Operation Manual of TR150D Rotary Drilling Rig

Operation Manual of TR150D Rotary
Drilling Rig
Beijing CSR Times Locomotive & Rolling Stock Machines Co., Ltd.
2012.3.15
Beijing CSR Times Locomotive & Rolling Stock Machines Co., Ltd. 1
Beijing CSR Times Locomotive & Rolling Stock Machines Co.,
Ltd., invested by CSR CORPORATION LTD & CSR ZHUZHOU
INSTITUTE CO., LTD is a modern heavy industry equipment
manufacturing enterprise and aims to provide technical equipment for the
national economic construction (such as railway, urban construction,
transportation, etc.) as well as research & manufacturing for the practical
technical engineering and construction machinery.
The company has developed a series of products for China's railway
construction and engineering construction. TR150D rotary drilling rig is
desgined and manufactured based on the integration of the advantages of
domestic and overseas drilling rigs, with the main performance
parameters having reached the international level of similar products, the
application of CAT and Rexroth products in key components and import
rubber hoses as oil tubes.
TR150D rotary drilling rig is fitted with advanced intelligent
electronic control system and load-sensing pilot control hydraulic system
to achieve safe and reliable machine operation as well as safe,
comfortable and highly-personalized human-computer interface.
Contents
Part I Operation Manual for Rotary Drilling Rig ................................................................................................... 8
Profile ..................................................................................................................................................................... 9
Chapter I General.......................................................................................................................................... 11
1.1 Application Scope of Drilling Rig ................................................................................................ 11
1.2 Technical Specification ................................................................................................................. 11
Chapter II Introduction of Structure and Functions ....................................................................................... 13
2.1 Structure of Rotary Drilling Rig ................................................................................................... 13
2.1.1 Over dimensions ................................................................................................................... 13
2.1.2 Introduction of drilling rig structure and functions............................................................... 14
2.2 Function Description .................................................................................................................... 17
2.2.1 Cab layout ............................................................................................................................. 17
2.2.2 Hydraulic system pilot control switch .................................................................................. 18
2.2.3 Pressure gauge ...................................................................................................................... 18
2.2.4 Mast leveling lever ............................................................................................................... 18
2.2.5 Traveling operating lever (pedal).......................................................................................... 19
2.2.6 Display screen ....................................................................................................................... 19
2.2.7 Engine monitoring panel....................................................................................................... 34
2.2.8 Working hourmeter ............................................................................................................... 70
2.2.9 Left and right operating levers .............................................................................................. 70
2.2.10 Limit switches ....................................................................................................................... 72
2.2.11 Warning device ..................................................................................................................... 74
2.2.12 A/C System ........................................................................................................................... 74
2.2.13 Operation description of radio .............................................................................................. 75
Chapter III Basic Operations of Drilling Rig .................................................................................................. 77
3.1 Before start of engine.................................................................................................................... 77
3.2 Start of engine ......................................................................................................................................... 77
3.3 Stop of Engine .............................................................................................................................. 79
3.4 Checking after Stop of Engine ...................................................................................................... 81
3.5 Operations of Drilling Rig ............................................................................................................ 81
3.5.1 Traveling of drilling rig ........................................................................................................ 81
3.5.2 Swing of superstructure ........................................................................................................ 88
3.5.3 Erection/lowering and verticality adjustment of mast .......................................................... 89
3.5.4 Lifting and lowering of luffing ............................................................................................. 91
3.5.5 Operations of main and auxiliary winches............................................................................ 92
3.5.6 Operations of pressing cylinder ............................................................................................ 94
3.5.7 Control of power unit............................................................................................................ 94
3.5.8 Depth measuring device........................................................................................................ 95
3.5.9 Extension of tracks ............................................................................................................... 95
Chapter IV Construction of Drilling Rig ......................................................................................................... 97
4.1 Construction preparations ............................................................................................................. 97
4.2 Positioning of drilling rig.............................................................................................................. 99
4.2.1 Measurement and setting-out ................................................................................................ 99
4.2.2 Positioning of drilling rig...................................................................................................... 99
4.2.3 Embedment of pile casing: ................................................................................................. 100
4.2.4 Positioning of pile hole ....................................................................................................... 102
4.3 Construction of drilling rig ......................................................................................................... 102
4.3.1 Collaring ............................................................................................................................. 102
4.3.2 Drilling................................................................................................................................ 103
Chapter V Disassembly and Installation of Drilling Rig.............................................................................. 106
5.1 Installation and disassembly requirements ................................................................................. 106
5.1.1 Safety .................................................................................................................................. 106
5.1.2 General precautions ............................................................................................................ 106
5.1.3 Precautions for installation and disassembly ...................................................................... 107
5.2 Installation of drilling rig ............................................................................................................ 108
5.3 Disassembly of drilling rig ......................................................................................................... 113
Chapter VI Transport of Drilling Rig ............................................................................................................ 118
6.1 Transport parameters .................................................................................................................. 118
6.2 Transport requirements ............................................................................................................... 118
6.3 Loading to or unloading from trailer .......................................................................................... 119
6.4 Marine transport requirements .................................................................................................... 120
6.4.1 Choice and basic usage of protective materials .................................................................. 120
