Geax EK75CFAJ160 Operation And Safety Manual Download

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OPERATION AND SAFETY

MANUAL

Rev.01/17

GEAX

s.r.l.

EK75CFA

J160

Summary of Contents for EK75CFAJ160

Page 1: ...OPERATION AND SAFETY MANUAL Rev 01 17 GEAX s r l EK75CFAJ160...

Page 2: ...Serial number 160J075E GEAX s r l via Campoceraso 13 60027 Osimo AN ITALY Tel 39 0717131953 Fax 39 071715199 www geax it info geax it...

Page 3: ...ions Before using the EK751 drilling rig for the first time new operators must read this OPERATION AND SAFETY MANUAL completely Once they are sure they have understood it they can proceed to use the r...

Page 4: ...o loose flaps that might hamper the operation of controls or get caught on edges or rotating shafts Gloves are necessary to protect the hands from cuts and abrasions that can be produced when gripping...

Page 5: ...ts that become hot during operation Situation procedure context or other factor that can lead to increased risk of intoxication or poisoning by harmful substances Situation procedure context or other...

Page 6: ...Hook the tip to the rope of the secondary winch Command a slight tensioning of the rope Loosen the recessed safety bolt and slip the pin off Lift the rotary so that the joint slips off and the tip re...

Page 7: ...uger fig 2 1 1 2 Rest the tool on the ground moving the rotary to the intermediate position Lean the ladder against the mast When a second operator at the base guarantees the stability of the ladder b...

Page 8: ...GEAX s r l Chapter 2 TRANSPORTING THE DRILLING RIG 3 fig 2 1 1 1 fig 2 1 1 2 2 1 2 Disassembly of mast support extension Before folding the mast the support extension must be disassembled...

Page 9: ...the pin V1 on the rotary guide to block downward sliding fig 2 1 3 2 3 Deactivate the down limit switch of winch 1 4 Lower the rotary until it rests on the pin V1 5 Further loosen the rope 30 cm to av...

Page 10: ...t fig 2 1 2 3 fig 2 1 3 3 10 Make sure no one is in the trajectory of the folding mast fig 2 1 3 4 11 Act on the selector D3 to fold the mast fig 2 1 3 4 12 Insert the bolt A to block movement of the...

Page 11: ...to open the mast If the mast has difficulty moving the operator can intervene to detach it making sure his body remains outside of the trajectory of the mast fig 2 2 2 1 fig 2 2 1 1 Make sure the rop...

Page 12: ...t the ground Act on the joystick D1 to achieve the perfect upright position of the mast Re activate all limit switches 2 2 2 Assembling tool The auger tool in two parts the tip can only be assembled w...

Page 13: ...the joint 9 Insert the pin and secure the safety bolt 10 Climb down the ladder and remove it Proceed as follows to assemble the central part of the auger fig 2 1 1 1 Position the rotary at the up lim...

Page 14: ...n 4 Lower the rotary tool so that the parts of the joint meet 5 Insert the pin and secure the safety bolt 6 Unhook the rope of the winch In the work configuration the winch 2 rope must be hooked to th...

Page 15: ...or overhead cables inside the drilling rig s manoeuvring space paying special attention if the mast must be positioned vertically fig 2 4 1 2 2 3 2 Loading and unloading When loading or unloading the...

Page 16: ...g 2 3 2 2 Figures 2 3 2 2 and 2 3 2 11 show the approximate point where the rig changes inclination when passing from the ramp to the deck or vice versa In this stage the rig should travel at its lowe...

Page 17: ...GEAX s r l Chapter 2 TRANSPORTING THE DRILLING RIG 1 2 fig 2 3 2 4 fig 2 3 2 5 fig 2 3 2 6...

Page 18: ...GEAX s r l Chapter 2 TRANSPORTING THE DRILLING RIG 1 3 Figures 2 2 2 7 8 9 10 11 show the unloading operation sequence fig 2 3 2 7 fig 2 3 2 8 fig 2 3 2 9...

