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Dando DUKE STAGE IV Operating And Maintenance Manual Download Page 5

200105253 - MAST SUB-ASSEMBLY 
200101191 - CROWN WIRELINE RETAINER ASSEMBLY 
200105526 - MAST HYD GUARD ASSEMBLY  
200105403 - INNER MAST WEAR STRIP ASSEMBLY 
200105404 - MAST RAISE BRACKET ASSEMBLY 
200105999 - OVERRUN DEVICE ASSEMBLY 
200105258 - WHIP CHECK ASSEMBLY 
200105238 - OUTER LEG SUB-ASSEMBLY [RIGHT] 
200105798 - OUTER LEG SUB-ASSEMBLY [LEFT] 
200105959 - MAST FOOT ASSEMBLY 
200105513 - MAIN MAST LIGHTING ASSEMBLY 
200105715 - 0.44 TONNE WINCH ASSEMBLY [NP05 - DANDO DUKE] 
200105963 - TIE BAR SUPPORT ASSEMBLY 
200105110 - HOISTING REEL ASSEMBLY 
200105131 - HOISTING DRUM ASSEMBLY 
200105132 - CLUTCH ASSEMBLY 
200105133 - BRAKE ASSEMBLY 
200105204 - BRAKE BEARING ASSEMBLY 
200105555 - DRUM SAFETY GUARD ASSEMBLY  
200105795 - MOTOR ASSEMBLY 
200108466 - GREASER EXTENSION ASSEMBLY  
200105191 - HEADACHE POST ASSEMBLY 
200105348 - HEADACHE POST SEAT ASSEMBLY 
200105520 - HEADACHE POST CANOPY NS ASSEMBLY 
200105171 - LEVELLING JACK ASSEMBLY 
200105357 - FUEL TANK ASSEMBLY (44L) 
200105358 - FUEL TANK LID ASSEMBLY 
200105365 - FILLER ASSEMBLY (44L FUEL TANK) 
200105783 - HYDRAULIC TANKS ASSEMBLY 
200105375 - HYDRAULIC HEADER TANK ASSEMBLY  
200105770 - HYDRAULIC CHASSIS TANK ASSEMBLY 
200109147 - HYDRAULIC TANK BREATHER ASSEMBLY 
200800297 - DANDO DUKE RETURN MANIFOLD ASSEMBLY 
200800305 - HYDRAULIC PUMP ASSEMBLY 
200105501 - ELECTRICAL CONTROL ASSEMBLY 
200800237 - COMPRESSOR MODULE 
200105510 - BATTERY ASSEMBLY 
200105355 - GUARD ASSEMBLY [HYD OIL TANK] 
200105152 - ENGINE ASSEMBLY 
200100925 - DUKE EXHAUST MK2 ASSEMBLY 
200800504 - ENGINE OIL DRAIN EXTENSION ASSEMBLY 
200105457 - CANOPY ASSEMBLY 
200105411 - FRONT CANOPY ASSEMBLY [OS] 
200105408 - FRONT CANOPY SUB-ASSEMBLY [OS] 
200105449 - 1/2" BSP HYD QUICK CONNECT ASSEMBLY 
200105663 - FRONT CANOPY DOOR AND PANEL ASSEMBLY [OS] 
200105412 - FRONT CANOPY ASSEMBLY [NS] 
200105907 - FRONT CANOPY SUB-ASSEMBLY [NS] 
200105914 - FRONT CANOPY [NS] DOOR AND PANEL ASSEMBLY 
200105917 - FRONT CANOPY [NS] DOOR  ASSEMBLY 
200105919 - FRONT CANOPY DOOR AND PANEL ASSEMBLY [NS] 
200105415 - REAR CANOPY ASSEMBLY 
200105414 - REAR CANOPY SUB-ASSEMBLY 
200105416 - REAR CANOPY DOOR & PANEL ASSEMBLY 
200105194 - REAR CANOPY DOOR ASSEMBLY [NS] 
200102246 - UMBILICAL DOOR ASSEMBLY 
200105428 - REAR CANOPY DOOR ASSEMBLY [OS] 
200105483 - CONTROL CONSOLE ASSEMBLY 
200105473 - RECEIVER TANK ASSEMBLY 
200106329 - SAFETY LATCH ASSEMBLY 
200105452 - LIFTING EYE ASSEMBLY 
200105460 - AIR HOSE REEL ASSEMBLY 

Summary of Contents for DUKE STAGE IV

Page 1: ...NDO DRILLING INTERNATIONAL LTD REF SO 1950010 PLEASE QUITE THIS NUMBER WHEN ORDERING SPARE PARTS DANDO DRILLING INTERNATIONAL LTD UNIT G FORD AIRFIELD INDUSTRIAL ESTATE FORD Nr ARUNDEL WEST SUSSEX BN18 0HY ENGLAND E MAIL info dando co uk WEB SITE http www dando co uk TEL 44 0 1903 731312 FAX 44 0 1903 730305 ...

