KLEMM KR 806-2 Technical Manual Download | Manualshive

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56

07/2004

KR 806 - 2 / Serial No. 64004

Changing filter insert of return - line filter KR 806 - 2

Pic. 1 - 7:

Changing hydr. filter insert

Pic. 8 - 11:

Changing ventilation filter insert

ATTENTION:
The cage must
be reused!

Filter insert

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Summary of Contents for KR 806-2

Page 1: ...HNICAL MANUAL Description Maintenance Operation for Zweigniederlassung der Bauer Maschinen GmbH Germany tel 49 0 2761 705 0 fax 49 0 2761 705 49 49 0 2761 705 50 All hydraulic crawler drill rig KR 806...

Page 2: ...and data subject to modifications In case of doubt the German text shall prevail COPYRIGHT REGULATIONS Layout and content of this manual is subject of international copyright re gulations Klemm Bohrt...

Page 3: ...stung kW Durch Weiterentwicklung bedingte Konstruktion nderungen behalten wir uns vor When making enquiries or orde ring spares please specify the fol lowing data to ensure prompt and reliable deliver...

Page 4: ...x KR 806 2 24 4 2 2 Engine control system KR 806 2 28 4 2 3 Electronic engine regulator ECM 29 4 2 4 Engine start up 30 4 2 5 Starting procedure of an KR 806 2 in cold ambient temperature conditions 3...

Page 5: ...ATAAC 64 6 4 Hydraulics 65 6 4 1 Hydraulic oil 65 6 4 2 Filtration 65 6 4 3 Oil Changes 66 6 4 4 Repairs 67 6 5 Service Intervals 67 6 6 Special Remarks Welding Instructions 68 6 7 Battery 69 6 7 1 Co...

Page 6: ...KR 806 2 for loading with the help of a crane 80 9 Bridge with rigging max 20t for loading the drill rig KR 806 2 81 10 Technical Data KR 806 2 82 10 1 Technical data of sound level measurement acc t...

Page 7: ...ly in unusual conditions Since these safety precautions cannot cover every possible situation everyone is expected to exercise good judgement foresight and common sense while operating or working with...

Page 8: ...ment must first read and thouroughly understand the operating instructions Operating instructions Operating instructions for the KLEMM Bohrtechnik drill rig must be complied with for operation mainten...

Page 9: ...within the danger zone In case of danger the operator must give warning signals Warning signals are generally given with horns Pre determined hand warning signals must be used if on site noise is lia...

Page 10: ...dures to allow for special site conditions 8 Special instruction to stability with mounted drill mast 7000mm lenght If the drill rig is equipped with a drill mast of 7000mm length or longer the mounti...

Page 11: ...inform the site manager if a utility line or its protective cover should be found or damaged Uncovered utility lines must be secured against swaying or slipping 12 Working near overhead electrical lin...

Page 12: ...atform when tramming 16 Before tramming the drill rig the drill mast must be placed on the drill mast support in horizontal transport position 17 The operating device must be activated only from the c...

Page 13: ...draulic plant must be checked regularly Replacement hoses or hydraulic components must be ORIGINAL spare parts of KLEMM Bohrtechnik This requirement must be complied with for safety reasons and applie...

Page 14: ...e stored tension free in a dry and clean environment Direct sunlight and UV irradiation must be avoided Storage time should not exceed four years 3 Operating hydraulic lines a After 6 years operation...

Page 15: ...ses The drill rig s main power source is an fluid cooled 6 cylinder diesel engine An open centre 3 circuit system with max operating pressures of 4060 psi supplies hydraulic power for all tram ming al...

Page 16: ...evers on the top back side of the rig Activation of these swit ches stops all of the rig s functions immediately The EMERGENCY switches are com posed of a red button with electrical shut off of the di...

Page 17: ...scillating crawler tracks carries power pack tanks hy draulic fluid and diesel as well as con trol and monitoring elements The boom assembly consisting of sle wing column swivel mechanism and mast car...

Page 18: ...oling of the hydraulic fluid is required to maintain the right operational tempe rature and retain optimum viscosity This is assured by a hydraulic oil coo ling device consisting of the cooler with hy...

Page 19: ...a set up and alignment under difficult circumstances e g in corners of buildings or structure The swivel head is mounted with bolt bearings on the upper end of the boom A hydraulic cylinder is used to...

