting:
Pull back the left operation handle to retract

auxiliary winch wire rope and lift the load.
Fig 5-71 Lifting Auxiliary Winch Rope
5.1.17 Rotary drive control
Positive rotation:
Push the right operation handle left to make

rotary drive rotate in a positive direction
(viewed from the cab, the rotary drive rotates
clockwise).

Reverse rotation:
Push the right operation handle right to make

rotary drive rotate in a reverse direction
(viewed from the cab, the rotary drive rotates
counterclockwise).
Rotary drive control method:
There are three modes of rotary drive control

(S, R, E).
Table 5–2 Rotary drive control method
Fig 5-72 E-pad

Button Name
Standard gear
Rock gear
Self-adaption gear

5.1.18 Depth measurement
The borehole depth and current depth are

both showed synchronously on the display.
Resetting depth: press depth reset button

on common function — calibration interface to
activate this function and the button turns yel-
low. At this time, the hole depth, current depth
and bucket depth all reset to zero.
NOTE：
In order to have more accurate borehole
depth readings, reset the depth to zero
when the bottom tooth of drilling bucket
hits the ground before drilling.
Fig 5-73
5.1.19 Calibration operation
1. Depth measurement compensation
Press parameter calibration on display to enter parameter calibration interface “Parameter

calibration interface” on page 4-48. Click the value, a keyboard will pop up. Input the parameter
value in the keyboard and click confirmation key.
2. Swing angle calibration

calibration interface” on page 4-48. Click the value, a keyboard will pop up. Input the parameter
value in the keyboard and click confirmation key.
3. Verticality calibration

calibration interface” on page 4-48. When the mast is vertical to the ground, press X or Y calibra-
tion icon to calibration mast verticality on X/Y axis.

5.1.20 Crawler extending and retracting
1. Ensure the four crawler pins (1) are re-

moved before retracting the crawler.
Fig 5-74 Crawler Retracted State
1. Pin
Fig 5-75 Crawler Extended State
1. Pin
2. First press panel activated button and then

press crawler extend/retract button on E-pad.
3. When the extending and retracting action is

finished, install the 4 pins.
Fig 5-76 E-pad

5.1.21 Parking the drilling rig
5.1.21.1 Regular parking
NOTICE
Risk of tipping over!
Parking the machine on the sloped area could cause the machine tipping over and result in ma-
chine damage.
• Always park the machine on level and solid ground. If parking on the sloped area cannot be
avoided, chock the crawlers on both sides.
It is important to understand the safety pre-

cautions in Parking safety in Safety chapter
before parking the rig.
1. Drive the machine on solid and even

ground.
2.Lower mast until the inclination is about 20°.
3. Lower the drilling tool until it rests on the

ground.
Fig 5-77 Parking the Drilling Rig on Sloped

Area
4. Turn the engine speed dial counterclock-

wise to low speed idle position. Run the en-
gine for about 5 min to cool it down.

5. Pull the Safety lock lever to locked position

(2). 1
6. Turn the engine start switch to OFF position 1

4
(3), and remove the key from the switch.
2
7. Close the window and cab door.

5.1.21.2 Checks during parking
Check the engine water temperature, oil pressure, fuel level and refill fuel.
If the ambient temperature is lower than -35°C or -31°F, be sure to drain coolant from the radiator
and engine jacket (freezing point of the antifreeze applied by SANY is -35°C or -31°F).

NOTE：
If the coolant is drained, be sure to mark
“NO WATER IN RADIATOR” tag at obvious
location. CAUTION
NO WATER IN RADIATOR
Fig 5-81 No Water in Radiator
5.1.21.3 Lockable areas
Be sure to lock the following areas after park-

ing the machine:
• Cab door lock (1) 4
The operator cab door is equipped with a
door lock to prevent unauthorized access.
Always lock the operator cab when the ma-
1
chine is not in use.
• Oil radiator lock (2) 2
3
• Water radiator lock (3)
• Engine hood (4) Fig 5-82 Lockable Areas I
• Pump chamber lock (5)
1. Cab door lock 3. Water radiator lock
• Main winch motor lock (6)
• Valve chamber lock (7) 2. Oil radiator lock 4. Engine hood
6 7
5
Fig 5-83 Lockable Areas II
5. Pump chamber 7. Valve chamber

lock lock
6. Main winch motor
lock

5.1.21.4 Long-term storage
Before storage:
• Clean and flush all the parts, and then place the machine indoor. If you have to store the ma-
chine outdoor, choose level ground and cover the machine.
• Before storage, refill the fuel tank (See: Chapter 6 Maintenance, “Fuel amount - check and
refuel” on page 6-48). Lubricate the lubrication points, and change engine oil (See: Chapter 6
Maintenance, “Engine oil level - check” on page 6-47).
• Apply a coat of grease on the metal surface of piston rod.
• Disconnect the negative terminal (-), and

cover the battery, or disconnect the battery
from the machine and have it stored
separately.
• If the ambient temperature is expected to
drop below 0° C (32° F), add antifreeze to
the coolant.
Fig 5-84 Disconnecting the Battery
During storage:
• Run the machine once a month to make the surface of moving parts applied with a layer of new
oil film. Meanwhile, charge the battery.
• For machines equipped with air-conditioner, run the air-conditioner.
• Run the crawler.
5.1.22 Operation in cold weather
5.1.22.1 Checks in cold weather
1. Checks during downtime:

• Keep the machine clean.
• Engine: Check for antifreeze level, oil quality, and fluid and oil leakage. Replace the fuel, oil and
gear oil with oils applicable for local temperature.
• Hydraulic system: Check for leakage of the motor, oil cylinder, main pump, pipeline and joints.
Check for scratch and corrosion to cylinder piston rod. Exposed part of the piston rod shall be
applied with grease for protection.
• Electrical system: Disconnect the battery, and place it indoor after charging.

• Conduct antirust running, and run air-conditioning system once a month, keep compressor lubri-
cated and certain thickness of oil slick at the O-rings of air-conditioning system, and prevent re-
frigerant leaking.
2. The antifreeze proportion is 45% when delivered, which is applicable for lowest tempera-
ture of -40°C (carry out according to local temperature and attached table).
Table 5–3 Table for oil fluid selection in low temperature condition
Gear Oil
Swing reduc- Rotary drive re-
Tempera- Engine Hydraulic er, traveling ducer, main Anti-
Fuel
ture Oil Oil reducer, and winch reducer, freeze
rotary drive and auxiliary
tank body winch reducer
TEEC-
-5℃ -10# 15W-40 HDZ46 85W–140 Gear oil 220
L35
TEEC-
-15℃ -20# 15W-40 HDZ46 80W-90 Gear oil 220
L35
TEEC-
-20℃ -35# 15W-30 HDZ46 80W-90 Gear oil 220
L35
TEEC-
-30℃ -35# 5W-30 VG32 80W-90 Gear oil 220
L35
Note: Engine oil must be above API CH-4 grade.
3. Regular checks:
Wash and clear the oxides from the battery terminal with hot water, and apply a layer of grease
after wiping to protect the terminal. For wet battery, check proportion of the battery acid, and add
distilled water or electrolyte if necessary.
4. Checks before starting the engine

• Before starting the engine, check oil and fluid level. Drain water or contaminants from the fuel
tank at least once a week.
• When the ambient temperature is lower than 3°C, turn on the preheating switch before starting
the engine so as to preheat the intake air.
• Start the engine and idle the engine for five to ten minutes. Operate the cylinder without load to
make hydraulic oil temperature reach 40°C, and then start construction.
• For construction in frozen weather, recommend operator to clear the mud from around the car-
rier rollers and idler with a shovel to prevent freeze on the next day.
• Drain water from water oil separator after work every day.

5.1.22.2 Operation tips in cold weather
The engine will not be able to start and the coolant may be frozen in a low temperature environ-
ment. The viscosity of the hydraulic oil may be increased.
The fuel shall be selected based on climate temperatures. Follow the steps described below:
1. Fuel and lubrication oil

All the components shall use low-viscosity fuel and lubrication oil.
2. Coolant of the cooling system
WARNING
Risk of poisoning or apnea!
Antifreeze is toxic and flammable, and it can cause serious personal injury or death when it is
spilled or a fire source is nearby.
• Do not use methanol, ethanol, or propane antifreeze.
• Avoid using any leak preventives, no matter it is used individually or mixed with antifreeze.
• Do not mix the antifreeze of different brands for application.
For areas where permanent antifreeze is not available, use ethylene glycol antifreeze without pres-
ervatives in cold season. In this circumstance, the cooling system should be cleaned twice a year
(spring and autumn). When adding to cooling system, add antifreeze in autumn instead of in
spring.
3. After-treatment system (if equipment)

• In snowy areas, where engines operate for long periods of time, exhaust gas may accumulate,
causing carbon monoxide poisoning. As a precaution, remove the snow around the equipment.
• During the regeneration process, the combustion of particulate matter (PM) may cause the tail
tube to emit white smoke for a short time, but this is not a fault.
• After engine preheating, manual regeneration is faster than in cold.
• When the coolant temperature reaches about 70°C (158°F), the manual regeneration can only
start. And the cooling temperature may increase during manual regeneration.
4. Battery

WARNING
The gases generated by the battery is flammable or explosive, which can cause severe personal
injury or death.
• The battery produces flammable gas, keep fire or sparks away from the battery.
• If the battery acid gets on your skin or in your eyes, flush the area immediately with fresh water
and seek medical attention.
• The battery acid could dissolve paint. If the battery acid splash on the machine, flush with water
immediately.
• If the battery acid is frozen, never charge the battery or start the engine with different power,
which may cause the battery to explode.
NOTICE
The gases generated by the battery is flammable or explosive, which can cause damage to the
machine.
• Flammable gases can be generated by the battery. Therefore, keep the battery away from fire
or sparks.
• If the electrolyte is frozen, do not charge or start the engine using different power supplies. Oth-
erwise, the battery may explode.
When the ambient temperature lowers, the battery capacity decreases. If the charge ratio is lower,
the battery acid will be frozen. Make sure the battery charging is close to 100% as much as possi-
ble. Make the battery insulated from low temperature so as to start the machine easily on the next
morning.
Battery Acid Temperature

Proportion
20℃ (68°F) 0℃ (32°F) -10℃ (14°F) -20℃ (-4°F)
Charging Ratio
100 1.28 1.29 1.30 1.31
90 1.26 1.27 1.28 1.29
80 1.24 1.25 1.26 1.27
75 1.23 1.24 1.25 1.26
Note: Measure the specified proportion of the battery acid, and acquire the charging ratio from the
charging ratio conversion table above.

NOTE：
• The battery capacity obviously decreases in cold temperature, so the battery shall be
wrapped or removed and located in warmer place.
• If the battery acid level is low, add distilled water before starting work in the morning. Do
not add water after daily operation to prevent liquid in the battery freezing in the evening.
5.1.22.3 After daily operation
To avoid mud or water on the undercarriage from being frozen which makes the machine unable to
move on the next morning, follow the precautions below.
• Thoroughly remove mud and water from the machine to avoid mud and dirt entering the inner
side of the sealing with water drops to damage the seal.
• Park the machine on solid and dry ground.
• If possible, park the machine on plank, which can prevent the crawler from being frozen with the
soil, so it can move on the next morning.
• After operation, refill the fuel tank so as to prevent condensed water when the temperature
drops.
5.1.22.4 After cold season
After the cold season, do the following steps:

• Change the fuel and oil of all the components with specified viscosity oils.
• If permanent antifreeze cannot be applied because of some reason, use ethylene glycol anti-
freeze (winter season, one season type) as substitute. Or if antifreeze is not available, com-
pletely drain the cooling system, and thoroughly wash the inside of the cooling system, and then
add fresh soft water.
5.2 Drilling Rig Construction

5.2.1 Operation requirements in construction and disassembly mode
NOTICE
If the drilling rig is improperly operated, the drilling rig may tip over, which can cause damage to
the machine.
• Strictly comply with the following operation requirements. Otherwise, it may cause serious
safety accidents.
Operation requirements and description in disassembly and construction mode:

• In disassembly mode, the luffing must be lowered to the lowest level, the outriggers must be re-
tracted, but the luffing cannot be retracted. Otherwise, accidents such as structural damage may
be caused.

• The forward tilting angle of the mast must be less than 4°, and the track chain must be extended
before the drill rod can be hoisted and disassembled. Otherwise, serious accidents such as tip-
over and structural deformation are may occur.
• The forward sloping angle of the mast must be less than 10° so that the disassembly mode can
be switched to the construction mode.
• The track chain can be retracted only upon loading and unloading the trolley.
Operation requirements and description in construction mode:

• In construction mode, the track chains cannot be retracted. Otherwise, it may cause serious ac-
cidents such as tip-over.
• If the forward tilting angle of the mast exceeds 4°, mast tilting forward and luffing extension are
not allowed. Otherwise, it may cause serious accidents such as tip-over and structural
deformation.
• During drilling, driving, swinging, luffing, and mast lowering are not allowed. Otherwise, it may
cause serious accidents such as mast deformation and drill rod damage.
5.2.2 Construction preparation
5.2.2.1 Drilling rig checks
NOTICE
If the drilling rig is improperly operated, the drilling rig may tip over, which can cause damage to
the machine.
• Strictly comply with the following operation requirements. Otherwise, it may cause serious
safety accidents.
1. Check oil level of winch reducer through the level gauge or oil level plug.
2. Check rotary drive oil level through the sight

glass (it should reach 1/2 to 2/3 of the sight
glass).
Fig 5-85 Sight Glass on Rotary Drive

3. Check oil level of swing reducer through

the dipstick (oil level should be between the
FULL mark and the ADD mark).
Fig 5-86 Oil Dipstick of Swing Reducer
4. Check engine oil level through the dipstick

(oil level should be between the FULL mark
and the ADD mark).
Fig 5-87 Engine Oil Dipstick
5. Replace fuel filter according to the mainte-

nance schedule set in this manual.
Fig 5-88 Fuel Filter

6. Check if the bottom gate of drilling bucket

works normally. Check the wearing conditions
of drilling teeth. The serious wearing parts
should be replaced.
Fig 5-89 Drilling Bucket
5.2.2.2 Drilling tool selection
• Verify the geological survey materials. Determine the bit diameter according to requirements of
the construction drawing. Usually the bit diameter is 10 cm to 20 cm (3.94 in to 7.87 in) smaller
than the specified borehole diameter. Be sure there is no overlarge fullness coefficient.
• During construction, according to layer in the geological report, select proper drilling tools in or-
der to improve construction efficiency and reduce cost.
• For the structure features of main drilling tools and their applicable layer, see: Chapter 5 Opera-
tion, Drilling Tool.
5.2.3 Drilling rig in place
1. Drive the machine to the position around the pile. Make sure the working surface of the drilling
rig is solid and level. If the ground surface is too soft, place steel plate under the crawlers to en-
hance the working stability.
2. Clearance between the drilling rig swing center and borehole should be 3.3 m to 4.0 m (10.83 ft
to 13.12 ft). Lift the boom mechanism.
3. Keep the drilling rig clear of obstacles within the swing radius.
4. Rotate the upper carriage. Extend and retract the boom cylinder, and adjust the mast to vertical
to make accurate alignment and make the tip of the drilling tool align with pile marking position.
5. After accurate alignment, reset the swing angle. Lower the drilling tooth to the same plane as
the casing. Reset the borehole depth.
6. Drilling can be carried out after the drilling rig is in place. The following section describes com-
mon strata drilling method.

5.2.4 Drilling
5.2.4.1 Drilling in clay layer
Clay layer is featured with large viscosity and small drilling resistance.
1. In drilling operation, the output torque of rotary drive cannot be too large. Control the operation
handle, and appropriately increase the rotary drive rotating speed, which is usually between 5 r/
min to 20 r/min.
2. Keep crowding in order to make the drilling teeth cut into the clay layer
Note:
Drilling depth is subject to the diameter and height of the drilling bucket. If the pile diameter is
above 800 mm (31.5 in), the drilling depth is 50% to 70% of the bucket capacity. If the pile diameter
is less than 800 mm (31.5 in), the drilling depth cannot exceed 50% of the drilling bucket capacity.
5.2.4.2 Drilling in sand layer
Sand layer is featured with strong water permeability, low compressibility, and big drilling
resistance.
1. Set rotary drive gear to high-torque and low-speed mode.
2. Lift drilling bucket up and down slowly and evenly. Pay special attention to avoid bucket burying
into the sand.
Note: Bailing bucket with double bottom is preferable.
5.2.4.3 Drilling in pebble layer
Pebble layer is featured with large pores, strong water permeability, low compressibility, and strong
shear strength.
• Set rotary drive gear to high-torque and low-speed mode.
• Strictly control each bucket drilling depth.
• Lift and lower the drilling bit as slowly and evenly as possible.
• For layers with larger content of gravel, use double layer core barrel. For boulder layer, use short
auger to loosen the boulder, and then convey the spoil with core barrel.
• In dense pebble layer, drill with low rotating speed. Hoist the Kelly bar with main winch rope, and
stir the pebbles with teeth clockwise and counterclockwise. When running into large resistance,
reversely rotate promptly and then convert to positive swing. Perform this circularly and repeat-
edly. When the pebble is loose, float and lower the Kelly bar.
• If it drills fast, keeps heavy-load drilling state via point crowding. Avoid back pressure and contin-
uous crowding. If no drilling is performed for long period, raise the auger bit for a little bit to pre-
vent bore hole collapse. Lower again in order to create free surface for further drilling.

• During bucket opening or closing, the bucket bottom hook is apt to be stuck by pebble and fails
to work. There is also possibility for hook falling at the bore hole bottom. It is better to seal the
hook position with steel plate.
• If it is not sealed, you will have to thoroughly close the bucket every time. Make sure the hook is
completely hitched so as to avoid the bucket bottom opening in the hole.
• Check set pins for teeth and the Kelly bar whenever dumping slag. Promptly replace the worn
and broken teeth.
5.2.4.4 Drilling in shale layer
Shale is a kind of sedimentary rock formed by mud and clay. It’s mainly composed of fine-grained
sediments without stratification and it appears block. It has strong cohesive force, lower compres-
sive strength (usually between 0.17 Mpa/24.66 psi and 10 Mpa/1450.4 psi), and cementing proper-
ties. It is very absorbent.
• Set the drilling teeth staggered with the angle of about 53°.
• When adopting friction Kelly bar, crowd continuously. When the layer resistance goes up, keep
on drilling. Adjust the crowding amplitude based on the resistance in order to force the drilling
teeth into primitive rock and maintain cutting state.
• When using interlocking Kelly bar, control crowding manner. When the fore part of the crawler is
nearly propped up, it means sharp crowding or no drilling. Now stop crowding and verify the
cause.
• If the layer changes little, the drilling time and depth for each bucket should be within a certain
range. Drilling depth for each bucket in shale layer should be 40 cm (15.75 in).
• When there is still drilling load, reverse and shut the bucket bottom. Now the bucket has certain
resistance, and can avoid the bucket bottom reversing with the core barrel. The reverse should
be no more than two turns. Too much reverse will flatten bore hole steps, which increases diffi-
culties for the drilling teeth to cut the rock.
5.2.4.5 Drilling in sandstone layer
• Sandstone is a kind of sedimentary rock, which is mainly cemented by sand grains (0.0625 mm/
0.0025 in～2 mm/0.787 in), of which the sand grain content is greater than 50%. The vast major-
ity of sandstones are composed of quartz or feldspar.
• The sandstone hardness varies greatly depending on the cementation method. Generally, under
the same conditions, the hardness decreases in the following sequence: siliceous cementation,
iron cementation, calcareous cementation, and muddy cementation. The compressive strength
varies greatly, generally between 20 MPa ～ 120 MPa (2900 psi～17404.5 psi).
• Sandstone belongs to the soft rock-hard rock stratum, and the mechanical locking rod is se-
lected according to the depth of the pile hole. Generally, a rock-socketed double-bottom bailing
bucket is used. For weakly or slightly weathered stratum with strong compressive strength, a
rock-socketed cased drill and an auger bucket are required for the construction.

• For moderately or strongly weathered stratum with medium compressive strength, directly use
the rock-socketed double-bottom bailing bucket to drill and remove the slag.
• When drilling into the hard stratum, you can select the rock-socketed cased drill and try to ex-
tract the core. Avoid breaking and removing the slag to improve the drilling efficiency. When the
core cannot be taken out, use the screw drill bit to break the core and then use the bailing bucket
to remove the slag. Use this method to carry out drilling in circulation.
• When drilling into the sandstone and conglomerate, properly select the gear, rotation speed,
pressurization method and pressurization time for the equipment.
5.2.4.6 Drilling in limestone layer
• Limestone is referred to as calcareous rock. This kind of stratum is easy to form karst caves or
dark rivers. When you drill into the limestone stratum, problems such as bias hole, drill jamming,
slurry leakage and over-size soil volume will occur. Limestone has strong compressive strength,
typically between 50 MPa to 80 MPa (7252 psi to 11603 psi).
• When drilling into the limestone stratum with karst caves, the drilling rig must have strong rock-
penetrating ability and the main winch must have large pulling ability. Use a mechanical locking
rod as the Drill rod. The drill bit should be equipped with a barrel drill, an auger bit and a pick
bailing bucket. Reasonable cooperation among them helps drill into this stratum.
• Way of crossing the karst cave top deck: The rock surface on the top of the karst cave changes
greatly, which is easy to cause hole inclination. According to the geological survey report, the
barrel drill should be replaced at a distance of 500 mm (19.69 in) from the karst cave top deck to
grind with lower pressure until it crosses the karst cave top deck.
• Operation essentials after drilling into the karst cave: Use the rock-socketed double-bottom bail-
ing bucket to drill with light pressure load.
• Drilling of slightly weathered limestone at the bottom of the karst cave: Use the rock-socketed
cased drill and the auger bit collaboratively to drill the free surface, and use the rock-socketed
bailing bucket to remove the slag. When drilling into the bottom layer of the karst cave, use a
barrel drill to drill with lower pressure, preventing hole inclination. Then, use the pulse pressure
load method to improve the drilling efficiency. When you lift the drill, the speed should be slow to
avoid damage to the drill tool or opening of holes on the bucket door.
• Pay close attention to the state of the mud level in the hole during the drilling process. When the
mud level drops rapidly, the bottom plate of the karst cave has been penetrated or the hole has
collapsed. Take measures according to the actual situation.
5.2.4.7 Drilling in granite layer
• Granite is a type of hard rock. The compressive strength of granite in a moderately weathered
state is above 60 MPa (8702 psi), making it difficult to drill.
• When drilling into the granite, select a large-power drilling rig and work with the mechanical lock-
ing rod, rock-socketed cased drill, and rock-socketed double-bottom bailing bucket. If the hard-
ness is greater than 80 MPa (11603 psi), it is recommended that you use the roller barrel drill.

• Use the dynamic-static combined breaking method when drilling into the granite. That is, use
timing low-pressure drilling, instantaneous pressurized drilling, and then resumed low-pressure
drilling in turn. Pay attention to control the rotation speed of the drill bit to 6 r/min to 8 r/min.
• When the roller barrel drill and the slurry hole wall protection process are used, the drill is usually
pressurized by its own weight. Do not apply with a too large pressure load to prevent the drill
from breaking. In addition, the drill bit should be lifted regularly and the rollers should be
cleaned.
• If the pile holes to be drilled have large diameter, graded drilling should be considered when the
efficiency of the drilling rig is insufficient or the torque of the Drill rod exceeds the rated torque:
drill in with a small diameter and enlarge the holes to drill out.
5.3 Rigging & Derigging

5.3.1 Requirements for rigging and derigging
5.3.1.1 Guidelines for rigging and derigging
WARNING
Rotational movements of the upper carriage during assembly work can cause the equipment to
tip over. This could result in serious or fatal injuries to persons.
• Only unlock the upper carriage and undercarriage when assembly work is complete.
For safety of yours and others, follow the requirements in this section.
Installation of accessories or optional parts that are not approved by SANY will impair the ma-
chine’s service life, and lead to accidents.
When accessories are not listed in Parts Manual, contact SANY authorized sales representative
immediately.
• Read Safety, Operation & Maintenance Manual thoroughly, and do not perform any installation
or dismantling operation until you’ve understand the manual.
• If Safety, Operation & Maintenance Manual gets lost, ask the manufacturer or accessory sales
company for a new copy.
• Before operation, make clear the operation signals, see: Chapter 2 Safety, “Signals to control
operation ” on page 2-48. When the drilling rig has been installed, its swing scope and gravity
center are different.

WARNING
Risk of getting crushed or getting cut!
Crushing surfaces and cutting edges are
produced, primarily when slewing and tilting
the tool, raising and lowering the crowd
sledge, raising or lowering the mast, folding
the masthead. If persons get between these
edges, they can receive serious or fatal
injuries.
• Maintain adequate safety distance.
• Do not insert any body parts between
Fig 5-90 Guard Line
moving components.
• Before starting operation, establish a guard

line to shield irrelevant staff.
• In order to avoid serious accidents incurred by wrong operation, do not put your feet on the ped-
als other than operating the pedals.
5.3.1.2 Notes on rigging and derigging
• Provide solid and level area for rigging and derigging.

• Before rigging, check all parts for possible damage resulting from transport.
• When more than 2 persons are operating the machine, clear signals should be followed. See:
Chapter 2 Safety,“Signals to control operation ” on page 2-48 .
• Use a crane when lifting or carrying heavy objects (more than 25 kg or 55 lb).
• When using a crane to lift a load, pay extra attention to its gravity center.
• When removing heavy parts, support them before dismounting in order to prevent them from
swaying or falling after being separated from the machine.
• When removing and installing parts, ensure that they are in a stable area, with no risk of falling
down.
• Do not walk under the load lifted by a crane.
• Personnel working on the mast or on the upper carriage must wear the prescribed fall protection
equipment.
• During rigging operations, the upper carriage must be in line with the crawler and be interlocked
with it. The crawler should be extended and locked.
5.3.1.3 Precautions for rigging and derigging
• Installation and removal must be done on a firm and flat ground.

• Before installation, check all components to determine whether they have been damaged during
transportation.

• When operations involve at least two persons, determine the signals and observe them during
operations.
• Use a crane if you need to hoist or handle a heavy object (more than 25 kg or 55 lb).
• If you need to remove a heavy component, be sure to support it before removal to prevent a pos-
sible swinging or fall when the component is away from the machine.
• When hoisting with a crane, pay attention to the position of the center of gravity of the weight.
• When putting down a removed component or installing a component, ensure that component is
stable and will not tip over. Do not walk under the load hoisted by the crane.
• Personnel carrying out installations on the mast or the upper carriage must wear a fall protection
device.
• During installation, the upper carriage must be parallel to the track chains and locked, and the
track chains must be fully expanded and locked.
5.3.1.4 Preparation for rigging and derigging
Ground: flat, solid, open, no barriers such as

high-voltage lines overhead.
Tools: tools attachment
Equipment: one crane weighing over 20 ton.
Staff: 1 crane operator, 1 drilling rig operator,

3 to 5 workers.
Fig 5-91 High-voltage

5.3.2 Rigging drilling rig
5.3.2.1 Removing locking bar
Locking bar:
1 2 3
It is located in front of chassis swing bearing.
During transportation, it is used to link the

upper carriage and H beam of the traveling
mechanism, to prevent the upper carriage
from rotating.
Operation procedures:
1. Move the rig to the designated location.
2. Remove the pin (1) that links the locking bar 1

4
(2) and upper carriage (3).
Fig 5-92 Locking Bar
3. Make the bar rest on the H beam (4).
1. Pin 3. Upper carriage
4. Reinstall the pin (1) to the original position.
2. Locking bar 4. H beam
NOTE：
• If the pin cannot be pulled out, operate the left operation handle repeatedly to make the
upper carriage rotate slightly. Then the pin can be removed.
• In order to avoid small parts loss, install connecting parts, such as pin and lock pin, to
their original positions.
5.3.2.2 Extending the crawlers
Extend crawlers before assembling other parts.
For detailed operation procedures, see: Chapter 5 Operation, “Crawler extending and retracting”
on page 5-49.

5.3.2.3 Mounting counterweight
WARNING
Risk of severe accident!
If the lifting device and counterweight are not correctly aligned with each other, the counterweight
can fall over or start swinging uncontrollably during lifting. Persons can be hit or trapped by the
counterweight.
• The lifting points of the lifting device must be positioned vertically above the lifting points of the
counterweight.
1. Raise boom mechanism and at the same

time check the display. Stop until “BOOM
NOT IN THE WORKSPACE” is indicated on
the display.
2. Raise the mast to enable the installation of

counterweight.
Fig 5-93 Raise the Mast

3. Connect sling and U ring to counterweight

lug. Use crane to lift counterweight, move it
from position (A) to position (B). Fasten with
bolts.
4. Install camera and other accessories on the

counterweight.
NOTE：
• Assemble the mast transport support,
bolts and nuts. Store them properly and Fig 5-94 Mounting the Counterweight I
guard against parts loss. A
B
• Connecting elements for lifting such as
U ring and slings shall meet the hoisting
requirement.
• Tighten the bolts according to the re-
quired tightening torque (See Mainte-
nance, “Tightening Torque” on page 6-26).
Fig 5-95 Mounting the Counterweight II
A. Position B. Position
5.3.2.4 Connecting upper mast and middle mast
WARNING
Risk of crushing hazard!
Even slight actuation of the mast cylinders leads to large movements of the mast. This could re-
sult in serious or fatal injuries to persons.
• Ensure constant visual contact with the person giving directions.

1. Lower mast and rest it on the mast support.
Fig 5-96 Connecting Upper Mast and Middle

Mast I
1. Pin
2. Pull out the pin (1) connecting the upper mast and the middle mast.
3. Pivot the upper mast until the contact surfa-

ces of the mast ends are resting flat against
each other.
Fig 5-97 Connecting Upper Mast and Middle

Mast II

4. Bolts mounting method: Insert a bolt (2)

that is sleeved with a spacer (3) into the mast
flange mounting hole. Be sure to insert it in
the direction from upper mast to middle mast.
Then put a washer (4) onto the bolt, screw on
a nut (5) and fasten it, screw on the locknut
(6).
6
5
3
2
Fig 5-98 Installing Bolts
2. Bolt 5. Nut
3. Spacer 6. Locknut
4. Washer
NOTE：
• Do not press electric wires when rotating upper mast.
• Tighten them gradually, following the sequence from middle to sides.
• Tighten the bolts according to the required tightening torque. (See Maintenance,
“Tightening Torque” on page 6-26).
5.3.2.5 Connecting masthead
WARNING
Risk of getting crushed!
Inappropriate work during pivoting the masthead can lead to crushing of body parts.
• During the assembly, do not insert any body parts between the two edges of masthead and
upper mast.

1. Remove transport support (1) connecting

1
masthead and upper mast.
Fig 5-99 Removing Transport Support
1. Transport support
2. Rotate the masthead around the hinged

shaft. When the masthead is jointed with mast
flange face, fasten them with bolts. For instal-
ling method, see: Chapter 5 Operation,
“Connecting upper mast and middle mast” on
page 5-69.
Fig 5-100 Connecting Masthead
NOTE：
• Clean flange surface and lock pin and check for damage.
• Do not damage electric wires when rotating masthead.
• When mounting bolts, tighten them gradually, from middle to sides.
• Tighten the bolts according to the required tightening torque (See Maintenance,

5.3.2.6 Installing lower mast
WARNING
Risk of accident!
The use of unsuitable lifting gear can lead to the tipping over of the lifting gear or the falling of
loads. Persons in the vicinity of the equipment could be hit and receive serious or fatal injuries.
• Only use suitable lifting gear with adequate load-bearing capacity.
• No person should be allowed to be near the machine during lifting process.
1. Connect sling and U ring to lower mast. En-

B A
sure that lower mast can remain vertical after
being lifted.
2. Use a crane to lift lower mast from position

A to position B.
1
Fig 5-101 Installing Lower Mast
1. Pin B. Position
A. Position
3. Connect middle mast and lower mast. In-

stall pin (1) and fasten them firmly.
4. Install connecting rod.
NOTE：
Use sling and U ring of required
specification.
Fig 5-102 Installing Connecting Rod

5.3.2.7 Installing rotary drive
WARNING
Risk of accident!
1. Attach lifting slings to lifting eyes and en- A

sure that crowd sledge guide remains vertical
after being lifted.
2. Use a crane to lift rotary drive, make the

crowd sledge guide slide into the guide rail, B
move it from position (A) to position (B).
NOTE：
Use sling and U ring of required
specification.
Fig 5-103 Installing Rotary Drive

5.3.2.8 Connecting rotary drive electrical harness
1. Pass the electrical wire harness of the ro-

tary drive up through the hole inside the rotary
drive oil seat, and use bolts to fix the wire har-
ness oil pipe connectors on the inside of the
rotary drive oil seat.
2. Connect the plug of the electrical wire har-

ness of the rotary drive.
Fig 5-104
Fig 5-105

5.3.2.9 Connecting hoses
NOTICE
Improper handling of used oil can cause environmental pollution.
• Never spill any oil on the ground.
• Put your used oil in a clean plastic container with a tight lid. Never store used oil in a container
• Do not mix the oil with anything else, such as antifreeze, solvent, or paint.
• Take used oil to a service station or other location that collects used oil for recycling.
1. Before removing hoses, prepare a container for collecting oil.
2. Unscrew drain plugs on rotary drive and ho-

ses. finally connect and fasten them according
to figures below in this section.
G5 G6 G7 G8 G9
Fig 5-106 Rotary Drive Hose Clamp
G5. Hose number G8. Hose number

G6. Hose number G9. Hose number
G7. Hose number
3. Connect and fasten them according to fig-

ures below in this section.
Table 5–4 Connecting rotary drive hoses
Confluence
Hose Hydraulic K5
Hose Name K3 K4
Number Block Oil
K1 K2
Port
Primary Hose A G5 K1 Fig 5-107 Diagram of Connecting Rotary Drive
Hose
Primary Hose B G6 K2
Motor Feeding K1. Oil port K4. Oil port
G7 K3
Hose K2. Oil port K5. Oil port
Motor Drain Hose G8 K4 K3. Oil port
Electrical hose G9 K5

5.3.2.10 Connecting middle mast and lower mast
WARNING
Risk of getting crushed!
• During the assembly, do not insert any body parts between the two edges of middle mast and
lower mast.
1.Raise the mast. Stop once lower flange face

of middle mast joints with the upper flange
face of lower mast. Connect them with bolts
securely. For installing bolts, see: Chapter 5
Operation, “Connecting upper mast and
middle mast”.
Fig 5-108 Connecting with Bolts
2. Remove the connecting rod (1) between

lower mast and triangle.
Fig 5-109 Dismantling Connecting Rod
1. Connecting rod

3.Connect rotary drive and crowd cylinder with

pin (2) and secure.
2
Fig 5-110 Connecting Rotary Drive and Crowd

Cylinder
2. Pin
NOTE：
• When there is trouble in removing connecting rod, adjust the mast angle by mast adjust-
ing lever to facilitate the removal of mast connecting rod.
• Store the dismounted connecting rod and pins properly, and guard against parts loss.
• When installing bolts, tighten them gradually, following the sequence from middle to
sides.
• Tighten the bolts according to the required tightening torque (see Maintenance,
“Tightening Torque” on page 6-26.).
5.3.2.11 Installing wire ropes
WARNING
If there is too little rope on the rope drum, the rope can become detached from the rope drum.
Persons could be hit by falling loads and thus seriously or fatally injured.
• The rope drum of a rope winch must always contain at least three windings of rope.
Installing main winch wire rope:
1. Operate crowd system until rotary drive rises to the mast pivot area.
2. Operate left control handle to extend wire rope. For detailed operation, see: Chapter 5 Opera-
tion, “Main winch operation” on page 5-43.