Page 2: ......

Page 3: ...ILLING OPERATIONS GENERAL 9 1 5 6 DRILLING OPERATIONS CABLE PERCUSSION 10 1 5 7 PLANT MAINTENANCE 11 1 5 8 SITE ABANDONMENT 12 1 5 9 TRAINING 13 1 5 10 WELFARE AND PERSONAL PROTECTION 14 1 5 11 WIRE ROPES GENERAL SAFETY AND MAINTENANCE 16 1 6 RECOMMENDATIONS 20 1 7 WARNINGS 21 SECTION 2 TECHNICAL DATA 23 2 1 RIG SERIAL NUMBER 25 2 2 GENERAL DATA 25 2 2 1 RIG DIMENSIONS TRAILER VERSION 25 2 2 2 RIG...

Page 4: ...53 4 4 COMPRESSOR OIL 53 4 5 BRAKE FLUID 53 4 6 TOOLING WINCH 53 4 7 BATTERY 53 4 8 GREASING POINTS 53 4 9 HYDRAULIC SYSTEM 54 4 9 1 HYDRAULIC HEADER TANK 54 4 9 2 HYDRAULIC CHASSIS TANK 55 4 9 3 HYDRAULIC TANK BREATHER ASSEMBLY 56 4 10 CONTROL CIRCUITS 56 4 11 TO FIT NEW LEVELLING JACK CYLINDER 56 SECTION 5 SPARE PARTS ILLUSTRATIONS AND LISTINGS 61 200105418 TRAILER MODULE 200105417 DRAW BAR ASSE...

Page 5: ... HYDRAULIC HEADER TANK ASSEMBLY 200105770 HYDRAULIC CHASSIS TANK ASSEMBLY 200109147 HYDRAULIC TANK BREATHER ASSEMBLY 200800297 DANDO DUKE RETURN MANIFOLD ASSEMBLY 200800305 HYDRAULIC PUMP ASSEMBLY 200105501 ELECTRICAL CONTROL ASSEMBLY 200800237 COMPRESSOR MODULE 200105510 BATTERY ASSEMBLY 200105355 GUARD ASSEMBLY HYD OIL TANK 200105152 ENGINE ASSEMBLY 200100925 DUKE EXHAUST MK2 ASSEMBLY 200800504 ...

Page 6: ...E ASSEMBLY MULTI HEIGHT SPT HAMMER 200106333 SPT STOWING WINCH ASSEMBLY 200105329 STRAP GUIDE ASSEMBLY SPT 200106815 MULTI HEIGHT SPT HAMMER ASSEMBLY 200106304 SPT HAMMER ASSEMBLY 200106201 DRIVE CHAIN ASSEMBLY 200106816 MULTI HEIGHT SPT KIT SECTION 6 HYDRAULIC CIRCUIT 261 SECTION 7 ELECTRICAL CIRCUITS 265 APPENDIX A ENGINE PERKINS 403D 15 285 APPENDIX B COMPRESSOR DYNASET HK450 8 14 397 APPENDIX ...

Page 7: ...SECTION 1 GENERAL 1 ...

Page 8: ...2 ...

Page 9: ...hese Manuals and are suitably instructed regarding the purpose of these Manuals and safety instructions In addition operators should be suitably and adequately trained in the use of the product 1 3 CODE OF SAFE DRILLING PRACTICE It is the responsibility of the owners and hirers of this equipment to ensure that the operators of the equipment are aware that drilling sites can be potential hazardous ...

Page 10: ...1 4 3 MAST RAISING CAUTION Before attempting to raise the mast ensure that the mast framework is clear of any obstructions 1 4 4 DRILLING OPERATIONS Before commencing any drilling operations ensure that the spreader bar and stay bars are fitted and secured 1 4 5 WARNINGS THIS RIG IS FITTED WITH AN ALTERNATOR DO NOT disconnect batteries when engine is running DO NOT turn ignition key to 0 position ...

Page 11: ...covers are removed Always disconnect the earth lead from the battery negative terminal when working on the rig engine Avoid spilling battery acid on the paintwork Wash off with water immediately if this occurs 1 4 7 TRAILER MOUNTED RIGS WARNING The trailer on which the rig is mounted is designed with a load carrying capacity for the rig only unless otherwise specifically stated Do not add platform...

Page 12: ...d stand squarely with a solid footing and should lift the load slowly by straightening the legs rather than the back f Care should be exercised when handling weights which must be moved with artificial means such as pipe used for casing etc g If pipe is to be moved by rolling by hand this must be done from the ends and the person must ensure that the hands are kept out of the ends of the pipe When...