Page 19: ...the ground at the same time In case of contact with power lines do not touch the vehicles involved especially the trailer as it has rubber tires If the cable remains in contact with the rig the operat...

Page 20: ...ng rig must be arranged in the configuration shown in figure 2 4 1 1 or with the mast facing backwards The front part of the mast should rest on the deck of the semitrailer in order to minimise the lo...

Page 21: ...s 2 4 3 Road transport The truck and trailer must be adequately sized to carry the drilling rig both in terms of dimensions and load capacity Make sure the rig is arranged compatibly with the maximum...

Page 22: ...e selector D2 until reaching the position used to fold it fig 2 1 2 3 4 Hook the rope of the winch 2 with the eyebolt at the top of the manifold connected to the shaft by means of the rotary joint 5 B...

Page 23: ...DRILLING RIG 1 8 fig 2 5 2 1 Fold the mast forwards by acting alternately on the lever D1 and selector D2 fig 2 5 2 2 An operator must be at the end of the support ready to sustain the weight 40 kg t...

Page 24: ...rwards by acting alternately on the lever D1 and selector D2 fig 2 5 2 2 Lift the support rod from the side of the bolts and insert the first one Lift the other end of the support rod 40 kg until the...

Page 25: ...the shaft so that the sliding guide can be inserted onto the support rod 6 Turn the shaft so that it blocks on the inserts of the rotary detail of fig 2 5 4 1 7 Move the winch 2 down to insert the sha...

Page 26: ...or lateral gradients which vary according to the rig s configuration within the limits described below The tool should be held at 20 30cm from the ground but not so low as to risk scraping on uneven g...

Page 27: ...direction of travel facing forward fig 3 1 1 1 Maximum upward slope 6 10 gradient with mast held vertically and cab aligned with the direction of travel facing forward fig 3 1 1 2 Climb the slope alo...

Page 28: ...t with mast lowered and cab aligned with the direction of travel facing backwards in reverse fig 3 1 1 3 fig 3 1 1 3 Climb the slope 30 gradient along the line of maximum gradient This prevents the la...

Page 29: ...ith the direction of travel facing either way fig 3 1 1 4 fig 3 1 1 4 Drive the rig at a low steady speed The recommended gradient limits must never be exceeded If the rig is subjected to rapid change...

Page 30: ...rig and inspect the path from a better viewpoint Maximum lateral slope 9 15 gradient with mast lowered as in fig 3 1 1 3 and cab aligned with the direction of travel facing either way fig 3 1 1 5 fig...

Page 31: ...gradient with mast held vertically cab turned sideways to the direction of travel and unstable centre of gravity fig 3 1 1 6 fig 3 1 1 6 Drive the rig at a low steady speed The recommended gradient li...

Page 32: ...d vertically cab turned sideways to the direction of travel and stable centre of gravity fig 3 1 1 7 Along the way maximum slope could rise up to 10 18 gradient on the sole condition that turret rotat...

Page 33: ...rrow or low passages overhead cables or any other obstacles that might interfere with the moving rig The speed of travel depends on the terrain s roughness and gradients slow down to minimum speed whe...

Page 34: ...its waiting place which should be visible from the rig s cab 3 3 2 Borehole drilling hazards Consult the jobsite supervisor or chief of operations to make sure that no underground distribution networ...

Page 35: ...d object is a power cable pull the tool out of the hole to eliminate the contact While the contact lasts the cab operator should not get off the rig and the ground operator should not touch it If it i...

Page 36: ...ed depth is reached it must be made safe by setting up barriers preventing access to the hole Placing the reinforcement cage inside the hole increases safety by contrasting the collapse of the hole s...

Page 37: ...r the operator at the controls like an automobile The risks for the ground operator are generally greater especially during operations involving the auxiliary winch Blasts of air caused by lightning s...