3. Remove the rope guard pins on two major

pulleys (1). Pass wire rope through the two 1
major pulleys on masthead. Unwind until rope 2
end reaches the area under rotary drive. As
shown in the figure below.
Fig 5-111 Tightening Wire Rope End
1. Major pulley 2. Rope guard pin
4. Install rope guard pins (2) and secure.
5. Use rope clip (4) and rope thimble (5) to

tighten rope end. As shown in the right figure.
NOTE：
4
• If the rope end is fixed by ferrule before
leaving the factory, ignore this step.
• change or shorten the rope, secure the
rope end according to this step. 5
Fig 5-112 Tightening Wire Rope End
4. Rope clip 5. Rope thimble

Installing auxiliary winch wire rope
1. Unwind wire rope. For detailed operation,

see: Chapter 5 Operation, “Auxiliary winch
operation” on page 5-45.
2. Remove the rope retainers on small pulleys

of pulley frame. Install auxiliary winch limit 6
switch counterweight (4). Thread the rope
7
through pulley frame small pulley.
3. Unscrew auxiliary winch limit switch coun-

8
terweight bolt (5), thread the rope into hole
(6). Tighten the bolt according to the tighten-
ing torque. Fig 5-113 Installing Auxiliary Wire Rope
6. Auxiliary winch lim- 8. Hole

4. Unwind until rope end reaches the area
it switch
under rotary drive. counterweight
5. Install rope guard pins and secure. 7. Bolts
6. Use wire rope clip and rope thimble to tight-

en rope end.
NOTE：
• If the rope end is fixed by ferrule before
leaving the factory, ignore this step.
• change or shorten the rope, secure the
rope end according to this step.
NOTE：
• When extending wire rope, perform
guiding operation. Provide wire rope √
with a load and avoid getting twisted.
• When installing rope clip, press the clip
holder onto the wire rope working sec- ×
tion, press U-bolt onto wire rope end.
Never lay out rope clip reversely or alter-
natively as shown in the right figure.
×
Fig 5-114
Installation precautions

1. Determination of rope clip number

The number of rope clip is related to wire rope diameter. Choose rope clips suitable for wire ropes.
The recommendation list of minimum number of rope clip for all types of wire ropes is as follows:
Table 5–5 Recommendation list of minimum number of rope clip
Wire rope nominal diame-

≤18 ＞18–26 ＞26–38 ＞38–44 ＞44–60
ter(mm)
Minimum rope clip
3 sets 4 sets 5 sets 6 sets 7 sets
number
2. Determination of distance between rope clips

The distance between rope clips shall be 5 to 6 times longer than the wire rope diameter.
3. Fastening method for rope clip

When installing rope clips, press clip holder onto the wire rope working section. Press U bolt onto
wire rope end. Never lay out rope clip alternatively.
When installing, rope clamp’s fastening strength shall not be below 85% of wire rope breaking
force.
When fastening rope clip, pay attention to each clip’s load-carrying capacity. The clip farthest from
the thimble should not be fastened at first. The clip nearest to the thimble (the first clip) shall be
placed as close as possible to the thimble. Ensure that clips are screwed tightly and the outer steel
wires should not be damaged.
Check rope clip after carrying load once or twice and screw the nuts tightly.
5.3.2.12 Drilling rig test run
CAUTION
Improper test run can cause damage to personnel injury.
• To test run the drilling rig, operate it at a very low speed. Pay careful attention in test run.
After mounting the drilling rig, main mechanism of drilling rig should be tested and oil leakage
should be checked.
1. Boom mechanism test run

Operate the handle to extend and retract boom cylinder. Operate derricking mechanism to check
whether its motions are normal. see: Chapter 5 Operation, “Adjusting drilling center distance” on
page 5-25.
2. Rotary drive test run

Operate the handle to make rotary drive rotate positively, rotate reversely or dump soil. see: Chap-
ter 5 Operation, “Rotary drive control” on page 5-46.
3. Mast mechanism test run

Operate mast adjusting lever to raise and lower mast; when mast is vertical, operate the lever to
adjust mast tilting state. Its sideward angle shall be ±3° and forward inclination shall be +4°. Check
if all these motions are normal. see: Chapter 5 Operation, “Raising and lowering the mast” on
page 5-27 and “Adjusting mast to verticality” on page 5-39.
4. Main winch test run

Operate the handle to make main winch lift or lower the load; when the handle is released, the load
shall be stopped at its current position. see: Chapter 5 Operation, “Main winch operation” on
page 5-43.
5. Auxiliary winch test run

Operate the handle to make auxiliary winch lift or lower the load; when the handle is released, the
load shall be stopped at its current position. see: Chapter 5 Operation, “Auxiliary winch
operation” on page 5-45.
6. Test effectiveness of all limit switches

Test the effectiveness of all limit switches, and alarms indicate normal working condition.
5.3.3 Installing drilling tool
5.3.3.1 Connecting Kelly guide to Kelly bar
1. Connect Kelly guide (1) to Kelly bar (5) by

bolt (2), spacer (3) washers (4) and nut (5), as
illustrated in the right figure. Tighten the bolts
according to the required tightening torque
and fasten with the cotter pin (6).
6 5 4 3 2
2. Remove the two pins near the crowd sledge
guides and rotate the two crowd sledge
1
guides outwards. Install pins to their original 7
position to prevent the crowd sledge guides
from rotating. Fig 5-115 Connecting Kelly Guide to Kelly Bar
1. Kelly guide 5. Nut

2. Bolt 6. Cotter pin
3. Spacer 7. Kelly bar
4. Washer
NOTE：
• Tighten the bolts gradually.
• Tighten the bolts according to the required tightening torque (See: Maintenance,

5.3.3.2 Connecting rope swivel to Kelly bar
Use pins (2), screws (6) and washers (5) to

1
connect rope swivel (3) to Kelly bar (1) firmly.
2
5
4 6
Fig 5-116 Connecting Rope Swivel to Kelly Bar
1. Kelly bar 4. Grease filter

2. Pin 5. Washer
3. Rope swivel 6. Screw
NOTE： D
• Upper part and middle part are jointed
as a whole. Connect the upper part to
A B
main rope and connect the lower part to
Kelly bar.
E
quired tightening torque (See: Mainte-
C
nance, Tightening torque).
Fig 5-117 Rope Swivel
A. Upper part D. Connect to main

rope
B. Middle part E. Connect to Kelly
bar
C. Lower part

5.3.3.3 Aligning drilling rig with Kelly bar upper end
Operation procedures are listed below:
1. Rotate Kelly guide. Ensure that rope swivel

lower part opening and Kelly guide opening
are in the same direction. It is convenient for
main winch to hoist Kelly bar.
2. Place Kelly guide opening downwards to

support the Kelly bar. Lay the Kelly bar down
lengthwise at front of the machine, in the cen-
terline of the machine.
Fig 5-118 Aligning Drilling Rig with Kelly Bar
5.3.3.4 Connecting wire rope and rope swivel
Operate mast adjusting lever slowly, tilt the

mast forward by 3° to 4°. Connect wire rope
(1) and rope swivel by pins (2), washers (3)
and screws (4).
1
2
3
Fig 5-119 Connecting Wire Rope and Rope

Swivel
1. Wire rope 3. Washer

2. Pin 4. Screw

5.3.3.5 Installing Kelly bar
WARNING
If the drilling tool is not mounted properly on the fitting, it could fall down or tip over during opera-
tion. Persons could be hit and receive serious or fatal injuries.
• During the rigging process, never raise the drilling tool higher than necessary.
• To avoid accident, no person should be allowed to be near the machine during lifting the Kelly
bar.
NOTICE
Risk of causing damage to components!
Careless handling of the Kelly bar could lead to collisions with the rotary drive and the equipment
components. These components could be damaged as a result.
• Avoid collisions between the Kelly bar, rotary drive, and components.
NOTE：
Incorrect alignment of the rope swivel
could cause the rope swivel to be dam-
aged when the Kelly bar is raised.
Always align the main rope and rope swiv-

el vertically to the direction of tension.
Fig 5-120

1. Operate main winch slowly to raise Kelly

bar and at the same time travel with the ma-
chine towards the Kelly bar. Keep angle as
small as possible between wire rope and
mast.
Fig 5-121 Diagram I of Raising Kelly Bar
2. Lift Kelly bar off the ground slowly.
NOTE：
Before lifting Kelly bar off the ground,
make sure the distance between the bot-
tom surface of mast and the ground is
more than 1.5 m or 4.9 ft. Otherwise, the
rear part of crawlers may tilt. If this occurs,
operate boom mechanism to adjust this
distance.
Fig 5-122 Diagram II of Raising Kelly Bar

3. Slowly adjust the mast until it is vertical.

Slowly retract main rope to lift Kelly bar. Stop
until its square stub is above the rotary drive.
Slightly rotate Kelly bar to make sure the Kelly
guide opening aligns with the mast. Release
main rope to slowly lower Kelly bar and insert
the mast guide rail into Kelly guide bracket.
Fig 5-123 Diagram I of Inserting Kelly Bar into

Rotary Drive
4. Lower boom mechanism. Rotate rotary

drive to align Kelly bar outer key with corre-
sponding key slot in rotary drive. Lower Kelly
bar slowly into the key sleeve of rotary drive.
Note: Rotary drive key sleeve is equipped

with key slots for two types of Kelly bars: fric-
tion Kelly bar and interlocking Kelly bar. When
installing Kelly bars, insert them into the right
key slots.
Fig 5-124 Diagram II of Inserting Kelly Bar into

Rotary Drive

5. Lift rotary drive to the position of mast pivot.

At the same time raise boom mechanism
slowly. Lower Kelly bar and do not let Kelly
bar touch the ground.
NOTE：
• Lower mast at low speed, and prevent
Kelly guide crowd sledge guide from
separating mast front face.
• Try to lower Kelly bar gravity center to
ensure the mast can be raised after
being lowered.
Fig 5-125 Diagram III of Inserting Kelly Bar into

Rotary Drive
5.3.3.6 Installing drilling bucket
1. Place drilling bucket on the ground, with the

Kelly box upwards.
2. Align Kelly bar square stub with Kelly box.
3. Lower Kelly bar slowly, rotate rotary drive to

align Kelly bar square stub with Kelly box. In-
sert Kelly bar square stub into Kelly box and Fig 5-126
fasten them with pin and lock pin.
5.3.4 Disassembling drilling tool
5.3.4.1 Disassembling drilling bucket
Before operation, extend the crawlers.

1. Set the mast upright.
2. Lay drilling bucket on ground.
3. Remove pin and lock pin, disassemble drill-

ing bucket.
4. Raise Kelly bar slowly until it is separated

from drilling bucket. Fig 5-127
NOTE：
• When the pin connecting Kelly bar and drilling bucket cannot be removed, operate main
winch repeatedly and slowly to loosen the connecting pin.
• Store pin and lock pin properly and guard against parts loss.
5.3.4.2 Removing Kelly bar
WARNING
Risk of injury!
If the drilling tool is not mounted properly on the fitting, it could fall down or tip over during opera-
tion. Persons could be hit and receive serious or fatal injuries.
• To avoid accident, no person should be allowed to be near the machine during lifting the Kelly
bar.
1.Set the mast to upright and move the rotary

drive to the lowest position. Deactivate main
winch upper limit. Lift Kelly bar until it is sepa-
rated from the rotary drive.
NOTE：
• Before lifting Kelly bar off the ground, make
sure the distance between the bottom sur-
face of mast and the ground is more than
1.5 m or 4.92 ft. Otherwise, the rear part of
crawlers may tilt. If this occurs, operate
boom mechanism to adjust this distance.
• Careless handling of the Kelly bar could
lead to collisions with the rotary drive and
the equipment components. These compo-
Fig 5-128 Diagram I of Raising Kelly Bar
nents can be damaged as a result.

2. Push mast lever forward slowly until mast

leans forwards by 3° to 4°. At this time, Kelly
bar and Kelly guide are away from mast front
surface.
Fig 5-129 Diagram I of Lowering Kelly bar
3. Lower Kelly bar slowly (lengthwise and cen-

trally in front of the equipment), until square
stub reaches the ground. Go on lowering the
Kelly bar and at the same time travel in re-
verse with the machine. Do not stop until Kelly
bar is laid on the ground entirely.
Fig 5-130 Diagram II of Lowering Kelly bar

4. Remove the rope swivel from the wire rope

(1) by removing pin (2), washer (3) and screw
(4).
5.Retract main rope to the suitable length and

1
fasten the rope end.
6. Retract auxiliary rope to the suitable length 4

and fasten the rope end. 2
3
NOTE：
Install the pin and bolts to their original po-
sition, in case of parts loss.
Fig 5-131 Connecting Wire Rope and Rope

Swivel
1. Wire rope 3. Washer

2. Pin 4. Screw
5.3.5 Disassembling drilling rig
5.3.5.1 Removing rotary drive and crowd cylinder
1. Raise mast slowly to vertical status.
2. Lower the rotary drive to the lowest end of

the mast.
3. Remove the pin (2) connecting rotary drive

and crowd cylinder.
Fig 5-132 Installing Connecting Rod
1. Connecting rod

4. Retract crowd cylinder.
5. Installing connecting rod (1). 2
NOTE：
Store dismantled bolts and washers prop-
erly and guard against parts loss.
Fig 5-133 Disconnecting Rotary Drive and

Crowd Cylinder
2. Pin
5.3.5.2 Disconnecting middle mast and lower mast
1. Remove bolts connecting middle mast and

lower mast.
Fig 5-134 Bolts
2. Lower mast and rest it horizontally on the

mast bracket.
Fig 5-135 Mast in Horizontal State
NOTE：
• Store dismantled bolts and washers properly.
• Do not damage electric wires during operation.

5.3.5.3 Removing rotary drive
WARNING
Danger of accident!
1. Disconnect electric lines and hydraulic

lines.
A
2. Attach lifting slings to lifting eyes. Ensure

that rotary drive crowd sledge guide remains
vertical after it is being lifted.
3. Use crane to lift off the rotary drive from po- B
sition (B) to position (A).
4. Put it into a packing box or on level and firm

ground.
NOTE：
• Use sling and U ring of required specification.
• Protect electric wire plug properly and block the removed oil pipe with plug to prevent it
from polluting hydraulic system.
• When rotary drive is about to separate from guide rail, operate slowly to prevent parts
from swaying to collide.

5.3.5.4 Removing lower mast
WARNING
Danger of accident!
loads. Persons in the vicinity of the equipment could be hit and received serious or fatal injuries.
1. Attach lifting slings to lifting eyes. Ensure B A

that it remains vertical after being lifted.
2. Slightly pre-stress the lifting sling.
3. Remove connecting rod between lower

mast and triangle. 1
4. Remove the pin (1) connecting lower mast

and middle mast. Fig 5-136 Removing Lower Mast
1. Pin B. Position
5. Use crane to lift lower mast from position B
A. Position
to position A.
6. Put lower mast on a level solid ground, with

guide rail side downwards.
NOTE：
• Use sling and U ring of required specification.
• When lower mast is about to separate from middle mast, motions must be very slow to prevent
parts from swaying.

5.3.5.5 Disconnecting masthead and upper mast
WARNING
Danger of getting crushed!
• During the assembly, do not insert any body parts between the two edges of masthead and
upper mast.
1. Remove bolts and washers connecting

masthead and upper mast. The removing
method is in reverse order of installing
method.
Fig 5-137 Mast in Horizontal State
2. Make the masthead rotate around hinged

1
shaft slowly. When masthead support plate
joints with upper mast support plate, install
transport support (1) and fasten it.
NOTE：
• Store dismantled bolts and washers
properly and guard against parts loss.
• Do not press electric wires when rotat-
ing masthead. Fig 5-138 Transport Support
1. Transport support
5.3.5.6 Disconnecting upper and middle mast
WARNING
Risk of crushing hazard!
Even slight actuation of the mast cylinders leads to large movements of the mast. This could re-
sult in serious or fatal injuries to persons.
• Ensure constant visual contact with the person giving directions.

1. Remove the bolts (2), spacer (3), washer

(4), nut (5) and locknut (6) connecting upper
mast and middle mast.
6
5
3
2
Fig 5-139 Removing Bolts
2. Bolt 5. Nut
3. Spacer 6. Locknut
4. Washer
2. Rotate upper mast around the hinged shaft.

Stop until the upper mast is totally folded and
parallel with the middle mast.
3. Install pin (1) and secure.

1
NOTE：
• Store dismantled bolts and washers
properly and guard against parts loss.
• Do not press electric wires when rotat-
ing masthead.
Fig 5-140 Installing the Pin
1. Pin

5.3.5.7 Removing counterweight
WARNING
If the lifting device and counterweight are not correctly aligned with each other, the counterweight
can fall over or start swinging uncontrollably during lifting. Persons can be hit or trapped by the
counterweight.
• The lifting points of the lifting device must be positioned vertically above the lifting points of the
counterweight.
1. Raise mast. Ensure that there are no bar-

riers over counterweight.
2. Connect sling and U ring to counterweight

lug. Use crane to lift counterweight, move it
from position (B) to position (A). Fasten with
bolts.
3. Lower mast and rest it horizontally on mast Fig 5-141 Diagram I of Removing
transport bracket. Counterweight
NOTE： A
B
• Connecting elements for lifting such as
U ring and slings shall meet the hoisting
requirement.
quired tightening torque (See Mainte-
nance, Tightening Torque).
Fig 5-142 Diagram II of Removing

Counterweight

5.4 Drilling Rig Transport

5.4.1 Safety guidelines for transport
WARNING
Risk of accident!
Improper use of lifting slings can cause an accident. This could result in serious or fatal injuries to
persons.
• Attach lifting slings only to the provided lifting points. Failure to do so may result in injury or pos-
sibly death.
The safety guidelines are as follows:
1. Only use hoisting equipment and lifting slings that have sufficient bearing capacity.
2. Attach and secure movable parts of the equipment.
3. Cover up sharp edges, projecting points and cutting blades.
4. The driver of the transporting vehicle is responsible for checking all the equipment, the machine
and accessories each time before driving.
5. The hauler in charge is responsible for the transport of the equipment, the machine and
accessories.
6. The hauler should be informed of the transport dimensions, the weights and the route.
7. Be familiar with transport dimension and weight which are regulated by local laws.
8. A road permit must be obtained.
5.4.2 Transport requirements
Before transport, be sure you have and read and fully understand the precautions and information
in Safety guidelines for transport in the Safety section of this manual. For details about the
transport regulations, please consult the local government:
1. When transporting drilling rig, follow all relevant local laws and regulations.
2. When transporting with a trailer, check transport dimensions before loading drilling rig. The
height of the rear of trailer should be under 1100 mm or 43.31 in, the height of the middle part of
trailer should be under 800 mm or 31.5 in.
3. Examine the transport route situation and transport regulation in advance.

5.4.3 Transport parameters
1. Transport status A
Fig 5-143 Transport status A
Table 5–6 Transport parameters of status A
Item Unit Data

A. Transport Length mm 19125
B. Transport Height mm 3690
C. Transport Width mm 3490
D. Crawler Length mm 6210
Track Width mm 800
Transport Weight t 86

2. Transport status B
Fig 5-144 Transport Status B
Table 5–7 Transport parameters of status B
Item Unit Data

Track Width mm 800
Transport Weight t 67
Table 5–8 Counterweight
Item Unit Data

E. Transport F
mm 3250
Length
F. Transport E G
mm 1557
Height
G. Transport Fig 5-145 Counterweight
mm 786
Width
Transport
t 11
Weight

Table 5–9 Rotary drive
Item Unit Data

H. Transport
mm 2140 I
Length
I. Transport
mm 2322
Height
J. Transport J H
mm 1406
Width
Transport Fig 5-146 Rotary Drive
t 7.85
Weight
3. Transport Status C
Fig 5-147 Transport Status C
Table 5–10 Transport parameters of status C
Item Unit Data


Table 5–10 Transport parameters of status C (continue)
Item Unit Data

Track Width mm 800
Transport Weight t 64.6
Table 5–11 Counterweight
Item Unit Data

E. Transport F
mm 3250
Length
F. Transport E G
mm 1557
Height
G. Transport Fig 5-148 Counterweight
mm 786
Width
Transport
t 11
Weight
Table 5–12 Rotary drive
Item Unit Data

H. Transport I
mm 2140
Length
I. Transport
mm 2322
Height
J. Transport J H
mm 1406
Width
Transport Fig 5-149 Rotary Drive
t 7.85
Weight
Table 5–13 Lower mast K
Item Unit Data

K. Transport 2550
mm M
L
Length
L. Transport 887
mm
Height
Fig 5-150 Lower Mast
M. Trans- 651
mm
port Width
Transport 1.05
t
Weight

5.4.4 Loading and unloading the machine
5.4.4.1 Requirement for loading and unloading
Precautions are listed as follows:

• Operate the traveling lever/pedal to make the machine slowly moving and avoid danger caused
by high-speed movement.
• Turn engine speed dial to low speed.
• When loading or unloading the machine, choose solid and level ground and keep a safe dis-
tance from road edge.
• Use a slope with sufficient width, length, thickness and strength, its maximum slope angle being
15°. When using a soil slope, compact the soil. When using the trailer’s ramp, its angle from the
ground shall not exceed 15°.
• When using ramp or a platform, place spacer blocks under trail wheels to prevent trailer from
moving.
• It is extremely dangerous to change direction when driving up or down a ramp. Drive back to
ground or trailer plate to change traveling direction.
• Because tracks are flat and straight, drilling rig may suddenly lean forwards or backwards when
passing the jointing point between ramp top and trailer plate. Drive through this point cautiously.
• When loading or unloading the machine, never swing the drilling rig to avoid possible rollover.
• When the machine is traveling on a slope, never operate any control lever other than traveling
lever.
• Before loading or unloading, clean ramp or platform and trailer thoroughly.
5.4.4.2 Loading the machine
1. Start the engine. Align tracks with ramp or slope, and drive drilling rig in reverse onto the trailer.
2. Raise mast to prevent working tools hitting the ground when the drilling rig is driving up a slope.
3. With the help of a guide person, drive drilling rig slowly onto ramp or slope. When traveling to
the jointing point between ramp top and trailer plate, the drilling rig will sway forwards or back-
wards. At this moment, adjust the drilling rig slowly and cautiously. Drive it onto trailer plate at its
minimum speed.

Fig 5-151 Loading the Machine
4. Stop drilling rig at a suitable position on the trailer plate. Ensure that the tracks of both sides
have an equal clearance from trail sides.
5. Stop the engine and remove the key. Operate control lever several times until pressure in hy-
draulic cylinder is released completely.
6. Pull hydraulic lock lever to locked position.
7. Shut cab window, ventilator and door, and cover air vent to shield wind or rain.
8. Install swing locking connecting rod.
5.4.4.3 Fastening method
Fasten the machine by chains or wire rope to prevent it from sliding during transportation.
NOTE：
Bind chains or wire ropes on the H beam, and never let them rest on or across hydraulic
lines or hoses.
5.4.4.4 Unloading the machine
The process of unloading the machine reverses that of loading it. See: Chapter 5 Operation,
“Loading the machine” on page 5-103 for detailed operation.
NOTE：
Raise mast height to prevent working tools hitting the ground.

5.4.5 Requirements for sea transportation
NOTICE
Risk of causing damage to the equipment or the components!
Incorrect attachment of the lifting device and lifting gear can result in damage to the equipment
and/or components.
• Only attach the lifting device to the lifting points provided for that purpose.
The key requirements for marine transportation are to protect the rotary drilling rig from seawater
corrosion. Selection and application method of protective materials are as follows:
1. Protection of non-paint finishing work piece (plated piece, phosphoresced piece)

Brush rust preventing oil 377-HF evenly twice.
Use polyethylene film (bags) or wrapping film for packaging. Use polyethylene tape for sealing
bandage.
2. Coating surface protection

To protect exposed painting surface, choose air bubble film to wrap, then use dust preventing
wrapping film to seal. Ensure that the wrapping overlap shall be not less than 150 mm or 5.9 in.
Relevant parts are wrapped tightly and fixed after being wrapped 3 rounds. Cover surface shall be
sealed by TESA (50530) paint protection film.
Cab interior surface, painting surface, seat, floor, operating handle, and control panel shall be
packed by TESA51136 inner protective film.
3. Protection of reducer, exposed pipe joint, bolts and pins end

Brush rust preventing oil 377-HF evenly twice. Use dust preventing wrapping film to seal after
wrapping 3 rounds (if part assembly is completed, use dust preventing wrapping film to seal by
wrapping the part assembly).
4. Glass window protection

Use TESA (51136) transparent glass protection film to perform sealing operation. Start applying
protection film from one end of outside glass surface while scrapping in the same direction by rub-
ber scrapper. Ensure that protection film and glass surface are jointed firmly, leaving no breakage
or obvious air bubble.
5. Protection of electrical appliance system and hoses

To protect power distribution box, use silicon protection coating 494-714 to spray on exposed plug
(socket) and contact point. Then use water proof plastic bag or wrapping film to seal it. Place des-
iccant into power distribution box and fasten it. Use wrapping film to seal and fasten exposed ho-
ses, electric appliance line and plug-in.
For desiccant, choose silica gel or surface, and pack with cotton cloth (bag), and it is easy to place
and fix.
Hoisting the machine

1. Set safety lock lever to locked position (2).

1
2. Shut down the engine. Remove the ignition
key.
3. Wrap protection material around steel chain

and support rod.
4. Thread steel chain (3) through undercar- 4

riage frame. Use support rod (4) to hold firmly.
3
Make sure the steel chains are installed onto
the crane.
Fig 5-153 Hoisting
3. Steel chain 4. Support rod
Precautions are listed as follows:

– Do not hoist the machine with person in the cab.
– Prevent anyone from being near or under the hoisting machine.
– Ensure that steel chain for hoisting the machine are strong enough. Do not use damaged or
aged steel chain or hoisting tool.
– If you have any question about hoisting method, types of hoisting steel chain and hoisting tool,
contact approved sales representatives or SANY.
– Pull control lever to locked position to prevent the machine from moving unexpectedly when
being hoisted.
– Do not hoist the machine at a high speed. Otherwise, hoisting steel chain and hoisting tool will
be overloaded to break.
– Do not hoist the machine when the upper carriage is turning to one side. Before hoisting the
machine, make sure that the upper carriage is in line with crawlers.
– When lifting the machine, keep it in horizontal status.

SR305RS10Rotary Drilling Rig Maintenance
Maintenance
6 Maintenance.......................................................................................................................6-1
6.1 Maintenance Guideline ........................................................................................................6-5
6.1.1 Overview.......................................................................................................................6-5
6.1.2 Maintenance information............................................................................................6-6
6.1.2.1 Maintenance personnel ......................................................................................6-6
6.1.2.2 Risks during maintenance ..................................................................................6-6
6.1.2.3 Before maintenance ............................................................................................6-9
6.1.2.4 During maintenance ............................................................................................6-9
6.2 Treatment of Oil, Fuel and Coolant...................................................................................6-11
6.2.1 Oil ................................................................................................................................6-11
6.2.2 Fuel .............................................................................................................................6-11
6.2.3 Coolant ...................................................................................................................... 6-12
6.2.4 Grease ....................................................................................................................... 6-12
6.2.5 Storage of engine oil and fuel................................................................................. 6-13
6.2.6 Filter element ............................................................................................................ 6-13
6.3 Electrical System Maintenance........................................................................................ 6-13
6.4 Wear Parts .......................................................................................................................... 6-14
6.5 Recommended Fuel, Coolant and Lubricating Oil ........................................................ 6-15
6.6 Drilling Rig Oil ..................................................................................................................... 6-18
6.7 Lubrication Points............................................................................................................... 6-22
6.8 Tightening Torque .............................................................................................................. 6-26
6.9 Regular Inspection ............................................................................................................. 6-28
6.10 Maintenance Schedule ................................................................................................... 6-29
6.11 Maintenance Procedures ................................................................................................ 6-32
6.11.1 Every 10 service hours .......................................................................................... 6-32
6.11.1.1 Crawler tension - check and adjust .............................................................. 6-32
6.11.1.2 Hydraulic cylinders- check............................................................................. 6-34
6.11.1.3 Shock absorbing device of rotary drive - check and replace.................... 6-36
6.11.1.4 Rotary drive bolts - check .............................................................................. 6-38

Maintenance SR305RS10Rotary Drilling Rig
6.11.1.5 Crawler track - inspect .................................................................................. 6-41

6.11.1.6 Wire rope - inspect ......................................................................................... 6-42
6.11.1.7 Wire rope - maintain ...................................................................................... 6-43
6.11.1.8 Wire rope - discard ......................................................................................... 6-44
6.11.1.9 Rope swivel flexibility - check........................................................................ 6-45
6.11.1.10 Rope swivel - check and lubricate.............................................................. 6-46
6.11.1.11 Engine oil level - check................................................................................. 6-47
6.11.1.12 Fuel amount - check and refuel .................................................................. 6-48
6.11.1.13 Water and sediment in fuel tank - drain ..................................................... 6-49
6.11.1.14 Coolant level - check and refill .................................................................... 6-50
6.11.1.15 Hydraulic oil level - check and refuel ......................................................... 6-51
6.11.1.16 Switches, buttons and operation handles - check ................................... 6-53
6.11.1.17 Kelly guide swing bearing - lubricate ......................................................... 6-54
6.11.1.18 Kelly guide swing bearing - check and replace ........................................ 6-54
6.11.2 Initial 50 service hours........................................................................................... 6-55
6.11.2.1 Engine oil and filter - change and replace ................................................... 6-55
6.11.2.2 Fuel tank strainer - clean ............................................................................... 6-58
6.11.3 Every 50 service hours .......................................................................................... 6-58
6.11.3.1 Winch reducers oil level - check ................................................................... 6-58
6.11.3.2 Rope hold-down rollers - check .................................................................... 6-59
6.11.3.3 Rotary drive sliding strip - check and replace ............................................ 6-60
6.11.3.4 Shock absorber - check ................................................................................. 6-61
6.11.3.5 Air intake and exhaust system - check ........................................................ 6-61
6.11.3.6 Window wiper - check .................................................................................... 6-61
6.11.3.7 Window washer - check ................................................................................. 6-62
6.11.3.8 Impact ring - check and replace.................................................................... 6-62
6.11.3.9 Track shoe bolts - check ................................................................................ 6-63
6.11.3.10 Spring of Kelly bar- check and replace...................................................... 6-64
6.11.3.11 Hydraulic hose - check and replace ........................................................... 6-64
6.11.3.12 Other maintenance item .............................................................................. 6-65
6.11.4 Initial 250 service hours......................................................................................... 6-66
6.11.4.1 Winch reducer oil - change............................................................................ 6-66
6.11.4.2 Rotary drive reducer gear oil - change ........................................................ 6-66
6.11.4.3 Bolts connecting swing bearing - check ...................................................... 6-68
6.11.5 Every 250 service hours........................................................................................ 6-68
6.11.5.1 Rotary drive gear oil level - check ................................................................ 6-68
6.11.5.2 Rotary drive gear oil - sample and test ........................................................ 6-69
6.11.5.3 Driver strip - check and change .................................................................... 6-70
6.11.5.4 Air conditioner circulation filter - clean ......................................................... 6-70
6.11.5.5 Air recirculation filter - inspect and replace ................................................ 6-72
6.11.5.6 Filter of water oil separator - replace............................................................ 6-72
6.11.5.7 Fuel filter - check and replace ....................................................................... 6-74

6.11.5.8 Hoses - check and replace ............................................................................ 6-75
6.11.5.9 Kelly guide sliding strip - check and replace ............................................... 6-76
6.11.5.10 Kelly bar locking recesses - check ............................................................. 6-76
6.11.5.11 Kelly bar tube - check ................................................................................... 6-76
6.11.5.12 Kelly bar drive gibs - check ......................................................................... 6-78
6.11.5.13 Kelly bar baffle - check................................................................................. 6-78
6.11.5.14 Wire rope sheaves - check.......................................................................... 6-79
6.11.5.15 Hydraulic system cleanliness - control ...................................................... 6-79
6.11.5.16 Generator belt - check and adjust .............................................................. 6-80
6.11.5.17 Fan belt - check and adjust ......................................................................... 6-80
6.11.6 Initial 500 service hours......................................................................................... 6-80
6.11.6.1 Rotary drive gearbox gear oil - change........................................................ 6-80
6.11.6.2 Travel reducer oil - change ............................................................................ 6-81
6.11.7 Every 500 service hours........................................................................................ 6-83
6.11.7.1 Air recirculation filter - replace ..................................................................... 6-83
6.11.7.2 Gear oil for swing reducer - change ............................................................. 6-83
6.11.7.3 Other maintenance items .............................................................................. 6-85
6.11.8 Initial 1000 service hours ...................................................................................... 6-86
6.11.8.1 Hydraulic oil - change..................................................................................... 6-86
6.11.8.2 Oil suction filter - replace ............................................................................... 6-89
6.11.9 Every 1000 service hours ..................................................................................... 6-90
6.11.9.1 Pilot filter element - replace ........................................................................... 6-90
6.11.9.2 Return filter - replace ...................................................................................... 6-91
6.11.9.3 Auxiliary pump filter element - replace......................................................... 6-93
6.11.9.4 Breather valve - check and replace.............................................................. 6-94
6.11.9.5 Battery - clean and recycle ............................................................................ 6-94
6.11.9.6 Other maintenance items .............................................................................. 6-95
6.11.10 Every 2000 service hours ................................................................................... 6-96
6.11.10.1 Other maintenance items ............................................................................ 6-96
6.11.11 Every 3000 service hours.................................................................................... 6-96
6.11.11.1 Generator belt - replace ............................................................................... 6-96
6.11.11.2 Fan belt - replace（if equipment）............................................................. 6-96
6.12 Storage of Drilling Rig ..................................................................................................... 6-96
6.12.1 Preparations before storage................................................................................. 6-96
6.12.2 Maintenance during storage................................................................................. 6-96
6.12.3 Routine maintenance of drilling rig ...................................................................... 6-97
6.12.4 Maintenance for removal of drilling rig from garage ......................................... 6-98
6.12.5 Maintenance for long-term storage ..................................................................... 6-99


6.Maintenance
6.1 Maintenance Guideline

6.1.1 Overview
NOTICE
Risk of damaging the equipment!
Failure to maintain the equipment in accordance with the requirements of this manual could
cause damage to the equipment.
• Drive the machine on safe place.
• Shut down the engine, perform maintenance after all the components stop running.
• Run the machine during any maintenance procedures only if directed to do so here. If the ma-
chine must be run during maintenance, it is important to follow relevant safety rules.
• Install the proper alert tag to the work equipment levers to warn others not to operate the
machine.
• Start the engine only after all the maintenance signs are removed.
• Before performing maintenance, carefully read Chapter 2. Safety. All the maintenance must be
performed under safe surroundings.
• When performing any maintenance and repair work, follow all the listed safety procedures.
• Pay attention to the warning messages. Maintain the machine according to requirements.
• Maintenance can only be carried out by after-sales service engineer or authorized skilled
personnel.
• Perform maintenance according to required intervals.
• Comply with the maintenance regulations of manufacturers of third-party parts used in the
equipment.
• Industrial oil liquids, especially used oils, will cause serious pollution to the environment. All
kinds of oil liquids must be handled in accordance with laws and regulations. Violators will face
severe penalties!
• This chapter focuses on the general risks that may be encountered in the maintenance of ma-
chine. Relevant security information will be described in detail in specific sections.
• Perform checks and maintenance work as required. Be sure to replace components according
to requirements.
• Keep all the handles, pedals, walking platform above the machine cover, and steps clear of dust,
snow, ice, and oil.
• During lubrication and maintenance, never allow unauthorized personnel near the machine.
• Wear protective equipment such as safety clothes, safety glasses, and mask.
• When washing the machine, do not spray water on electrical components.