Page 20: ...g parts of the drill mast When drilling mast has to be pressed and fixed to ground or to the wall in or der to prevent mast from damages Safety Instructions for preparing to install or remove the feed...

Page 21: ...or mechanical deformations must be replaced Roller chains have to be checked weekly for elongation The permitted elongation should not exeed 2 The elongation test is realised on a grease free and clea...

Page 22: ...w no kinks or are jammed Absolutely ckeck before the START a Ball valve in pump suction line opened b All control levers in neutral O position c Hydraulic fittings tight d Oil level adequate Engine tr...

Page 23: ...and monitoring elements for the main drive diesel engine and the ope rating selector switch are located at the sound proof cover of the drill rig see chapter 4 2 1 Control elements for tramming func t...

Page 24: ...ons and diagnostic oppotunities on the display of the engine control box Normal Indication first line diesel engine rpm second line coolant temperature if overheated a warning is indicated behind the...

Page 25: ...1 is indicated In position inching the input is 0 Input 2 inching reset ESS If the button inching reset is pressed 1 is indicated If this button is not activated the input is 0 Input 3 ESS drill mast...

Page 26: ...lve ESS If the conditions of the ESS limit switch activating are fulfilled the output for the solenoid valve will be set 1 and the hydr pilot control is activated If one of these conditions is not ful...

Page 27: ...ent error messages can be indicated This error messages can not be recieped After error correction and a new start of the diesel engine the messages are distinguished The following errors can be indic...

Page 28: ...an 111 C the power of the diesel engine will be reduced up to 70 by the ECM system If temperature of cooling fluid is 118 C switching off diesel engine To low oil pressure If oil pressure is 200kPa 2b...

Page 29: ...cover see pic 2 1 2 3 pic 1 pic 2 Engine control distribution Electronic engine regulator ECM Detected failures of the electronics are indicated in the ECM and by a control lamp and specified in the...

Page 30: ...g attempts d Return accelerator potentio meter to idling speed as soon as the engine is running smoothly Trouble shoot by referring to the engine manual Attention Always ensure that the engine and sta...

Page 31: ...ion combined with common sense must be the primary consideration at all times START UP with diesel engine 1 Check filling level of hydraulic oil tank on level indicator as required 2 All consumers at...

Page 32: ...influence Furthermore inclinations of the planed subgrades are considered Simplified we can say The closer the point of gravity comes to the center of the above explained rectangel the better is the...

Page 33: ...ibited to activate the release switch of the oscillating automatic The following sketch showes the starting position in the lower section and the according rig position in the upper section The stand...

Page 34: ...AMMING SETTING UP AND DRILLING OPERATIONS 1 3 2 Symbols Do not apply levers fully to begin with but activate as if accelerating a car Le ver position determines the degree of opening of the control va...

Page 35: ...n to use free fall winches to avoid sliding down or rollover of the machine on slopes The winch must be equipped with a safety brake system The cable connector point must be designed and tested for dy...

Page 36: ...or backward from the centre setting Push or pull the levers to activate the corresponding hydraulic cylinders All cylinders are fitted with load bearing valves locking the cylinder in position even wh...

Page 37: ...tilt swivel head I forward Pull tilt swivel head I backwards 7 Push swivel head to the left around its axle Pull swivel head to the right around its axle 8 9 Push drill mast displacement to the front...

Page 38: ...lly adjustable hydraulic pressure regulator for feed pressure 11 Push close clamp Pull open clamp Push Pull rotate breaking clamp Push close breaking clamp Pull open breaking clamp 13 14 12 10 11 12 1...

Page 39: ...nly for double head unit operation 16 Manually adjustable pressure regulator for drifter percussions only for hydr drifter operation 17 Press 19 manually adjustable drifter percussions frequency only...

Page 40: ...itional drill string rotation l h and r h rotation Pull waterpump on off 23 26 Manual Valve RPM regulation for drill string right increasing RPM left reducing RPM for double head unit operation RPM re...

Page 41: ...r flow left side of the machine Hold back device feed fast feed mounted on the lifting arm of the control panel DRUCKWAAGE press maintaining valve ATTENTION After every adjustment of the drill mast yo...