Page 13: ...g Consideration should be given to other road users who may become impatient and take risks it is advisable to pull into the side occasionally to let them pass h Where wide long or heavy loads are to be moved it is advisable to have all lights on for road travel even in broad daylight i On arrival at the site ground conditions should be checked before driving in and a watch kept for temporary over...

Page 14: ...ce and assess the general hazards which may arise during construction and drilling due to the nature of the ground the existence of high water gas or oil pressures in the strata surface and underground installations and services d The site should be inspected before rig entry to find a safe approach route to the proposed drilling position Some guidance may be required for winching or lowering rigs...

Page 15: ...ould be neatly stacked preferably on appropriate racks and maintained in a clean condition f Threads and connectors should be regularly cleaned and greased and preferably protected with thread protectors g Tools and materials should be laid out according to requirements and in order of use 1 5 5 DRILLING OPERATIONS GENERAL a Drilling may entail the employment of some personnel inexperienced in thi...

Page 16: ... should keep clear of suspended equipment and use a rope strap or bail hook to swing tools away from the borehole They should never look down the borehole beneath a suspended tool f When the drive clamps are suspended or in use the operator should not place his hand on the drive head When casing is being driven the drive clamps should not be suspended above the operator s head Short lengths of cas...

Page 17: ...g and lubrication The system should include a three part sequence of inspection thorough examination and testing Results of each stage are to be recorded and signed c Cleaning repair maintenance oiling or greasing of machines or the topping up of fuel tanks should not be carried out whilst a machine is operating d If inspection involves the running of a petrol or diesel engine in an enclosed space...

Page 18: ... in serviceable condition o A flammable liquid within the classification of Class A or Class B petroleum should not be used for cleaning purposes except in very special circumstances and then by written permission only p Loose boards and materials not in use should be removed from the derrick floor q Steps and guard rails where applicable should be maintained in good condition If it is necessary t...

Page 19: ...nd to so work with the other members of the crew that good and safe team work becomes instinctive e This not only results in steady and safe progress but secures higher production f All training whatever the size of the organisation should be formally programmed throughout the number of stages required by the personnel concerned Each step in the training module or syllabus should be monitored by a...

Page 20: ...disposal sites f Suitably ventilated chemical toilets housed to provide privacy should be available These should be regularly serviced and contents disposed of in accordance with manufacturer s instructions Personnel should be encouraged to wash after using these facilities g Potable drinking water should be available and containers clearly marked as such to distinguish from non potable non drinka...

Page 21: ... p If overalls are not worn long sleeved shirts with tails tucked in will provide protection against sunburn insect bites scratches hazardous chemicals and flash burns q Safety helmets must be worn by members of the drilling crew and visitors to the site Safety boots or safety wellingtons should also be worn r When working on or adjacent to the public highway a top coat jerkin or waistcoat with fl...

Page 22: ...nd signed report of rope condition kept on file and readily available d Any deterioration resulting in appreciable loss of original strength such as described below should be carefully noted and the rope should not be used if any of the following situations are present i Reduction of rope diameter below nominal diameter due to loss of core support internal or external corrosion or wear of outside ...

Page 23: ...g narrow U or series of U s with as wide a radius for the turn of the U as possible i When handling wire rope it should be manipulated so that its natural twisting action will not cause it to kink j A replacement rope must be of the same type and specification as the original fitted to the rig by the manufacturer and of the correct safe working load k Care should be taken when installing ropes on ...

Page 24: ...socket type of fastening is used the dead of shortened end of the rope should be clipped with a U bolt or otherwise made secure against loosening y Winch ropes should not be lopped knotted or kinked around themselves or any other object except suitably designed D etc z Lifting hooks or shackles should be attached to the winch rope via a swivel connection which can operate under maximum load aa Whe...

Page 25: ...f rope is used to haul equipment to the working areas a straight pull should be maintained from the winch through the pulley to the equipment gg Protective gloves should be used when handling wire ropes 19 ...

Page 26: ...CHECK ALL CONTROLS ARE IN NEUTRAL WHEN STARTING UP 4 ALWAYS ENSURE HANDBRAKE IS ON BEFORE RAISING LEVELLING RAMS 5 ATTEMPT AT ALL TIMES TO ENSURE PERFECTLY CLEAN HYDRAULIC OIL IS MAINTAINED 6 WASH OFF AS SOON AS POSSIBLE ANY HYDRAULIC OIL THAT GETS INTO CONTACT WITH SKIN 7 INSPECT WIRELINES AND HOSES FOR WEAR DAILY 8 ALWAYS REPLACE WIRELINES AT THE FIRST SIGN OF WEAR THE SIGNS OF WEAR ARE FLATTENI...