• Keep the machine clean to facilitate the detection of oil leakage, cracks, loose connectors and
other abnormalities. In particular, keep the nozzle, ventilation hole and oil dipstick clean to pre-
vent dust entering into the parts.
• Only use genuine SANY spare parts.
• For any problems during lubrication and maintenance process, contact SANY after sales service
department.
6.1.2 Maintenance information
6.1.2.1 Maintenance personnel
All maintenance to be performed on this machine must be by trained and authorized personnel. It
is important to follow all maintenance procedures and safety information as outlined in this manual
and in the service manual.
6.1.2.2 Risks during maintenance
• For some potentially hazardous location, use special caution when performing lubrica-
tion and maintenance work.
• On the warning decals, different signal words are used to express the potential level of
hazard, including “notice, caution, warning, or danger”. Its level goes up successively,
and caution should be enhanced.
Swing injury
Standing within the swing radius range may

result in injury or death.
Related parts: Counterweight, and upper car-

riage components.
Related maintenance: Add grease to the

swing gear ring of upper carriage.
Measures: Sound the horn to alert before

starting the machine. Never allow personnel
to stand within the swing radius.
Fig 6-1

Hand injury and dragging hazard
Be cautious of hand injury. All the rotating and

moving parts may cause hazards of hand in-
jury, body being caught, or dragging.
Related parts: Wire rope, all the pulleys,

winches, undercarriage, swing mechanism,
and boom mechanism.
Related maintenance: Replace wire rope;

add grease to crawler tensioning cylinder,
check and change for driving gear oil, etc.
停止STOP
Measures: When replacing wire rope, adding
grease to crawler tensioning cylinder, check Fig 6-2
and change for driving gear oil, arrange au-
thorized person.
Falling hazard
Climbing on and off the machine in incorrect

way easily poses falling hazard.
Related parts: All the climbing position, and

walking position.
Related maintenance: All the maintenance

to the upper carriage.
Measures:
• Use the steps and handrails when climbing

on and off the machine. Check and clean
the steps and handrails before climbing on
Fig 6-3
the machine.
• When getting on and off the machine, al-
ways face the machine and maintain a
three-point contact with the handrails and
steps.
• When it requires to walk on the mast, be
sure to lower the mast in place and take ef-
fective measures to prevent slipping or
falling.

Burn hazard
High temperature may cause burn to mainte-

nance personnel.
Related parts: Engine exhaust system, water

tank, engine, and working hydraulic system.
Related maintenance: Engine maintenance,

change of coolant, and hydraulic system
maintenance.
Measures: After long time running for the en-

gine, do not immediately do maintenance to
hydraulic system, engine coolant, air intake,
air exhaust, and all that directly contacts the Fig 6-4
engine cylinder. Do this when the temperature
of the maintained position drops to the extent
that you can touch with hand.
High pressure fluid hazard
The spurting out fluids under pressure such

as diesel, hydraulic oil and grease can pene-
trate skin or rip into eyes, and cause serious
injury, blindness, or death.
Related parts: Hydraulic pipeline compo-

nents, crawler tensioning cylinder.
Related maintenance: Maintenance of hy-

draulic system, and maintenance of crawler Fig 6-5
tensioning devices.
Measures:
• Tighten all the connections before
pressurizing.
• Release pressure before disconnecting the
hydraulic pipeline.
• Use a card to check for leakage and protect
your hands and body against high pressure
fluids. Wear mask or glasses in order to
protect your eyes. Fig 6-6

Fire hazard
Leakage of fuel, hydraulic oil, and grease may

cause a fire.
Related maintenance: Hydraulic oil pipeline,

fuel system, and electrical system.
Measures:
• After maintenance, clean up the fuel, hy-
draulic oil, grease, debris, and other flam-
mable material. Check and clean the
machine everyday in order to promptly re-
move the accumulated flammable Fig 6-7
materials.
• Clean and tighten all the circuit connection.
Check for looseness, twist, hardening, or
cracks of the cable and electrical wire.
• Prepare fire extinguishers on site.
6.1.2.3 Before maintenance
• Notify the operator and assign a supervisor.

• Run the machine during any maintenance procedures only if directed to do so here. If the ma-
chine must be run during maintenance, it is important to follow relevant safety rules.
• Park the machine on solid and level ground.
• Make sure unauthorized person cannot start the machine (lock the cab door). Install the proper
alert tag to the work equipment levers to warn others not to operate the machine.
• Before performing lubrication and maintenance, lock the power switch and ignition switch of the
electrical system.
• Before starting maintenance, clean the machine, and especially remove lubricant, fuel, or any
additives at the joints and coupling. Do not use corrosive detergent. Use non-fibre cleaning rag.
• Before spraying with water or steam or using any other detergent, cover all the components that
may be affected by water, steam, or detergent.
• After cleaning, remove the covering articles. Check for residues within these areas.
• After cleaning, check for leakage of all the fuel pipeline, engine oil line, and hydraulic oil line.
Check the joints for looseness, cracks, or damage.
• During maintenance, oil fluids may overflow. Prepare a suitable container.
6.1.2.4 During maintenance
• Suitable space and auxiliary equipment are needed for maintenance.

• When replacing a single component or a large component, park it. Make sure there is no
damage.
• Only use auxiliary equipment with enough bearing capacity.
• Do not stand, walk, or work under hoisted load.
• Only assign experienced personnel to direct within the view of the operator.
• When performing maintenance work, connect loose bolts.
• If the safety equipment needs to be removed during maintenance, it must be reinstalled
afterwards.
• Make sure all the tools and parts meet the requirements of environment protection and safety.
• Be sure flammable materials are stored away from places with fire hazard.
• Regularly check the electrical equipment of the machine. Immediately repair or change the loose
joints and burnt cable.
• Only qualified electrician or trained personnel under the supervision of qualified electrician can
perform maintenance to the electrical system according to electrical regulations.
• Only replace fuse with one of the same capacity.
• Before performing maintenance to the hydraulic system, release pressure first.
• Regularly check for leakage of all the hoses and joints of the hydraulic system. Check for dam-
age to appearance. If any damage is found, repair or replace immediately.
• Only professional person with hydraulic knowledge can perform lubrication or maintenance to
hydraulic system.
• When handling lubricants, grease, or other chemical substances, abide by safety regulations for
corresponding products.
• Use caution when handling high temperature system (scald or burn hazard).
• Avoid over lubrication.
– over lubrication will cause grease or lubricant to leak, and result in operation fault.
– lubricant or grease dropped on passage way will cause people to slip over.
– over filling oil level will cause oil foam, which could result in high oil temperature and result in
the oil overflowing.
– if too much grease is added, it will cause the bearing sleeve push-out.
• Be sure no tools are left in the machine after maintenance.

• Be cautious of the protection for pipe opening, joint, and wire to avoid oil leakage.
• During maintenance, store small parts properly, and take proper anti-pollution measures.
• Before welding and grinding, keep the machine clear of dust and flammable materials. Only per-
form such tasks in a suitable environment with adequate ventilation.

6.2 Treatment of Oil, Fuel and Coolant

6.2.1 Oil
• The oil in the engine and hydraulic equipment will continuously deteriorate due to extremely
harsh working conditions (high temperature and pressure).
• Be sure to use the oil recommended in this manual and matching the highest and lowest ambi-
ent temperatures.
• The oil shall be changed within the specified oil change interval even if it is not dirty.
• Prevent foreign matters (water, metal particles or dust) from entering in to lubricating oil.
• Most of the machine’s failures are caused by oil with impurities. During storing or filling oil, spe-
cial care shall be taken to prevent any foreign matter from getting into the oil.
• The oil shall be filled according to the specified amount of oil, otherwise it will cause abnormality.
• Do not mix different grades or brands of oil.
• If the oil in the work equipment is not clean, there is water in the oil, or the air gets into the oil
pipes, contact the authorized agent of Sany.
• Perform oil analysis at regular interval.
• When changing oil , be sure to replace related filter elements. When replacing the oil filter ele-
ment, remember to add the oil of the given specification to the new filter element before
installation.
• Use the oil recommended by Sany.
• When changing hydraulic oil, drain the residual oil in pipes and cylinders. It is allowed to mix a
small amount of two types of oil.
6.2.2 Fuel
NOTICE
Risk of damaging the machine!
If use unqualified diesel, it could cause damage to the machine.
• Use genuine diesel.
• To ensure good fuel consumption and exhaust characteristics, the engine mounted on the ma-
chine uses a mechanically controlled high-pressure fuel injection device. This device requires
high-precision parts and lubrication, so its durability will be significantly reduced if you use low-
viscosity fuel with low lubricating capacity.
• Sulfur in the fuel will produce sulfur oxides during burning and react with water to become dilute
sulfuric acid, causing the engine damage. Be sure to use the fuel containing less than 10 mg/
kg of sulfur.
• Be sure to fill the fuel tank after daily work in order to prevent the condensation of moisture in
the air and the formation of water in the tank.
• The fuel injection pump is a precision part and it will not work properly if the fuel being used con-
tains any water or dirt.

• Drain the sediment and water from the fuel tank before starting the engine or 10 min after
refueling.
• Flush the fuel tank and the fuel system if there is foreign matter in the fuel tank.
• If the engine has run out of fuel, or if the filter element has been replaced, the air in the pipes
must be vented.
• Be sure to use the fuel specified in this manual. The fuel will solidify when it is used below the
specified temperature, especially at temperatures below -15° C (5° F). When the fuel is used
above the specified temperature, its viscosity will decrease and the output power will drop.
• During storing or refueling, take care to prevent foreign matters from getting into the fuel.
6.2.3 Coolant
• Coolant has important anti-corrosion and anti-freeze features. Even in areas not requiring anti-
freeze measures, it is essential to use antifreeze coolant.
Sany recommends TEEC-L35 antifreeze with a concentration of 50% and without dilution. With
excellent anti-corrosion, anti-freeze and cooling characteristics, TEEC-L35 antifreeze can be
used continuously for 1 year or 2000 h.
• Sany does not recommend using any coolant other than TEEC-L35 antifreeze. If you use other
coolant, it could cause serious problems such as corrosion of the engine and cooling system
parts made of light metals including aluminum.
If you use commercially available antifreeze as the coolant, be sure to keep its concentration fall
between 30% and 68% to ensure its corrosion resistance characteristic.
The mixing ratio of antifreeze and water is determined by the lowest ambient temperature, as
shown in the mixing table below.
Mixing ratio of water and antifreeze

Minimum atmos- ℃ -10 -15 -20 -25 -30 -35 -40
pheric
temperature ℉ 14 5 -4 -13 -22 -31 -40
Antifreeze volume ratio (%) 30 36 41 46 50 54 58
NOTE：
• Use distilled or tap water (soft water) when diluting the anti-freeze coolant.
• Natural water, such as river and well water (hard water), contains a lot of minerals (calcium and
magnesium), which are easy to form fouling inside the engine and the radiator. The fouling
formed inside the engine or the radiator will be difficult to be removed. Poor heat exchange may
also cause overheating.
6.2.4 Grease
• Grease is used to prevent twisting and noise at the connections.

• Fill grease if any part becomes inflexible or produces noise after used for a long time.

• Be sure to use the recommended grease, and select grease in accordance with the replacement
cycle and ambient temperature recommended in this manual.
• When filling grease, wipe away the old grease that has been squeezed out. Be sure to wipe
away the old grease that has been stained with sand and dirt, otherwise it will cause wear of the
rotating parts.
6.2.5 Storage of engine oil and fuel
• Place them indoors to prevent water, dust, or other debris from getting into them.
• When storing the oil drums for a long time, place the drums side so that the filler ports of the
drums are on the side (to prevent inhalation of moisture). If the oil drums have to be placed out-
doors, cover them with tarpaulins or take other protective measures.
• In order to prevent the oil or fuel from deteriorating during long-term storage, it must be used in
the order of first-in and first-out (namely the lubricating oil or fuel stored for longer time is used
first).
6.2.6 Filter element
• The filter element is an extremely important safety component that prevents foreign matters in
the oil and air lines from getting into important devices and causing malfunctions. Replace all fil-
ter elements regularly. When used under harsh conditions, the filter element shall be replaced
within a short period based on the sulfur content in all lubricating oil and fuel.
• Do not reuse cleaned filter element but replace it with a new one.
• Check whether metal particles are adsorbed on the old filter element when replacing it. If you
found metal particles, contact the authorized agent of Sany.
• Do not unpack the spare filter elements before use.
• Use Sany genuine filter elements.
6.3 Electrical System Maintenance
• Wet electrical equipment or damaged wire claddings will cause electrical short circuits and ma-
chine malfunctions. Do not flush the cab with water. When rinsing the machine, take care to pre-
vent water from getting into the electrical components.
• Electrical system maintenance includes checking the fan belt tension and checking the fan belt
for damage and wear.
• Do not install any electrical component other than those specified by Sany.
• External electromagnetic interference may cause malfunction of the controller in the control sys-
tem. Contact the authorized agent of Sany. when you install radio receivers or other wireless
devices.
• When working on a beach, carefully clean the electrical system to prevent corrosion.
• When installing the electrical equipment, connect it to a dedicated power connector. Do not con-
nect the optional power supply to the fuse, starter switch or battery relay.
6.4 Wear Parts
• Wear parts (such as filter elements, and bucket teeth) shall be replaced during regular mainte-
nance or before reaching their wear limits.
• In order to use the machine economically, wear parts shall be replaced correctly.
• High-quality Sany original parts shall be used for replacement.
• When ordering such parts, check the part numbers in the Parts Manual.
Table 6–1 Table of wear parts
Item Part name Replacement interval

Every 250 h clean or every 500 h
Air filter primary filter element
replace filter element
Water oil separator filter element Every 250 h
Power system Fuel fine filter element Every 250 h
Engine oil filter element First 50 h, then every 500 h
Every 250 h check and every 3000
Drive belt
h replace
Oil return filter element Every 1000 h
First 1000 h, then every 2000 h
Oil suction filter element
replacement
Hydraulic
Pilot filter element Every 1000 h
system
First 1000 h, then every 2000 h
Hydraulic filter element
replacement
Breather valve filter element Every 1000 h
Lamp
Electrical Replace when the parts do not
Camera
system work.
Temperature sensor
Wiper assembly
Wiper motor
Wiper controller
Replace when the parts do not
Cab Front movable window left side lock
work.
Front movable window right side lock
Door lock assembly
Door sealing rubber strip
External air filter
Every 250 h clean/check, and re-
Air conditioner Internal air filter
place when the parts do not work.
V belt

Table 6–1 Table of wear parts (continue)
Item Part name Replacement interval

Grease valve
Tensioning device
Crawler bolt
Traveling Maintenance according to
Crawler nut
mechanism requirement
Track shoe
Main pin
Traveling drive
6.5 Recommended Fuel, Coolant and Lubricating Oil
• Unless specified, the machine is filled with the oil and coolant listed in the table below when it is
shipped from the factory.
Table 6–2 Recommended type
Item Type
Engine oil pan Diesel engine oil CJ-4 15W-40 or higher
Swing mechanism box
Gear oil 85W/140
Final gearbox
Hydraulic oil system Anti-wear hydraulic oil HDZ46-Ⅱ(ISO VG46)
Radiator TEEC-L35 antifreeze
Swing bearing 2# lithium grease
• In order to keep the best condition of the machine for a long time, it is essential to follow the oil
operation and maintenance instructions in this manual. Failure to do so may result in excessive
wear of the engine, drive system, cooling system, and other parts, thus shortening their service
lives.
• Using commercially available lubricating oil additives could cause damage to the machine. Sany
does not recommend any lubricating oil additive.
• The specified capacity means the total amount of oil in the tank and lines. The adding capacity
means the amount of oil that needs to be added to the system during inspection and
maintenance.
• When starting the engine at temperatures below 0℃ (32°F), be sure to use the recommended
multi-grade oil even if the ambient temperature is high in the daytime.
• Use the recommended SANY oil and recommended oil according to the ambient temperature in
the table below.

Engine oil, fuel and coolant

Environmental temperature
-2- 1-
Fluid -4 -14 32 50 68 86 122℉ Recommend-
System 2 04
type ed oil fluid
-3- --
-10 0 10 20 30 40 50℃
0 20
5W-30
5W-40
Engine oil
Engine oil 10W-30
pan
15W-40（note）
40
HDZ32-Ⅱ
(ISO VG32)
Hydraulic Hydraulic
system oil
HDZ46-Ⅱ
(ISO VG46)
Swing mech- GL-5 85W-140

Gear oil
anism box Gear oil
No. -30 diesel
No. -10 light

Fuel tank Diesel
diesel
No. 0 light
diesel
TEEC-L35
Radiator Coolant
antifreeze

NOTE：
The HTHS (high temperature high shear viscosity at 150°C) specified by ASTMD4741 must be no
less than 3.5 MPa·s, and the engine oil 15W-40 recommended by Sany is the most suitable.
1. Engine oil
Select and use the oil with a suitable viscosity grade according to the specified air temperature
range during oil change.
Engine oil grade: above APICJ-4
Recommended engine oil: CJ-4 15W-40 engine oil or higher level.
2. Engine fuel
Light diesel
NOTICE
Risk of causing damage to machine!
Using nonstandard fuel and diesel could result in damage to machine.
• Use low sulfur fuel with a cloud point of at least 10°C below the minimum desired fuel tempera-
ture. Cloud point means the temperature at which the waxy crystals in the diesel begin to form.
• Use commercial universal brands diesel. The sulfur content of diesel should be less than 10
mg/kg.
• When refueling, keep the fuel clean and free of moisture or impurities; for fuel with high mois-
ture and impurities, shorten the changing cycle according to the actual blockage conditions of
the filter element.
3. Hydraulic oil

NOTICE
Risk of causing damage to hydraulic system!
If the ambient temperature is below 0°C, the following warming operation is not carried out, which
could cause damage to the hydraulic system.
• Start the engine. Run it at idle speed for 7 min~10 min. And then increase the speed to 1000 r/
min~1500 r/min. Do not perform any operation, and allow it to run for 30 min~40 min or more
under no load in order to increase the hydraulic oil temperature to 20°C or higher.
• After completing the heating operation, the normal construction operation can be carried out,
and the heating time should be adjusted appropriately according to the ambient temperature.
During normal construction operations, the operation of the handle and pedal valve should be
slow and pay close attention to the operation. Working at a temperature of hydraulic oil below
20°C can damage hydraulic components.
• Select the appropriate hydraulic oil according to the working area. Before the machine leaves
the factory, our company will be responsible for filling the appropriate hydraulic oil; after the ma-
chine leaves the factory, the user shall be responsible for changing the oil. Users can consult
Sany after-sales service engineer to obtain the correct hydraulic oil specifications and brand
numbers.
Adopt anti-wear hydraulic oil HDZ46-Ⅱ (ISO VG46).
6.6 Drilling Rig Oil

The filler inlets are shown in Fig. For details of oil consumption, refer to the Table .

3 2 9 1
8
7
10
4 5
6 11 12
Fig 6-8 Filler Inlets
Table 6–3 Recommended fluids
Compartment Refill Vol- Recommended

SN Remark
or System ume (L) Type
0# or 10# Select the oil type according to the
（≥0℃） ambient temperature. The percentage
1 Fuel tank 630
-10# or -20# or of oil is maintained between 13% and
-35# (≤0℃) 15%.
Coolant system Long life coolant
2 59 Pipeline capacity: 2 L
water tank (LLC)+cooling

Table 6–3 Recommended fluids (continue)
Compartment Refill Vol- Recommended

SN Remark
or System ume (L) Type
1. Preferred grade: 15W-40

3E-9900 or 15W-
Engine oil tank 40, APICH-4 or 2. Choose the viscosity grade accord-
3 42～52
higher level ing to the ambient temperature
3. Recommended refill volume: 45 L

Wide temperature When the cylinders totally extend, add
Hydraulic oil
4 600 46# anti-wear hy- oil until it reaches minimum scale of
tank
draulic oil tank liquidometer.
Industrial gear oil
5 Swing reducer 7
85W-140
Industrial gear oil
6 Travel reducer 2×9
85W-140
Rotary drive Industrial gear oil
7 125
gearbox 80W-90
Rotary drive Industrial gear oil
8 2×16.7
reducer 220
9 Main winch Industrial gear oil
16.5
reducer 220
Auxiliary winch Industrial gear oil
10 5.5
reducer 220
11 Swing gear ring 45 NLG12
Crawler ten- As
12 NLG12 Adjust according to requirements.
sioning cylinder required
Note: The refill volumes listed in the chart are only for reference, please take filler inlet as
standard.

NOTE：
• If there is any change to the above number of oil adding locations or adding times, con-
sult SANY after sales service department.
• When operating the drilling rig with the ambient temperature lower than 0°C, perform the
following warm-up operation in order to guarantee the safety of the hydraulic system.
• After running the engine at idle speed for 7 min to 10 min, increase the speed to 1000 r/
min to 1200 r/min. Perform no action to the drilling rig. Run the machine without load for
30 min to 40 min or even longer time in order to increase hydraulic oil temperature and
make the hydraulic oil temperature reach 200°C.
• After the above operation, conduct normal operation. Meanwhile, properly adjust the
warm-up time according to ambient temperature.
• When starting normal construction, operate slowly and pay close attention to the running
situation of the system.

6.7 Lubrication Points

Do not perform any maintenance and/or repairs not authorized in Safety, operation & maintenance
manual for these machines. Always observe and follow all safety precautions and use the proper
tools when performing any maintenance procedures.
Hour Meter Reading
Always keep track of the hour meter reading on a daily basis. Confirm meter readings with the re-
quired maintenance schedule listed in this manual.
Genuine SANY replacement parts
Always use genuine SANY replacement parts listed in the parts manual.
Genuine SANY lubricants
Always use genuine SANY machine oil and grease. Select machine oil and grease of suitable vis-
cosity according to ambient temperature.
Window washer fluid
Use automotive windshield washer fluid only, which shall not be contaminated by foreign
substances.
Oil and lubricants
Always use clean oils and greases. Keep the oil reservoir and grease reservoir clean, which shall
be free from any impurities. Drained oil and used filter element after changing the oil and replacing
the filter element. Check the used oil and filter element for signs metal particles and foreign materi-
al. If large amount of metal particles and/or impurities are found in the used oil and filter element,
report to the personnel in charge and take proper measures.
Hydraulic hoses, lines or components
If any hydraulic components have been replaced or removed, always bleed the air from the system
before resuming operation. Be sure there are no leaks and the hoses or lines do not rub on any
other components.
Welding on the machine

• Turn off the ignition key switch and wait for 1 min before disconnecting the negative (-) terminal
of the battery.
• Connect the ground cable of the welder at least 1 m (3.3 ft.) Away from the place being welded.
• If the ground cable is connected to any electrical components (instrument, connector, etc.), The
instrument will be out of function. If there are any seals or bearings between the welder and the
grounding point, choose another grounding point away from these parts.
• Never use a grounding point in the vicinity of the work equipment pin or hydraulic cylinder.

• Never apply more than 200 V continuously.
Dusty work site
Observe the following items before working in a dusty place.

• When inspecting your machine or changing the oil, park your machine in a dust-free place in or-
der to prevent dust from getting into the oil.
• Clean the air filter element immediately if the filter’s alarm indicates clogging.
• Clean the fins and other heat exchanger parts frequently to avoid them being clogged.
• Clean and replace the fuel filter frequently.
• Clean the electrical components, especially the start motor and the alternator, to prevent dust
from building up on them.
Lubricants of different brands
Never mix lubricants of different brands and/ or grades together. If you need to use the lubricant of
another brand or grade, drain the old lubricant completely and replace it with the new brand.
Inventory your tools and parts
After performing maintenance or repairs to the machine, always take time to inventory your tools,
parts used and nuts and bolts to be sure none of these items were left on or inside the machine.
Failure to do so could result in unexpected failure or damage to the machine.
Securing access cover
When servicing the machine with the access covers open, use a locking lever to secure the cover
to certain position. Otherwise, the cover can be swung close by wind and cause bodily injury.
Checks after maintenance or repairs
Always do the following after performing any maintenance or repairs to the machine.
With the engine OFF.

• Be sure you have completed all the steps in the maintenance or repair of the machine you have
worked on.
• If necessary, have a co-worker inspect your work for correct and proper completion.
• Be sure to inventory your tools and parts after completion.
With the machine running.

• Check for any leakage or overheating in the system you have completed repairs or maintenance
on.
• Be sure there are no abnormal sounds coming from the engine or hydraulic system and nothing
is loose.

Lubrication points location and interval
Main lubrication points are illustrated in below Figure. For details, refer to below Table.
滑轮架铰接座 PULLEY YOKE HINGED SEATS

滑轮架油缸 PULLEY YOKE CYLINDERS
上桅杆铰接座 UPPER MAST HINGED SEATS
导向滑轮架滑轮轴 GUIDE PULLEY FRAME PULLEY SHAFTS
随动架回转支承 KELLY GUIDE SWING BEARINGS
提引器 ROPE SWIVEL
加压油缸铰点 CROWD CYLINDER HINGED POINT
滑轮架滑轮轴 PULLEY YOKE PULLEY SHAFTS
动力头箱体油封 ROTARY DRIVE GEARBOX OIL SEALS
桅杆油缸十字接头 MAST CYLINDER CROSS JOINTS
副卷扬末端支承 AUXILIARY WINCH END BEARINGS
桅杆导轨 MAST GUIDE RAILS
桅杆转盘两侧耐磨键 MAST PIVOT WEAR KEY ON TWO SIDES
桅杆转盘轴 MAST PIVOT SHAFTS
下桅杆铰接座 LOWER MAST HINGED SEATS
底盘回转支承滚珠滑道 CHASSIS SWING BEARING BALL GROOVES
主卷扬末端支承 MAIN WINCH END BEARING
展宽油缸 EXTENDING CYLINDERS
底盘回转支承齿圈 CHASSIS SWING BEARING GEAR RING
底盘伸缩梁表面 CHASSIS TELESCOPIC BEAM SURFACES
动臂上轴 BOOM UPPER SHAFTS

支承臂上轴 SUPPORT ARM UPPER SHAFTS
变幅油缸铰点 BOOM CYLINDER HINGED POINTS

主卷扬钢丝绳 MAIN WINCH WIRE ROPE
副卷扬钢丝绳 AUXILIARY WINCH WIRE ROPE
发动机机油 ENGINE OIL 45

行走减速机 TRAVEL REDUCERS
主卷扬减速机 MAIN WINCH REDUCER
副卷扬减速机 AUXILIARY WINCH REDUCER
动力头箱体 ROTARY DRIVE GEARBOX
动力头减速机 ROTARY DRIVE REDUCERS
Fig 6-9 Schematic Diagram of Lubrication Points of Rotary Drilling Rig
Table 6–4 Zoom Table of Grease Lubrication points
No. of
No Lubrication Parts Interval
Points
1 PULLEY YOKE HINGED SEATS 2 Every 250 hours
2 PULLEY YOKE CYLINDERS 2 Every 250 hours
3 UPPER MAST HINGED SEAT 2 Every 250 hours
4 GUIDE PULLEY FRAME PULLEY SHAFTS 2 Every 10 hours
5 KELLY GUIDE SWING BEARINGS 2 Every 10 hours
6 ROPE SWIVEL 1 Every 10 hours
7 CROWD CYLINDER HINGED POINT 1 Every 50 hours
8 PULLEY YOKE PULLEY SHAFTS 4 Every 10 hours

Table 6–4 Zoom Table of Grease Lubrication points (continue)
No. of
No Lubrication Parts Interval
Points
9 ROTARY DRIVE GEARBOX OIL SEALS 11 Every 50 hours
10 MAST CYLINDER CROSS JOINTS 8 Every 10 hours
11 AUXILIARY WINCH END BEARINGS 1 Every 250 hours
MAST GUIDE RAILS 2 Every 10 hours
12 MAST PIVOT WEAR KEY ON TWO SIDES 11 Every 10 hours
MAST PIVOT SHAFTS 2 Every 10 hours
13 LOWER MAST HINGED SEATS 2 Every 250 hours
CHASSIS SWING BEARING BALL
14 4 Every 250 hours
GROOVES
15 MAIN WINCH END BEARING 1 Every 50 hours
16 EXTENDING CYLINDERS 4 Every 250 hours
17 CHASSIS SWING BEARING GEAR RING 1 Every 50 hours
CHASSIS TELESCOPIC BEAM
18 8 Every 250 hours
SURFACES
BOOM UPPER SHAFTS 6 Every 10 hours
SUPPORT ARM UPPER SHAFTS 4 Every 10 hours
19
BOOM CYLINDER HINGED POINTS 4 Every 10 hours
MAIN WINCH WIRE ROPE 1 Every 10 hours
20 AUXILIARY WINCH WIRE ROPE 1 Every 250 hours
First 50 hours, then every
21 ENGINE OIL 1
500 hours
First 500 hours, then
22 TRAVEL REDUCERS 2
every 1000 hours
First twice 250 hours, then
23 MAIN WINCH REDUCER 1
every 500 hours
AUXILIARY WINCH REDUCER 1
every 1000 hours
24
ROTARY DRIVE GEARBOX 1
every 1000 hours
First twice 250 hours, then
25 ROTARY DRIVE REDUCERS 2
every 500 hours
Note:

1. All lubrication points will be filled with the grease to the extent that the fresh grease is
overflowing. The application range is -20°C to 110°C. The grease model is KP2K, and the
product name is Shell Albania EP2. Brush-on lubrication could be applied for the environ-
ment at -30°C to 110°C.
2. As for Russian area, if customer agrees, they can select Shell Albia SLC 460, which could
be applied for working condition -40°C Maintenance.
6.8 Tightening Torque
NOTICE
Risk of causing damage to machine!
If the nuts, bolts, or other parts are not tightened to the specified torques, the tightened parts
could become loose or damaged, causing the machine faults or problems during operation.
• Tighten to the specified torque.
Unless specified, the metric nuts and bolts

shall be tightened to the torques shown in the
table below.
If the bolts or nuts need to be replaced, they B

shall be replaced with the same sizes of Sany
genuine parts.
Fig 6-10
A. Diameter of screw B. Edge width

thread
Table of tightening torques (JG/T5011.11-92) Unit: N·m
Performance level 10.9 12.9

Proof stress MPa 830 970
M6 13.2±1.4 16.2±1.6
M8 31±3 38.7±4
M10 66±7 78±7
Bolt M12 113±10 137±10
Specification M14 177±19 210±20
M16 279±30 339±30
M18 382±39 450±40
M20 549±59 664±59
Performance level 10.9 12.9

Proof stress MPa 830 970
M22 697±70 864±85
M24 927±103 1100±100
M27 1320±140 1683±150
M30 1785±170 2200±200
M33 2295±200 2900±280
M42 4700±450 5985±590
M48 7140±650 9100±900
Tightening torque (feeling method):
When you do not have torque wrench at the construction site and the bolts must be installed by tor-
que, you can refer to the following table:
Control method Tightening torque Operation method

45 N Only apply wrist power
70 N Apply wrist and elbow power
130 N Apply whole arm power
Apply the power of the upper
Feeling method 180 N
part of the body
Apply the power of the whole
320 N
body
Use the weight of the whole
500 N
body
When tightening, divide the standard torque of the corresponding bolt by the wrench length used
(unit: m) to obtain the required operating force and operate according to the operation methods in
the above table. Generally, the errors of an experienced operator can be controlled at ±40%.
Example: Tighten the 10.8 level bolt of the M30 connected to the middle mast and the upper mast,
with a standard tightening torque of 2100 N·m. using a 2 m extended sleeve wrench, you need to
apply a force of 2100/2=1050 N. According to the operation methods, it is recommended that 3
people applying the power of whole body.
• The following table for hydraulic hose
Hose
Nut Torque (N·m) Connector Torque (N·m)
M14 24.5±5 M14 34.3±5
M18 51±8 M16 54±5
M22 74±14 M18 70±10
M26 105±20 M20 93±10

M30 135±20 M22 125±10

M36 166±26 M24 142±20
M42 240±30 M26 180±20
(Hose) connector
Metric Torque (N·m) Imperial Torque (N·m)
M14 24.5±5 G1/8″ 16.7±2
M16 45±7 G1/4″ 36.7±2.5
M18 51±8 G3/8″ 73.5±5
M20 58±8 G1/2″ 107.8±7.8
M22 74±14 G3/4″ 161.7±14.7
M24 74±14 G1″ 220±25
M26 105±20
Plug
Metric system Torque (N·m) Imperial Torque (N·m)
M20 49±5 G3/8 68.6±20
M24 68.6±10
Nozzle
British system Torque (N·m)
G3/4（A） 161.7±14.7
6.9 Regular Inspection
NOTICE
Risk of losing the right to claim!
If the maintenance is not carried out according to the specified time, this could cause a risk of
damage to the equipment.
• The equipment maintenance personnel should record each maintenance of the machine in the
Maintenance Log, which must be signed by the maintenance personnel and supervisors. In the
event of a dispute over damage to equipment, Sany has the right to view the Maintenance Log.
Purpose on regular inspection:

• Preparation for operation
• Enhance the performance of machine
• Shorten the failure occurring interval
• Reduce maintenance cost
Special tips
• Check and maintain hydraulic parts indoors or in a clean place.
• During maintenance, shut down the engine and the put a sign with the words "Inspection and
Repair" on the cab door.