Page 42: ...Serial No 64004 4 2 11 ESS control box on slewable control panel 1 RPM regulation for diesel engine 2 Horn 3 Start button 4 Feed gear switching normal fast 5 EMERGENCY switch off Functions on the elec...

Page 43: ...d to protect the percussion unit of the hydr drifter In the double head operation mode the right element of the control block is used for the funktion inner rotation clockwise anticlockwise To avoid h...

Page 44: ...um thus protecting the drive components of drilling equipment Important Klemm Bohrtechnik declines all claims if DHD is used without shock absorber in combination with hydr hammer 5 Drilling with DHD...

Page 45: ...45 07 2004 KR 806 2 Serial No 64004 DHD drill rod shock absorber hydr hammer flushing head Exemplary setup of a DHD system on drill rigs...

Page 46: ...ure to align the drill mast horizontally resting on the mast support bracket The drill head unit must be positioned between mast carrier and mast support bracket 6 Never attempt to turn the drill rig...

Page 47: ...for the right drilling method single rotary head single drifter double head with two rotary mechanism double head with 1 rotary and one rotary percussion drifter double rotation both heads same direc...

Page 48: ...der 3 until the track chain tension is right e To decrease track tension exhaust grease by loosening the Tensioning Cylinder 3 Grease Fitting 1 PLEASE NOTE Do not remove the Grease Fitting And do unde...

Page 49: ...e grease of this tensioning cylinder it is required to remove the special adapter nipple for grease release When the chain is slackening without tension the adapter nipple must be closed Chain repairs...

Page 50: ...Machinery and to augment availability Machine down time on site always entails additional costs and loss of precious time High availability of machinery and the reduction of down time requires a well...

Page 51: ...the operational safety of equipment Specialist experts are persons who on the basis of their qualification experience and competence have the special knowledge to assess the operational safety of the...

Page 52: ...oil VG 46 field of use for outer temperatures from 15 C up to 40 C Original Klemm oil filling mineral hydr oil HLP 68 VG 68 VG viscosity class 500 Feed gear Option BP ENERGOL GR HP 150 ESSO SPARTAN E...

Page 53: ...For short running times warm up phase of diesel engine the permissible viscosity range is 1000mm2 s The permitted operating viscosity range for the hydraulic components should be between 10mm2 s und 3...

Page 54: ...fferent types of oil from the same manufacturer are mixed it can lead to silting and sedimentations These facts can create malfunctions and damages of the hydr system Caution Mineral oils and syntheti...

Page 55: ...e filter mesh size 10 micron Part no filter cpl 1 piece 401466 Part no filter insert 1 piece 401473 Part no dirt indicator 1 piece 402439 The return line filter insert is mounted on the hydr oil tank...

Page 56: ...4 KR 806 2 Serial No 64004 Changing filter insert of return line filter KR 806 2 Pic 1 7 Changing hydr filter insert Pic 8 11 Changing ventilation filter insert ATTENTION The cage must be reused Filte...

Page 57: ...ilter change of the element must be done after 50 working hours The same procedure has to be carried out all further 250 working hours or sooner in case the dirt indicator needle moves up After the fi...

Page 58: ...Serial No 64004 Diesel engine filter for Caterpillar 3056 EATAAC Engine oil filter Part no oil filter 2 pieces 400090 The engine oil filter see photo must be changed every 250 hours or all three mont...

Page 59: ...e rear engine cover door The fuel filter must be changed every 250 hours Fuel filter Filter water separator Part no elemnt filter water separator 1 piece 400761 The filter water separator is located o...

Page 60: ...filter elements must be changed every 250 working hours ATTENTION Never run the diesel engine without properly mounted air filter because the motor will be damaged by abrasive airborne particles Outer...

Page 61: ...t catalogue First Service after 100 hours The following steps have to be followed up engine oil and oil filter to be changed change of hydr filters check all bolt connections and fittings retighten if...

Page 62: ...anufacturers Manual Check V belt tension Manufacturers Manual Check valve clearance 1st after 20 h Replace Diesel filter cartridge 2 Hydraulic oil tank Check oil level Check for leaks Check oil temper...

Page 63: ...Feed Chain tension Check Bearings and Bushings Check wear of rod centralizer approximate max clearance with respect to rod centralizer rod diameter 4mm 9 Glide slide Check wear of guiding strips max...