6.4.2 Hoisting of machine ............................................................................................................ 121
Chapter VII kelly bar and drilling tool ........................................................................................................... 123
7.1 Types and choice of kelly bar ..................................................................................................... 123
7.1.1 Types of kelly bar ............................................................................................................... 123
7.1.2 Choice of kelly bar.............................................................................................................. 123
7.2 Use of kelly bar........................................................................................................................... 124
7.2.1 Use of friction kelly bar ...................................................................................................... 124
7.2.2 Use of interlock kelly bar.................................................................................................... 125
7.3 Structural types of drilling tool ................................................................................................... 128
7.4 Connection types between drilling tools and kelly bar ............................................................... 128
7.5 Choice of drilling tool ................................................................................................................. 128
Part II Maintenance Manual for Rotary Drilling Rig..................................................................................... 130
Profile ................................................................................................................................................................. 131
Chapter I Maintenance Safety Instruction .................................................................................................. 132
1.1 Maintenance Preparation ............................................................................................................ 132
1.2 Precautions for Maintenance ...................................................................................................... 133
Chapter II Routine Inspection for Rotary Drilling Rig ................................................................................ 135
2.1 Daily Maintenance ...................................................................................................................... 135
2.2 Lubrication on all Lubricating Points ......................................................................................... 136
2.3 Scheduled maintenance for Initial 50 Working Hours of Rotary Drilling Rig ........................... 137
2.4 Scheduled maintenance for Initial 250 Working Hours of Rotary Drilling Rig ......................... 138
2.5 Scheduled maintenance for Initial 500 Working Hours of Rotary Drilling Rig ......................... 139
2.6 Scheduled maintenance for Initial 1000 Working Hours of Rotary Drilling Rig........................ 140
Chapter III Checking and Maintenance of Critical Parts .............................................................................. 142
3.1 Engine ......................................................................................................................................... 142
3.2 Rotary Mechanism ...................................................................................................................... 165
3.3 Rotary Reduction Gear ............................................................................................................... 166
3.3.1 Check the gear oil level ...................................................................................................... 166
3.3.2 Change of gear oil ............................................................................................................... 167
3.4 Winch .......................................................................................................................................... 168
3.4.1 Inspection of gear oil level in reducer. ................................................................................ 168
3.4.2 Change of gear oil in reducer.............................................................................................. 168
3.4.3 Inspection of winch rope guider ......................................................................................... 169
3.5 Wire Rope ................................................................................................................................... 169
3.5.1 Replacement of wire rope ................................................................................................... 169
3.5.2 Initial use of wire rope ........................................................................................................ 172
3.5.3 Inspection of wire rope ....................................................................................................... 172
3.5.4 Maintenance of wire rope ................................................................................................... 173
3.5.5 Replacement standard for wire rope ................................................................................... 173
3.6 Hydraulic oil cylinder ................................................................................................................. 175
3.7 Elevator....................................................................................................................................... 176
3.7.1 Check of elevator ................................................................................................................ 176
3.7.2 Maintenance of elevator...................................................................................................... 177
3.8 Servo Frame ................................................................................................................................ 177
3.8.1 Maintenance of servo frame ............................................................................................... 177
3.8.2 Replacement of swing support on the servo frame ............................................................. 178
3.8.3 Replacement of nylon board on the servo frame ................................................................ 178
3.9 Pulley .......................................................................................................................................... 179
3.10 Mast ............................................................................................................................................ 179
3.11 Kelly Bar..................................................................................................................................... 180
3.11.1 Scheduled maintenance of kelly bar ................................................................................... 180
3.11.2 Check and maintenance contents of kelly bar..................................................................... 180
3.12 Rotary Drive ............................................................................................................................... 183
3.12.1 Name diagram of main parts ............................................................................................... 183
3.12.2 Maintenance and lubrication............................................................................................... 184
3.12.3 Check the lubricating oil of power unit drive unit .............................................................. 185
3.12.4 Replace lubricating oil of power unit gear.......................................................................... 185
3.13 Crawler Traveling ....................................................................................................................... 186
3.14 Air Cleaner in the Cab ................................................................................................................ 188
3.15 Hydraulic System........................................................................................................................ 189
3.16 Electric System ........................................................................................................................... 194
3.17 A/C ............................................................................................................................................. 199
Chapter IV Storage of Kelly Bar ................................................................................................................... 202
4.1 Cleaning of kelly bar .................................................................................................................. 202
4.2 Maintenance during Long Term Storage .................................................................................... 202
4.2.1 Kelly bar maintenance during storage ................................................................................ 202
4.2.2 Maintenance when moving the kelly bar out of garage ...................................................... 204
Annex I Tightening Torques for Bolts (from GB/T 5000.10-2007).................................................. 206
Annex II Lubricant Viscosity Table ................................................................................................... 207
Annex III Table for Amount of Solvents and Oil ................................................................................ 209
Annex IV Warranty List of Main Parts of TR150D Model Rotary Drilling Rig ................................. 211
Part I Operation Manual for Rotary Drilling Rig
Profile
This manual is mainly prepared for the driver and repair personnel. Before
using this drilling rig, make sure to carefully read all safety information provided in
the operation manual and the drilling rig.