• Do not assemble or adjust pumps, valves, motors and other components in the hydraulic
system.
• Strictly follow the maintenance safety instructions.
Regular inspection and maintenance

• The time intervals listed in the following inspection and maintenance items are suitable for "gen-
eral working conditions". Under severe working conditions, such as excessive dust or corrosive
air, abnormal outdoor high and low temperatures, great loads, very frequent or long-term opera-
tion cycles, etc., the lubrication cycle needs to be shortened. Before accumulating enough expe-
rience to establish a lubrication cycle that can meet your own operating conditions, the time
cycle provided in this chapter should be followed.
• If the bearing and bushing are overheated, the movable parts are too loose or corrosion accu-
mulation occurs, shorten the lubrication cycle.
• In addition to checking the oil level of the reducer according to the maintenance time, check the
oil level and add grease in the following two situations:
– Before the initial start-up.
– Stored for more than 3 months.
NOTE：
• The inspection can be carried out according to the working hours or the maintenance in-
tervals, whichever comes first.
• Maintenance intervals are cumulative. For example, when the 1000 h interval is reached,
maintenance work of 10 h, 50 h, 250 h and 500 h is also required.
• If the equipment works under particularly humid or dusty conditions, the frequency of
maintenance should be increased appropriately.
• Refer to the engine manual for the maintenance of engine.
6.10 Maintenance Schedule

The standard calendar time or operation time is used as inspection and maintenance time, which-
ever occurs first.
Maintenance Schedule
Every 10 service hours
Crawler tension - check and adjust............................................................................................ 6-32
Hydraulic cylinders- check ......................................................................................................... 6-34
Shock absorbing device of rotary drive - check and replace ..................................................... 6-36
Rotary drive bolts - check........................................................................................................... 6-38
Crawler track - inspect .............................................................................................................. 6-41
Wire rope - inspect .................................................................................................................... 6-42

Wire rope - maintain .................................................................................................................. 6-43

Wire rope - discard ..................................................................................................................... 6-44
Rope swivel flexibility - check .................................................................................................... 6-45
Rope swivel - check and lubricate ............................................................................................. 6-46
Engine oil level - check .............................................................................................................. 6-47
Fuel amount - check and refuel ................................................................................................. 6-48
Water and sediment in fuel tank - drain ..................................................................................... 6-49
Coolant level - check and refill ................................................................................................... 6-50
Hydraulic oil level - check and refuel ......................................................................................... 6-51
Switches, buttons and operation handles - check ..................................................................... 6-53
Kelly guide swing bearing - lubricate ......................................................................................... 6-54
Kelly guide swing bearing - check and replace.......................................................................... 6-54
Initial 50 service hours
Engine oil and filter - change and replace.................................................................................. 6-55
Fuel tank strainer - clean............................................................................................................ 6-58
Winch reducers oil level - check ................................................................................................ 6-58
Rope hold-down rollers - check ................................................................................................. 6-59
Rotary drive sliding strip - check and replace ........................................................................... 6-60
Shock absorber - check ............................................................................................................. 6-61
Air intake and exhaust system - check ...................................................................................... 6-61
Window wiper - check ................................................................................................................ 6-61
Window washer - check ............................................................................................................. 6-62
Impact ring - check and replace ................................................................................................. 6-62
Track shoe bolts - check ............................................................................................................ 6-63
Spring of Kelly bar- check and replace ...................................................................................... 6-64
Hydraulic hose - check and replace........................................................................................... 6-64
Rotary drive bolts - check........................................................................................................... 6-38
Winch reducer oil - change ........................................................................................................ 6-66
Rotary drive reducer gear oil - change....................................................................................... 6-66
Bolts connecting swing bearing - check..................................................................................... 6-68
Rotary drive gear oil level - check .............................................................................................. 6-68
Rotary drive gear oil - sample and test ...................................................................................... 6-69

Driver strip - check and change ................................................................................................. 6-70

Air conditioner circulation filter - clean ....................................................................................... 6-70
Air recirculation filter - inspect and replace ............................................................................... 6-72
Filter of water oil separator - replace ......................................................................................... 6-72
Fuel filter - check and replace .................................................................................................... 6-74
Hoses - check and replace......................................................................................................... 6-75
Rotary drive sliding strip - check and replace ........................................................................... 6-60
Kelly bar locking recesses - check............................................................................................. 6-76
Kelly bar tube - check................................................................................................................. 6-76
Kelly bar drive gibs - check ........................................................................................................ 6-78
Kelly bar baffle - check ............................................................................................................... 6-78
Wire rope sheaves - check......................................................................................................... 6-79
Hydraulic system cleanliness - control....................................................................................... 6-79
Generator belt - check and adjust.............................................................................................. 6-80
Fan belt - check and adjust ........................................................................................................ 6-80
Rotary drive gearbox gear oil - change...................................................................................... 6-80
Travel reducer oil - change ........................................................................................................ 6-81
Air recirculation filter - replace ................................................................................................... 6-83
Gear oil for swing reducer - change ........................................................................................... 6-83
Fuel tank strainer - clean............................................................................................................ 6-58
Engine oil and filter - change and replace.................................................................................. 6-55
Winch reducer oil - change ........................................................................................................ 6-66
Rotary drive reducer gear oil - change....................................................................................... 6-66
Bolts connecting swing bearing - check..................................................................................... 6-68
Hydraulic oil - change................................................................................................................. 6-86
Oil suction filter - replace............................................................................................................ 6-89
Pilot filter element - replace........................................................................................................ 6-90
Return filter - replace.................................................................................................................. 6-91
Auxiliary pump filter element - replace....................................................................................... 6-93
Breather valve - check and replace ........................................................................................... 6-94
Battery - clean and recycle......................................................................................................... 6-94
Rotary drive gearbox gear oil - change...................................................................................... 6-80

Travel reducer oil - change ........................................................................................................ 6-81
Hydraulic oil - change................................................................................................................. 6-86
Oil suction filter - replace............................................................................................................ 6-89
Generator belt - replace ............................................................................................................. 6-96
Fan belt - replace（if equipment） ............................................................................................ 6-96
6.11 Maintenance Procedures

6.11.1 Every 10 service hours
6.11.1.1 Crawler tension - check and adjust
WARNING
Risk of personal injury or possibly death!
Grease coming out of the relief valve under pressure can go into the body causing injury or possi-
bly death.
• Watch the crawler or crawler adjustment cylinder to see if the crawler is being loosened instead
of watching the relief valve.
• Loosen the relief valve one turn only. If crawler does not loosen, contact your SANY after-sales
service department.
• Wear suitable personal protective equipment in the form of protective clothing, gloves, safety
glassed and head protection to prevent against the sudden release of pressurized grease.
1. Operate the machine in the direction of the 1

idlers. Stop with one crawler pin (1) directly
above the front carrier roller (2). Stop the
engine.
Fig 6-11 Crawler
1. Crawler pin 2. Carrier roller

2. Put a straight edge (4) on top of the crawler.

The straight edge must be long enough to 4
reach from the idler (3) to the carrier roller (2).
A
3. Measure the maximum amount of sag in
the crawler. The sag is measured from the
highest point of the crawler grouser to the bot-
tom of the straight edge. A crawler that is
properly adjusted will have sag amount of the
crawler (A) of 10.0 mm to 30.0 mm (0.394 inch 3 2
to 1.18 inch).
Fig 6-12 Measuring Sag Amount of the
Crawler
2. Carrier roller 4. Straight edge

3. Idler A. Sag amount of the
crawler
If the crawler is too tight or too loose, adjust

the crawler tension according to the proce-
dures below:
Fig 6-13 Crawler Adjuster Position
Tightening the track:

5 6
1. Clean grease fitting (5) before adding

grease.
2. Add grease through grease fitting (5) until

the correct tension is reached.
3. Operate the machine back and forth to

equalize the pressure.
Fig 6-14 Crawler Adjuster
4. Examine the amount of sag. Tighten the
5. Grease fitting 6. Relief valve
crawler as needed.
Loosening the track
1. Loosen relief valve (6) carefully until the crawler starts to loosen. One turn should be the
maximum.
2. Tighten the relief valve (6) to 34±5 N·m (25±3.7 lb-ft).

3. Operate the machine back and force in order to equalize the pressure.
4. Examine the amount of sag. Adjust the crawler as needed.
6.11.1.2 Hydraulic cylinders- check
Every 10 operating hours or daily, and every time before starting up again after longer period of
rest, clean all cylinders and check them for tightness.
Table 6–5 Table for cylinder inspection
Cylinder
No. Qty. Inspection Method
Name
Pulley yoke When operating the cylinder, the

1 1
cylinder pulley yoke rotates smoothly.
1
Crowd Support the mast by operating

2 1
cylinder support cylinder.
When operate the mast cylinder, 2

the two cylinders should extend/
retract slowly and simultaneously.
When the mast leveling button is
Mast
3 2 depressed, the mast shall per-
cylinder
form forward, backward, left, or
right action. During forward and
backward inclination, the two cyl-
inders must be synchronous.
When operate the boom cylinder,

the two cylinders should slowly 3
Boom
4 2 retract/extend simultaneously.
cylinder
The two cylinders must be
4
synchronous.
When the crawler extension/ re-

Crawler ex- traction button depressed, the
5 tending 4 four cylinders should move slowly
cylinder and the cylinders on one side
should move simultaneously. 5

NOTICE
Risk of damage to piston rods!
Steam jet devices, tools with sharp edges, Corrosive environments, caustic fluids or cleaning
agents can damage the piston rods.
• Do not clean the piston rods with the above mentioned devices and cleaners.
• Move extended piston rods in and out multiple times according to environmental factors or treat
with hydraulic oil.
• Preserve extended piston rods with acid-free grease for longer downtimes.
Daily maintenance for hydraulic cylinder
1. Check the lubrication on joint bearings on

both ends of hydraulic cylinder daily. Add
grease every week (or every 10 h).
2. Visually check for cracks of various structur-

al elements for hydraulic cylinder. Immediately
repair or replace when necessary.
3. Apply hydraulic oil to the piston rod or re- Fig 6-15 Grease Filling Place
tract/extend the piston rod several times once
or twice a week.
4. Before a longer standstill, preserve piston

rods with an acid-free grease.
Checking hydraulic cylinder for tightness
1. Check for looseness of hydraulic joints con-

necting the cylinder before and after each
working shift. If loose, tighten immediately.
2. Check for oil leakage of hydraulic cylinder

before and after each shift. Replace damaged
elements when necessary.
3. If barrel is damaged, replace hydraulic cyl-

inder when necessary (if the hydraulic cylin-
ders are used in pair, the matched cylinder
should be replaced at the same time).
Precautions for cylinder maintenance

1. Check the hydraulic cylinder during construction. If the hydraulic cylinder acts slowly, or no ac-
tion, immediately shut down the engine for inspection.
2. The cylinder on the rotary drilling rig bears load. Use caution during repair or replacement.
3. When repairing or replacing the balance valve on the cylinder, retract the cylinder piston rod to
minimal extent, then dismantle and replace it.
4. If you have any questions, contact SANY after sales service department.
6.11.1.3 Shock absorbing device of rotary drive - check and replace
WARNING
Risk of entanglement!
Inappropriate work on the rotary drive can lead to entanglement of bodyparts.
• During the inspection tasks, do not insert any body parts between the rotary drive. Do not insert
your fingers into openings of the rotary drive.
Check the shock absorbing device for wear and loosening on daily basis.
Checking
Visually check that the springs, buffer plates, cotter pins, nut, and washers are in proper working
order. If any wear or loosening appears, replace as the following procedures.

Replacing shock absorbing spring
1. Remove cotter pin (3). Turn the nut (1)

counterclockwise with open-ended wrench in 1
order to loosen it for about one turn. 2
2. Remove all the nuts (1) and washers (2).

Store them properly. 3
Fig 6-16 Replacing Shock Absorbing Spring

Diagram I
1. Nut 3. Cotter pin

2. Washer
3. Remove the buffer plate (4).

Diagram II
4. Buffer plate

4. Check the removed shock absorbing

springs (5) successively. Replace them if
crack or deformation appears.
5. Install the removed buffer plate (4).
6. Install washers (2) and nuts (1), and tighten

with torque wrench. Install the cotter pin (3).

Diagram III
5. Shock absorbing spring
Replacing hydraulic buffer
1. Remove the buffer plate (4) according to

the procedures above.
2. Remove the fixing bolt (6). Take out the hy-

7
draulic buffer (7) and replace with a new one.
Fig 6-19 Replacing Hydraulic Buffer
6. Fixing bolt 7. Hydraulic buffer
6.11.1.4 Rotary drive bolts - check
NOTICE
Risk of causing damage to rotary drive!
Excessive tightening of the rotary drive bolts could cause sealant breaking, loosening the bolts
and possibly damaging the rotary drive.
• Tighten the bolts to the specified torque.

Check the bolts on crowd sledge (1), the bolts

on reducer (2), the bolts on buffer and the
gearbox (3), and the bolts on lower cover (4). 3
2
Check them at the initial 10 hours, then check
them every 50 hours.
1. Visually check if the bolts are firm.
2. Unscrew the loose bolts. Clean them and

apply loctite to threads. Reinstall and tension 1
the bolts with the specified torque.
4
3. When changing oil, check the bolts on gear-
box for damage.
Fig 6-20 Mounting Bolts
1. Bolts on crowd 3. Bolts on buffer and

sledge gearbox
2. Bolts on reducer 4. Bolts on lower
cover
Service requirements for bolts on crowd sledge:
1. Tighten the bolts on crowd sledge guide according to the table below:
Specification Performance Rating Specified Torque Interval

M24 10.9 1030±50 Every month

2. Check the bolt (5) on the crowd sledge

and tighten them with the specific torque.
Fig 6-21 Bolts
5. Bolts

6.11.1.5 Crawler track - inspect
WARNING
Risk of crushing and entanglement!
Rotating parts can cause crushing, entanglement, or shearing of body parts. This could result in
serious or fatal injuries to persons.
• The machine must be stationary during work on the undercarriage. A reliable communication
between the person working at the undercarriage and the operator in the cab must be provided
at all times.
1. With the upper carriage positioned crosswise, thoroughly clean crawlers until they are free of
mud and dirt.
2. Walk around and inspect for wear, damage and leakage of oil, especially on following
components:
1 2 3 4
8 7 6 5
Fig 6-22 Crawler Assemblies
1. Track shoe 4. Front idler 7. Bolt

2. Track link 5. Crawler roller 8. Traveling drive
3. Carrier roller 6. Track guide

6.11.1.6 Wire rope - inspect
Before inspection, read and follow the safety instructions in Chapter 2 Safety Wire rope safety
information.
For regular inspection intervals, consider the

following items:
1. laws and regulations of the country.
2. equipment variety.
3. working environment.
4. working grade of the machine.
5. previous inspection results and defective Fig 6-23 Inspecting Wire Rope
conditions.
6. serviced time of the wire rope.
Pay special attention to the following parts:
1. moving parts and fixed end of the wire rope.
2. the rope section wound over the pulley.
3. rope section may be worn because of external factor.

• Observe any visible section for the rope full length every day, in order to discover wear and de-
formation. When broken wire, wear, corrosion, or deformation is found, judge for discard accord-
ing to the regulations in code of practice for examination and discard of GB/T5972 crane wire
rope.
• Inspect the wire rope section extracted from the fixing end. Check deformation or wear for the
fixing device. Inspect the broken wire and corrosion condition in the fixing device and the rope
end. Guarantee the tightness of wedge connector and rope guard (detachable devices: wedge
connector, rope guard, and holding plate, etc.).
• Check the rope end device whether it complies with requirements of corresponding standard.
The remaining section of the wedge connector should be checked visually for broken wire. If bro-
ken wire occurs near the rope end device or inside the rope end device, cut the rope short and
reinstall it onto the fixing device for service. But the rope length must meet the requirements of
minimum loops on the drum. Usually safe loops are 1.5 to 2 turns. Normally we take 3 loops.

6.11.1.7 Wire rope - maintain
• Promptly remove the dirt off the wire rope after work so as to avoid corrosion.
• The wire rope must be regularly lubricated during application. Specially lubricate the bending
part of the wire rope.
• When using wire rope in highly corrosive environment, shorten the lubrication interval for wire
rope.
• The applied rope grease variety should accord with the grease recommended by wire rope
manufacturer.
• The lubricants used must be accord with the lubricant recommended by wire rope manufacturer.
• If ends of broken wires, which may damage adjacent wires, are detected during inspection, re-
move them.
• Bend the wire end repeatedly to and from

with your fingers or a tool until the wire
breaks at the point where it is bonded in the
structure of the rope.
Fig 6-24 Broken Wire Rope

6.11.1.8 Wire rope - discard
Follow the rules listed below when judging issues about the wire rope:
1. If the wire rope is straight when not loaded, and if it is bent when loaded: A problem of the rope.
2. If the wire rope is straight when loaded, and if it is bent when not loaded: A problem of the
equipment.
Only the shorter part of the first and second layers of the wire rope on the reel stranded together is
generally damaged. This part can be cut off and the remaining part can still be used for a period of
time.
The discarding of the wire rope depends on the condition of breakage, wear, and corrosion. If one
of the following conditions is satisfied, the rope shall be disposed of immediately and shall not con-
tinue to be used.

1. The breakage concentrates within a rope

length range of less than 6 d.
2. If the breakage occurs (See the figure "wire

rope breakage" on the right) and gradually in-
creases after the wire rope is used for a period
of time, determine to discard it according to
the standards.
3. A whole strand is broken.

Fig 6-25 Wire Rope Breakage
4. The rope diameter is reduced due to any
damage to the rope core.
5. If the wire rope shows various signs of re-

duced elasticity, it shall be discarded as per
the standards.
6. When the wear of the outer layer of the wire

rope reaches 40% of its diameter, the diame-
ter of the wire rope decreases by 7% or more.
Fig 6-26 Wire Rope Deformation
7. The wire rope shows various deformations
(See the figure "Wire rope deformation" on
the right).
8. If the wire rope shows various signs of re-

duced elasticity, it shall be discarded as per
Fig 6-27 Reduced Diameter of the Wire Rope
the standards.
9. The external wire rope has deep pits due to corrosion.
10. The rope diameter is reduced (See the figure "Reduced diameter of the wire rope" on the
right).
11. The wire rope shows the signs of wire breakage, reduced gap between strands, and increased
diameter due to internal corrosion.
6.11.1.9 Rope swivel flexibility - check
Check the flexibility of rope swivel before and after work every day. Rotate it by hand to see if it ro-
tates flexibly.

1. Lower mast to horizontal position. At this time, pay attention to the position of rotary drive and
Kelly bar.
2. Rotate the main winch in order to loosen the wire rope connecting the rope swivel. Keep proper
slack for the wire rope during rotating process so as to avoid rope disorder for main winch.
3. Fix one end, and rotate the other end. If it rotates freely, it means the rope swivel is in good con-
dition. If the rope swivel still cannot rotate after being greased, repair or replace immediately.
Note:
During machine operation, when the rope swivel is pulled out from the drilled hole, the rope swivel
will rotate at a high speed. If the rope swivel fails to rotate, shut down the engine and inspect.
6.11.1.10 Rope swivel - check and lubricate
NOTICE
When injecting grease to filler hole, if the screw plug on release hole is not removed, the oil pres-
sure will cause damage to the oil seal.
• Before injection, make sure the plug on release hole is removed.
Check lock screw, lock bolts on rope swivel and add grease on daily basis.
A A
1
2 4
2
3
4 5
Fig 6-28 Rope Swivel
1. Filler hole 3. Contact face 5. Release hole

2. Lock screw 4. Lock bolt A. Back side
Check:
1. Check the lock screw (2). Tighten the loose ones if necessary. (2 lock screws on front and back
sides).

2. Check the lock bolt (4). Tighten the loose ones if necessary. (2 lock bolts on upper and lower
parts).
Lubricate:
1. Set the mast to horizontal position.
2. Release main rope slowly. Stop until the rope swivel can rotate freely.
3. Remove the screw on filler hole (1) and the screw plug on release hole (5). Inject grease to the
filler hole (1) until the gease escapes from the release hole (5).
4. Clean the escaped grease and reinstall the screw plug.
NOTE：
• Add grease once a day. (2# lithium base grease for summer and 1# lithium base grease
for winter).
• If the ambient temperature is below 0°, clean the rope swivel after each work shift and dry
it up with cotton. It is necessary to grease the contacting face (3) to avoid the face getting
frozen.
6.11.1.11 Engine oil level - check
CAUTION
Risk of scald!
Direct contact with hot oil and components could cause personal injury.
• Never take out the dipstick or filler plug when the engine oil is hot.
NOTICE
Risk of causing damage to the engine!
If the engine oil level is above the FULL mark on the oil dipstick, which could cause damage to
the engine.
• The engine oil level should be kept between the FULL and ADD marks on the oil dipstick.
When the engine is stopped, check engine oil level. Never check oil level while the engine is
running.

1. Open the engine hood.
2. Take out the dipstick. Wipe off oil from the

dipstick, and re-insert the dipstick.
3. Take out and examine the dipstick. The oil

level should be between FULL and ADD
marks.
4. If necessary, remove the filler plug in order

to add lubricant. Fig 6-29 Position of Engine Hood
5. Clean and install the filler plug.
6. Close the engine hood.
NOTE：
When checking oil level, park the drilling
rig on level ground. Oil level could be
checked accurately after the machine has
been shut down for about three hours.
Fig 6-30 Engine Oil Dipstick
6.11.1.12 Fuel amount - check and refuel
WARNING
Fuel leakage or spilling to hot surfaces or electric elements may cause fire, which could cause
personal injury.
• Remove any leaked or spilled fuel.
• No smoking when working on the fuel system, and keep the fuel system away from fire
sources.
NOTICE
Risk of causing damage to the engine!
If the engine is filled with contaminated fuel, the engine could be damaged.
• Do not fill the oil tank with fuel before installing the fuel filter and removing the contaminated
fuel.
Before adding fuel, make sure the fuel tank has been at standstill for at lease 48 hours.

Fill the fuel after daily work to reduce sediments. For fuel type and volume, see Drilling rig oil on
chapter maintenance.
Checking
Observe fuel level from the drilling operation

interface. Add fuel if the fuel level is low.
Fig 6-31 Fuel Level
Adding fuel
1. Open the fuel tank cap.
2. Add fuel. Be cautious not to splash fuel onto

the machine when refueling.
3. When the warning mark of the float at fuel

tank filler port is higher than the filler port, stop
adding fuel.
Fig 6-32 Fuel Tank Cap
4. Reinstall the fuel tank cap onto the filler
port. Lock the cap.
6.11.1.13 Water and sediment in fuel tank - drain
NOTICE
For more information, go to http://www. epa.gov/osw/conserve/materials/usedoil/

1. Place a suitable container for catching the

waste oil beneath the drain valve.
2. Loosen the drain valve.
3. Securely tighten the drain valve by turning

the valve clockwise.
Fig 6-33 Drain Valve
6.11.1.14 Coolant level - check and refill
CAUTION
Risk of scalding and other injuries!
Engine coolant is hot and under pressure during operation. The radiator and all lines of heaters
and engine contain hot coolant or steam. Any contact can cause severe burns.
• Remove cooling system pressure cap slowly to release pressure only when engine is stopped
and cooling system pressure cap is cool enough to touch with your bare hand.
1. Open the rear access door on the left side.
2. Check the coolant level in coolant tank.

Make sure the coolant level is between FULL
mark and LOW mark. If the coolant tank is
empty, carry out the following procedures:
1
1) Unlatch and raise the engine hood.
2
Fig 6-34 Coolant Tank
1. FULL level 2. LOW level

2) Slowly loosen the pressure cap of cooling

system in order to relieve all the pressure.
Remove the pressure cap.
Fig 6-35 Pressure Cap
3) Add appropriate coolant to the cooling system. See Table recommended fluids on topic
“Drilling Rig Oil”.
4) Start the engine. Operate the engine without the pressure cap until the coolant level stabilizes.
5) Maintain the coolant level within 13 mm (0.5 inch) of the bottom of the filler pipe.
6) Inspect the gasket on the pressure cap. If the gasket is damaged, replace the pressure cap.
7) Install the pressure cap of cooling system.
8) Shut down the engine.
9) Close and latch the engine hood.
4. If additional coolant is necessary, remove the reservoir and add appropriate coolant solution.
5. Install the reservoir cap.
6. Close the rear access door on the left side.
6.11.1.15 Hydraulic oil level - check and refuel
CAUTION
Risk of scald!
Hot oil and components can cause personal injury.
• Never take out the dipstick or filler plug when the engine oil is hot.

NOTICE
Risk of causing damage to the hydraulic oil pump!
If the fill plug or vent plug on the hydraulic fluid reservoir is removed when the hydraulic oil is hot,
which could cause damage to the oil pump.
• Therefore, the fill plug or vent plug on the hydraulic fluid reservoir shall be removed after the
hydraulic oil cools down.
1. Park the machine on level ground. Set the

1
safety lock lever to unlocked position (1). Op-
erate the handle and adjust the mast, boom,
crowd cylinder in order to retract all the cylin-
der piston rods. Then shut down the engine.
2. Open the access door on the right side.
3. Check the hydraulic oil level. It should be in

the middle position of oil gauge. Close the ac-
cess door.
Fig 6-37 Hydraulic Oil Level

If the oil level is low, perform the following

procedures to add oil:
1
1. Remove the valve cover(1).
2. Loosen the breather valve (2) slowly to fully

2
release the pressure.
3. Add hydraulic oil.

Fig 6-38 Breather valve
4. Check the filter of the breather valve. If the
filter is damaged, replace with new one. 1. Valve cover 2. Breather valve
5. Clean and install the valve cover and

breather valve.
6.11.1.16 Switches, buttons and operation handles - check
1. Start the engine. Set Safety lock lever to un-

locked position (1).
1
2. Operate the switches, buttons and handles

in the operator’s cab. Check whether the func-
tions of them are normal. If it is not, then main-
tain and service them. 2

6.11.1.17 Kelly guide swing bearing - lubricate
Check the operation of the Kelly guide swing

4
bearing every day, and fill grease on two lubri-
cation points once a day or every 10 h.
1
Fig 6-40 Kelly Guide Swing Bearing
1. Kelly guide 3. Lubricant cup

2. Kelly bar 4. Swing bearing
6.11.1.18 Kelly guide swing bearing - check and replace
Check Kelly guide swing bearing every. If

damages appear, replace the swing bearing.
1
1. Remove the Kelly bar from the drilling rig.
2
Dismount the Kelly guide from the Kelly bar.
2. Locate the Kelly guide with crane at the po-

sition illustrated in the right figure.
3. Turn thin nut (1) and nut (2) counterclock- 3

wise with open-ended wrench and pneumatic
wrench. Loosen them for about one turn.
4. Remove thin nut (1), nut (2) and bolt (3).

Properly keep them together. 4
5
5. Successively remove the remaining Fig 6-41 Kelly Guide

fasteners.
1. Thin nut 4. Swing bearing
6. Remove the swing bearing (4). Use caution 2. Nut 5. Kelly guide body
to fix the Kelly guide body. 3. Bolt
7. Erect the Kelly guide without swing bearing and fix it.

8. Align the new swing bearing horizontally with Kelly guide body (6) in accordance with mounting
position.
9. Use thin nut (1), nut (2) and bolt (3) to fix swing bearing (4) and Kelly guide body (5) at three lo-
cations with 120° clearance.
10. Install thin nut (1), nut (2) and bolt (3) on the remaining installation holes.
11. Turn the swing bearing (4) for two turns with hand. Check for abnormality. If it is not smooth,
add grease from the swing bearing fill port.
12. Place the replaced Kelly guide at specified location, or mount to the machine for use.
6.11.2 Initial 50 service hours
6.11.2.1 Engine oil and filter - change and replace
CAUTION
Risk of burning and scalding!
Direct contact with hot hydraulic oil or components could lead to burning or scalding of body
parts.
• Always wear the appropriate personal protective equipment and never allow hot hydraulic oil or
components to come in contact with skin.
NOTICE
1. Park the machine on level ground. Start the

engine until the engine temperature reaches
80°C.
2. Place a container under the drain valve for

waste oil. Open the drain valve.
3. Reinstall and tighten the drain valve until

the waste oil totally flows into the prepared
container. Fig 6-42 Drain Valve

4. Open the access door on the right side of

the machine.
5. Remove the oil filter with strap type wrench.
Fig 6-43 Engine Oil Filter
6. Clean the base. Remove the seals.
7. Apply a thin coat of lubricating oil to the

new filter seal.
Fig 6-44 Filter Seal
8. Install the new oil filter by hand. When the gasket comes in contact with filter base, turn the filter
for additional 3/4 of a turn to tighten the filter.
Note:
Every filter has an index mark. The clearance between mark is 1/4 of a turn. Use index mark
to facilitate this procedure.
9. Close the access door.
10. Unlatch and raise the engine hood.

11. Remove the oil filler plug. Add new oil to

the crankcase.
12. Start the engine to heat the lubricating oil.

Check the engine for leaks. Shut down the
engine.
Fig 6-45 Oil Filler Plug
13. Wait for 30 minutes to allow the oil to drain

back into the crankcase. Check the oil level
with the dipstick. Keep oil level between FULL
and ADD mark on the dipstick.
14. Close and latch the engine hood.
Fig 6-46 Dipstick
NOTE：
• If the sulphur content in the fuel is greater than 1.5% by weight, use an oil that has a TBN
of 30 and reduce the oil change interval by one-half.
• If lubricant is deteriorated or badly contaminated, change lubricant no matter how long
the service interval is.
• Drain the crankcase while the oil is warm. This allows waste particles that are suspended
in the engine oil to drain.

6.11.2.2 Fuel tank strainer - clean
1. Remove the fuel tank cap.
2. Inspect seal for damage. Replace the seal,

if necessary.
3. Remove screws, filter assembly, drain

valve, and gaskets.
4. Remove the strainer that is located in the

filler port.
5. Wash the strainer and the fuel tank cap in a Fig 6-47 Removing Cap and Strainer
clean, nonflammable solvent.
6. Install a new cap filter kit. Install the gas-

kets, drain valve, filter assembly, and screws.
7. Install the strainer into the filler port.
8. Install the fuel tank cap.
6.11.3.1 Winch reducers oil level - check
NOTICE
Risk of damaging the winch!
The winch bears the load. Maintain or repairing the winch with load could cause severe damage
to the components.
• Before any maintenance, first remove the load such as Kelly bar.