Page 27: ...S KEPT AWAY FROM THE VICINITY OF THE ALTERNATOR AND ANY NYLON PIPING OR RUBBER HOSE FAILURE TO COMPLY WITH THESE WARNING WILL LEAD TO COMPONENT DAMAGE AND MAY CAUSE INJURY 4 THE TRAILER ON WHICH THE RIG IS MOUNTED IS DESIGNED WITH A LOAD CARRYING CAPACITY FOR THE RIG ONLY UNLESS OTHERWISE SPECIFICALLY STATED DO NOT ADD PLATFORMS ETC FOR CARRYING ADDITIONAL ITEMS AS THIS WILL OVERLOAD THE TRAILER C...

Page 28: ...R CABLES 11 DO NOT WORK UNDER LOAD SUSPENDED ON WINCH LINE 12 AT THE END OF EVERY OPERATION DO NOT LEAVE CONTROLS IN ENGAGED POSTIONS BUT ALWAYS RETURN THEM TO THEIR NEUTRAL MINIMUM OFF POSITION 13 DO NOT FORGET TO SWITCH OFF THE BATTERY ISOLATOR IF LEAVING THE RIG 22 ...

Page 29: ...SECTION 2 TECHNICAL DATA 23 ...

Page 30: ...24 ...

Page 31: ...0m Min Height Mast Erected 4 915m Min Useable Height Mast Erected 4 000m Max Width Mast Erected 2 204m Travelling Length 4 476m Travelling Width 1 870m Travelling Height 2 056m 2 2 2 RIG DIMENSIONS TRACKED VERSION Total Gross Weight 3417kg Max Length Mast Erected 5 646m Max Height Mast Erected 6 364m Max Useable Height Mast Erected 5 673m Min Length Mast Erected 4 869m Min Height Mast Erected 4 91...

Page 32: ...6 2 2 7 MAST Maximum Derrick SWL 6000 Kg Max Working Height 5 5m Min Working Height 4m 2 2 8 STABILISING OR LEVELLING JACKS Four levelling jacks one at each corner of rig 2 2 9 MAIN FEE FALL WINCH Drum Capacity 90m of 16mm wireline BARE DRUM FULL DRUM MAX PULL HIGH SPEED 82m min 154m min 1490kg LOW SPEED 40m min 82m min 3000kg 2 2 10 TOOLING WINCH Dinamic Oil NP05 Drum Capacity 20m of 8mm wireline...

Page 33: ...HTS TRAILER VERSION Total Mass 2940kg Axle 1 Max 1750kg Axle 2 Max 1750kg 2 2 13 FINE FEED BRAKE CONTROL Fine Feed Brake Control Working Load Limit WLL 500kg 2 2 14 SPT HAMMER ASSEMBLY OPTIONAL EXTRA Total Mass 197kg 27 ...

Page 34: ...28 ...

Page 35: ...SECTION 3 OPERATING INSTRUCTIONS 29 ...

Page 36: ...30 ...

Page 37: ... understood These instructions cover the standard basic rig and controls but may differ if customer special requirements have been made to the system in which event these controls functions will be labelled accordingly 3 2 TRANSPORT The rig is available in both trailer and track mounted versions The vehicle used to tow the trailer version should be of sufficient size and power for this function Th...

Page 38: ...Figure 3 1 TOP CONTROL PANEL A Circular Level B Receiver Tank Air Pressure Gauge C Front Right Jack Control D Front Left Jack Control E Rear Left Jack Control F Rear Right Jack Control C D E F A B 32 ...

Page 39: ... Gauge B Auxiliary Function Oil Pressure Gauge C Engine Oil Pressure Warning Indicator D Engine Water Temperature Warning Indicator E Key Switch F Tachometer G 12V DC Cigarette Lighter Socket H Recoil Air Line Control A B C D E F G H 33 ...

Page 40: ...o engage the brake the Brake Lever is pushed away from the operator This lever is spring operated and when released will engage the brake To disengage the brake the Brake Lever is pulled towards the operator There is a brake safety latch situated on the lever This will locate in the recess to lock the brake on It is important that the brake control be left in the locked position when the machine i...

Page 41: ...OF RIG 3 4 1 SITE PREPARATION Before moving the drilling rig to the proposed drilling position the drilling site should be inspected and prepared by removing debris and any obstructions if possible In selecting a suitable position for the rig it is essential there is sufficient room for the deployment and erection of the mast assembly including support legs spreader bar and sidestays The ground on...

Page 42: ...2 Remove spreader bar pin unlock clamp bracket remove spreader bar Figure 3 4 stay bar pins stay bars Figure 3 5 and lower leg pins Figure 3 6 FIGURE 3 4 FIGURE 3 5 36 ...

Page 43: ...d tooling winch hooks from their stowage positions Figure 3 7 Extend main and tooling winch cables at least 2m FIGURE 3 7 4 Remove the SPT Auto Hammer upper pins from the mounts on the mast if the SPT Auto Hammer is required Figure 3 8 37 ...