This manual contains the detailed descriptions of the drilling rig, including the
detailed parameters and the installation and transportation guidance for the drilling
rig.
This drilling rig can be used for the applications designated in this manual.
Beijing CSR Times Locomotive & Rolling Stock Mechanics Co., Ltd. will not
be liable for any of your losses arising from the your error use, abuse, or
negligence.
The user must strictly abide by all instructions and provisions related to the
operation safety of the drilling rig.
Special notice: All relevant personnel must carefully read and understand
all contents of the Operation Manual for TR150D Rotary Drilling Rig and the
attached Safety Manual for Rotary Drilling Rig. Especially, the operator shall
never operate any operation explicitly prohibited by the manuals. (If the Safety
Manual for Rotary Drilling Rig is not available, make sure to contact our
company, obtain this manual, and understand all contents before the
operations, in order to prevent causing unnecessary injuries and losses.)
This manual shall be intactly preserved for the periodical reading of relevant
personnel. At the transfer of this machine to other party, please make sure to hand
over the Operation Manual for TR150D Rotary Drilling Rig and the Safety Manual
for Rotary Drilling Rig to new user along with this drilling rig.
If you have any questions whether this drilling rig complies with the national
operation standards and specifications and about the relevant operations of this
drilling rig, please contact Beijing CSR Times Locomotive & Rolling Stock
Mechanics Co., Ltd. before using this drilling rig.
Chapter I General
1.1 Application Scope of Drilling Rig
The rotary drilling rig is one kind of soil-bored cast-in-place pile construction
machinery, which fulfills the periodic operation cycles by driving the rotary bucket
via kelly bar to cut the soil and then lifting out of the pile hole for soil dump.
TR150D rotary dirlling rig is mainly avalibale for the construction of
industrial and civil buildings, bridge, etc., and is only applicable for the drilling
with kelly bar equipment. Do not use other drilling equipment.
1.2 Technical Specification
Technical specification for TR150D rotary drilling rig

Item Parameter Item Parameter
Maximum output 150KN.m Traction force 38T
torque
Maximum drilling 1,500mm Undercarriage model CAT323D
diameter
Maximum drilling 50000mm Track width 800mm
depth
Drilling speed 6-30rpm Undercarriage 4300
extension width
Maximum pressing 100KN Overall dimensions of 12700X3000X3273
force machine under
transport status
Maximum lifting 140KN Engine manufacturer Caterpillar
force
Travel of pressing 3500mm Engine mode C6.4 electronic injection
system turbocharged engine
Left/right tilting angle 4° Maximum lifting 50KN
of mast force of auxiliary
winch
Forward inclination of 4° Rope diameter of 16mm
mast auxiliary winch
Engine power 117KW Maximum lifting 90m/min
speed of auxiliary
winch
Rope diameter of 26mm Swing speed 4-6rpm
main winch
Maximum lifting 150KN Total weight, 49T
force of main winch including standard
Maximum lifting 75m/min kelly bar
speed of main winch
Chapter II Introduction of Structure and
Functions
2.1 Structure of Rotary Drilling Rig
2.1.1 Overall dimensions
4300 (transport 3m)
2.1.2 Introduction of drilling rig structure and functions
1. Undercarriage It provides the power source to the drilling rig and
fulfills the traveling of complete machine, swing of
actuating mechanism, and movement of complete
machine.
2. Boom It connects the superstructure and triangular
mechanism and its rotation can adjust the spacing
between the mast and the rotation center.
3. Luffing cylinder It control s the rotation angle of boom.
4. Support rod It rotates synchronously with the boom to ensure
parallel of triangular mechanism to the
superstructure.
5. Lower mast It’s functioned for the guidance and lower limit of the
power unit.
6. Triangular mechanism It connects the mast and boom as well as support rod
and luffing cylinder.