1. Park the machine on level and flat ground.

Adjust the winch position until the oil level 2
gauge (1) is vertical.
1
2. Unscrew the plug (2) and remove the oil
dipstick.
3. Check the oil level (it should be between

the high level and low level). If necessary, add
oil. Fig 6-48 Winch Reducer
4. Dry the dipstick with a clean and lint-free 1. Oil level gauge 2. Plug
cloth.
5. Cleaning sealing surfaces, check seal for

wear and damage, replace as required.
6. Reinsert the dipstick and screw the plug (2)

down tight.
6.11.3.2 Rope hold-down rollers - check
1. Check rope hold-down rollers for wear and

proper function.
2. Check the roller is parallel to the drum of

the winch.
3. Check the roller mounting bolts are properly

in place and firm.
Fig 6-49 Rope Hold-down Roller
4. Adjust the tension screws until all springs
are equal. Do not tension worn-out springs
too much but replace them with new ones.
5. Re-align protecting bars that are bent, or re-

place them with new ones.

NOTE：
• If there is excessive play, replace the roller center pin, bushings and spacers respectively with
new ones.
• If roller have created groove, reface the roller, or replace it with a new one. Mind that a refaced
roller will have a diminished diameter so that the respective tension will have to be pre-tensioned
correspondingly.
6.11.3.3 Rotary drive sliding strip - check and replace
Check the sliding strip on rotary drive crowd sledge, and change the slide strip if any of the follow-
ing appears:
• Cracks or deformation appears.
• The distance between wear surface and fastening screw is less than 2 mm or 0.079 in.
Replacing narrow sliding strip (A)
1. Loosen and remove screw (1).
2. Remove the pressure plate (2) from the nar-

row sliding strip (A).
2
3. Replace with a narrow sliding strip and bolt. 1
4. Press the narrow sliding strip with the pres-

sure plate (2), and tighten with screw (1). A B
Replacing wide sliding strip (B)
1. Remove the screws (1) and put together.

Fig 6-50 Sliding Strip I
2. Replace with new wide sliding strip (B).
1. Socket head screw A. Narrow sliding
3. Fix the new sliding strip on crowd sledge
strip
with screws (1).
2. Pressure plate B. Wide sliding strip

6.11.3.4 Shock absorber - check
Check shock absorbers every week. If it de-

forms greatly and fails to work, replace them
immediately.
Fig 6-51 Shock Absorber
6.11.3.5 Air intake and exhaust system - check
1. Open the two access doors on the left side

of chassis.
2. Check for black smoke or any abnormality.

If occurs, maintain and service air intake and
exhaust system.
Fig 6-52 Two Access Doors
6.11.3.6 Window wiper - check
1. Check whether the window wiper works

properly every week.
2. Check the condition of the wiper blades. Im-

mediately replace the wiper blades if the wiper
blades are worn or damaged.
Fig 6-53 Window Wiper

6.11.3.7 Window washer - check
1. Check the fluid volume in the washer tank. If the level is low, open the cap and add washer fluid.
2. In winter season, use all-season antifreeze windshield washer fluid.
6.11.3.8 Impact ring - check and replace
Check impact ring every week. If the wear

range is above 20 mm or 0.787 inch, replace
it according to the following procedures:
1. Unscrew the nut (1).
2. Remove the retainer (2).
3. Pull out inner Kelly bar from drive stub by

using auxiliary equipment, such as excavator.
4. Replace impact ring.

Fig 6-54 Location of Impact Ring
5. Install inner bar into outer Kelly bar.
6. Install retainer. Tighten the nut with torque

wrench. Tightening torque is 500 N·m or
368.5 lb-ft.
2 1
Fig 6-55 Replacing Impact Ring
1. Nut 2. Retainer

6.11.3.9 Track shoe bolts - check
1. Visually check if the track shoe (1) bolts are firmly in place.
2. Tighten the loose bolts.
1 2 3 4 5
7 6
Fig 6-56
Table 6–6
Item Tightening torque Maintenance interval

Track shoe (1) 697±70 N·m（M22） 50 h
Swing bearing (2) 1320±140 N·m（M27） First 50 h, then every 2000 h
Crawler frame (3) —— 250 h
Carrier roller (4) 549±59 N·m（M20） 250 h
Travelling drive (5) 382±39 N·m（M18） 250 h
Crawler roller (6) 549±59 N·m（M20） 250 h
Track guide (7) 1785±170 N·m（M30） 250 h
Travel reducer 927±103 N·m（M24） 250 h

6.11.3.10 Spring of Kelly bar- check and replace
Check Kelly bar spring for damage every day.

Replace it immediately if damage occurs. The
replacement procedures are as followings:
1. Unscrew the nut (1).

2 1
3. Pull out inner Kelly bar from drive stub by
Fig 6-57 Replacing Impact Ring
using auxiliary equipment, such as excavator.
1. Nut 2. Retainer
4. Remove impact ring.
5. Replace spring (3).
6. Install inner bar into outer Kelly bar.

3
7. Install retainer. Tighten the nut with torque
wrench. Tightening torque is 500 N·m or
368.5 lb-ft.
Fig 6-58 Spring of Kelly Bar
3. Spring
6.11.3.11 Hydraulic hose - check and replace
Checking
Hose assemblies must be inspected at least once a year by after sales staff. Check leakage for all
the hoses on regular basis. In visual inspection, even if slightest damage is found, immediately re-
place all the defective hoses.
The potential defects of hoses are:
1. The joint slides in the hose.
2. The outer rubber layer is damaged, cut, or worn (any explosion of reinforcing layer).
3. Hardening, crack, and burn of the hose.
4. Crack, damage, and severe corrosion of the joint.
5. Leakage of joint or hose.

6. Winding, crush, flattening, and distortion of hose.
7. Blistering, softening of hose outer layer.
Other items for daily inspection:
For the following items, tighten, repair, or replace if necessary.

• Oil leakage.
• Dirt plugging.
• Pipe clamp, sleeve, and guard material.
• Beyond storage and service life.
NOTE：
• If the pipeline and joints of hydraulic pump in engine compartment are damaged because
of mechanical effect/thermal effect, immediately replace.
• Make sure the entire pipeline and hoses maintain enough distance from the hot engine
components (such as exhaust system). Make sure they will not rub against each other.
• Hoses and hose assemblies are to be stored in a cool and dry place free of dust. Avoid
exposure to direct sunlight or UV radiation.
Replacing
Even there is no damage, replace the hydraulic hoses at least 6 years later, including 2 years stor-
age time.
Precautions for changing hydraulic hoses:
1. Calculate working time and storage time according to the production date on hydraulic hoses.
2. Before installing each components in hydraulic lines, clean them.
3. Protect the hose port from entering dust.
6.11.3.12 Other maintenance item
Maintenance item Maintenance instruction

Rotary drive bolts-check “Rotary drive bolts - check” on page 6-38

6.11.4.1 Winch reducer oil - change
CAUTION
Hot lubricating oil and components could cause personal injury. Gear oil could spurt out and pose
hazard.
• Never allow hot oil or components to contact skin. Change gear oil only when the winch is off.
1. Park the machine on level and flat ground.

2
Adjust the winch position until the oil level
gauge (1) is vertical. 1
2. Unscrew the plug (2) and remove the oil

dipstick.
3
3. Remove the drain plug (3) and drain the
gearbox.
Fig 6-59 Main Winch Reducer
4. Clean sealing surfaces, check seal for wear
1. Oil level gauge 3. Drain plug
and damage, replace if necessary.
2. Plug
5. Reinstall the drain plug (3).
6. Refill with new oil through the plug (2).
7. Check the oil level.
8. Reinsert the dipstick and screw it down

tight.
6.11.4.2 Rotary drive reducer gear oil - change
CAUTION
Risk of injury!
Escaping pressurized fluids can cause injury to body parts.
• Before assembling or dismantling media-conducting components such as hydraulic hoses or
plugs, make sure that they are pressure-free.

Petrol or diesel oil can cause damage to the reducer.

• Never use petrol or diesel oil to rinse the reducer housing and allow the rinsing fluid to drain off
completely.
Before any operation, make sure the oil is at

operating temperature and prepare a suitable 2
container for waste oil.
Changing oil procedure:

3
1. Place the container beneath the drain plug
(1).
2. Prepare a plastic tube or hose to connect

drain port and container. 1
3. Remove the drain plug (1). Install the tube

Fig 6-60 Rotary Drive Reducer
or hose onto the plug.
1. Drain plug 3. Oil gauge
4. Tilt the rotary drive by raising the mast.
2. Oil filling plug
5. Drain out used oil. (If the outside tempera-
ture is low, heat new oil to approximately 50°
C. Then use the new oil to rinse the reducer
housing).
6. Unscrew the oil filling plug (2). Fill the oil un-
til it reaches the middle of sight glass.
7. Check the oil level by the oil gauge (3).
8. Screw the plug (2) and tighten.
NOTE：
Benzol or flushing oils may also be used here for rinsing.

6.11.4.3 Bolts connecting swing bearing - check
1. Visually check if the swing bearing bolts (1)

1
are firmly in place.
2. Tighten the loose bolts, and replace

cracked or defective bolts (tightening torques:
1320±140 N·m).
Fig 6-61
1. Swing bearing bolt
6.11.5.1 Rotary drive gear oil level - check
NOTICE
Risk of damaging the rotary drive!
Clouding of the oil indicates the entry of water. The rotary drive could be damaged during subse-
quent operation.
• Take an oil sample, have the oil analyzed, and change the oil if there is a negative result to the
oil analysis.
• The oil level must be in the 1/2 to 2/3 position of the sight glass.
Before any operation, make sure the rotary drive has been at standstill for at least 15 minutes and
the oil is at operating temperature.
Checking oil level of gearbox:
1. Set the rotary drive to the vertical position.
2. Check the oil level through the sight glass.

Make sure it reaches 1/2 to 2/3 position of the
sight glass.
3. If the oil level is below the required position

of sight glass, add oil.
Fig 6-62 Sight Glass

Checking oil level of rotary drive reducer:
1. Set the rotary drive to the vertical position. 1
2. Check the oil level through the sight glass

(2). Make sure it reaches the middle position
2
of the sight glass. At the same time, check if
the exhaust valve (1) is damaged or blocked.
3. If the oil level is below the required position

of sight glass, add oil.
Fig 6-63 Rotary Drive Reducer
1. Exhaust valve 2. Sight glass
6.11.5.2 Rotary drive gear oil - sample and test
Check whether the oil becomes black.

• If the oil becomes black, the operating temperature exceeds 100°C (212°F). This results in pre-
mature wear of the gear oil and loss of lubrication. Therefore, be sure to shorten the period of oil
change properly.
Check water and contaminants in the oil.

• If any contaminant or water is found in the oil, the seal ring must be checked. Replace it if
required.
Check solids in the oil (abrasive dust).

• The maximum allowable content of solids in the reduction case shall not exceed 0.15% the total
amount of filled oil. The size of the solid particles shall not exceed 5 μm or 0.0002 in (according
to DIN51592). Otherwise, disassemble the rotary drive for inspection regardless of the quantity.

6.11.5.3 Driver strip - check and change
Check the wear conditions of drive strip. If the

wear range is above 8 mm or 0.315 in, replace
2
with a new one. Replace socket head bolts
and washers with new ones as well.
1. Remove nut (1) and hexagon socket screw

(2). 4 3 1
2. Take out the driver strip (4) need to be

replaced.
3. Take out all the washers (3) in the hole. Fig 6-64 Driver Strip
4. Replace with a new driver strip (4). 1. Nut 3. Washer

2. Hexagon socket 4. Driver strip
5. Fit the new driver strip to sleeve with wash- screw
ers and socket head bolts in sequence (tight-
ening torques: 305±25 N·m).
6.11.5.4 Air conditioner circulation filter - clean
The filter shall be cleaned once every 250 h, or more frequently in dusty workplace. If the filter is
blocked, the air volume will be decreased and the air conditioning unit will make an abnormal
noise.
Clean the internal air filter
1. Remove the screw from the sight glass on

the bottom of the left rear of the cab, and then
press down the locknut (1) and remove the in-
ternal air filter (2) protection frame.
Fig 6-65

2. Clean the filter with compressed air. If the

filter is oily or dirty, flush it with neutral me-
dium. After rinsing with water, make it dry thor-
oughly before use. Replace the filter with a
new one each year. If the blocked filter cannot 1
be cleaned with air or water, replace it with a
new one. 2
Fig 6-66
1. Locknut 2. Internal air filter
Clean the external air filter
1. Open the cover (3) by hand, remove the

nut, and take out the external air filter (4) . 3
2. Clean the filter with compressed air. If the

filter is oily or dirty, flush it with neutral me-
dium. After rinsing with water, make it dry thor-
oughly before use. Replace the filter with a
new one each year. If the blocked filter cannot
be cleaned with air or water, replace it with a Fig 6-67
new one.
3. Cover
3. After cleaning, put the filter in place, tighten
the nut, and close the cover.
4. The external air filter must be installed in

the correct direction. When installing, insert
the long end (L) of the filter into the filter box.
If the short end is installed first, the cover will 4
not be closed.
Fig 6-68
4. External air filter

6.11.5.5 Air recirculation filter - inspect and replace
The air recirculation filter is located on the

upper carriage.
1
1. Take away the cover (4) of recirculation fil- 2
ter. Remove the main filter element (2) and
3
safety filter element (1). 4
2. Tap the air filter gently to remove the dirt.
3. Check the filter element. If the filter element

is damaged or badly contaminated, replace
with a new one. Fig 6-69 Location of Air Recirculation Filter
1. Safety filter 3. O-ring

4. Reinstall the filter element.
element
NOTE： 2. Main filter element 4. Cover
The clogged filter element will decrease
the performance of air conditioner and cab
heater. Clean the filter element as
necessary.
6.11.5.6 Filter of water oil separator - replace
NOTICE
If add fuel to the new filter before it is installed, the fuel could be contaminated during the mainte-
nance procedure. The contaminated fuel could cause abnormal wear to fuel system.
• Never add fuel to the filter before installation.

1. Open the access door on the left side of the

machine.
2. Open the drain valve (1) by turning counter-

clockwise. The drain valve is located at the
bottom of the water oil separator.
3. Place a container under the drain valve (1).

Drain sedimentary water to the container.
4. Securely tighten the drain valve (1) after

sedimentary water totally flows into the
container.
5. Remove filter (4) from the filter base (3).

Loosen the filter with wrench. Fig 6-70 Location of Water Oil Separator
6. Remove the filter (4) from the bowl (2).
3
7. Clean the internal surface of the filter base
(3) and bowl (2).
4
8. Remove the cap from the bottom of new fil-
ter (4). Remove seals from the cap.
9. Install the seal into groove of the bowl (2).

2
10. Install the bowl (2) onto new filter (4) and
1
lock it.
11. Install filter (4) onto the filter base (3), and Fig 6-71 Water Oil Separator
lock it.
1. Drain valve 3. Filter base
12. Close the access door. 2. Bowl 4. Filter
NOTE：
This kind of filter is cartridge type paper filter and cannot be used repeatedly.

6.11.5.7 Fuel filter - check and replace
WARNING
Risk of fire or explosion!
If the fuel ignite, persons can suffer burns.
• Remove all spilled fuel. Never smoke when working on the fuel system.
• When replacing the fuel filter, turn the circuit breaker off or disconnect the battery.
NOTICE
Prepare a container. Drain the used oil in fuel filter before checking.
1. Open the access door on the left side of the

machine.
2. Remove the fuel filter.
3. Clean the mounting base of the fuel filter.
4. Replace the fuel filter with a new one.
Fig 6-72 Fuel Filter

5. Apply a thin coat of clean diesel fuel onto

the sealing surface of the new fuel filter.
6. Install the new fuel filter onto the base.

When the gasket comes in contact with filter
base, turn the filter by additional 3/4 of a turn.
Note:
Every filter has a index mark. The clear-

ance between mark is 1/4 of a turn. Use in-
dex mark to facilitate this procedure.
7. Add fuel to the fuel tank.
Fig 6-73 Apply Clean Diesel Fuel
8. Open electrical pump switch. At the same time unscrew the exhaust plug on fine filter. Screw
the exhaust plug until there is no air bubbled up through the hose. Release the pump switch to re-
lease it to the original position.
9. Close the access door on the left side of the machine.
6.11.5.8 Hoses - check and replace
1. Unlatch and raise the engine hood.
2. Check for leakage of all the hoses. Check clamp.
3. Replace cracked or softened hoses. Tighten the loose clamps.
4. Loosen the cooling system pressure cap slowly in order to relieve all the pressure. Remove the
pressure cap.
5. Drain the coolant from the cooling system and replaced the hose.
6. Loosen the hose clamp and disconnect the damaged hose.
7. Replace the damaged hose with a new one.
8. Replace and tighten the hose clamp.
9. Add appropriate amount of coolant to the cooling system.
10.Latch the engine hood.

6.11.5.9 Kelly guide sliding strip - check and replace
Check wear condition of Kelly guide nylon plate. After the first inspection, perform the second in-
spection based on the working condition. If it is excessively worn, replace it.
1. Remove the Kelly bar from the drilling rig.
2. Place the Kelly guide horizontally by using crane.
3. Check for the sliding strip. If it is excessively worn, replace.
6.11.5.10 Kelly bar locking recesses - check
Locking recesses transfers pressure. If the

wear is less than 10 mm (0.394 in), repair
welding in construction site. If the wear is
above 10 mm, contact SANY after sales staff.
Procedures for checking locking recesses:
1. Remove the baffle.
2. Pull out inner Kelly bar from drive stub.
3. Check inner Kelly bar locking recesses.
4. Install Kelly bar in reverse way. Fig 6-74 Locking Recesses
NOTE：
Check outer Kelly bar every 250 h or every month. Check inner Kelly bar every 500 h.
6.11.5.11 Kelly bar tube - check
Tube is on the lower part of each section of

bar and are used frequently. Procedures for
disassembling Kelly bar and checking inner
Kelly bar drive gibs:
Fig 6-75 Tube

Disassembly steps:
1. Remove the screw (1) 1 2
2. Remove the baffle (2)
3
1
Fig 6-76 Removing Baffle and Retainer
1. Screw 3. Retainer
2. Baffle
4. Remove baffle ring (4).
NOTE：
If the ring is too heavy and it is difficult to 4
disassemble manually, you can use auxili-

ary tools to facilitate disassemble.
Fig 6-77 Removing Baffle Ring
4. Baffle ring
5. Use auxiliary equipment such as forklifts,

nylon cranes to slowly pull out the core bar (5)
in the direction shown in the figure, and in-
spect wear-resistant spring seat (6), rubber
shock ring (7) and other parts. If the wear is
serious, repair or replace it. 6 7 5
Fig 6-78 Pulling out Core Bar
5. Core bar 7. Shock ring

6. Spring seat
NOTE：

6.11.5.12 Kelly bar drive gibs - check
Drive gibs are located on the top of each sec-

tion of bar and are used frequently. If open
welding occurs, repair it immediately.
Procedures for checking inner Kelly bar drive

gibs:
3. Pull out other sections.
4. Check inner Kelly bar drive gibs. Fig 6-79 Drive Gibs
5. Install Kelly bar in reverse way.
NOTE：
6.11.5.13 Kelly bar baffle - check
Check the Kelly bar baffle every week. If the

baffle deforms badly and cannot function well,
replace it.
Fig 6-80 Kelly Bar Baffle

6.11.5.14 Wire rope sheaves - check
1. Sluggish or seized rope sheaves subject

the rope to excessive wear and abrasion and
make the load distribute unevenly on the rope
structure.
2. Repair or replace the rope sheaves if

necessary.
Fig 6-81 Wire Rope Sheaves
6.11.5.15 Hydraulic system cleanliness - control
The following requirements must be met to ensure the cleanliness of oil/liquid in the hydraulic
system:
1. Ensure that the hydraulic fluid reservoir is clean before filling oil.
2. When filling oil, clean the area around the filler by wiping, and fill oil to the oil tank using a high-
precision oil filter. When filling is not needed, cover the filler cap to ensure sealing of the oil tank.
3. After the first startup for 500 h, clean or replace the filter element of the oil filter to filter the hy-
draulic oil in the oil tank. Clean or replace the filter element and hydraulic oil every 500～1,000
working hours. If the machine is not in operation for more than 1 year, replace or filter the hydraulic
oil.
4. If the machine is not in operation for a long time, the moisture-containing air will enter the oil tank
through the air filter. As a result, moisture enters the hydraulic oil, and the hydraulic oil may be
emulsified or deteriorated. Therefore, be sure to start the machine to ensure that it operates for a
period of time to raise the oil temperature, so as to remove the moisture from the hydraulic oil.
NOTE：
• In case of low cleanliness of the oil, hydraulic components may be worn more quickly, the hy-
draulic valve spool may be stuck, and the orifice may be blocked.
• The cleanliness of the hydraulic oil must be lower than NAS level 9.

6.11.5.16 Generator belt - check and adjust
Check the tension of the generator belt, press the middle of the belt with a force of about 98 N,
check the deflection measurement and adjust it (5.5 mm~7.5 mm), and change the generator belt
in time if the belt is scratched or broken. If you have any questions, please contact the authorized
agent of Sany.
6.11.5.17 Fan belt - check and adjust
Check the tension of the fan belt, press the middle of the belt with a force of about 98 N, check the
deflection measurement and adjust it (5.5 mm~7.5 mm), and change the fan belt in time if the belt
is scratched or broken. If you have any questions, please contact the authorized agent of Sany.
6.11.6.1 Rotary drive gearbox gear oil - change
CAUTION
Risk of injury!
Before any operation, make sure the oil is at operating temperature and prepare a suitable contain-
er for waste oil.

1. Set the rotary drive in the vertical position.

3
2. Place a suitable container for catching the

waste oil beneath the drain plug (1).
3. Remove the guard board (3).
4. Unscrew the drain plug (1) and drain the

used oil. 4 5
5. Clean the surface of the sealed compo-

nents and check. If there is any damage, re-
place immediately.
1 2
6. Install the drain plug (1). Fig 6-82 Rotary Drive
7. Remove the air filter assembly (4) by un- 1. Drain plug 4. Air filter assembly
screwing the filling plug (5). Add oil to the 1/2 2. Sight glass 5. Filling plug
– 2/3 position of the sight glass (2). 3. Guard board
8. Install the air filter assembly (4) and the

guard board (3).
6.11.6.2 Travel reducer oil - change
CAUTION
Risk of injury!
NOTICE
For more information, go to http://www. epa.gov/osw/conserve/materials/usedoil/

Before changing oil:
• Oil is at operating temperature.

• Prepare a suitable container for old oil.
1. Turn the oil drain screw plug (D) of the trav-

el reducer on one side to the bottom position.
F
2. Remove the oil drain screw plug and oil lev-
L
el screw plug (L). Allow the oil to drain into a
D
suitable container.
3. Clean the plug, and check O-ring. If there is

wear or damage, immediately replace the oil
A
drain screw plug, oil level screw plug, and O-
ring.
4. Install the oil drain screw plug. Add oil to the

travel reducer in order to make the oil level
reach the bottom of the oil level screw plug.
Install the oil level screw plug. Fig 6-83
5. Perform the above procedures for the travel A. Oil level F. Oil filling plug
reducer on the other side. Use another con- D. Drain screw plug L. Oil level screw
tainer in order to separate the oil sample of plug
two travel reducers.
6. Completely remove the oil splashed onto the surface.
7. Start the engine and run the travel reducer for a few turns.
8. Shut down the engine and check the oil level (A).
9. Check the drained oil for metal chips or metal particles.
10. Correctly dispose of the drained material.

6.11.7.1 Air recirculation filter - replace
The air recirculation filter is located on the

upper carriage.
1
1. Take away the cover (4) of recirculation fil- 2
ter. Remove the main filter element (2) and
3
safety filter element (1). 4
2. Tap the air filter gently to remove the dirt.
3. Check the filter element, replace with a new

one.
Fig 6-84 Location of Air Recirculation Filter
4. Reinstall the filter element.
1. Safety filter 3. O-ring
NOTE： element
The clogged filter element will decrease 2. Main filter element 4. Cover
the performance of air conditioner and cab
heater. Clean the filter element as
necessary.
6.11.7.2 Gear oil for swing reducer - change
CAUTION
Risk of injury!
NOTE：


1. Remove the access cover located below

the swing drives.
2. Remove drain hose from holder on the

upper beam. Face the end of the hose toward
the container.
3. Use a universal joint with a socket exten-

sion to loosen the drain valve in the hole.
Drain the oil into a suitable container.
4. Tighten the drain valve. Hook the drain

hose to the holder. Make sure the end of the Fig 6-85 Drain Hose
hose faces upward.
5. Remove dipstick. Add oil.
Fig 6-86 Dipstick
6. Make sure that the oil level between the

FULL mark and the ADD mark.
7. Check if metal chips or particles are in the

waste oil. Consult SANY after sales service
department if any metal chips or metal par-
ticles are found.
Fig 6-87 FULL Mark and ADD Mark

6.11.7.3 Other maintenance items
No. Maintenance items Maintenance instructions

1 Fuel tank strainer - For details, see: Chapter 6 Maintenance, “Fuel tank strainer -
clean clean” on page 6-58.
2 Engine oil and filter - For details, see: Chapter 6 Maintenance, “Engine oil and filter
change - change and replace” on page 6-55.
3 Winch reducer oil - For details, see: Chapter 6 Maintenance, “Winch reducer oil -
change change” on page 6-66.
4 Rotary drive reducer For details, see: Chapter 6 Maintenance, “Rotary drive reducer
gear oil - change gear oil - change” on page 6-66.
5 Bolts connecting swing For details, see: Chapter 6 Maintenance, “Bolts connecting
bearing - check swing bearing - check” on page 6-68.

6.11.8.1 Hydraulic oil - change
CAUTION
Risk of injury and cutting!
Suddenly escaping media can lead to the cutting of body parts.
• Before assembling or dismantling media-conducting components such as hydraulic hoses,
make sure that they are pressure-free.
Precautions for hydraulic oil selection
Know the operating temperature of relevant circuits (closed circuit) in order to correctly select oil.
Select hydraulic oil like this: The operating viscosity in working temperature range is in the opti-
mum range (Vopt) (see red area of the selection diagram). We recommend high viscosity grade
oils.
E.g. Under the ambient temperature of X°C, the circuit working temperature is 60°C, and the corre-
sponding viscosity grade is VG46 to VG68 in operating viscosity range (Vopt red area). VG68
should be selected.
NOTE：
The hydraulic fuel tank volume is 600 L, the fuel tank volume is 630 L, and the cooling sys-
tem water tank is 59 L.
Procedures for changing hydraulic oil
1. Park the machine on level ground.
2. Open the access cover.
3. Loosen the protection cap from the breather

valve to release the pressure in hydraulic
tank.
Fig 6-88 Breather Valve

4. Remove the access cover under the hy-

draulic tank. Check the drain valve.
Fig 6-89 Drain Valve
5. Remove screw plug to drain the oil to a suitable container.
6. Clean the screw plug and reinstall it into the original position. Tighten it to a torque of 75±5 N·m.
7. Open the right access door.
8. Clean the pump, the hydraulic lines, and the hydraulic tank.
9. Remove bolts (5), washers (6), cover (7),

spring (8), and strainer (9). 5 8
6
NOTE：
Do not allow spring (8) to fall back into the
7
tank.
Fig 6-90 Removing Spring and Strainer
5. Bolts 8. Spring
6. Washers 9. Strainer
7. Cover
10. Wash the strainer in clean and nonflammable solvent. Allow the strainer to dry. Inspect the
strainer. Replace the strainer, if the strainer is damaged.

11. Remove O-ring seal (10) from the strainer.
10
Fig 6-91 O-ring Seal
10. O-ring seal
12. Inspect O-ring seal (7) and (8). Replace the O-ring seals if wear or damage is evident.
13. Install O-ring seal (7) on strainer (6).
14. Install strainer (6), spring (5), cover (7), washers (6), and bolts (5).
Remark:
Make sure that the O-ring seals and the spring are properly positioned during installation.
15. Fill the hydraulic system tank according to required capacity. see table recommended fluids
on topic “Drilling Rig Oil”.
16. Inspect the O-ring seal on the filler plug for damage. Replace the O-ring, if necessary. Clean
the filler plug. Install the filler plug.
17. Start the engine. Operate the engine at idle speed for 5 min. Shut down the engine.
18. Check the hydraulic oil level.
19. Close the access door. Close and latch the engine hood.

6.11.8.2 Oil suction filter - replace
1. Park the machine on level ground and shut

5 8
down the engine.
6
2. After hydraulic oil cools down, loosen the
air-bleed plug, and screw it after bleeding the 7
air.
3. Loosen fastening bolts (5), and remove cov-

9
er (7). When removing the cover, press it by
hand, so as to avoid being hurt by the cap.
4. Plug out the end of the rod, and remove

spring (8) and strainer (9).
5. Clear the dust off the strainer. Flush with

clean diesel oil. If the strainer is damaged, re-
place it. Fig 6-92 Removing Spring and Strainer
6. Reinstall the strainer, and install gasket seal 5. Bolts 8. Spring
(11) into the protuberant part of oil tank. 6. Washers 9. Strainer

7. Cover
7. Install cover and fasten bolt. Make sure the
protuberant part could be inserted with spring.
Fasten bolt.
8. Clean the work site after replacing it. Keep

the machine clean. Keep oil tank port and cov-
10 11
er clean during changing filter element.
Fig 6-93 O-ring Seal
10. O-ring seal 11. Gasket seal

6.11.9.1 Pilot filter element - replace
CAUTION
Risk of scalding!
Direct contact with hot parts can lead to burning or scalding of body parts.
• When handling hot parts always wear the appropriate personal protective equipment.
See: Chapter 2 Safety, “Environment Protection” 2-66 before proceeding with this procedure.
1. Park the machine on level ground.

1
2. Move the safety lock lever to unlocked posi-
tion (1).
3. Turn the engine ignition key to the ON

position.
4. Move the handles and travel levers/pedals

to the full stroke positions in order to relieve 2
the pressure in the pilot lines.
5. Turn the engine ignition key to OFF position

and return the safety lock lever to locked posi-
tion (2). 1. Unlocked position 2. Locked position
6. Slowly loosen the breather valve to relieve

the internal pressure of the hydraulic tank.
7. After the pressure is relieved, tighten the

breather valve.
8. Open the access door on the right side of

the machine.

9. Clean this area to remove the dirt.
NOTE：
Dispose the old filters according to local
regulations.
10. Remove the used pilot filter element from

the filter base.
Fig 6-96 Pilot Filter
11. Clean the filter base.
12. Coat the seal of a new pilot filter with clean

hydraulic oil.
13. Install the new pilot filter on the filter base.

Tighten the pilot filter by hand.
Fig 6-97 Applying Hydraulic Oil
6.11.9.2 Return filter - replace
WARNING
High pressure fluid can result in injury or casualty.
• Never remove any hydraulic parts before pressure is released.
NOTE：
Hydraulic fluid is hot and under pressure. Always wait for the machine to cool down to below 160°
F (71°C) before attempting to open the hydraulic fluid system. Failure to do so could result in minor
or moderate injury.

1. Loosen the breather valve in order to re-

lease all the pressure. Tighten the valve after
the hydraulic tank pressure is relieved.
Remove filter cartridge. Procedures are as

1
follows:
6 2
1. Remove bolts (1), washers (2) and cover 3
(3、6). 7
4
2. Check cover (3、6) and O-ring (4、7). Re-
place if damage appears.
8
5
3. Remove the used return filter.
4. Install the filter elements. Procedures are

against removing procedures. (Tightening tor-
que: 29±5 N·m).
Fig 6-99 Removing the Return Filter
1. Bolts 5. Filter cartridge

2. Washers 6. Cover
3. Cover 7. O-ring
4. O-ring 8. Filter

6.11.9.3 Auxiliary pump filter element - replace
CAUTION
Risk of injury!
Grease escaping under pressure can cause injuries to body parts.
• Release the pressure in hydraulic system before changing the filter element.
If the machine equip auxiliary pump, place replace the filter element for the first time after 250 op-
erating hours or a month. Then change oil after every 1000 operating hours.
1. Place a suitable container underneath the

filter housing and unscrew the bottom (1).
2. Remove filter element (2) from housing (3),

and dispose of with hazardous waste. 3
3. Clean the top and bottom of the housing.
4. Install a new filter element in the top of the 2

housing.
5. Install the bottom of the housing.

1
Fig 6-100 Filter Element
1. Bottom 3. Housing
2. Filter element

6.11.9.4 Breather valve - check and replace
Visually check the valve for damage. Replace

the valve according to the instructions indi-
cated on the valve.
6.11.9.5 Battery - clean and recycle
WARNING
Improper jumper cable connections can cause explosion. Electrolyte is an acid and IT can cause
personal injury if it contacts the skin or eyes. Personal injury or possibly death can result from bat-
tery fumes or explosion.
• Prevent sparks near the batteries.
• Never allow jumper cable ends to contact each other or the engine.
• Always wear protective glasses when working with batteries.
Battery-clean
Clean the battery surface with a clean cloth. Keep the terminals clean and keep the terminals
coated with petroleum jelly. Install the post cover after you coat the terminal post with petroleum
jelly.
Battery-recycle
Always recycle a battery. Always return the used batteries to one of the following locations:
• a battery supplier.
• an authorized battery collection facility.
• recycling facility.
Battery hold-down-tighten

Tighten the hold-downs for the battery in order to prevent the batteries from moving during ma-
chine operation.
Battery, battery cable, or battery switch-

replace
1. Turn the engine ignition switch key to the

OFF position. Turn all the switches to the OFF
position.
2. Turn the battery switch to the OFF position.
3. Disconnect the negative battery cable at

the battery.
4. Disconnect the positive battery cable at the

battery. Fig 6-102 Battery Switch
5. Disconnect the battery cables at the battery

switch.
6. Connect the battery cable at the battery

switch.
7. Connect the positive battery cable of the

battery.
8. Connect the negative battery cable of the

battery.
Fig 6-103 Disconnecting the Battery

1 Rotary drive gearbox For details, see: Chapter 6 Maintenance, “Rotary drive
gear oil - change gearbox gear oil - change” on page 6-80.
2 Travel reducer oil - For details, see: Chapter 6 Maintenance, “Travel reducer oil -
change change” on page 6-81.