Page 64: ...0 60 23 9 4 F 50 50 37 34 6 F 60 40 51 59 8 F The cooling medium capacity of the Caterpillar diesel engine 3056 EATAAC is 15 1 Liter Do always use the a m mixture of water and fluid when adding missin...

Page 65: ...detales see Recommanded Oils and Lubricants page 52 Old oil or oils having been subjected to temperatures in excess of 70 C lose important operating characteristics and reduce the service life of seal...

Page 66: ...The formation of foam can be chek ked through the inspection glass PLEASE NOTE Park the drill rig on an incline Let the fluid settle and cool down Drain the oil water mixture and dispose of in accord...

Page 67: ...cumulator effect 6 5 Service Intervals To ensure the reliability of the drill rig maintenance and service intervals must be adhered to The specified intervals are adequate for machines being subjected...

Page 68: ...Welding operations at the drill rig are forbidden Necessary welding operations may only be done by specially trained personnel of Klemm Bohrtechnik ATTENTION The battery disconnecting switch must be...

Page 69: ...to start your engine warming up indoors or in a water filled container to approx 20 C may be helpful If the charge level is insufficient a Use second unit and jump leads b Check battery and recharge...

Page 70: ...Introduction and precaution instructions Klemm accumulators are in accordance the european regulation 97 23 EG Pres sure Equipment Directive article 3 chapter 3 If an accumulater will be detached and...

Page 71: ...ulator the nitrogen has to be released take off the cap plug unscrew inlet screw carefully for approx 1 1 5 revolutions until nitrogen escapes hiss effect Don t take off the inlet screw completely unt...

Page 72: ...eals and screws have only beused in accordance to the Klemm parts lists and shall be bought from Klemm only 6 8 4 Putting into operation All persons who doing repair or maintenance works at the accumu...

Page 73: ...be carried out by qualified personnel only If hydraulic oil is detected in the gas chamber of the accumulator during in spection or repairs the diaphragm is damaged and must be replaced imme diately P...

Page 74: ...air or replace tubes or hoses Fluid freezing Fluid level in tank too low Wrong hydraulic fluid Fittings in suction line take air in Porous suction line Replenish to right level Replace with correct fl...

Page 75: ...ow or insufficient engine capacity Coupling faulty or Engine damaged Repair defect Leakage from pressure port to return line Wrong pressure settings Safety valve does not close Dirt or wear particles...

Page 76: ...em not properly ventilated Bleed system See also Start up in structions d Temperature of fluid too high Cause Reason Remedy Hydraulic fluid is pumped under pres sure through pressure limiting or safet...

Page 77: ...which are secured against inexpert regulation An adjustment of the system pressure during the guarantee is only allowed with explicity permission of the KLEMM Bohrtechnik Non compliance leads to imme...

Page 78: ...the same solvents chemicals mentioned above Caution 1 Make sure that shaft seals never get into contact with aggressive solvent chemicals 2 Make sure when removing corrosion inhibitors with solvents...

Page 79: ...79 07 2004 KR 806 2 Serial No 64004 7 Attachment points for truck transport A D Attachment points to lash the drill rig for truck transport A B D C...

Page 80: ...4 8 Rope attachment points A D on the drill rig type KR 806 2 for loading with the help of a crane ATTENTION Loading the drill rig with the help of a crane is only allowed after consultation with comp...

Page 81: ...max 20t for loading the drill rig KR 806 2 For loading KLEMM drill rigs with drill mast in transport position with help of a crane you have to use a bridge with two riggings see sketch rigging spare p...

Page 82: ...Hydraulic system Hydraulic pumps 1 x 290 l min load sensing 1 x 35 l min constant 1 x 12 l min constant System pressure max 280 bar Hydr tank capacity approx 500 l Fuel tank capacity 340 l Electrics...

Page 83: ...with loading full throttle of engine 113 dB with running drill head unit rotating 113 dB with running drill head unit rotating percussion 135 dB A registered sound pressure level LPA in different oper...

Page 84: ...ast movements KR 806 2 Kinematic possible mast movements KR 806 2 basic version Kinematic possible mast movements KR 806 2 basic version For special and additional equipment differences must be discus...

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