Page 44: ... using the levelling jacks Controls A D Figure 3 1 Suitable timbers or pads can be used to protect the ground or provide more stability on soft surfaces 6 Extend the inner legs and pin through the outer legs to secure the inner legs in their drilling position Figure 3 9 FIGURE 3 9 38 ...

Page 45: ...7 Extend the mast boom fully Figure 3 10 Control K Figure 3 3 FIGURE 3 10 8 Raise the mast to the vertical position Figure 3 11 Control L Figure 3 3 FIGURE 3 11 39 ...

Page 46: ...the front of the rig Figure 3 12 FIGURE 3 12 10 Retract the mast boom until both feet touch the floor note that if drilling on soft or uneven terrain wooden boards may be placed underneath the feet to spread the load and level the rig 11 Raise the stay bars to the drilling position and pin Figure 3 13 Figure 3 14 FIGURE 3 13 40 ...

Page 47: ...FIGURE 3 14 12 Place the spreader bar between legs and pin Figure 3 15 FIGURE 3 15 41 ...

Page 48: ...supporting timbers the mast is level positioned central to the rig chassis Wooden beams may be used to help level the mast if required The rig is now fully erected and ready for drilling Figure 3 16 FIGURE 3 16 3 4 3 TAKE DOWN PROCEDURE 1 Unpin and remove the spreader bar Figure 3 17 FIGURE 3 17 42 ...

Page 49: ...2 Unpin and remove the stay bars Figure 3 18 Figure 3 19 FIGURE 3 18 FIGURE 3 19 43 ...

Page 50: ...ol K Figure 3 3 be aware that the legs will move towards the rig Figure 3 20 FIGURE 3 20 4 Bring the mast back to the vertical position Control L Figure 3 3 whilst guiding the legs into their stowage position Figure 3 21 FIGURE 3 21 44 ...

Page 51: ...y Control K Figure 3 3 7 Remove the pins connecting leg inners and outers Retract the inner legs and pin the inner legs in their stowed position Figure 3 23 FIGURE 3 23 8 Retract the levelling jacks Controls A D Figure 3 1 9 Fit the side stays and spreader bar in their stowing positions Pin side stays and spreader bar securely 45 ...

Page 52: ...tch the drilling rig to the towing vehicle This completes the Take Down procedure 3 5 SPT AUTO HAMMER DEPLOYMENT 3 5 1 Deployment Procedure 1 To deploy the SPT hammer set the mode switch to drilling Control J Figure 3 3 2 Attach the SPT Auto Hammer extension cable to the tooling winch hook Figure 3 24 and raise tooling winch to take out slack Control M Figure 3 3 FIGURE 3 24 46 ...

Page 53: ...n the SPT Auto Hammer 7 Connect the extension hoses to the motor quick connect fittings Ensure the quick connections are twisted into the lock position 8 Connect the other ends of the extension hoses to the auxillary power take off PTO of the rig Use the top two outputs on the PTO as the lower one is case drain only Ensure that the quick connections are twisted into the lock position 9 The SPT Aut...

Page 54: ...n be adjusted to get the lugs close to the slots See 3 27 for recommended height indicated by red line FIGURE 3 27 3 Lower the tooling winch until the locking bracket fabrication lugs on the SPT Auto Hammer locate in the top stowage fabrication slots of the mast The tool winch should be lowered until the top section of the auto hammer is resting against the mast and the tool winch cable is slack F...

Page 55: ...uts on the rig PTO see 3 5 1 The PTO lever on the main console Control H Figure 3 2 controls the SPT Auto Hammer motor The height of the SPT Hammer can be adjusted using the tooling winch control Control M Figure 3 3 3 7 CABLE PERCUSSION OPERATION To operate in Cable Percussion mode set the mode switch to drilling Control J Figure 3 3 With the brake off Control A Figure 3 3 the Clutch Control on t...

Page 56: ...50 ...

Page 57: ...SECTION 4 RIG MAINTENANCE AND SERVICE 51 ...

Page 58: ...52 ...

Page 59: ...ne coolant should be ATSM D4985 compliant Maintenance should be limited to ensuring that the correct level of coolant is maintained 4 4 COMPRESSOR OIL Use SAE 10W 30 mineral oil Refer to compressor operating maintenance manual Appendix B 4 5 BRAKE FLUID Use DOT 4 brake fluid Maintenance should be limited to ensuring that the correct level of brake fluid is maintained 4 6 TOOLING WINCH Use HLP ISO ...

Page 60: ... added via the breather filler cap located on top of the headache post mounted header tank Figure 4 1 Item 15 This tank assembly includes a combined level and temperature gauge Figure 4 1 Item 11 It is preferable to keep the system well topped up with the level being maintained within the sight glass However it should be remembered that the maximum level will be indicated when all rams are withdra...