1 Hydraulic oil - change For details, see: Chapter 6 Maintenance, “Hydraulic oil -
change” on page 6-86.
2 Oil suction filter - For details, see: Chapter 6 Maintenance, “Oil suction filter -
replace replace” on page 6-89.
6.11.11.1 Generator belt - replace
Please contact the authorized agent of Sany for replacement of generator belt.
6.11.11.2 Fan belt - replace（if equipment）
Please contact the authorized agent of Sany for replacement of fan belt.
6.12 Storage of Drilling Rig

6.12.1 Preparations before storage
1. Thoroughly wash the machine after work or before storage. Disconnect all the batteries before
washing so as to avoid short circuit.
2. Flush with clean water. Use special detergent to remove dirt, if necessary. Do not wash with acid
or alkaline solution so as to avoid corrosion to the machine surface.
3. When washing with high pressure water, use caution to protect electrical and hydraulic elements
in order to prevent damage to elements or looseness of cable interface.
4. When washing in cold weather, immediately dry the drilling rig so as to avoid freezing of the drill-
ing rig surface.
6.12.2 Maintenance during storage
1. Check the machine. Repair the worn or damaged parts. Replace with new parts, if necessary.
2. Clean the air cleaner filter element.
3. Retract the retractable hydraulic cylinder. Exposed hydraulic cylinder piston rod shall be applied
with grease.

4. Lubricate all the lubrication points.
5. Park the drilling rig on solid enough, level ground. If necessary, chock the tracks with enough
area thick steel plate or wood plate.
6. Wash the drilling rig. Especially when stored in winter season, different parts of the drilling rig es-
pecially the crawler shall be washed up.
7. After the battery is charged with enough power, disconnect the battery and store it in dry, safe
place. If you do not disconnect the battery, separate the battery negative cable from the negative
terminal.
8. In winter season, use antifreeze or drain out coolant completely. SANY adopts coolant with the
freezing point of -35°C (-31°F). If the ambient temperature is lower than -35°C (-31°F), drain the
coolant. If the cooling system is drained, attach a warning tag “radiator without coolant” in conspic-
uous place.
9. Loosen the alternator belt and cooling fan belt.
10.Apply paint at some position in order to prevent rust. e.g. use grease to guard the telescopic
beam surface and mast rail.
11.Park the machine in dry, safe place. If stored outdoor, it should be covered with waterproof
guard.
12.If storing the machine for long period of time, run the machine at least once a month.
13.During storage period, usually remove dust from the gear ring and driving wheel surface. Check
for rust. If necessary, clear of the rust and apply grease for lubrication.
6.12.3 Routine maintenance of drilling rig
1. Check whether the amount of oil in each oil tank is enough, and whether the oil quality is normal.
2. Check for oil leakage.
3. Check the wire rope of the main and auxiliary winches for damage, check the connection for reli-
ability, and check the rope retainer for strength.
4. Check the rotation of the rope swivel for flexibility, and check the grease inside for
contamination.
5. Check the steel structure for cracks, rusts, desoldering and other damages.
6. Tighten the loose rubber hoses and bolts.

7. Check the lubricated positions of each moving mechanism. For example, for positions with a
large swinging surface, such as the slewing bearing of the upper body, make sure sufficient grease
is applied on the entire swinging surface.
8. Check the lubrication of the main and auxiliary winch wire ropes. Make sure each strand is fully
applied with grease.
9. Check whether the three surfaces of the mast guide rail is fully applied with grease.
10.Check the circuit breakers for aging and check the wires for damage.
11.Check the drill rod keys for signs of desoldering and cracks.
12.Check whether the follower bracket bearing is properly lubricated with grease.
13.Check the coolant level and the oil level in the engine oil pan.
14.Check water and precipitate in the oil water separator to drain off the water and precipitate.
15.Check the air inlet for signs engine damages, such as wear points, pipe damage, and clamp
looseness.
16.Check the cooling fan for cracks, bending and rivet looseness.
17.Check the breathing tube of the crankshaft for mud, powder or ice, especially under cold weath-
er conditions.
6.12.4 Maintenance for removal of drilling rig from garage
The engine can only be started at places with proper ventilation.
In case of long-time storage of the machine, the thin oil layer on the sliding surface may be dam-
aged. It is necessary to allow the drilling rig to perform circulated travel and swinging, and operate
the hydraulic functions of the hydraulic system for 2-3 times to lubricate the sliding surface.
1. If the piston rod of the hydraulic cylinder is applied with grease before storage, be sure to re-
move the grease.
2. Adjust the tension of the belt for the alternator and fan.
3. Check all hoses and their connections.
4. Install a new fuel filter, change the engine oil filter, and fill the oil into the engine.
5. Fill the fuel tank, and vent the fuel system.
6. Check all oil levels and the oil quality.
7. Start the engine. Before full-load operation, run the engine at a 50% rated velocity for a few
minutes.
8. Circulate all hydraulic functions for several times.

After long-time storage of the machine, perform the following steps:
1. Check all hoses and their connections.
2. Preheat the engine.
3. Turn off the engine.
4. Install a new fuel filter. Change the engine oil filter and fill the oil into the engine.
6.12.5 Maintenance for long-term storage
If the machine has been stored for long period of time, the thin oil layer on the sliding surface may
be damaged. It is necessary to repeatedly travel, swing, and operate the hydraulic system for twice
or three times in order to lubricate the sliding surface.
1. Apply grease to the hydraulic cylinder piston rod before storage. Remove the grease.
2. Adjust tension of alternator belt and fan belt.
3. Check condition of all the hoses and the connections.
4. Install the new fuel filter. Replace the engine oil filter and fill oil to the engine.
5. Pad the fuel tank in order to bleed gas from the fuel system.
6. Check all the fluid levels and oil quality.
7. Start the engine. Before full load operation, run the engine at half speed for a few minutes.
8. Circulate all the hydraulic functions for several times.


SR305RS10Rotary Drilling Rig Troubleshooting
Troubleshooting
7 Troubleshooting ..............................................................................................................7-1
7.1 Special Instructions...............................................................................................................7-3
7.2 Precautions during Troubleshooting ..................................................................................7-3
7.3 Common Troubleshooting and Solutions ..........................................................................7-4
7.4 Solutions to Common Non-quality Problems ..................................................................7-11
7.5 When Battery Feed Fails to Start Up............................................................................... 7-14
7.6 When Battery Feed Needs to Be Charged..................................................................... 7-17
7.7 When Engine Coolant Temperature Too High ............................................................... 7-19
7.8 When Engine Oil Pressure (Low Pressure) Abnormal ................................................ 7-19

Troubleshooting SR305RS10Rotary Drilling Rig

7.Troubleshooting
7.1 Special Instructions
If the following similar situations occur during the use of your device, it is normal and meets indus-
try standards. Please feel free to use it.
1. This function is not available at the time of product design, but it is mistaken for a failure because
you don't understand the product function (for example, unable to adapt to work conditions above
4 km above sea level).
2. The engine suddenly loses speed or there is a slight black smoke in operation, but the on-site
detection value belongs to the normal range of the engine operation. When the ambient tempera-
ture is <30°C, the instantaneous load smoke level value is not greater than 4.5 RP, and the stable
load smoke value is not greater than 1.5 RP.
3. Excessive consumption of engine oil and fuel occurs but turn out in the normal range specified
by the manufacturer in the field test.
4. Poor operation stability, grade ability, offset travel and slow movement occurs due to your un-
skilled operation and you are not familiar with working condition, but all the parameters are proved
by the field test in the normal range specified by the manufacture.
5. The hydraulic system gives abnormal noise (such as abnormal oil return noise, pipeline abnor-
mal noise, etc.), check hydraulic system and make sure the hydraulic oil return filter has no iron
chips, copper chips, aluminum chips and other impurities, and which does not affect the normal op-
eration of the equipment.
6. Common phenomena in the industry, such as discoloration or blackening of piston rod, reverse
or automatic movement of cylinder, and start difficulty of engine in low temperature winter days.
7.2 Precautions during Troubleshooting

Note the following during fault diagnosis:
• Park the machine on the horizontal ground, and confirm the function of safety pin, cushion block
and parking brake.
• Avoid adding hydraulic oil, replacing the filter or repairing the machine in rainy days, days with
strong wind or a dusty place.
• When filing the hydraulic oil, do not let oil sludge or dust mix in.
• During the collaborative operation, the signal shall be strictly unified and no irrelevant personnel
can be allowed to be close to it.
• If the radiator cap is removed when the engine is hot, hot water will be sprayed and cause burn-
ing, so maintenance shall be carried out after the engine is cooled down.
• Do not touch any hot parts or hold any rotary parts.

• Always turn off the power before disconnecting or connecting the connector.
• Always remove the negative [-] terminal of the battery first when disconnecting the battery cable.
• When removing the internal oil pressure, water pressure or air pressure plug or cap, release the
internal pressure first.
• When installing the measuring equipment, ensure that the connection is correct.
7.3 Common Troubleshooting and Solutions

If there is an abnormal failure in the operation of the machine, you can make a simple fault diagno-
sis and repair according to the common fault phenomena and solutions listed in the following table.
You can also contact Sany or an authorized dealer for machine fault analysis or repair.
Before you repair the machine, you can do some preliminary inspections according to the fault
phenomenon, such as checking whether the fuel level, coolant level, engine oil level, etc. are nor-
mal, checking whether the battery terminal has looseness or corrosion, and whether there is oil
leakage, etc. For example, when the machine has a high temperature phenomenon, you can
check whether the machine has a coolant leakage and whether the electronic fan is working
normally?
Fault phenomenon: Engine can run, but fails to start up and there is no smoke in exhaust
Possible Cause Suggested Action
No fuel in fuel tank Check fuel level. If fuel level is low, add fuel ac-
cording to “fuel amount - check and refuel” in
Maintenance.
Improper start-up procedures Start the engine according to steps illustrated
in “Starting the engine” in Operation.
Drain water oil separator or replace fuel filter.
Fuel filter clogged See “Filter of water oil separator - replace” and
“Fuel filter - replace” in Maintenance.
Check exhaust system for clog. See “Air intake
Air intake or exhaust system clogged
and exhaust system - check” in Maintenance.
Fault phenomenon: Engine starts, but can not keep running

Check fuel level. If fuel level is low, add fuel ac-
Fuel level too low cording to “fuel amount - check and refuel” in
Maintenance.
Drain water oil separator or replace fuel filter.
Fuel filter clogged See “Filter of water oil separator - replace” and
“Fuel filter - replace” in Maintenance.

Fault phenomenon: Engine unstable idle (speed fluctuation)

Check fuel level. If fuel level is low, add fuel ac-
Fuel level too low cording to “fuel amount - check and refuel” in
Maintenance.
Fault phenomenon: Engine idle rough (irregular ignition or engine vibration)

Preheat engine to operating temperature. See
Engine temperature low
“Starting the engine” in Operation.
Replace fuel filter and fuel tank strainer. See
Fuel supply clogged “Fuel tank strainer – clean” and “Fuel filter –
replace”.
Fault phenomenon: engine running rough or lacking fire

Engine temperature low Preheat engine to operating temperature. See
Replace fuel filter and fuel tank strainer. See
Fuel supply clogged “Fuel tank strainer – clean” and “Fuel filter –
replace”.
Fault phenomenon: The engine speed cannot reach the rated speed
Engine overload Check and confirm that the correct gear is
used for operation by referring to the system
function section "Engine button".
Fault phenomenon: Engine output power low

Engine oil level too high or too low Check and adjust the engine oil level by refer-
ring to the maintenance section "Engine oil lev-
el-check".
Air exhaust is blocked Check the exhaust system by referring to the
maintenance section "Air intake and exhaust
system-check".

Fault phenomenon: Too much black smoke is exhausted

The engine stall speed occurs due to overload Use the low-speed gear by referring to the sys-
tem function section "Engine button".
Air intake is blocked Check or replace the air filter and check for
other blockage by referring to the maintenance
section "Air recirculation filter - inspect and
replace".
There is more than one seal washers under Remove the excess washer
the injector
Fault phenomenon: Too much white smoke is exhausted

The starting steps are incorrect Preheat engine to operating temperature. See
Fault phenomenon: : The coolant temperature is higher than the normal temperature and
overheat occurs gradually
Check and add coolant by referring to the
Coolant level low
maintenance section "Coolant Level – check".
Engine oil level high Check and adjust the engine oil level by refer-
ring to the maintenance section "Engine oil lev-
el-check".
The radiator, cylinder cap, cylinder cap gasket, Flush the cooling system and add new coolant
or coolant pipeline of the cylinder body is by referring to the maintenance section "Cool-
blocked ant Level – check and refill".
Fault phenomenon: coolant loss

Engine coolant leakage Check and add coolant by referring to the
maintenance section "Coolant Level – check".

Fault phenomenon: engine oil pressure low

Check and adjust the engine oil level by refer-
Engine oil level low ring to the maintenance section "Engine oil lev-
el-check".
The engine oil viscosity too low, the engine oil Confirm that the correct engine oil is used by
is diluted or does not meet technical referring to the maintenance section "Drilling
specifications rig oil".
The engine oil filter clogged Replace the engine oil filter by referring to the
maintenance section "Engine oil and filter –
change and replace".
The engine oil viscosity too high Confirm that the correct engine oil is used by
referring to the maintenance section "Drilling
rig oil".
Fault phenomenon: Engine oil consumption too high

An external leakage occurs Visually inspect whether the oil leaks.
The engine oil is not qualified (does not meet Confirm that the correct engine oil is used by
the technical specification or have the required referring to the maintenance section "Drilling
viscosity) rig oil".
Engine oil cooler leakage Check whether there is engine oil in the cool-
ant by referring to the maintenance section
"Coolant Level – check".
Fault phenomenon: The coolant contaminated

Evaluate the coolant replacement interval by
The agent and coolant not rustproof, and anti-
referring to the maintenance section "Mainte-
freeze not mixed correctly
nance Schedule".
Evaluate the replacement interval of the engine
oil and filter by referring to the maintenance
section "Maintenance Schedule".
The coolant contains excessive sludge
Confirm that the correct engine oil is used by
referring to the maintenance section "Drilling
rig oil".

Fault phenomenon: The exhaust manifold has a fuel or engine oil leakage
The turbocharger oil return pipe is blocked Check and clean the oil pipeline by referring to
the maintenance section "Hose – check and
replace".
Fault phenomenon: The chassis and the whole machine have no action
The oil in the hydraulic fluid reservoir is not Add hydraulic oil by referring to the mainte-
enough, and the main pump sucks air nance section "Hydraulic oil – check and add".
The oil suction filter is clogged Clean the system by referring to the mainte-
nance section "Oil suction filter – clean".
Fault phenomenon: The chassis and the whole machine move slowly
Insufficient hydraulic oil in the tank Add hydraulic oil by referring to the mainte-
nance section "Hydraulic oil – check and add".
The engine speed too low Use the low-speed gear by referring to the sys-
tem function section "Engine button".
Due to the aging sealing kits on the rotary drill- Replace the hydraulic oil by referring to the
ing rig chassis that has been used for long, the maintenance section "Hydraulic oil – change".
hydraulic components gradually wear and the Contact Sany service personnel to replace the
hydraulic oil deteriorates, so that the operation sealing kits of the whole machine and readjust
becomes slow and weak with the temperature the clearance and pressure of the hydraulic
increases components.
The engine filter is clogged, resulting in serious Replace the engine oil filter by referring to the
loading speed drop and stalling in case of seri- maintenance section "Engine oil and filter –
ous clogging change and replace".

Fault phenomenon: The hydraulic oil temperature too high

The hydraulic oil used does not meet the re- Change oil by referring to the maintenance
quirements of the rotary drilling rig chassis section "Hydraulic oil – change".
The oil level in the hydraulic fluid reservoir too Add hydraulic oil by referring to the mainte-
low nance section "Hydraulic oil – check and add".
The hydraulic oil is polluted, so that the internal
spare parts or sealing kits of the motor, main
valve, cylinder and other hydraulic components
are worn faster, resulting in internal leakage. Replace the filters by referring to the mainte-
As the result, the oil temperature rises, the nance section "Pilot filter – replace", "Return fil-
traveling, swinging, and working devices act ter – replace", "Oil suction filter – replace".
slowly and weakly, and the hydraulic oil deteri-
orates, the safety valve cannot close tightly,
and overflow loses due to high temperature
Fault phenomenon: Abnormal noise and vibration occur during working of the rotary drill-
ing rig chassis
Insufficient oil in the hydraulic fluid reservoir Add hydraulic oil by referring to the mainte-
The oil contains too much water and air Change oil by referring to the maintenance
section "Hydraulic oil – change".
The filter is clogged Replace the engine oil filter by referring to the
maintenance section "Engine oil and filter –
change and replace".
The engine speed is uneven Adjust engine gear by referring to the system
The bearing of the working device is not lubri- Apply lubricant or contact Sany service person-
cated or is damaged nel to replace the axis or sleeve.
Fault phenomenon: The oil pump system does not supply oil or supplies insufficient oil
The engine speed is too low Adjust engine gear by referring to the system
There is not sufficient oil in the tank Add hydraulic oil by referring to the mainte-

Fault phenomenon: The rope swivel does not rotate or the rotation is not flexible
The rope swivel is not used for a long time or Check whether the rope swivel is lubricated
rustproof treatment is not performed and lubricate it if required by referring to the
maintenance sections "Rope swivel flexibility –
check" and "Rope swivel - check and
lubricate".
The rope swivel is installed too tightly Reinstall the rope swivel by referring to the
maintenance section "Rope swivel flexibility –
check".
Fault phenomenon: Abnormal noise in the rotary drive reducer.

Gear oil insufficient Add gear oil to the reducer by referring to the
maintenance section "Rotary drive reducer
gear oil - change".
Fault phenomenon: wire rope damage

Rope hold-down roller do not rotate Check rope hold-down roller r by referring to
the maintenance section "Rope hold-down roll-
er – check".
Wire rope excessive wear Replace and reinstall the wire rope by referring
to the operation section "Installing wire rope".
Fault phenomenon: the whole equipment lack of power

Hydraulic oil deteriorated Change hydraulic oil. See “Hydraulic oil –
change”.
Fault phenomenon: Fans run normally, but air volume is small

There are obstacles in air intake side
Fins of evaporator or condenser clogged, poor Check the condition of air conditioner. See “Air
heat transfer conditioner circulation filter – clean”.
One of blowers jammed or damaged

7.4 Solutions to Common Non-quality Problems
During the use of the equipment, the piston rod of the cylinder is "blackened" occa-
sionally, but there is no oil leakage in the cylinder. How should the customer handle
it?
• Because the hydraulic oil contains additives with complex components, under the action of spe-
cific temperature and high pressure of hydraulic oil, the additives will crystallize and attach to the
surface of the piston rod, and the piston rod is discolored under the action of the shear force of
the oil seal of the hydraulic cylinder.
• Different brands of hydraulic oil should not be mixed, otherwise the quality of the oil will decline
and, in serious cases, the oil will deteriorate. The hydraulic oil contains a variety of special addi-
tives. When the oil products with different systems of additives are mixed, it will affect its per-
formance, and even make the additives precipitate and deteriorate. In this case, it is also easy to
cause piston rod coloring.
When the new equipment is used for the first time, some hydraulic components
(such as cylinder) show signs of “residual oil”. How should the customer handle it?
• The residual oil will not affect the performance of the machine: In case of assembly of the upper
end cover of the cylinder barrel, in order to achieve the cleaning of the end cover and the lubrica-
tion effect of the sealing ring assembly, the end cover will be cleaned and applied with hydraulic
oil. It will cause part of the hydraulic oil remaining in the seal groove of the end cover, seeping
from the dustproof ring of the end cover in the working process and forming oil stains.
• Judgment and handling of this residual oil phenomenon: If you find that there are oil stains on
the cylinder head of the machine within 100 hours, clean and wipe the cylinder head, and then
follow up; observe for 2 days, if there are still oil stains, clean it for the second time with the same
method as the first cleaning, and continue to follow up. If there are still oil stains, judge whether
there is an oil leakage or not.
Why is it necessary to drain the water at the bottom of the “fuel-water separator”
and “fuel tank” of the equipment every day? What is its function? Otherwise, which
components of the equipment will be damaged?
• Due to the harsh site environment, diesel oil is easy to be mixed with water and impurities, which
can be discharged through the drain valve at the bottom; the oil-water separator also has the
function of separating the water; the engine high-pressure oil pump and nozzles are lubricated
and cooled with fuel, and the water and impurities will lead to early wear of the oil pump nozzles.

The equipment is maintained regularly and quantitatively in accordance with the re-
quirements of the factory, how can there be such faults as large lower exhaust of
the engine, oil burning, etc.?
• The air filter element in the power system of the equipment meets the operating conditions in the
conventional environment, and the impurities in the air can be filtered through the air filter to
avoid the early wear of the four sets of the engine and the phenomena of large lower exhaust
and oil burning. However, when the site environment is very harsh, the air filter will be blocked or
damaged by excessive impurities, and the phenomena of “choking”, “black smoke” and “speed
drop” will occur when the engine is blocked, and the damage of the filter element will lead to air
impurities entering into the air cylinder and malfunction. Therefore, it is necessary to check,
clean or replace the outer element of the air filter every day to prolong the service life of the
engine.
How to handle the “large clearance” of the swing bearing?
All bearings must have a clearance, and those with a clearance that does not exceed the standard
are normal.
• A swing bearing consists of inner and outer rings, internal balls, isolation sleeves and inner and
outer dustproof seals. As a component that can produce relative motion, the swing bearing must
have a gap. The bearing gap is called clearance, which can be classified as radial clearance
and axial clearance in accordance with the relative movement direction of the inner and outer
rings. It can be classified as original clearance, installation clearance and working clearance in
accordance with the state of the bearing.
• In accordance with the working characteristics of the machine, the original clearance of the
swing bearing is controlled by the bearing manufacturer, and Sany and other manufacturers in
the industry have adopted the specified measurement methods to carry out the measurement
and quality control of the installation clearance of the swing bearing.
• If the value measured in accordance with the standard installation clearance measurement
method does not exceed the standard range, it is normal. If you have any concerns, we can take
you to try other equipment of the same model.
• Since there is a gap between the components of the bearing, if the grease is added improperly,
it will be extruded from the gap between the inner and outer rings. The swing bearing shall be
applied with grease in several times with a small amount, and when the viscosity of the grease
is too low, the lubricating grease penetration index grease is more likely to be extruded and
dripped.
• The faults caused by improper operation and maintenance are not covered by the warranty. The
operation and maintenance shall be carried out in strict accordance with the provisions of the op-
eration and maintenance manual: If the swing bearing accidentally enters the liquid, the old oil

and impurities shall be extruded by thoroughly applying the grease as soon as possible to re-
duce the possibility of damage.
How to handle the wear of the idler, sprocket, track roller, carrier roller and track
shoe? Is it a fault?
Wear will occur when the metal parts are rubbed against each other, and the degree of wear has a
lot to do with the environment and track tension.
• The idler, sprocket, track roller, carrier roller and track shoe are in direct contact with the ground,
and they will move and wear relative to each other and with the ground.
• The state and service life of the idler, sprocket, track roller, carrier roller and track shoe are
highly related to the use time and working environment.
• The wear of the idler, sprocket, track roller, carrier roller and track shoe is not only related to the
working environment and working intensity, but also related to the use habit and track tension.
During traveling, especially turning, turning through alternate use of the left/right traveling motor
or changing the position of a certain traveling control lever slightly in advance to make the ve-
hicle body turn more smoothly, have different wear degrees on the idler, sprocket, track roller,
carrier roller and track shoe, especially the contact surfaces on the left and right sides of them.
The equipment that often works at a 90° angle between the vehicle body and the traveling body
has a greater impact on the wear of the side parts of the idler, sprocket, track roller, carrier roller
and track shoe. Whether the track tension can be adjusted in time in accordance with the work-
ing environment has a great impact on the wear degree of the front contact parts of the idler,
sprocket, track roller, carrier roller and track shoe. Therefore, good operating habits and correct
track tension are closely related to the wear degree of the idler, sprocket, track roller, carrier roll-
er and track shoe.
Is it normal for the equipment to jitter in extremely cold weather? How should we
handle it?
The temperature characteristics of hydraulic oil show that: the change of oil temperature will di-
rectly affect its viscosity. The lower the temperature is, the higher the viscosity is, and the poorer
the fluidity is. Since there are a large number of orifice devices in the hydraulic system (e.g. han-
dle, main pump regulator, main valve, etc.), when the low temperature hydraulic oil has a high vis-
cosity, the resistance increases when the oil passes through the orifice, which leads to abnormal
flow (unsmooth flow) and pressure fluctuation, resulting in equipment jitter; when the hydraulic oil
is heated, the throttling returns to normal.
• The above jitter caused by ambient temperature and oil characteristics is a normal phenomen-
on. The customers are recommended to warm up the machine for 15 min~20 min after the
equipment is started, and the normal construction can be carried out after the oil temperature ris-
es to 45℃~55℃ (113°F~131°F), so as to avoid the occurrence of jitter phenomenon.

What are the hazards of the “chloride ions” contained in inferior diesel oil?
There is a chemical reaction between the chloride ion and iron in the fuel, which leads to the sur-
face erosion of the fit parts and finally the seizure fault.
• The main cause for the chloride ions contained in the fuel is that the additive containing exces-
sive chlorine is added to the crude oil in the refining process, e.g. SAE demulsifier, water shutoff
agent, desalting agent, etc. The excessive chlorine element is inorganic chlorine in molecular
form and organochlorine in atomic form. After the fuel is burned inside the engine, the two forms
of chlorine will produce HCl gas (hydrochloric acid), while HCl can easily dissolve in water, re-
sulting in the formation of an acidic substance (commonly known as dilute hydrochloric acid).
• When the cooler is started, the water vapor in the exhaust device will dissolve the HCl to form an
acidic substance-dilute hydrochloric acid, and will form chemical corrosion with the iron on the
surface of the exhaust manifold, EGR and cooler. Due to the small opening gap of the EGR
valve, the mixed carbon deposition of the corroded oxides will cause seizure, and there is a fault
of perforation and leakage in the cooler.
With regard to the cylinder, how to tell if it is an oil leakage fault?
Method and standard for judging cylinder oil leakage:
• If the cylinder pressure is normally held within 5 min (equipment overflow pressure) and there is
no obvious oil droplet hanging at the cylinder head, it will be considered as normal; otherwise, it
will be considered as oil leakage fault in the cylinder.
• In case of engine warning up, if the cylinder extends and retracts for 20 times in the whole
stroke, the infiltration width of the cylinder head is less than 1/2 circumference of the piston rod,
and there is no accumulation of oil droplets below, it will be considered as normal; otherwise, it
will be considered as oil seepage fault in the cylinder.
7.5 When Battery Feed Fails to Start Up

When the battery cannot be started, you can use the auxiliary cable on the machine to start the en-
gine. Follow the instruction in the operation manual when starting the engine by connecting auxili-
ary cable. Incorrect operation will lead to battery explosion or the machine out of control, and
cause casualties. It is forbidden to start the engine by auxiliary cable without permission. Please
contact the authorized agent of Sany if necessary.

• 2 persons are needed to cooperate to start

the engine by auxiliary cable (one sits on
the driver's seat and the other operates the
battery).
• Wear goggles and rubber gloves before
starting the engine by auxiliary cable.
• When connecting the normal machine with
the machine with malfunction by auxiliary
cable, the battery voltage of the former shall
be the same as that of latter. Meanwhile,
pay attention not to making two machines
contact each other.
• As diethylether cold starting fluid is ex-
Fig 7-1
tremely inflammable and explosive, read
the instructions on the container before
use. Don’t use diethylether when the engine
is equipped with a glow plug or other types
of devices.
Connect and disconnect auxiliary wire
WARNING
Risk of serious injury!
Improper operation of the battery could cause explosion or casualties.
• When connecting the wires, do no let the positive terminal (+) contact the negative terminal (-).
• Avoid the contact between normal machine and failed machine. so as to prevent sparks being
generated around the battery igniting the hydrogen released from the battery.
• Be careful not to make mistakes in connecting auxiliary wires. At the end of connection (i. e.
connection with upper frame), sparks will come up, so you need to connect the wire as far away
from the battery as possible. (But always avoid work equipment since it is not good conductor)
• When removing the auxiliary wire, be extremely careful not to let the wire clamps touch each
other or contact the chassis.

NOTE：
• The starting system of the machine adopts 24 V voltage, and is normally supplied by two 12 V
batteries in series.
• The specification of auxiliary wire and clamp should conform to the battery specification.
• The battery should have the same capacity with the engine which it will start.
• Check whether the wires and clamps are broken or corroded.
• Make sure the wires and clamps fixed well.
• Check whether the hydraulic lock lever of the two machine both at the “LOCK” position.
• Check whether all levers stay at the neutral position.
Auxiliary wire connection

A
Keep the ignition switches of normal machine
and failed machine at OFF.
3 2 1
Connect the auxiliary wire according to the
number order marked on the picture.
1. Connect the clamp of auxiliary wire (A) to

D C
the positive terminal (+) of the failed machine
4
battery (C). E
B
2. Connect the other clamp of auxiliary wire
(A) to the positive terminal (+) of the normal Fig 7-2
machine battery (D).
1. Step 1 B. Auxiliary cable
3. Connect the other clamp of auxiliary wire 2. Step 2 C. Battery
(B) to the negative terminal (-) of the normal 3. Step 3 D. Battery
machine battery (D).
4. Step 4 E. Swing frame
4. Connect the other clamp of auxiliary wire A. Auxiliary cable
(B) to the failed machine swing frame (E).
Start the engine
WARNING
Accidentally touching the safety lock control lever could cause the machine to move and could
cause serious injury.
• No matter when the machine is operating normally or has failed already, always check the ma-
chine, and keep the safety lock control lever at the “LOCK” position, and check whether all lev-
ers stay at the neutral position.
1. Make sure that the clamps and battery terminals connected firmly.
2. Start the engine of a normal machine and run it at high idle speed.
3. Turn the ignition switch of the failed machine to the “START” position and start the engine.
Auxiliary wire disconnection

A
After the engine starting, disconnect the auxili-
ary wires in the reverse order of connecting
3 2 1
them.
1. Disassemble a clamp of auxiliary wire (B)

from swing frame of the failed machine (E).
D C
2. Disassemble the clamps of auxiliary wire
4
(B) from the battery (D) negative terminal (-) B E
of the normal machine.
3. Disassemble the clamps of auxiliary wire Fig 7-3

(A) from the battery (D) positive terminal (+) of
1. Step 1 B. Auxiliary cable
the normal machine.
2. Step 2 C. Battery
4. Disassemble the clamps of auxiliary wire 3. Step 3 D. Battery
(A) from the battery (C) positive terminal (+) of 4. Step 4 E. Swing frame
the failed machine.
A. Auxiliary cable
7.6 When Battery Feed Needs to Be Charged
WARNING
Improper operation of the battery is dangerous and could cause an explosion.
• Always disassemble the battery from the machine before charging when the battery is installed
on the machine.
• When checking or handling the battery, always shut down the engine.
• When handling the battery, always wear goggles and rubber gloves.
• When disassembling the battery, disconnect earthing cable (negative terminal-) first. When
mounting, first mount the positive terminal (+).
• If the terminal is loose and in poor contact, or if the tool comes into contact with the positive ter-
minal and chassis, sparks will be generated, which may cause an explosion.
• If the battery electrolyte freezes, do not charge the battery. Otherwise it will ignite the battery
electrolyte and result in battery explosion.
Charge battery

When the battery needs to be recharged, always operate according to the battery and charger
specifications, and do as follows:
1. Remove the battery from the machine.
Fig 7-4
2. Always adjust the charger voltage to match

the battery.
3. Connect the charger positive terminal (+) to

the battery positive terminal (+), and connect
the charger negative terminal (-) to the battery
negative terminal (-). Always fix the clamp.
4. Adjust the charging current to the 1/10 of

the rated battery capacity; in case of fast
charging, tune down the charging current
under rated battery capacity.
5. Install the battery on the machine after

charging, and install the positive (+) terminal
of the battery first when installing the battery
cable. Fig 7-5

7.7 When Engine Coolant Temperature Too High
CAUTION
Risk of scalding!
Opening the radiator cover when the coolant is hot could cause water vapor emission, which
could cause scalds.
• Do not open the radiator cover when the coolant is hot.
• When the temperature of the coolant goes down, please pad a thick cloth on the cover and
open it slowly.
NOTICE
The sudden stop of the engine could lead to a sharp rise in water temperature, and the sudden
addition of cryogenic coolant when the temperature is very high could damage the engine parts.
• Do not stop the engine immediately. Otherwise, it will lead to a sharp rise in water temperature.
• When the engine is hot, please slowly charge the cryogenic coolant in several times.
When the reading of the water thermometer exceeds 100℃ and the indication light is on, it means
the water temperature of the radiator exceeds the limit. Please do as follows:
1. Please stop the device, and keep the engine running at a speed a little higher than idle speed to
cool down.
2. When the pointer of the water thermometer goes to the center and the High Temperature Light
is off, stop the engine.
3. Check whether there is coolant leakage of the cooler rubber hose.
4. Check the amount of coolant. Please refill coolant when it is insufficient.
5. Check whether the belt of the water pump is broken and the tension of the belt normal.
6. Check whether there is object in front of the cooler.
7. Coolant leakage or constant water temperature out-of-gauge indicates cooling system failure.
Please contact the authorized agent of Sany in time for fault handling.
7.8 When Engine Oil Pressure (Low Pressure) Abnormal
NOTICE
Continuing to run the engine when the engine oil pressure is abnormal could damage the engine.
• When the indicator warns abnormal oil pressure, please turn off the engine immediately.