Page 38: ...dust When ambient darkness is such as to increase the risk factors work with the rig must be halted The electric spotlights installed on the drilling rig should be used to improve visibility in the w...

Page 39: ...both winches In particular before bringing the mast to its vertical position check the location of the ropes their proper placement within the throats of the pulleys and fasten the hook on the auxili...

Page 40: ...alies may be wiped away if the rig is washed down after a work shift see Par 4 1 2 4 2 Anomalies 4 2 1 Anomalies during operation Should you detect any anomaly during the rig s operation trace its ori...

Page 41: ...and disables the controls when turned vertically except for the mast alignment controls which remain enabled the mast alignment functions have their own safety control which is located on the panel o...

Page 42: ...rotary head or of the auxiliary which left right controls rotary head rotation L Undercarriage translation controls look at Hitachi manual P1 Button Controls the acoustic alarm P2 Button It increases...

Page 43: ...Rotating control Opening and closing upper mast extension not active in Kelly configuration D4 Selector Allows selecting various rotary head speeds D5 Selector Allows locking the crawler during drill...

Page 44: ...the left will enable the mast alignment controls D1 D2 and the automatic mast alignment Turning selector D5 to the position shown will enable the undercarriage controls L and turn on the acoustic alar...

Page 45: ...1 5 Mast opening controls Turn knob D3 anticlockwise to fold the mast laterally for transport position This operation must be done only when the mast is in a horizontal position Turn knob D3 clockwis...

Page 46: ...d on the operator s left side regardless of the position of lever E Movements produced by D1 can be automatically activated until reaching full vertical position by pressing buttons P6 or button Pr on...

Page 47: ...ol the automatic mast vertical extension procedure The system activates both axes as does control D1 Warning light S2 flashes throughout the procedure and remains steady once the alignment is complete...

Page 48: ...ted on the right and is labelled D2 the control is enabled only by pressing simultaneously safety button C1 on panel C located on the operator s left hand side regardless of the position of lever E Tu...

Page 49: ...attention to the position of F1 mast movement selected Push joystick B forward to lower the mast Pay attention to the position of F1 mast movement selected Push joystick B backward to lift the mast Pa...

Page 50: ...daNm 2 V2 medium speed reduced automatically by increasing the torque 3 V3 high speed reduced automatically by increasing the torque Move joystick B to the left towards the seat to make the rotary hea...

Page 51: ...ading the tool In CFA mode do not use to download the auger 5 1 10 Main winch and turret controls The main winch and turret controls are grouped together on joystick A located on the left hand side an...

Page 52: ...oating of the main winch this way the tool lowers at the set speed The button works only when enabled with selector F1 Move joystick A to the right towards the seat to make the turret turn clockwise M...

Page 53: ...is possible to lift the mast pushing joystick B backward leaving the tool at the bottom of the bore to start the pull down Selector F1 in left position enables mast movement Maintaining selector F2 ro...

Page 54: ...tton P2 on joystick B sets the system to a higher speed when lowering and raising the auxiliary winch Pay attention to the position of D7 a beep is activated when the winch is selected Push joystick B...

Page 55: ...level a if the tool protrudes inferiorly from the mast of a distance s start to drill slowly lowering the mast while the tool is penetrating into the soil b if the tool doesn t protrude from the mast...

Page 56: ...buckets the use of a single pump simplifies some rotary head rotation simultaneous controls e g mast lifting and rotation in CFA mode is recommended to work with only one pump Rotate selector D6 to ch...

Page 57: ...s turned off in normal operation limit switches enabled see par 5 1 14 5 2 Emergency stop button 5 2 1 Using the emergency stop button There are two emergency buttons one installed on the front of the...

Page 58: ...in the allowable limits move lever D1 left or right to compensate the inclination When the mast is within 5 of vertical it can be set to vertical by means of the automatic system The automatic vertica...