Page 61: ... using the magnetic plug fitted to the base of the tank The hydraulic oil return filter is mounted on the Hydraulic Chassis Tank Figure 4 2 Item 9 A pressure gauge is mounted on top of the filter a pressure above 1 5 bar will indicate the filter becoming blocked and bypassed The hydraulic oil filter should be replaced at the intervals indicated on the Maintenance Checks Table FIGURE 4 2 HYDRAULIC ...

Page 62: ...ing the bottom section of the jack the ram can now be worked upward sufficiently to enable a cross bar to be put through the ram head The bottom section of the jack unit can now be disconnected by driving out the cross pin which locates the ram rod at the bottom of the jack extension tube The ram can now be lifted from the housing for servicing see illustration of stabilising rams in spare parts l...

Page 63: ... GREASE POINTS MATERIAL SLIDES ETC General Purpose Lithium Based Grease e g Shell Alvenia R3 Mobil Grease MP BP Energrease LS2 Grease Gun or Brush as appropriate WIRE ROPES SHELL CARDIUM COMPOUND MOBIL MOBILTAC A BP ENERGOL WRP CASTROL RUSTILO DWX 32 RIG ENGINE OIL 15W 40 Refer to Manufacturers Handbook for equivalents Oil Filled RIG ENGINE COOLANT EXOL Antifreeze ASTM D4985 Compliant Oil Filled A...

Page 64: ... 133 F HLP 46 SHF 46 THB 46 HYPSIN VG 46 NUTO H46 D346 TELLUS 46 RANDO HD46 62 C 143 F HLP 68 SHF 68 THB 68 HYPSIN VG 68 NUTO 68 D368 TELLUS 60 RANDO ID68 74 C 165 HLP 100 SHF 100 THB 100 HYPSIN VG 100 NUTO H100 D3100 TELLUS 100 RANDO HD100 80 C 176 F HLP 100 SHF 100 THB 150 HL 150 HYPSIN AWS150 NUTO H150 TELLUS 150 RANDO HD150 TABLE 4 2 HYDRAULIC OIL CHART 58 ...

Page 65: ...Compressor and Receiver Tanks X FOR TRAILER MOUNTED DUKE ONLY 18 Tire Pressure and Tread Depth X 19 Wheel Nut Indicators X 20 Lights Reflectors and Number Plate X 21 Mudguards X 22 Tow Hitch and Breakaway Cable X 23 Nose Weight X 24 Handbrake Function X 25 Jockey Wheel and Clamp X 26 Wheel Bearing Play X WEEKLY PLUS 1 25 27 Hoisting Drum Brake and Clutch X X 28 Battery Electrolyte Level X 29 Mast ...

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Page 67: ...SECTION 5 SPARE PARTS ILLUSTRATIONS AND LISTINGS 61 ...

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Page 267: ...SECTION 6 HYDRAULIC CIRCUIT 261 ...

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Page 269: ...LLY DRIVEN 1 21 C102G0053 3 8 BSP FEMALE FLAT FACE SNAP COUPLING 1 22 ST01875X168 1 2 BSP MALE SNAP COUPLING 1 23 ST01876X168 1 2 BSP FEMALE SNAP COUPLING 1 24 700200271 FLOW CONTROL VALVE 0 375in 0 55LPM 2 25 700200255 HYDRAULIC MOTOR 32CC 1 26 700200272 HYDRAULIC DOUBLE OVERCENTRE VALVE 0 375in 1 1 3 PILOT RATIO 1 27 200109147 HYDRAULIC TANK BREATHER 1 10 V1 V2 C1 C2 8 10 10 A B A B A B A B A B ...

Page 270: ...264 ...

Page 271: ...SECTION 7 ELECTRICAL CIRCUITS 265 ...

Page 272: ...266 ...

Page 273: ...PB21 W7 W3 SVC4 AN2A W6 LT7C BE1AFL LT9C LT8C PB11KSL ACC IGN VR1B IN1TAC FM1 S S OPS11 WTS11 LT7R LT3A LT1OC PS1 PS2 W2 PB22L5 W T001 W32 W33 W34 W35 W31 REVISION REVISION DESCRIPTION DATE INITIALS A INITIAL RELEASE 10 09 2019 SB A 17 09 2019 10 09 2019 SB DUKE TRAILER RIG SCHEMATIC Document Type Company Confidential Checked Approved Date Drawn Date This drawing and any information or descriptive...

Page 274: ...268 ...

Page 275: ...1AFL LT9C LT8C PB11KSL ACC IGN VR1B IN1TAC FM1 S S OPS11 WTS11 LT7R LT3A LT1OC PS1 PS2 W2 W31 W32 W33 W34 W35 PB22L5 W W25 W25 W25 W26 W25 800105111 REMOTE UNIT DI1 DI2 SVC5 W9 W5 W1 REVISION REVISION DESCRIPTION DATE INITIALS A INITIAL RELEASE 10 09 2019 SB A 17 09 2019 10 09 2019 SB DUKE TRACK RIG SCHEMATIC Document Type Company Confidential Checked Approved Date Drawn Date This drawing and any ...