When the indicator warns abnormal oil pressure. Stop the machine, and shut down the engine im-
mediately and do as follows.
1. Check whether the engine oil leaks.
2. Check the engine oil level, and refill if insufficient. Refer to “Engine oil level-check/refuel” in
Maintenance chapter .
When the engine oil is at required level, but the warning light still indicates abnormal pressure,
please contact the authorized agent of Sany to repair.
NOTE：
When the engine is just started, oil pressure gauge indicates high pressure. After adequate pre-
heating operation, check the oil pressure again.

SR305RS10Rotary Drilling Rig Accessories and Options
Accessories and Options
8 Accessories and Options ...........................................................................................8-1

8.1 Safety Precautions................................................................................................................8-3
8.2 Options ...................................................................................................................................8-4
8.2.1 Overview.......................................................................................................................8-4
8.2.2 Kelly bar configuration................................................................................................8-4
8.2.3 Kelly bar - check ..........................................................................................................8-5
8.3 Kelly Bar .................................................................................................................................8-7
8.3.1 Instructions...................................................................................................................8-7
8.3.2 Welding.........................................................................................................................8-8
8.3.3 Transport and storage ............................................................................................. 8-13
8.4 Drilling Tool.......................................................................................................................... 8-15
8.4.1 Overview.................................................................................................................... 8-15
8.4.2 Kelly box .................................................................................................................... 8-15
8.4.3 Drilling tool categories ............................................................................................. 8-15
8.4.3.1 Drilling bucket double cut................................................................................. 8-15
8.4.3.2 Cone auger ........................................................................................................ 8-18
8.4.3.3 Straight auger.................................................................................................... 8-20
8.4.3.4 Core barrel ......................................................................................................... 8-21
8.4.3.5 Double-layer core barrel .................................................................................. 8-23
8.4.3.6 Underreamer bit ................................................................................................ 8-24
8.4.3.7 Casing drive adapter ........................................................................................ 8-24
8.4.3.8 Easily worn parts of drilling rig ........................................................................ 8-25
8.4.4 Drilling tool operation............................................................................................... 8-25
8.4.4.1 Drilling bucket.................................................................................................... 8-25
8.4.4.2 Auger .................................................................................................................. 8-26
8.4.4.3 Core barrel ......................................................................................................... 8-27
8.4.4.4 Belling tool ......................................................................................................... 8-28
8.5 Wire Rope ........................................................................................................................... 8-29
8.5.1 Installing wire rope ................................................................................................... 8-29
Accessories and Options SR305RS10Rotary Drilling Rig
8.5.2 Unloading and storing wire rope ............................................................................ 8-35

8.5.3 Discarding wire rope ................................................................................................ 8-35
8.6 Central lubrication system ................................................................................................ 8-37
8.6.1 Central lubrication parameter setting .................................................................... 8-37
8.6.2 Adding grease to lubrication pump ........................................................................ 8-44
8.6.2.1 Recommended grease..................................................................................... 8-44
8.6.2.2 Instructions on adding grease......................................................................... 8-44
8.6.2.3 Operation instructions on manual grease charger....................................... 8-45
8.6.2.4 Operation instructions on quick connector.................................................... 8-48
8.6.3 Troubleshooting methods ....................................................................................... 8-48
8.6.3.1 Common troubleshooting methods ................................................................ 8-48
8.6.3.2 Fault code troubleshooting method................................................................ 8-49
8.6.3.3 Air exhausting methods of lubrication pump................................................. 8-50
8.6.3.4 Air exhausting methods of distributor ............................................................ 8-52
8.6.4 Maintenance on central lubrication system .......................................................... 8-53
8.7 Maintenance Chart............................................................................................................. 8-55
8.8 Common Misoperation ...................................................................................................... 8-67

8.Accessories and Options

8.1 Safety Precautions
Pay attention to safety while installing accessories or options. Comply with the following precau-
tions for selection, installation and use of accessories or options:
Precautions for selection
• Before installing accessories or options on board, consult the authorized agent of Sany. Depend-
ing on the type of accessory or option, front guard, overhead guard or other safety structures
may be required to be installed additionally.
• Only accessories or options approved by the authorized agent of Sany shall be installed. Sany
will take no responsibility for the accident, damage or malfunction caused by unapproved acces-
sories or options.
Read the Operation & Maintenance Manual carefully
• Before installing and using any accessories or options, be sure to read carefully and understand
the contents of the corresponding Operation & Maintenance Manual.
• If the manual was lost or damaged, you should ask the manufacturer of accessories or the au-
thorized agent of Sany for a new one.
Precautions for removal and installation
Ensure safety while removing and installing accessories or options. Comply with the following
precautions:
• Remove and install the accessories or options in a flat and solid place.
• When the cooperative work between two or more persons is required, one should be the
commander and others follow his/her commands.
• Use the crane to carry the object over 25 kg or 55.12 lb. (The crane must be operated by quali-
fied and experienced staff with official license.) It is forbidden to stay under the lifted object.
• During removal and installation process, do not use the machine while any object is being lifted.
Use a holder to avoid the object falling if necessary.
• Before removing some heavy parts, consider the effect of the removal on the balance of the ma-
chine. To prevent rollover, the machine may be supported before removal of some heavy parts,
if necessary.
• Ensure the accessories or options to be installed or removed ones are stable and would not turn
over.
• As for more details about removal or installation, consult the authorized agent of Sany.

Precautions for use
Keep in mind the following precautions while installing large or heavy accessories or options.
• Before operation, move the machine to a safe place for trial operation and make sure that you
have clearly known the movement, center of gravity and working range of the machine.
• Do not swing the machine if it is inclined; otherwise, the machine would be in the risk of turning
over.
• In the process of operation, make sure to keep a safe distance from the machine to the sur-
rounding obstacles. Pay attention to the followings while installing heavy accessories or options.
• The turning circle of heavy accessories or options may be large. Incorrectly calculating their
turning circle could cause a risk of hitting other objects. Please reserve a large space for rota-
tional motion.
• When the lifting process stops, the heavier the accessories or options are, the longer distance
they will move downwards under their dead weight. Therefore do not stop them at the lifting posi-
tion, but lower them down to the ground.
• Never swing, lower or stop the accessories or options abruptly to prevent the machine from turn-
ing over.
• Never extend or retract the boom cylinder abruptly to avoid machine rollover due to impact.
8.2 Options
8.2.1 Overview
In addition to random standard Kelly bars, you can also purchase other specifications. The drilling
depth is subject to the different specifications of Kelly bars.
8.2.2 Kelly bar configuration
Machine Kelly Bar

Rated Torque Kelly Type Remark
Type Specification
SK508J417 Interlocking Drilling depth 61 m
SK508J418 Interlocking Drilling depth 65 m
SR305R 360 kN·m SK508M617 Friction Drilling depth 94 m
SK508M618 Friction Drilling depth 100
m

8.2.3 Kelly bar - check
1. Check the Kelly bar baffle
Check the Kelly bar baffle every week. If the

baffle deforms badly and cannot function well,
replace it.
Fig 8-1 Kelly Bar Baffle
2. Check Kelly bar drive gibs
Drive gibs are located on the top of each sec-

tion of bar and are used frequently. If open
welding occurs, repair it immediately.

gibs:

Fig 8-2 Drive Gibs
3. Pull out other sections.
4. Check inner Kelly bar drive gibs.
NOTE：
Check outer Kelly bar every 250 hours or
every month. Check inner Kelly bar every
500 hours.

3. Check Kelly bar tube
Tube is on the lower part of each section of

bar and are used frequently.

gibs:
3. Pull out other sections from top of Kelly bar.

Fig 8-3 Kelly Bar Tube
4. Check inner Kelly bar tube.
NOTE：
500 hours.
4. Check Kelly bar locking device
Locking device transfers pressure. If the wear

is less than 10 mm, repair welding in construc-
tion site. If the wear is above 10 mm (0.394
in), contact SANY after sales staff.
Procedures for checking locking devices:

Fig 8-4 Kelly Bar Locking Device
3. Check inner Kelly bar locking devices.
NOTE：
500 hours.

8.3 Kelly Bar

8.3.1 Instructions
During construction process, Kelly bar transfers torque and pressure onto drilling tool. To
avoid damages to Kelly bar and misoperation, observe the followings:
• Not all types of Kelly bars are designed for the max. torque of rotary drive. Be aware of the max.
permissible torque of Kelly bar and do not exceed this value.
• Kelly bars and drilling tools are allowed to be used only for drilling holes, other applications such
as earth moving, conveying and levelling are not permissible.
• If the Kelly bar is inserted into a borehole, do not perform swing or mast operation.
• If the mast is displaced from its initial position by working forces, it must be readjusted.
• Do not insert the bar into the concrete.
• Start the drilling operation only when the Kelly bar has been fully inserted in the borehole and
the auger bit hits the bottom of the borehole.
• For drilling in hard formations, the Kelly bar must be interlocked firmly. Or it will cause excessive
wear or damage to the Kelly bar.
• In extremely tough weather, ensure that there is no additional force applied on Kelly bar: adjust
the drilling pressure to suitable value.
• In conditions where the borehole is extremely deep and the diameter extremely large, special at-
tention must be paid that the drilling teeth are in good working conditions. If wear or damage ap-
pears, replace them in time. Do not attempt to make up for worn teeth by increasing crowd force
on Kelly bar.
• When extending Kelly bar, adjust torque and pressure to adapt to the condition.
• When retracting a Kelly bar from borehole, pay special attention to the outermost section: if the
outermost section lifts from its rest on the rotary drive, one of the inter sections is not properly
unlocked, stop lifting by main winch. To avoid locking mechanism will open, or the section would
slip through and get damage, reinsert Kelly to the bottom of the borehole, and then rotate rotary
drive counterclockwise and pull by the main winch to completely unlock and properly retract all
sections.
NOTE：
• Kelly bar and mast must be parallel at all times during operation.
• After one section is retracted, the winch load is increased, it will cause the base machine
to tilt forward slightly.

8.3.2 Welding
WARNING
Risk of explosion or fire!
Welding, torch cutting, and grinding tasks on the equipment can cause fire or explosions.
This could result in serious or fatal injuries to persons.
• Before starting work, clean flammable or explosive substances away from tools and the
environment.
• Protect or shield all heat-sensitive components, such as hydraulic hoses, from the area
being thermally processed.
• Protect persons and the work environment from flying sparks.
• Before performing welding work on the equipment, protect sensitive electronic parts
from current.
The repair welding work can be only carried out by trained and qualified welding personnel.
After welding, retract each section completely one by one, and check if it is normal.
Steps for repairing:
1. Grind the jointed face (1).
If the break is ragged, it is necessary to re-

place the section with a new tubing. Make
sure the dimension (A) is the same with the
original one.
A
Fig 8-5
1. Jointed face A. Dimension

2. Remove burrs and clean weld zone free of grease.
NOTE：
The square stub and steel pipe with diameter of 377 mm or below are made from alloy steel
and require preheating.
• Use a sheltered location with enough space (workshop).
• Preheat the weld zone (approximately 200 mm outwards on both sides of weld joint) to approxi-
mately 200 C° – 250 C°).
• Perform welding.
Precautions for welding several parts together:
• Keep dimension (A) of inner bar.

• Keep alignment.
• After welding, grind the welds.
Welding:
1. Butt welding 1
1) Use a fix-up equipment to hold parts.
2) Weld.
Fig 8-6
1. Jointed face

2. Weld key bars.

2
• Jointed dislocation spacing should be more
than 100 mm.
• Jointed spacing must be 4 mm and welding
melting point angle should be about 40°.
• One-side wear must be less than 30%.
3
Fig 8-7
2. Jointed dislocation 4. Welding melting

spacing point angle
3. Jointed spacing
Fig 8-8
5. One-side wear
Note:
• Uniform wear on key bars and locking devices must not exceed 10 mm.
• One-side wear on material requires repair, to prevent functional failure.

Weld key bars onto the Kelly bar:

X X
• Fit-up key bars and spotweld.
• Spotweld on both sides at the same time 6
and spotweld angle should be about 45°.
• Avoid pitting surfaces.
• Produce flush welds.
NOTE： Fig 8-9

• In this status, do not preheat the key
6. Spotweld angle
bars.
• To weld key bars, weld from the middle
of Kelly bar.
• Avoid irregular distribution of heat over
the bar, keep the differences in tempera-
ture at a minimum to prevent distortion.
To keep the temperature in balance during

welding, interactive manner is recommended:
after welding key bar (300 mm), rotate Kelly
bar for 120°, then weld another key bar and
repeat.
NOTE：
Do not weld at devices in zones between
arrows. Fig 8-10
3) Replace Kelly bar square stub.
If support board or guiding ring tips off slightly,

repair welding.
Fig 8-11
If square stub or the connection part of square

stub and steel pipe breaks, send back to fac-
tory and repair. If on-site repair is needed
under special circumstances, perform repair-
ing under the guidance of Kelly bar Institute of
R&D.
Fig 8-12

Requirements for repairing technique
Cur-
Welding Keep
SN Types of weld seams Preheat (C°) rent
rod warming
(A)
Do not need preheat
Butt seams of key bar J506/
1 when ambient temper- —— 160±20
and key bar J507
ature ≥ 10°C
Butt seams of small di-
Insulation
2 ameter steel pipe ( ≤ φ 70 kg 200℃ – 250℃ 160±20
cotton
377 mm)
Butt seams of large di- Do not need preheat
J506/
3 ameter steel pipe( ＞φ when ambient temper- —— 160±20
J507
377 mm) ature ≥3 °C
Seams of key bar and Do not need preheat
J506/
4 large diameter steel pipe( when ambient temper- —— 200±20
J507
＞ φ377 mm) ature ≥3°C
Seams of key bar and Do not need preheat
5 small diameter steel pipe 70 kg when ambient temper- —— 200±20
(≤ φ377 mm) ature ≥ 10°C
Adjust
the cur-
rent ac-
Besides item 2, preheat the others
Remove rust, scale and cording
Remark —— to the temperature above the mini-
water before welding to the
mum temperature required
welding
ma-
chine
List of repair equipment
SN Name Quantity Purpose

1 Level bar 1 Level
2 Arc welder YD-400SS (DC) 1 /
3 Cutting torch G01-100 2 Cut
4 Angle grinder GWS14-150 3 Grind
5 Welding clamp 5 /
6 Torque wrench 3 Secure locknut
7 Inner hexagon spanner M16 2 Remove guiding ring
8 Adjustable spanner 2 /
List of consumables

SN Name Quantity Purpose

1 J506/J507/A302 (φ4) 100 KG Weld
2 J706/J707 (φ4) 60 KG Weld
10 – 12 safety goggles against
3 20 Pieces Cut
radiation
4 Protective glove 20 /
5 Cutting nozzle 10 /
Protective goggles against flying chips
6 5 /
of grinding wheel
7 Dry powder fire extinguisher 2 /
8 Alkyd paint diluent 2 /
8.3.3 Transport and storage
Transport
WARNING
Risk of accident!
Unsuitable lifting gear or improper loading/unloading can lead to tipping over of the lifting gear,
the equipment, or the transport vehicle, or to the falling of loads. Persons in the vicinity of the
equipment could be hit and receive serious or fatal injuries.
• Lifting equipment and slings used for loading and unloading must be safe and of sufficient ca-
pacity. Avoid abrupt and quick movements when lifting, to prevent the load shifting and sliding
away.
Preparation before transport
“A” ≤ 13000 mm, underpinned with 2 timbers

A
preferably
“A” ＞ 13000 mm, underpinned with 3 timbers

preferably
Fig 8-13
A. Length
Storage
Kelly bars must be underpinned when put into storage:

“A” ≤ 13000 mm, underpinned with 4 timbers

A
preferably
“A” ＞ 13000 mm, underpinned with 5 to 6 tim-

bers preferably
Fig 8-14
A. Length
NOTE：
Do not put Kelly bar on the ground directly.
Do not put Kelly bar on gravel heap directly to avoid gravel falling into Kelly bar.

8.4 Drilling Tool

8.4.1 Overview
There are many categories of drilling tools: drilling bucket double edge, cone auger, straight auger,
and core barrel.
8.4.2 Kelly box
There are three specifications of Kelly box: 200, 250 and 300 (unit: mm).
A B C
Fig 8-15
A. 200 B. 250 C. 300
8.4.3 Drilling tool categories
8.4.3.1 Drilling bucket double cut
Fig 8-16

D. Diameter H. Height
Table 8–1 Parameters
Drilling bucket for soil layer Drilling bucket for rock layer
D (mm) H (mm) Flat teeth D (mm) H (mm) Round chisels
1000 1500 6 1000 1200 11
1200 1500 7 1200 1200 13
1500 1500 9 1500 1200 17
1800 1000 10 1800 1000 25
2000 1000 12 2000 1000 26
2200 1000 12 2200 1000 29
—— —— —— 2500 1000 32
—— —— —— 3000 1000 37
—— —— —— 3500 800 41
Note:
The bucket parameters can be customized according to special needs.
Teeht arrangement methods:

Teeth arrangement Illustration Structure characteristics and applications

Characteristics:
1. Cross type alignment knife.
2. Equipped with V20, FZ80 flat teeth.

Flat teeth
Main applications:
1. Silt and all type of soft soil.
2. Sand and gravel.

Characteristics:
2. Equipped with V20, FZ80 flat teeth.
Combination teeth 3. Add skirting and weld B47K rould chisels on

skirting.
Main applications:
1. All types of dense soil.
2. Cemented rock formation.

Characteristics:
2. Add skirting and weld B47K rould chisels on

Round chisels skirting.
Main applications:
1. Pebble and gravel.
2. Hard and medium hard weathered rock.

8.4.3.2 Cone auger
L
H
Fig 8-17 Parameters
D. Diameter H. Height L. Length

Table 8–2 Cone Auger Parameter
Size Tooth type and number

Single start Single start Double start
D (mm) L (mm) H (mm) single auger double auger double auger
(B47K) (B47K) (B47K)
600 600 1500 10 14 14
800 600 1500 14 20 20
900 600 1500 14 21 21
1000 600 1500 15 23 23
1200 600 1500 16 28 28
1300 600 1500 18 30 30
1400 600 1500 20 32 32
1500 600 1500 22 36 36
Note:
• Cone auger is generally 2.5 times the height of pitch. Increasing auger flights can in-
crease slag carrying capacity and enhance guidance ability. Reducing auger flights can
increase rotation speed and reduce resistance. Number of teeth in the table refers to 360°
cone screw teeth arrangement number.
• The parameters in the table above are just for reference and can be customized accord-
ing to customers’ needs.

Cone auger can be divided into three types in terms of structure: single-start single-flight, double-
start single-flight and double-start double-flight. Teeth are arranged on cone spiral flights to form
spiral cone corner. It is suitable for drilling pebble, gravel, hard and medium hard weathered rock.
Teeth Structure characteristics and applying

Illustration
arrangement layers
Characteristics:
1. Three round chisels form the central guide

teeth, with a good positioning effect.
2. Arrange teeth upwards along the spiral

flights of one side.
Single side 3. Small drilling resistance and easy to dump

slag.
Main applications:
1. Highly cemented gravel and permafrost

layer.
2. Cemented rock formation.
3. Highly or moderately weathered hard rock.

Characteristics:
1. Three round chisels form the central guide

teeth, with a good positioning effect .
2. Arrange teeth upwards along the spiral

flights of two sides.
Double side
3. Good guidance ability, great drilling resist-
ance and high slag carrying capacity.
Main applications:
1. Gravel formation or clay layer.
2. Highly weathered hard rock.

8.4.3.3 Straight auger
L
H
Fig 8-18 Parameters
D. Diameter H. Height L. Length

Table 8–3 Straight auger parameter

Single side Double side
D (mm) L (mm) H (mm)
(FZ80) (FZ80)
800 600 1500 2 4
1000 600 1500 3 4
1200 600 1500 3 /
Note:
L, H and teeth parameters in the table above are just for reference and can be customized
according to customers’ needs.
Straight auger can be divided into three types: single-start single-flight, double-start singleflight
and double-start double-flight. Teeth are welded in a straight line. Wear resistant alloy flat teeth
can be used alone, or with round chisels.
Straight auger is mainly used for drilling soil above underground water level, sand, and dense sand
layers with small amount of clay and gravel with small particle diameters.

Teeth Structure characteristics and applying

Illustration
arrangement layers
Characteristics:
2. V20, FZ80 flat teeth and B47K round

Single side
chisels can be equipped.
3. Weld round chisels on skirting.

Main applications:
Clay, sand and gravel
Characteristics:
2. V20, FZ80 flat teeth and B47K round

Double side
chisels can be equipped.
3. Weld Round chisels on skirting.

Main applications:
Clay, sand and soft-hard interceded layer.
8.4.3.4 Core barrel
Fig 8-19 Core Barrel
D. Diameter H. Height

Table 8–4 Core barrel parameter

D (mm) H (mm) Round chisels Roller bits
800 1500 10 6
1000 1500 12 8
1200 1500 16 10
1500 1200 20 12
1800 1200 24 16
2000 1000 24 16
2200 1000 28 18
2500 1000 32 20
Note:
The parameters in the table above are just for reference and can be customized according
to customers’ needs.
For hard bedrock, large boulder and hard permafrost layer, it is very hard for rotary drilling bucket
to drill in. But core barrel has more advantages in this case. Core barrel has wide applications and
various structures. Common structures include annular Round chisels core barrel, annular gear
core barrel. Core barrel can change different drilling teeth according to stratum characteristics.
Teeth Structure characteristics and

Illustration
arrangement applications
Main applications:
1. Medium weathered hard rock.

Round chisels
2. Pebble and boudler.
3. Backfill.
Main applications:
Roller bits Slightly weathered hard rock and
bedrock.

8.4.3.5 Double-layer core barrel
H2
H1
D2
D1
Fig 8-20 Double-layer Core Barrel
D1. Diameter H1. Height

D2. Diameter H2. Height
Table 8–5 Double-layer core barrel parameter

D1 (mm) D2 (mm) H1 (mm) H2 (mm) B47K Rollers
1000 N/A 1700 1500 11 9
1200 N/A 1700 1500 12 10
1250 N/A 1700 1500 13 10
1500 N/A 1700 1500 16 N/A
Note:
The parameters in the table above are just for reference and can be customized according
to customers’ needs.
Double-layer core barrel is a special drilling tool designed and produced by SANY. Compared to
other types of rotary drilling tools, double-layer core barrel has the advantages of high efficiency in
drilling in gravel, strong spoil carrying capacity and low drilling tooth. This barrel has won the Na-
tional Invention Patent.

8.4.3.6 Underreamer bit
Table 8–6 Underreamer bit parameter D1
Size
D1 (mm) D2 (mm)
800 1600
1000 2000
1200 2000
1800 3000
In the same layer, enlarging pile tip base area

can greatly increase pile load-bearing ca-
pacity without increasing the hole diameter. In
general, underreamer bit accompanied with
D2
rotary drilling rig includes soil underreamer bit,
which is suitable for drilling common soil and
Fig 8-21 Underreamer Bit
equipped with round chisels made of alloy
block or alloy drill head, and rock under- D1. Upper diameter D2. Lower diameter
reamer bit, which is suitable for drilling hard
bed rock and hard frost soil and equipped with
cutting tool made of round chisels.
8.4.3.7 Casing drive adapter
Casing drive adapter connects rotary drive

and casing. During operation, rotary drive
transfers torque to casing to make it rotate. At
the same time, rotary drilling rig crowding de-
vice presses rotary drive down and transfers
force through rotary drive to casing to push it
down into ground.
Fig 8-22 Casing Driver

8.4.3.8 Easily worn parts of drilling rig
A B C
Fig 8-23 Teeth
A. Bauer teeth B. B47K teeth C. V20 teeth
D E F
Fig 8-24 Teethholder
D. Bauer teethholder E. B47K teethholder F. V20 teethholder
8.4.4 Drilling tool operation
8.4.4.1 Drilling bucket
• Before placing a new bucket into hole, check whether drilling teeth are all complete. Check
whether unlocking mechanism works well.
• For single-edge bucket, raise it when spoil reaches 5/6 of bucket load capacity. For double-edge
bucket, raise it when spoil reaches 2/3 to 4/5 of bucket load capacity. Before raising drilling buck-
et, rotate bucket counterclockwise 1 to 2 rounds under crowding. Raise bucket when bottom
gate is closed.
• If bucket is jammed when being raised, move bucket upwards and downwards while rotating it
at a low speed. Raise bucket when it is released from jamming. Never raise it by force.
• If spoil cannot be automatically dumped or dumped entirely when bucket bottom gate is opened,
repeatedly rotate drilling tool to dump soil thoroughly. Never use up and down lifting or left and
right swaying to strike other fixed objects to dump soil.
• Replace or repair drilling teeth if they are seriously worn out or drop off.
• Never run in hole if there are any foreign matters in hole.

• Never use drilling tools to deal with accident.
8.4.4.2 Auger
• Before placing a new bucket into hole, check whether drilling teeth are all complete.
• When using cone auger to drill hard rock, never rotate at a high speed. When it is difficult to drill
into boulders, lift auger for a while and drill again. Repeat several times until boulder is loosened,
then take it out.
• In general, raise auger slowly when drilling

to 2 to 3 times of pitch to prevent it from col-
liding with hole wall, which leads to spoil
leakage or auger jamming. When raising
auger under mud, rotate slowly to prevent
interlocking rod from locking Kelly bar.
• If bucket is jammed when being raised,
move bucket upwards and downwards
while rotating it at a low speed. Raise buck-
et when it is released from jamming. Never
Fig 8-25 Auger
raise it by force.
• If spoil cannot be automatically dumped or dumped entirely, repeatedly rotate drilling tool to
dump soil. Never use up and down lifting or left and right swaying to strike other fixed objects to
dump soil.
• Replace or repair drilling teeth if they are seriously worn out or drop off.
• Never run in hole if there are any foreign matters in hole.

8.4.4.3 Core barrel
• Before placing a new bucket into hole,

check whether drilling teeth are all complete
and connection is good.
• Raise auger when barrel is full. Raise auger
at a low speed. Because auger is equipped
with inner knife, it can remove core or large
boulder. It can forms a cutting free surface,
and is able to break rocks, facilitating bail-
ing bucket or short auger to drill.
• Replace drilling teeth of same specification
if they are worn out or damaged.
• Never run in hole if there are any foreign
matters in hole. Never use drilling tools to
deal with accident.
Fig 8-26 Core Barrel

8.4.4.4 Belling tool
• Before running in hole, check whether bit

can retract and extend freely. Lift bit and
lower reamer wing slowly to retract or ex-
tend. Repeat several times until bit can
move freely.
• Determine bit’s stroke according maximum
reaming diameter required by construction.
Lift bit to its retraction status, and then lower
it slowly to under reaming diameter. Write
down the position difference of upper tube
and lower tube in the two cases (for push-
down belling tool, write down connecting
central pin position difference between
upper and lower positions against outer
tube in the two cases). The difference is
under reaming travel.
• Belling tool is not equipped with spoil re-
moving mechanism. When under reaming
depth reaches 1/3 of total stroke, raise bit,
use bit lower tray to bring out rock dust, or
take out hole bottom drilling spoil by lower- Fig 8-27 Belling Tool
ing bucket or auger or through positive/re-

verse circulation. In general, under reaming
is completed after 3 to 4 returns of drilling.
• If belling tool meet with resistance or retracting mechanism cannot move freely when the bit is
being raised, do not raise bit by force. Do not feed on hole bottom, rotate bit several times to
complete bit raising.
• If retracting mechanism cannot retract because it is covered by clay, it is not recommended to
ream in the soil layer. If reaming is required, add adequate amount of medium. Idle run drilling
tool for several rounds at hole bottom to get rid of resistance before raising bit.
• Whenever bit is pulled out, check to see if switching mechanism works freely and whether
Round chisels are damaged. If there are questions, repair them before lowering bit into hole.

8.5 Wire Rope

8.5.1 Installing wire rope
WARNING
If a rope is being moved by a rope drum or rope pulley, persons in the area of the rope
drum or rope pulley could be seriously or fatally injured, caught or entangled.
• Do not reach between the rope and the rope drum or rope pulley.
• Always wear personal protective equipment when handling ropes.
• Do not touch moving ropes.
1. Before installation:
• Replaced wire rope should have the same type and specifications with the original wire rope. If
adopting a different type of wire rope, be sure the performance of the new wire rope is not inferi-
or to the original one.
• When a long wire rope is cut off, the both sides of the point where the cut is made should be
seized.
• Inspect the grooves on drum and pulley to see if they meet requirements of replaced rope, be-
fore the wire rope is installed on the machine.
• Before the wire rope is put into service, make sure all the devices related with wire rope opera-
tion are in readiness and runs normally.
• Before the wire rope is installed, lay of direction should be known.
2. Unwinding wire rope:

• Wire rope shipped in coils can be unwound
either with the aid of a rotary plate or by roll-
ing off the rope on the ground. If rolling off
the rope on the ground, the ground should
be clean to prevent sand sticking to the
rope’s lubricant. Sand and dirt may cause
damage to the rope during operation.
Fig 8-28 Unwinding Way

• Never unwind a wire rope from a reel or coil

in a sideways direction to the winding of the
rope. Sideways unwinding of wire rope
causes the rope to twist and will eventually
form loops.
NOTE：
• Be cautious of knotting of the wire rope
when extending the wire rope.
• Wire rope with knot is caused by load
and unable to return to normal. It must
be replaced. Fig 8-29 Wire Rope with Knot
3. Cutting and seizing wire rope:
• Wire rope scissors can be used to cut wire ropes up to 8 mm (315 in) in diameter. For wire rope
of larger diameters mechanical or hydraulic cutters are available.
• It is highly recommended to use high-speed disk cutter to cut wire rope. Electric welding and air
cutting is only used on the condition that the wire rope is to be discarded.
• It is imperative to seize wire rope ends with iron wire to avoid strands slacken. Procedures are
listed below:
1) Mark the point of the cut. Span the seizing

wire horizontally along the rope at an
enough length.
Fig 8-30 Winding Iron Wire I
2) Wind the seizing wire around the wire rope from the point of the cut.

3) Tightly wind the seizing wire around the

wire rope until the seizing is 3 times the
length of the wire rope’s diameter.
Fig 8-31 Winding Iron Wire II
4) Twist the two ends of seizing wire together

with pliers.
Fig 8-32 Winding Iron Wire III
5) Cut the twisted seizing wire with pliers to

the length of the wire rope’s diameter.
Lightly stamp the end of the twisted seizing
wire into a valley between two outer
strands. Cut the wire rope with an abrasive
wheel.
Fig 8-33 Winding Iron Wire IV
4. Wire rope installation:

• When installing wire rope, be careful to remove wire rope from reel or drum without twisting
force. Ensure that there is no damage to outer surface.
• Protect the abrasion part between wire rope and the machine.
• Discard the used wire rope before installing new wire rope. Do not weld the old and new wire
rope or bind them together directly.

5. Winding wire rope from reel onto winch:

• Each wire rope is manufactured with a
bending line. Make sure that the correct √
bending line is maintained when the wire
rope is wound directly from the shipping
reel onto winch.
• If the wire rope is wound from the bottom of
winch, the wire rope should be released ×
from the bottom of winch, vice versa.
Fig 8-34 Winding Wire Rope from Reel onto

Winch
6. Winding wire rope under load:

• In the case of multiple layers winding on the
rope drum it may be necessary to tension
the wire rope.
• If the initial tension is not enough, the drum
may be too loose, which could damage wire
rope.
• The initial tension should be approximately
1% to 2 % of the wire rope’s breaking load. Fig 8-35 Winding Wire Rope under Load
• Initial tension is produced by braking or by
operating a brake sheave mounted to the
outside of the reel.
NOTE：
Never generate initial tension by clamping
the rope. For example, by passing the rope
between wooden clamps may lead to irrep-
arable deformations.
Fig 8-36 Wrong Tensioning Way
7. Connecting and securing wire rope:

In order to extend the wire rope service life and guarantee safe and reliable application, properly
install the wire rope according to the following requirements.
1) Fixing the rope ends

• When fixing with rope clamp, abide by
regulations in GB/T5976 wire rope
clamps. In correct mounting, its strength
should be no less than 85% of the rope
breaking force. √ √
• When fixing with wedge and sleeve, ×
abide by regulations in GB/T5973 wire
rope wedge joints, its strength should be Right R
no less than that of the rope breaking

force.
√ ×
Fig 8-37 Wedge Joints
2) Rope clamp layout
Mounting of rope clamp is illustrated in the figure √

on right. Buckle the clamp holder onto the rope
working section. Buckle U helix onto the tail sec-
tion of the wire rope. Do not lay the rope clamps
×
alternately on the wire rope in reverse direction.
×
Fig 8-38 Layout of Wire Rope Clamp
Installation precautions
1. Determination of rope clamp number

The number of rope clamp is related to wire rope diameter. Choose rope clamps suitable for wire
ropes. The recommendation list of minimum number of rope clamp for all types of wire ropes is as
follows:
Table 8–7 Recommendation list of minimum number of rope clamp
Wire rope nominal diame-

≤18 ＞18 – 26 ＞26 – 38 ＞38 – 44 ＞44 – 60
ter(mm)
Minimum rope clamp
3 sets 4 sets 5 sets 6 sets 7 sets
number
2. Determination of distance between rope clamps

The distance between rope clamps shall be 5 times to 6 times longer than the wire rope diameter.
3. Fastening method for rope clamp

• Press clamp bracket onto the wire rope working section. Press U bolt onto wire rope tail end.
Never lay out rope clamp alternatively.
• The fastening strength of rope clamp shall not be below 85% of wire rope breaking force.
• When fastening rope clamp, pay attention to the load-carrying capacity of each clamp. The
clamp farthest from the thimble shall be fastened alone at first while the clamp nearest from the
thimble (the first clamp) shall abut against the thimble as close as possible. Ensure that clamps
are screwed tightly and do not break out layer steel wires of wire rope.
• Rope clamp shall be checked after carrying load once or twice. Nuts shall be further screwed
tightly in most cases.
4. Test run:
• After the wire rope is mounted, formal test runs should be performed with low load.
• After the wire rope is installed according to requirements, if the wire rope rubs against some part
of the machine, provide proper clamp to the part that it may contact.
• In order to stabilize and position the wire rope, test run the moving parts of the machine with
about 10% of the load for several times.
• Avoid wire ropes twisting, knotting, distorting, bending and rubbing.