Page 59: ...vice and interrupt the work session If the rotary does not stop automatically exceeding the end of travel damages the rope and pulley 6 2 2 Testing the auxiliary winch 2 up limit switch At the start o...

Page 60: ...ecur to the procedure in paragraph 6 3 2 using the rotary mast block 6 Turn selector F1 to the winch 1 floating position 7 Command clockwise rotation of the rotary joystick B to the left and step on t...

Page 61: ...ides fig 6 3 1 3 which discharges the weight of the rotary onto the tool fig 6 3 1 3 10 The rotary starts to turn once again joystick B to the left pressing the P5 button to ensure floating 11 Drillin...

Page 62: ...om the ground in this phase the rotary is lowered the tool remains still due to friction with the ground to be hooked to the base of the extension rod inverse operation than point 9 when the rod is ho...

Page 63: ...en moving the joystick forwards move the mast slowly downwards when moving down the rotary is blocked with the mast and its thrust has a repercussion on the tool fig 6 3 2 3 It must move slowly to kee...

Page 64: ...not rotate and the operator must use a suitable tool e g shovel 6 4 Operation of auxiliary winch 6 4 1 Operation and limitations of use of auxiliary winch In order to use the winch you must first unlo...

Page 65: ...hen lowering a reinforcement cage inside the borehole to increase its downward speed and get past narrowings where the cage might get stuck Perform this operation with caution and only when at least 1...

Page 66: ...move the mast to increase the lifting capacity of the winch 2 Once you have finished using the winch lock the pedal flipping the lever on the side before you do anything else For further information...

Page 67: ...provided with a check valve of the suction hose fig 7 1 1 1 inside the can and make sure it is well immersed in the fuel Switch on the electric pump Fig 7 1 1 2 and leave it on until the fuel indicato...

Page 68: ...en which is a highly explosive gas 7 1 3 Checking other fluids Checking or topping up other fluids e g lubricating oil hydraulic oil should be done when the rig is cold before the start of a work shif...

Page 69: ...ses In case of overheated solid parts the thickness of the protections used would make it difficult or unsafe to perform servicing 7 2 2 Cooling circuit The cooling circuit is pressurized Never loosen...

Page 70: ...s see Manual No 2 7 3 2 Leaks in hydraulic circuits If you discover a leak from a hydraulic circuit or device stop the rig in a stable configuration if possible and request maintenance Continuing to u...

Page 71: ...ents Keep the footboards clean from mud or earth in order to ensure a good grip between the shoes and the metal Clean you shoes before entering the cab Mud and earth can obstruct the proper operation...

Page 72: ...s possible so that they may alert each other even by gestures of any dangerous situation that might arise 7 7 Additional information on using the auxiliary winch 7 7 1 General considerations The auxil...

Page 73: ...novative articulation of the mast that allows a wide range of operative positioning The mast is supported by a long articulated boom which connects it to a tracked crawler This architecture allows gre...

Page 74: ...3 DaN Auxiliary winch Max pull 3700 DaN Mass without accessories 24000 kg Tracked crawler JCB JS160 NLC Diesel engine power 93 kW 8 3 2 Noise levels LwA Acoustic power level of airborne noise 102 dB A...

Page 75: ...ng order Symbol Dimension mm Note A 19600 Max height in working conditions E 5000 Extension kelly stroke Ip 2740 Tail swing Ra 2300 3800 Front radius fifth wheel axis bucket axis B 11000 Rotary stroke...

Page 76: ...Lt 10500 Length C 3100 Cab height including safety guards Resting point of mast bottom on loading deck inside crawler tracks perimeter fig 8 4 2 1 Dimensions At and Lt are subject to considerable var...

Page 77: ...during positioning manoeuvres fig 8 4 3 1 The unbroken red line shows the maximum reach of the top of the rig during the positioning manoeuvres The dashed line shows the positions that must not be ass...

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