SUNWARD SWDM40 - Interior Operation Instructions

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SWDM40 OPERATION & MAINTENANCE MANUAL

3.2 INTERIOR OPERATION INSTRUCTIONS

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Table of Contents3
Safety Rules9
Safety Instruction9
Safety Level9
Safety Signs9
Safety Sign9
Other Signs10
Allowed Working Slope10
Regulation of Parking Space10
Travel on Slope10
Regulation of Cross Fall11
Regulation of Working Fall11
Equipment Stability12
General Conditions12
Rated Load12
Working Area13
Operator Visibility14
Safety Precautions14
Preparation and Solutions for Emergencies14
Wearing Protective Devices15
Keeping Machine Away from Power Transmission Line and Aerial Obstacles15
Fire Prevention15
Avoiding Incontrollable Accidents16
Safety Maintenance17
Machine Cleaning17
Safety Precautions18
Precautions before Working18
Precautions for Working19
Precautions When Assembly and Disassembly20
Precautions for Winch Operation21
Precautions for Drilling21
Precautions for Travelling22
Precautions for Transportation22
Preventing Accidents While Backing or Swinging22
Preventing Battery Explosion23
Prevention of Splashing Objects23
Prevention of Flying-Out Parts23
Keeping Away from Transmission Parts23
Preventing Inhaling Asbestos Dust24
Be Cautious of Inhalation of Smoke or Exhaust Gas24
Preventing Scald24
Be Cautious of High Pressure Liquids24
Be Careful of High Pressure Gas24
Avoiding Heating Near Pressure Oil Pipes25
Avoiding Heating Pipes Containing Flammable Liquids25
Precautions for Welding25
Safe Disposal of Liquids25
Safe Disposal of Chemicals25
Safety Facilities26
Emergency Exit26
Fire Extinguisher26
Emergency Stop26
Safety Handle27
Height Limit27
Prohibition of Private Modification28
Overview29
Applicable Range29
Conditions of Using Environment29
Technical Characteristics30
Machine Structure30
Undercarriage31
Upper-Carriage and Luffing Mechanism32
Power System35
Air-Conditioning System36
Rotary Drive37
Kelly Bar, Drilling Tools38
Operation40
Console Operation Instructions40
Interior Operation Instructions46
Operating Interfaces of Display Screen49
Membrane Key Panel68
Engine Use73
Precautions for Engine Use73
Precautions for Engine Preheating and Idling73
Precautions for Engine Shutdown73
Correct Filling of Coolant74
Other Operation Precautions74
Use and Maintenance of Post-Processing System75
Air Conditioner76
Use of Air Conditioner76
Common Failures and Solutions80
Control82
Travel82
Crawler Extension and Retraction84
Upper-Carriage Slewing85
Boom Luffing87
Erecting Mast89
Main Winch91
Auxiliary Winch95
Rotary Drive ROTATION97
Pressurization100
Mast Outrigger103
Crowd Winch Wirerope Tension104
Cathead Lift Cylinder106
Movements of Rotary Brake Cylinder108
Drilling110
Preparation and Check-Up before Working110
Starting Engine110
Machine Positioning111
Machine Assembly112
Machine Positioning112
Self-Assembly and Self-Disassembly of Drill Mast112
Kelly Bar Mounting112
Machine Work115
Rig Trial Running115
Drilling Tool Selection115
Hole Opening and Sleeve Installation115
Drilling116
Machine Transposition117
Machine Shutdown and Emergency Stop118
Steps of Changing Drilling Mode to Transportation Mode119
Assembly, Disassembly and Transport120
Machine Assembly120
Upper/Under-Carriage Assembly Installation (Case of Disassembly of Upper/ Under-Carriage)120
Drill Mast Installation121
Steel Rope Assembly of Main and Auxiliary Winch121
Assembly of Rotary Drive122
Machine Transport123
Transport Rules123
Transport Parameter124
Driving Onto / off a Platform Trailer129
Requirements129
Driving Onto a Platform Trailer129
Tying down the Machine130
Driving off a Platform Trailer130
Requirements for Sea Transport131
Precautions for Transportation132
Notes for Machine Assembly and Disassembly132
Tying Machine down132
Storage133
Storage Preparation133
During Storage133
After a Long-Term Storage133
Remote Operation134
Kelly and Drilling Tools136
Kelly136
Introduction of Kelly136
Correct Model Selection for Kelly138
Correct Operation of Kelly138
Kelly Disassembly141
Maintenance for Kelly143
Requirements of Long-Time Storage and Transport for Kelly144
After-Sale Service Code for Kelly144
Simple Repair Technology for Kelly146
Drilling Tools148
Common Drilling Tools and Application148
Maintenance and Service153
Safety Instructions for Maintenance153
Overview153
Note for Maintenance153
Regular Maintenance161
Lubrication Maintenance Chart161
Oil167
Regular Check168