Page 276: ...270 ...

Page 277: ...TRACK SOLENOID PS1 12V SOCKET PB21 RIG LIGHT SWITCH PS2 CIGARETTE LIGHTER SOCKET OPS11 OIL PRESSURE SWITCH LT7C RIG LIGHT WTS11 WATER TEMPERATURE SWITCH LT8C RIG LIGHT SVC1 DRILLING SOLENOID LT9C RIG LIGHT SVC2 RIGING SOLENOID LT10C PANEL LIGHT SVC3 BRAKE SOLENOID LT7R OIL PRESSURE WARNING LIGHT SVC4 FUEL SOLENOID LT3A WATER TEMPERATURE WARNING LIGHT CR1 9 GLOW PLUG RELAY COIL AN1A REVERSING TRACK...

Page 278: ...272 ...

Page 279: ... BULB LT2R BRAKE LIGHT BULB LT3R SIDE LIGHT LIGHT BULB LT1C REVERSE LIGHT BULB LT2C NO PLATE LIGHT BULB LT3C NO PLATE LIGHT BULB LT4C REVERSE LIGHT BULB LT4R SIDE LIGHT LIGHT BULB LT5R BRAKE LIGHT BULB LT6R FOG LIGHT BULB LT2A INDICATOR LIGHT BULB A 17 09 2019 10 09 2019 SB DUKE TRAILER LIGHTS SCHEMATIC Document Type Company Confidential Checked Approved Date Drawn Date This drawing and any inform...

Page 280: ...274 ...

Page 281: ...R TRACK RIGHT FORWARD SVC8 CRAWLER TRACK RIGHT BACKWARD SVC9 SPEED CONTROLL SOLENOID A 17 09 2019 10 09 2019 SB DUKE TRACK RADIO REMOTE SCHEMATIC Document Type Company Confidential Checked Approved Date Drawn Date This drawing and any information or descriptive material set out on it are the confidential and copyright property of Dando Drilling International Ltd and MUST NOT BE DISCLOSED COPIED LO...

Page 282: ...276 ...

Page 283: ...HASSIS EARTH VARIABLE RESISTOR CONNECTOR MALE PE EARTHING SWITCH PRESSURE SWITCH CABLE CONNECTION E STOP LIGHT WITH INTERNAL SWITCH 2ND NORMALLY CLOSED CONTACT FLOAT LEVEL SWITCH NORMALLY CLOSED TACOMETER 2ND NORMALLY OPEN CONTACT GLOW PLUG STARTER MOTOR A 17 09 2019 10 09 2019 SB SCHEMATIC SYMBOL KEY Checked Approved Date Drawn Date Drawn by A3 Sheet Size Description Checked Approved by JOHN FARR...

Page 284: ...278 ...

Page 285: ...VANISED STEEL FLEXIBLE CONDUIT BLACK 16MM ST22017X224 PVC COATED GALVANISED STEEL FLEXIBLE CONDUIT BLACK 12MM ST11388X224 T PIECE CABLE CONDUIT FITTING NYLON 16MM CABLE FITTINGS 800100110 HEATSHRINK ADHESIVE LINED TUBING 19MM 800100111 HEATSHRINK ADHESIVE LINED TUBING 24MM 800100100 BOOTLACE FERRULE 1 5MM RED SINGLE CORE 800100101 BOOTLACE FERRULE 2 5MM BLUE SINGLE CORE 800100103 BOOTLACE FERRULE ...

Page 286: ...280 ...

Page 287: ...R C102C0085 HEAVY DUTY 3 PIN 12V METAL PLUG C100C0086 FUEL SENDER UNIT 800105102 TRAILER DUKE ELECTRONICS 800100270 13 PIN IN LINE FLYING SOCKET 12V 800100185 RADEX 6900 6 F CLUSTER RH 800100186 RADEX 6900 6 F CLUSTER LH 800100183 REVERSING ALARM HEAVY DUTY 12 48V 97dB 800100187 ASPOCK REGPOINT PLATE LAMP LARGE 800100184 WIRING HARNESS WITH 13 PIN PLUG 6M 800100272 CONNECTION LEAD 13 PIN TYPE WITH...

Page 288: ...282 ...

Page 289: ...rty of Dando Drilling International Ltd and MUST NOT BE DISCLOSED COPIED LOANED in whole or part or used for any purpose without the written permission of Dando Drilling International Ltd Drawn by A3 Sheet Size Description Checked Approved by JOHN FARROW 9 of 9 Legal Owner Drawing Number Revision Sheet SIGNATURE SCHEMATIC DRAWING A A B B C C D D E E F F 8 8 7 7 6 6 5 5 4 4 3 3 2 2 1 1 800105100 Da...