8.5.2 Unloading and storing wire rope
When unloading the wire rope, thread a rod

into the hole of rope winder and lift the rope
with a forklift for loading and unloading. Do
not push the wire rope down from high place
directly.
When rolling wire rope, crowbar can only be

used on flange of reel. Do not contact the wire
rope directly. The ground should be level.
During storage, put wire rope evenly. Store

the wire rope on pallets and cover them for
protection against rain. Fig 8-39 Right Operation I
Fig 8-40 Right Operation II
Store the wire rope in a clean and dry place.

Provide the specifications of wire rope for re-
cording and checking.
During storage, check the conditions of wire

rope frequently. Clear sand and mud off the
rope and add grease.
Fig 8-41 Wire Rope Storage
8.5.3 Discarding wire rope
Discarding of wire rope is subject to broken wire, wear, or corrosion condition. Immediately replace
for any of the following condition. Never use for continuous service.

• Broken wire occurs at the rope end or nearby.

• The broken wire gathers within the range of 6d rope length.
• If broken wire appears after a period and in-

creases gradually, discard according to
standard.
Fig 8-42 Wire Rope Broken Wire
• The whole strand ruptured.

• Damage of rope core causes the rope diameter to reduce.
• For different situations of decreasing flexibility, discard according to standard.
• If outer wire wear reaches 40% of its diameter, the wire rope diameter decreases 7% or even
more.
• Various visible deformations appears on the

wire rope.
Fig 8-43 Wire Rope Deformation
• Deep pits appears because of corrosion of outer wire rope.
• Rope diameter reduces.
Fig 8-44 Wire Rope Diameter Reduces

• Broken wire, decrease of strand clearance,

and increase of rope diameter appear be-
cause of inner corrosion.
NOTE：
• In some application, fatigue is the main
cause of wire rope damage. Even no de-
fects are visible from the outer appear- Fig 8-45 Wire Rope Diameter Bending
ance, there may be broken wire inside.
Therefore, if the wire rope is qualified
but out of service life, replace with new
wire rope in time.
• When discarding wire rope, check
whether the wire rope damage is caused
by mechanism defects. Clear of these
defects before replacing with new wire
rope.
8.6 Central lubrication system

8.6.1 Central lubrication parameter setting
Central lubrication system parameter setting methods:

• on the display in the cab
• on the lubrication pump control panel
Setting methods on the display

1. Click to switch to menu interface.
Fig 8-46 Menu Interface
2. Click “Central lubrication” on the guide bar

to enter central lubrication interface.
Fig 8-47 Central Lubrication Interface I

3. Press parameter setting, the parameters

of central lubrication system will be shown on
the display. The default mode is auto lubrica-
tion. Refer to the table below for parameters
setting ranges:
Fig 8-48 Central Lubrication Interface II
Parameters Setting range

Interval (1P) The default value: 2 h, setting range: 1 h～30 h.
Time from the end of the last operation to the start of the current operation.
Positive rota- The default value: 6 min, setting range: 1 min～60 min.
tion time (2P) During positive rotation, when there is no reversing pressure, the time from the
motor positive rotation to the end of rotation. During the motor positive rotation
and oiling operation, the reversing pressure signal is detected, and when there
is a reversing signal, the pressure-holding operation is performed; when there
is no reversing pressure, it remains until the end of 2P to enter the stopping and
pressure relief state.
Reverse rota- The default value: 6 min, setting range: 1 min～60 min.
tion time (3P) During the reversing rotation, when there is no reversing pressure, the time
from the motor reversing rotation to the end of rotation. During the motor revers-
ing rotation and oiling operation, the reversing pressure signal is detected, and
when there is a reversing signal, the pressure-holding operation is performed;
when there is no reversing pressure, it remains until the end of 3P to enter the
stopping and pressure relief state.
Temperature The default value: –15℃, setting range: 0℃～–50℃.
protection val- When the temperature reaches this value, the countdown will end and the pump
ue (4P) motor will no longer be supplied with DC24 V to protect the motor from blocking,
while "C-XX" and "stop" will be displayed.


Setting methods on the lubrication pump control panel
Fig 8-49 Control Panel
R. Manual running on/off E. Function confirm/alarm deactivate

▲. Setting + ▼. Setting -
Control panel description:
Setting interface Description
Stop state
Running: no pressure signal detected
Running: pressure signal detected

Setting interface Description
Low temperature standby
Low level warning state
Low level alarm (sounds alarm and contin-

ues to run 6 times before shutting down.
Alarm is automatically cleared after topping
up grease)
Insufficient grease alarm (does not affect

system operation, automatically clears the
fault if the next operation is normal)
Over-pressure alarm, when the pipeline

pressure detected during lubrication is
greater than the set 8P pressure value, the
lubrication alarm will start.
Operation method:
1. Press “▲” and “▼” at the same time. Hold for 3 s. Press "E" to enter the menu item directly after
the "beep" sound. Press "E" again to select "1P, 2P, 3P, 4P, 5P, 6P, 7P, 8P" and confirm.
2. Press "▲" or "▼" to set the parameters according to the actual value of each setting item, and
the parameters can be set as follows.

Parameter
Setting range:
name
Number of lu- The default value: 1, setting range: 1～99.
brication The forward process and the reverse process are each one working process,
cycles (5P) and the completion of these two working processes is counted as one working
cycle. The number of lubrication cycles is how many working cycles there are.
Pressure- The default value: 1 min, setting range: 1 min～60 min.
holding time After detecting the reversing pressure, continue running to maintain the pres-
(6P) sure in the pipeline.
Reversing The default value: 15 MPa, setting range: 5 MPa～20 MPa.
pressure val- The pressure sensor monitors the pressure in the line in real time, and when
ue (7P) the pressure reaches the reversing pressure value, it enters the pressure-hold-
ing operation, and when the detected line pressure reaches the reversing pres-
sure value, the screen "OFF" changes to "ON".
Overpressure The default value: 28 MPa, setting range: 16 MPa～30 MPa.
alarm pres- When the line pressure is greater than this value, the oiling operation will be
sure value stopped immediately and the alarm will indicate EE-5 overpressure alarm
(8P) immediately.
3. After querying all parameters, press "E" key again to return to stop state, not more than 3 s, you
can press "E" key again to enter the menu item, after more than 3 s, the menu item exits, the state
is locked. If you want to enter the menu item again, you need to press the "▲" and "▼" at the same
time for 3 s and then press the "E" key to enter.

8.6.2 Adding grease to lubrication pump
8.6.2.1 Recommended grease
NOTICE
Due to the different manufacturers, the applicable temperature range of grease labeling
may not be able to meet the pumping performance at this temperature. It is recommended
to use grease products produced by regular manufacturers.
Instructions for selecting grease：
Environment Grease type Additional information

temperature
Recommended 1# lithium the operating temperature is -20°C~120°C
-10°C~70°C
grease to 1# extreme pressure lithium grease.
Recommended 1# or 0# low- the operating temperature is -30°C~120°C
-20°C~-10°C
temperature lithium grease to 1# extreme pressure lithium grease.
Recommended 1# or 0# ultra- the operating temperature is -40°C~120°C
-30°C~-20°C
low temperature lithium grease to 1# extreme pressure lithium grease.
8.6.2.2 Instructions on adding grease
1. Set the grease upper level according to

the product capacity.
Fig 8-50 Lubrication Pump

2. Exhaust the air in the lubrication pump before adding grease for the first time.
3. Add grease to the upper level.
NOTE：
If there is air in the lubrication pump, exhaust the air before adding grease.
8.6.2.3 Operation instructions on manual grease charger
1. Put pressure plate in the barrel (when the grease is sticky, you need to press down the plate with
both hands to expel the air until the center hole of the plate is level with the grease), then insert the
nozzle rod vertically into the center hole of the plate and lock the three M8 handles around it in
turn.
Fig 8-51 Installing Pressure Plate and Grease Nozzle
Fig 8-52
NOTE：
Press the pressure plate against the upper surface of the grease to exhaust the air to pre-
vent the air from entering into the two-line pump, causing the lubrication pump to pump
out, and the system cannot be effectively lubricated.

2. Exhaust the air in hose assembly before us-

ing grease nozzle for the first time.
Operation method: One person uses a screw-

driver to hold down the check valve inside the
quick plug, and another person lifts and
presses the grease nozzle handle up and
down until the lubricant flows from the quick Fig 8-53 Exhaust the Air in Hose Assembly
plug connector.
NOTE：
• When the grease nozzle hose is not connected to the two-line pump, it is forbidden to lift
and press the grease nozzle handle (except for exhausting air in the hose assembly), oth-
erwise the quick plug connector of the grease nozzle hose can not be connected to the
quick plug connector of the pump.
• The air in the hose must be totally exhausted, otherwise the residual air in the hose will
be injected into the pump and affect the normal operation of the pump.

3. Clean the fill port, remove the fill port dust cover, then connect the quick plug female end of the
grease nozzle hose assembly and the quick plug male end of the pump and secure to prevent
holding pressure.
4. Lift up and down on the nozzle handle to refill the pump. Remove the female end after refilling is
complete, put away the fuel pump and cover the port dust cap.
NOTE：
• You can use a standard 15 kg oil barrel for this operation. In addition, before adding
grease, check whether the grease is expired and whether water is in it.
• If you can not pump grease, open the lid of the barrel and observe the remaining amount
of grease, if there is not much grease, pour the remaining grease into another barrel. You
can also use a clean shovel or other tools to clean up, do not use tools with dirt and dust
objects to clean up.

8.6.2.4 Operation instructions on quick connector
1. Remove the dust cap (2), pull down the

1
snap ring (3) of the female end of the quick
2
connector and at the same time connect the
female end (4) with the male end (1). Pull the
connector to check if it is firmly connected. 3
Fig 8-54 Quick Connector
1. Male end 3. Snap ring

2. Dust cap 4. Female end
2. When disassembling the quick connector,

pull down the snap ring (3), the internal spring
will pop the male end (1) and female end (4)
apart, then pull out the female end as a whole
downward to complete the disassembly.
Fig 8-55
3. Reinstall the dust cap.
NOTE： 2
When using quick connectors, make sure
that there is no pressure on both the male
and female ends.
Fig 8-56
2. Dust cap
8.6.3 Troubleshooting methods
8.6.3.1 Common troubleshooting methods
No. Checking list Troubleshooting methods

1 Check the alarm information on alarm interface /
2 Check whether the oil in the tank is at low level. Add oil

No. Checking list Troubleshooting methods

Check the grease type. Adopt 1# grease, 2#, 3#
3 grease is prohibited. If the temperature around the Use the correct grease
pump is below -10℃, use low temperature grease.
4 Check the parameters Reset the parameters
Check harness connectors and pump connectors for
5 Connect the connectors
loose or missing connections.
6 Check the lubrication tank for air Exhaust the air
Check the quick connector of whole lubrication
7 Connect the connectors
system
8 Check the whole lubrication system for leakage Tighten the connector
Program failure or CAN commu-
9 Check the monitor for proper count.
nication abnormal
8.6.3.2 Fault code troubleshooting method
No. Fault state Troubleshooting methods

Lubrication system
Check automatic lubrication mode is selected, if not, select auto
1 does not operate
lubrication mode.
automatically
1. First run it manually to check if the alarm is removed; 2. Check
the parameters. If the pressure value is 0, check whether the oil
pressure sensor harness is firmly connected; 3. Check the pres-
sure value, if the value is smaller than 15 MPa, check if the posi-
2 Low pressure failure
tive and reverse rotation time is 6 min (485 model is 8 min). If
not, adjust the value to 6 min (485 model is 8 min); run manually
for 1 cycle to see if this alarm still occurs, if it still alarms, contact
the manufacturer.
Check the grease level. If the level is below the lower level, add
3 Fluid level alarm
grease.

No. Fault state Troubleshooting methods

Check if the set value of lubrication pump monitor 8P is 28 MPa.
4 Overpressure alarm If not, run manually for 1 cycle to see if this alarm still occurs, if it
still alarms, contact the manufacturer.
1. Check whether the wire harness is firmly connected; 2. Run
manually once to see if the alarm is removed; 3. Check if the in-
dictor lever on distributor. If there is no action, contact the manu-
facturer; 4. Check if the sensor indicator lights up and turns off
within 1 working cycle, if not, it means there is a problem with
5 Clogging alarm
the sensor or harness, contact the manufacturer; 5. If the F1FF
does not change to 1111 within 1 working cycle after pressing
the "▼" button in the operation mode, it means there is a prob-
lem with the wiring harness, contact the manufacturer for
solution.
8.6.3.3 Air exhausting methods of lubrication pump
The improper operation during adding grease can take air into the lubrication system and affect
the normal operation. If there is air injected into the lubrication pump tank, it may cause the pump
to evacuate; when the air in the grease is delivered to the distributor, it may lead to the distributor
inaction, grease can not be delivered to each lubrication point.

Air exhaust methods:
1. If the air is above the grease, add grease

by the grease nozzle, see “Operation
instructions on manual grease charger” on
page 8-45. When the lower edge of the piston
reaches the upper level (1), continue to add
grease slowly, and when the lower edge of the
1
piston reaches the exhaust hole (3), the air
near the piston will be discharged through the
exhaust hole.
NOTE： 2
Normally, grease must not exceed the
upper level. Or it will overflow from the ex-
haust hole. During the air exhausting proc- Fig 8-57 Grease Level
ess, it is normal that a small portion of
grease will flow out. Clean the grease. 1. Upper level 2. Lower level
Fig 8-58 Exhaust Hole
3. Exhaust hole
If the air is inside the grease, remove the two

connectors (4) of the pump, and then set the
lubrication system to manual mode for contin-
uous operation to exhaust the air mixed with
the grease until the air inside the grease is
completely discharged. 4
Fig 8-59 Removing the Connector
4. Connectors

8.6.3.4 Air exhausting methods of distributor
The improper operation during adding grease can take air into the lubrication system and affect
the normal operation. If there is air injected into the lubrication pump tank, it may cause the pump
to evacuate; when the air in the grease is delivered to the distributor, it may lead to the distributor
inaction, grease can not be delivered to each lubrication point.
Air exhausting methods:
If the distributor fails to work, press the indica-

tor lever (1) of the distributor so that the end
of the indicator lever is substantially flush with
the end of the connector (2) to vent the air.
Fig 8-60 Distributor
1. Indicator lever 2. Connector
1. Press the indicator lever with hand.
Fig 8-61 Pressing the Indicator Lever

2. Press with the aid of a tool such as a

wrench.
Fig 8-62 Pressing the Indicator Lever
3. If you cannot press the indicator lever,

loosen the plug (3) about 2~3 turns, then
press the indicator lever again, at this time the
indicator lever will be rapidly retracted back
and forth for a few seconds, and the air inside
the distributor will be exhausted.
Fig 8-63 Loosening the Connector
8.6.4 Maintenance on central lubrication system
Daily maintenance
1. Start the lubrication pump and observe the monitor to check if it is running normally.
2. Check if there is grease flowing from all lubrication points.
3. Check if the hoses are fixed and the wire harnesses are connected firmly.
4. The sealing parts can not be reused. During maintenance, if the sealing parts are disassembled,
replace with new ones.
5. Check all pipelines for damage, if damage appears, repair the pipeline in time.
6. Check the grease in the lubrication tank and add grease in time.

7. Make maintenance records.

Maintenance interval: every 250 h
1. Turn on the ignition switch, select the manual mode of lubrication system, and check whether
the lubrication system is operating normally.
2. Check main pipeline for leakage and damage. Check if all lubrication points can be filled with
grease.
3. Check if the hoses are fixed and the wire harnesses are connected firmly.
4. Clean the whole system of dirt and lubrication point oil seepage.
5. Check the grease in the lubrication tank and add grease in time.

8.7 Maintenance Chart

Base machine
Maintenance interval
500 h 1000 h
Components 10 h 50 h 250 h 2000 h
3 6
Daily Weekly Monthly Yearly
months months
Visual inspection:
—Check structural parts ●
—Check missing or damaged
●
parts
—Missing or loose pin and
●
bolt connections
—-Missing or damaged safety
devices, such as fire extin-
●
guisher, first aid kits, warning
signs
—Leakage ●
—Air intake and exhaust
●
system
—Window wiper ●
—Window washer ●
Function check:
—Control and display devices
such as switches, buttons, ●
handles and display
—Safety devices such as
emergency stop button, hy-
●
draulic lock lever, limit
switches
Working platform:
—Missing or loose pin/ screw
●
connections
—Check the locks can move
easily and are working ●
properly
—Check and replace hoses ●
—Thorough inspection ●
Lubricating Refer to Lubricating Chart in operator’s cab

500 h 1000 h
Components 10 h 50 h 250 h 2000 h
3 6
Daily Weekly Monthly Yearly
months months
● Recurring
■ Once after start-up
Key components
50 h 250 h 500 h 1000 h 2000
Components 10 h
Week- Month- 3 6 h Note
Daily
ly ly months months Yearly
Masthead
—Check if the bolts
and screws between
the pulley yoke and ■
mast are firmly
connected
—Replace the bolts
Every
connecting pulley yoke
10000 h
and mast
Kelly guide
—Swing bearing Lubricate
for every
10 h, re-
●
place if
damage
appears
—Check sliding strip Replace
if dam-
●
age
appears
—Check the bolts con- Replace
necting Kelly guide and if dam-
●
Kelly bar age
appears
Mast
Mast
—Check plug connec- Tighten if
tions and screw ■ necessa-
connections ry

50 h 250 h 500 h 1000 h 2000
Components 10 h
Daily
—Check locking ele- Tighten if
ments for firm seating ■ necessa-
ry
—Replace installing Every
pins and bolts 5000 h
Mast outrigger (if equipped)
—Check the pin
●
connections
Mast pivot
—Check pins and bolts Tighten if
for fastening condition ● necessa-
ry
—Replace bolts with Every
new ones 10000 h
Boom mechanism
—Check pins and bolts Tighten if
for fastening condition ● necessa-
ry
—Replace pins and Every
bolts with new ones 10000 h
Winch
Check reducer gear oil level
—Main winch ●
—Auxiliary winch ●
—Crowd winch (if
●
equipped)
Change winch reducer gear oil

50 h 250 h 500 h 1000 h 2000
Components 10 h
Daily
—Main winch Change
for the
first two
250 h,
after run-
ning for
500 h,
change
for every
500 h
—Auxiliary winch ■ ●
—Crowd winch (if
●
equipped)
Check the bolt connec- Tighten if
tions on winch ■ necessa-
ry
Replace bolts with new Every
ones 10000 h
Cylinder
—Piston rod
●
maintenance
—Cylinder check and
●
daily maintenance
Wire rope and accessories
Wire rope and connector
—Check wear and
●
damage conditions
—Wire rope
●
maintenance
Rope swivel
—Check the pin
●
connections
—Check the flexibility ●
Rope hold-down roller
assembly

50 h 250 h 500 h 1000 h 2000
Components 10 h
Daily
—Check if the roller is
parallel to the winch ●
drum
—Check roller for wear
●
and damage
—Check that connec- Tighten if
tion elements are com- ● necessa-
plete and secure ry
Wire rope guide pulley
—Check pulley for
wear, damage and ●
movement clearance
—Check pulley for ro-
●
tating condition
—Check pulley for fas-
●
tening condition
—Check pulley groove
●
for deformation
Check wire rope
●
retainer
● Recurring
Working device
50 h 250 h 500 h 1000 h
Components 10 h 2000 h
Week- Month- 3 6 Note
Daily Yearly
ly ly months months
Rotary drive
—Clean ●
—Check rotary drive
●
for wear and damage
—Check rotary drive
●
for leakage
—Check magnetic bar
●
for iron filings
50 h 250 h 500 h 1000 h
Daily Yearly
ly ly months months
—Check buffer device Replace if
● damage
appears
—Check sliding strip Replace if
● damage
appears
—Check drive key Replace if
● damage
appears
—Check drive belt ●
Check gear oil level
—Rotary drive gearbox ●
—Rotary drive reducer Check
every 100
h or every
week,
whichever
comes
first
Change gear oil
—Rotary drive gearbox ■ ●
—Rotary drive reducer Change
for the first
two 250 h,
after run-
ning for
500 h,
change for
every 500
h
—Take oil sample and
●
check its purity
Check rotary drive bolt Tighten if
■ ●
connections necessary
Check pressure gauge
●
(if equipped)

50 h 250 h 500 h 1000 h
Daily Yearly
ly ly months months
Check the breather Check
valve on rotary drive every 100
reducer for damage h or every
week
(whichev-
er comes
first); Re-
place if
clog
appears
Check the breather Replace if
valve on rotary drive ● clog
gearbox for damage appears
Universal joint (if equipped)
—Check rubber cush-
●
ion for damage
—Check suspension
pin for location and ●
damage
Central lubrication (if equipped)
Clean and check lubri-
●
cation pump
Check lubrication lines
●
for damage or leakage
Check if harness con-
●
nectors are firm
Check if each lubrica-
tion point can be lubri- ●
cated normally
Kelly bar
—Check spring seat ●
—Check spring ●
—Check rubber buffer ●
—Check torque trans-
●
mission groove
—Check lower tube ●

50 h 250 h 500 h 1000 h
Daily Yearly
ly ly months months
—Check locking
●
device
—Check baffle plate ●
Drilling tool
—Clean and check for
●
wear and damage
● Recurring
Swing mechanism
50 h 250 h 500 h 1000 h
Components 10 h 2000 h 3000
Daily Yearly h
ly ly months months
Engine (refer to engine service manual)
Clean crankcase
●
breather
Lubrication system
—Check engine oil
●
level
—Change engine oil
and replace filter ■ ●
element
Fuel system
—Drain water and
●
sediment
—Check fuel
●
amount and add fuel
—Clean fuel tank
■ ●
strainer

50 h 250 h 500 h 1000 h
Daily Yearly h
ly ly months months
—Check water oil Drain
separator, primary water
filter element and and
secondary filter sedi-
element ment
●
in
water
and oil
sepa-
rator
—Check water oil
separator, primary
filter element and
●
secondary filter ele-
ment and clean oil
pump strainer
Cooling system
—Clean ●
—Check coolant
●
level
—Change coolant ●
Air intake and ex-
haust system
—Clean and check Clean
air filter element if filter
ele-
ment
●
alarm
is
soun-
ded
—Replace air filter
●
element
Hydraulic system
Hydraulic tank
—Check hydraulic
●
oil level

50 h 250 h 500 h 1000 h
Daily Yearly h
ly ly months months
—Change hydraulic
■ ●
oil
—Take oil sample
●
and check its purity
Hose quality (oil leakage, damage, etc.)
—Check the dam-
age conditions by ●
professional staff
Replace filter element
—Pilot filter ●
—Check and clean Same
oil suction filter inter-
element val
with
chan-
ging
hy-
draulic
■ ●
oil;
Re-
place
if
dam-
age
ap-
pears
—Return filter
●
element
—Drainage filter
●
element
—Auxiliary pump fil-
ter element (if ●
equipped)

50 h 250 h 500 h 1000 h
Daily Yearly h
ly ly months months
—Check and clean Re-
breather valve place
if
● dam-
age
ap-
pears
Hydraulic oil radiator
—Clean ●
—Check if damage
●
appears
Accumulator
—Charge nitrogen ●
Swing mechanism
—Check bolt Tight-
connections en if
■ ● nec-
essa-
ry
—Check swing re-
●
ducer gear oil level
—Change swing re-
●
ducer gear oil
—Add grease on the
bottom of swing ●
reducer
Counterweight
—Check that the
connection elements
●
are complete and in
proper working order
Electric system
Accumulator
—Check electrolyte
●
concentration

50 h 250 h 500 h 1000 h
Daily Yearly h
ly ly months months
—Accumulator
●
maintenance
—Check electrolyte
●
level
—Check the cable
●
connections
Electric cabinet
—Check fuses ●
—Check electronic
components and ●
connectors
Air-conditioning system
—Run the air
●
conditioner
—Clean filter ●
—Clean condenser ●
—Check compres- Re-
sor belt and wheel place
if
● dam-
age
ap-
pears
● Recurring
Traveling mechanism
50 h 250 h 500 h 1000 h 2000
Components 10 h
Daily
Visual check:
—Check missing or damaged
●
parts
—Check structural parts ●

50 h 250 h 500 h 1000 h 2000
Components 10 h
Daily
—Check that the bolt connec- Tight-
tions of front drive, reducer, en if
travelling guide and carrier ● nec-
roller are complete and secure essa-
ry
Travel reducer
—Check gear oil level ●
—Change gear oil ■ ●
Track shoe
—Check tensioning conditions Ad-
of crawlers just if
● nec-
essa-
ry
—Check that the bolt connec- Tight-
tions of track shoe are com- en if
plete and secure ● nec-
essa-
ry
Chassis telescopic beam surface
—Clean ●
● Recurring
8.8 Common Misoperation

Category Failure analysis
During travelling, the rig does not extend its crawlers.
The rig travels on unstable or inclined ground, such as backfill, sloping fields,
gully and slide etc.
Common mi- During travelling, the rig does not incline backward or the inclination angle is
soperation to little.
causing rollover Sudden acceleration and deceleration; sudden rotation of upper carriage and
the whole machine.
During travelling up and down the slope, the rig is operated so brutal that its
gravity center suddenly changes and the rig becomes unstable.


The rig changes its direction, moves transversely or stops on the slope. The
rig swings during travelling up and down the slope.
If the mast inclines backward too much when travelling up the slope, the Kelly
bar will slip down and the rig will incline backward due to loss of gravity center.
If crawler does not extend when erecting the mast, rollover will happen when
swinging the machine.
The borehole is not vertical because the rig starts drilling borehole without ad-
justing mast verticality. If you adjust it halfway, the drilling head will probably
get stuck.
The mast cannot be raised because the mast extends too little when lowering
the mast. The weight of Kelly bar is easily to deform the mast or even break
the mast.
When lifting the Kelly bar, limit switch is not noticed. Wire rope clip damages
large pulley too much.
If travel is unlocked when drilling, the Kelly bar will deform and crack due to
misoperation of travelling handle.
Other common The drilling head levels the ground and it causes square head cracking.
misoperation
When connecting upper mast and masthead, the harness in mast is broken.
When removing connection rod, the rod bends if adjust verticality directly by
auto mast erecting due to uneven ground.
The boom is lowered without completely lowering the mast. If the mast is ad-
justed then, the cab will be crashed.
Use square head to drag drilling head (The weldment of square head easily
cracks).
If the boom is not raised enough when the rig is driving down the trailer, rotary
drive flange will touch the ground, which may deform the flange, when the rig
is driving down the ladder.
Kelly bar kinks or cracks due to pulling heavy load.
When installing Kelly bar, main winch lifting and rig travelling coordinates not
so well that Kelly guide collides with crowd cylinder and cylinder damages.
The boom is so high and backward when drilling that the drilling bucket
touches crawler when swinging and dumping soil.
Other common Travel reducer is too heated and damaged because of traveling too long one
misoperation time.
Rotary drive rotation speed is too fast when drilling the floating rock. The sud-
den resistance when hitting the floating rock results in square head cracking.
When operating with lockout rod, the rod is locked and the rod may smash ro-
tary drive reducer and rotary drive oil seal (or even smash the cylinder con-
necting rotary drive or wire rope, causing fall of rotary drive).


The operator uses auxiliary laterally, which causes wire rope slipping from
pulley.
Releasing rope so fast that the rope breaks or damages.
Releasing auxiliary rope so loose when lowering mast that cab roof steel
frame is scraped when raising the boom, or even the screws are torn.
The mast presses the wire rope into the mast holder when lowering the mast.
The wire rope damages.
After dumping soil, the Kelly bar is lowered directly without swing returning to
zero, which will cause larger borehole , more concrete and slip of casing.
When the engine output power is large, shut down the engine, and it may
shorten the life of turbocharger and engine.
The engine output power is large without heating the engine (especially when
the temperature is too low).
Welding the drilling tool without removing it. The electricity of the rig is not
switched off and harness or controller is damaged.
When removing the Kelly bar, swing to lower the Kelly bar. The wire rope and
mast is not parallel.
When operating the rig, answering telephone and chatting with people will
cause misoperation.
NOTE：
The table above is only for reference. If you have any questions, please feel free to contact
SANY after sales department.


SR305RS10Rotary Drilling Rig Warranty Information
Warranty Information
9 Warranty Information....................................................................................................9-1
9.1 Warranty Information ............................................................................................................9-3
9.2 References.............................................................................................................................9-3
9.3 Disposal of the Old Machine................................................................................................9-3

Warranty Information SR305RS10Rotary Drilling Rig

SR305RS10Rotary Drilling Rig Warranty Information
9.Warranty Information
9.1 Warranty Information
Emissions warranty information (no such requirement for National standard III).
Follow the maintenance requirements of the regulations, the engine system service life can be ex-
pected to work properly during the regulatory warranty period.
For details about the maintenance requirements, see Maintenance chapter.
9.2 References
You can purchase more information about your product from an authorized agent of Sany, and you
can also use the product name, sales model and serial number to obtain correct information about
your product.
9.3 Disposal of the Old Machine
• When the product is no longer in use, the disposal of products will vary according to local
regulations.
• Improper disposal of waste can pose a threat to the environment. Comply with all local regula-
tions on the decommissioning of and disposal materials.
• Use the correct personal protective equipment for decommissioning and disposal of products.
• Consult the nearest authorized agent of Sany for more information which includes information
about component remanufacturing and recycling.

Warranty Information SR305RS10Rotary Drilling Rig

www.sanygroup.com
BEIJING SANY INTELLIGENT TECH-

NOLOGY CO., LTD
Sany Industry Park, Nankou, Changping District, Beijing, P.R. of China 102202
Service hotline (complaint/enquiry): 0086

4006098318
E-mail: crd@sany.com.cn

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Quality Changes the World

Rotary Drilling Rig

Operation & Maintenance Manual

Operation & Maintenance Manual-October 10, 2023 1

Operation & Maintenance Manual-October 10, 2023

Obey the rules on the manual when you operate or do maintenance.

• Be responsible for supplying approved products and correct documents.

Duty of Owners or Other Approved Personnel

Operation & Maintenance Manual-October 10, 2023 1

• Check related personnel safety consciousness during working at regular interval.

Duty of All Personnel

2 Operation & Maintenance Manual-October 10, 2023

Operation & Maintenance Manual-October 10, 2023 I

2.3.3 Mechanical injury....................................................................................................... 2-22

II Operation & Maintenance Manual-October 10, 2023

2.4.14 Winch operation ...................................................................................................... 2-61

4 System Function .............................................................................................................4-1

Operation & Maintenance Manual-October 10, 2023 III

4.12.1 Control panel............................................................................................................ 4-25

IV Operation & Maintenance Manual-October 10, 2023

5.1.3 Starting the engine .....................................................................................................5-11

Operation & Maintenance Manual-October 10, 2023 V

5.2.4 Drilling ......................................................................................................................... 5-61

VI Operation & Maintenance Manual-October 10, 2023

5.3.5.2 Disconnecting middle mast and lower mast................................................... 5-92

Operation & Maintenance Manual-October 10, 2023 VII

6.11 Maintenance Procedures ................................................................................................ 6-32

VIII Operation & Maintenance Manual-October 10, 2023

6.11.4.3 Bolts connecting swing bearing - check........................................................ 6-68

Operation & Maintenance Manual-October 10, 2023 IX

6.11.11.1 Generator belt - replace ................................................................................ 6-96

8 Accessories and Options ...........................................................................................8-1

X Operation & Maintenance Manual-October 10, 2023

8.4.3.8 Easily worn parts of drilling rig.......................................................................... 8-25

Operation & Maintenance Manual-October 10, 2023 XI

XII Operation & Maintenance Manual-October 10, 2023

Operation & Maintenance Manual-October 10, 2023 1-1

1-2 Operation & Maintenance Manual-October 10, 2023

This manual is a guide for correct use of the

Only qualified and experienced operators with

Operation & Maintenance Manual-October 10, 2023 1-3

1.2 Legal and Regulatory Requirements

Laws and regulations on unauthorized equipment modification

1-4 Operation & Maintenance Manual-October 10, 2023

1.3 Safety Information

Examples of safety warnings

Operation & Maintenance Manual-October 10, 2023 1-5

a. Examples of literal safety decals 履带松紧调节警示牌

1-6 Operation & Maintenance Manual-October 10, 2023

b. Examples of graphic safety decals

Safety icons are graphic representations of

In the graphic symbols at right side, the safety

1.4 Reading Instruction

Sany rotary drilling rig is designed for the following operations:

2. Engaged pile construction;

3. Diaphragm wall grab pile construction.

Operation & Maintenance Manual-October 10, 2023 1-7

1.5.2 Machine directions

All views are taken from the seat (1) facing A