Every 10 Hours Maintenance169
Checking and Adjusting Track Tension169
Hydraulic Cylinder Maintenance171
Checking Oil Level in Rotary Drive Gearbox173
Checking Cushion Device of Rotary Drive173
Check Track Components for Lost or Damaged173
Wire Rope Inspection174
Discarding Criteria of Wire Rope175
Wire Rope Maintenance176
Checking Swivel Joint for Flexibility177
Lubrication of Wire Rope Swivel Joint177
Checking Engine Oil Level179
Draining Water and Sediment in Diesel Tank180
Checking Hydraulic Oil Level and Quality181
Checking Gear Oil Level for Reduction Gearbox181
Checking Coolant Level182
Checking Fuel Capacity and Filling Fuel Oil184
Checking Switches, Buttons and Operating Handles185
Maintenance for Initial 50 Hours of Operation186
Changing Engine Oil and Filter186
Replacing Fuel Filter189
Changing Oil-Water Separator190
Cleaning Filter Screen for Fuel Tank191
Maintenance for Every 50 Hours192
Checking Wire Rope Retainer Parallel with Roller192
Checking Slewing Bearing Junction Bolts192
Checking Bolts Tightening for Key Parts of Rotary Drive192
Checking and Changing Drive Key Bar for Kelly193
Checking and Changing Rotary Drive Wear Plate194
Checking Mounting Bolt of Track Shoe for Secure194
Visual Inspection of Air Intake System195
Checking Wiper195
Checking Front Window Clean Device195
Changing Slewing Bearing of Servo-Frame195
Checking Air Compressor Belt196
Maintenance for Every 100 Hours197
Checking Oil Level for Swing Reduction Gearbox197
Checking Oil Level for Travel Reduction Gearbox197
Checking Oil Level for Auxiliary Winch Reduction Gearbox198
Checking Hydraulic Oil Filter Element198
Draining Water and Sediment in Hydraulic Oil Tank200
Maintenance for Every 250 Hours201
Checking and Changing Servo-Frame Wear Plate201
Inspection and Repairing of the Pressing Plate of Kelly Bar201
Rotary Drive Gear Oil Sample and Inspection202
Checking and Changing Hoses202
Cleaning Fuel Tank Filter Screen -See Chapter 8.4.4203
Cleaning Air Conditioner Condenser203
Maintenance for Initial 250 Hours of Operation204
Changing Gear Oil for Main Winch Reduction Gearbox204
Change Gear Oil for Rotary Drive Reduction Gearbox205
Changing Gear Oil for Swing Reduction Gearbox205
Changing Gear Oil for Travel Reduction Gearbox206
Changing Gear Oil for Auxiliary Winch Reduction Gearbox206
Changing Gear Oil for Rotary Drive Gearbox207
Changing Air Filter, Return Filter Element and Pilot Filter Element See207
Chapter 8.6.4207
Checking and Replacing Air Filter207
Maintenance for Every 500 Hours209
Checking Wire Rope Sheave209
Changing Main Winch Reduction Gear Oil- See 8.8.1209
Replacing Rotary Drive Gearbox Gear Oil- See 8.8.2209
Changing Engine Oil and Filter -See 8.4.1209
Changing Fuel Filter- See 8.4.2209
Changing Oil-Water Separator Filter- See 8.4.3209
Checking and Changing Inner and Outer Air Filter Element of Air Conditioner209
Changing and Replacing Air Filter See-Chapter 8.8.8209
Maintenance for Every 1000 Hours210
Changing Air Filter, Return Filter Element, Pilot Filter Element See -Chapter210
Changing Swing Reduction Gearbox Oil See-Chapter 8.8.3210
Changing Travel Reduction Gearbox Oil See-Chapter 8.8.4210
Changing Auxiliary Winch Reduction Gearbox Oil See-Chapter 8.8.5210
Changing Rotary Drive Reduction Gearbox Oil See -Chapter 8.8.6210
Hydraulic Hoses Inspection210
Hydraulic Hoses Replacement211
Cleanness Control for Hydraulic System211
Hydraulic Oil Temperature Control211
Use of Battery212
Maintenance for Every 2000 Hours215
Changing Hydraulic Oil215
Maintenance for Every Two Years or 3000 Hours216
Changing Coolant216
Machine Storage217
Cleaning Machine217
Storing Machine217
Daily Maintenance218
Maintenance for a Long-Term Storage219
Troubleshooting220
Common Failures and Solutions220
Accidents and Solutions During Drilling221
Environment Protection /Waste Disposal222
Overview222
Storage and Transport for Auxiliary & Running Material of Machine and System222
Note for Machine Cleanness223
Machine Shut-Down223
Machine Disassembly223
Waste Disposal224
Waste Disposal for Running Material, Lubrication Material and Auxiliary Material224
Waste Disposal for Metal Parts and Plastic Parts224
Waste Disposal for Electrical Engineering and Electrical Components224
Special Garbage225
Recycling225
Appendix226
Swdm40 Configuration and Dimension226
Main Parameters227
Manufacturer Information228

SUNWARD SWDM40 - Interior Operation Instructions

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