Page 290: ...284 ...

Page 291: ...APPENDIX A ENGINE PERKINS 403D 15 285 ...

Page 292: ...286 ...

Page 293: ...ge From a packaging point of view the 403 15 is the ideal engine for small industrial applications Its simple robust mechanical fuel system makes it easy to install and maintain A 1 5 litre IOPU offering you the advantages of an industrial engine with the convenience of a cost effective cooling and filtration solution Designed to meet EU Stage IIIA U S EPA Tier 4 Interim equivalent emission standa...

Page 294: ...As a 400 Series end user you also benefit from Perkins world class product support and service coverage that comes from being a full range power solutions provider Compact design The compact design of these engines makes them suitable for a range of applications including skid steer loaders mini excavators wheel loaders welders lift platforms lighting towers small tractors air compressors turf car...

Page 295: ...ant temperature switch Mounted radiator and fan Flywheel and flywheel housing SAE 4 flywheel housing SAE flywheel size 7 Fuel system Fuel injection pump Fuel filter General Cast iron engine block Glow plug starting aid Oil system Lubricating oil pressure switch Lubricating oil sump Spin on lubricating oil filter Page M 3 of M 4 Produced In England 2017 Perkins Engines Company Limited MSS IND 10000...

Page 296: ...d may not reflect final specification All information is substantially correct at time of printing and may be altered subsequently Final weights and dimensions will depend on completed specification 403D 15 Industrial Open Power Unit 18 4 25 1 kW 24 7 33 7 hp 2800 3000 rpm EU Stage IIIA U S EPA Tier 4 Interim equivalent SS 10435263 1000002617 005 SS Page 4 of 5 290 ...

Page 297: ...to 7 1 liters are based on ISO TR14396 inlet air standard conditions with a total barometric pressure of 100 kPa 29 5 in Hg with a vapor pressure of 1 kPa 0 295 in Hg and 25 C 77 F Performance is measured using fuel to specification EPA 2D 89 330 96 with a density of 0 845 0 850 kg L 15 C 59 F and fuel inlet temperature 40 C 104 F TSS 3096 00 PERIOPU PERIND 10435263 pdf Produced In England 2016 Pe...

Page 298: ...292 ...

Page 299: ... lb in relative humidity 30 0 Sound level Average sound pressure level for bare engine without inlet and exhaust at 1 metre 80 4 dB A General installation Caution The airflows shown in this table will provide acceptable cooling for an open power unit operating in ambient temperatures of up to 53 C 46 C if a canopy fitted If the power unit is to be enclosed totally a cooling test should be done to ...

Page 300: ...403D 15 IOPU Left side view 793 753 74 APPROX C OF G 179 APPROX C OF G 294 ...

Page 301: ...403D 15 IOPU Front view 296 457 208 354 295 ...

Page 302: ...403D 15 IOPU Right side view 55 40 90 TO END FW HSG 0 75 7 TO FLYWHEEL FLAT FACE 59 5 TO Ø241 SPOT FACE PILOT HOLE Ø206 2 296 ...

Page 303: ...403D 15 IOPU Rear view 255 6 234 5 250 241 7 274 24v OPTION 297 ...

Page 304: ...403D 15 IOPU Plan view 403D 15 IOPU Underneath view 324 310 156 349 7 Ø 1 3 Ø 1 3 103 5 211 1 298 ...

Page 305: ...f injection Pintle nozzle Fuel injection pump Cassette type Nozzle opening pressure 14 7 MPa 2 13 lb in Fuel lift pump flow hour 63 l hr 13 8 gal hr pressure 10 0 kPa lb in Maximum suction head 0 8 m using 6 mm Ø bore pipe Maximum pressure head 3 m using 6mm bore pipe Governor type Mechanical Fuel specification USA FED Off Highway Density 0 840 0 865 kg l 15 C Viscosity 2 0 3 2 mm s 40 C Sulphur c...

Page 306: ...28 68 lb in Max continuous oil temperature 125 C Max 135 C intermittent Recommended SAE viscosity A single or multi grade lubricating oil which conforms to API CG4 CH4 or ACEA E3 E5 must be used see illustration below Mountings Maximum bending moment at rear face of block TBA Nm lbf ft Viscostiy grade 50 40 30 20 10 0 10 20 30 40 50 60 0W 20 0W 30 0W 40 5W 30 5W 40 10W 30 10W 40 15W 40 Ambient Tem...

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Page 308: ...ng explains the hazard and can be either written or pictorially presented Operations that may cause product damage are identified by NOTICE labels on the product and in this publication Perkins cannot anticipate every possible circumstance that might involve a potential hazard The warnings in this publication and on the product are therefore not all inclusive If a tool procedure work method or ope...

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