7. Main winch It lifts and lowers the kelly bar via wire rope.
8. Auxiliary winch It lifts the auxiliary tools such as pile casing via wire
rope and is one auxiliary lifting mechanism for the
drilling rig.
9. Mast cylinder It adjusts the angle of mast.
10. Middle mast It’s functioned for the guidance of kelly bar and
power unit.
11. Upper mas It is functioned for the guidance of kelly bar.
12. Cathead It’s fitted with wire rope guide pulley to support and
guide the wire rope.
13. Servo frame It is functioned for the guidance of kelly bar and the
installation of swing support fort the kelly bar.
14. Kelly bar The telescoping kelly bar transmits the torque and
pressure of the power unit to the drill bucket and its
length determines the drilling depth.
15. Pressing cylinder It provides the drilling pressure and lifting force for
the power unit.
16. Power unit It provides drilling torque to the kelly bar and drilling
tool.
17. Drilling bucket It is used to load the slag drilled.
2.2 Function Description
2.2.1 Cab layout
Forward tilting of mast
Forward Forward
Leftward Rightward traveling traveling
tilting tilting of left track of right track
of mast of mast
Backward traveling Backward traveling Pressing of Caterpillar monitoring panel

of left track of right track pressing cylinder
Backward tilting of mast Retraction o
luffing mechanism
Lowering of main winch Forward rotation Reverse rotation
Lowering of of power unit of power unit
auxiliary winch
Leftward rotation Rightward rotation
of superstructure of superstructure
Extension of
luffing mechanism
Lifting of
Lifting of pressing cylinde
auxiliary winch
Lifting of main winch
Working hourmeter
Seat
Seat
1. Track extension 2. Main electric cabinet

3. Mast leveling lever 4. Traveling operating lever
5. Display screen 6. Engine working monitoring panel
7. Auxiliary monitoring panel 8. Working hourmeter
9. Engine starter switch 10. Accelerator (10 levels)
11. Right operating lever 12. Left operating leer
13. Hydraulic system pilot control switch 14. CD/radio
15. Retraction of tracks 16. Traveling lock 17. Auxiliary winch lock
2.2.2 Hydraulic system pilot control switch
Pull up this operating lever to turn on the hydraulic system so that the hydraulic
system of the complete machine can work normally. While leaving the cab, make
sure to push down this lever to vertical position to cut off the hydraulic system, in
order to prevent the accidental touch of operating lever while accessing the cab
from causing action of drilling rig and unnecessary losses.
2.2.3 Pressure gauge
Three pressure gauges indicate the pressures of two main pumps and the oil
supply pressure of auxiliary pump respectively.
2.2.4 Mast leveling lever
Operate this lever to adjust the angle of mast. The specific operation is as below:
Firstly click the manual button under the horizontal setup interface on the display
screen to switch to manual adjustment mode. While pressing and holding the button
on the top of the operating lever, push forward the operating lever to tilt forward the
mast, pull backward to tilt backward the mast, push leftward to tilt leftward the
mast, and push rightward to tilt rightward the mast.
Special instruction: The movement speed of the mast cylinder and so on is
directly related to the displacement of the operating lever. Low displacement of
lever leads to low movement speed of the mechanism being controlled. High
displacement of lever leads to high movement speed of the mechanism being
controlled. The mechanism being controlled moves at highest speed when the
displacement of the lever reaches the maximum position. In other words, the
movement speed of the mechanism being controlled can be controlled by the
displacement size of the operating lever.
2.2.5 Traveling operating lever (pedal)
There are two control methods for the traveling control of this machine, namely
the manual operating lever and the pedal. During the actual operations, choose any
of two operation methods, as two operation methods are interlocked.
2.2.6 Display screen
The display screen is a brand-new human-machine interface system that
integrates the functions of display, monitoring, and intelligent diagnosis and
incorporates intelligentized display module with high performances and CAN
communication mode.
The display screen is DC10V~DC32V in input voltage range, 600mA in power
consumption (working voltage of 24V), -25℃～80℃ in working temperature
range, 20～85％RH in ambient humidity (no condensation), and IP65（EN60529）
in protective grade. It's mainly used to display the depth, swing angle, set the depth,
and fulfill the functions for some indicators. The entire interface mainly includes 4
basic interfaces, namely startup interface, main interface, input/output testing
interface, warning record interface, horizontal setting interface and parameter
setting interface, of which the setting interface also includes 4 different parameter
setting interfaces.
Once powered on each time, the system enters into the startup interface and then
enters into the corresponding main interface after the language (Chinese/Englihs) is
selected:
a. Main interface (Chinese)
The main interface digitally displays the date, time, pressure of the main and
auxiliary pumps, real-time position and drilling depth of the drilling tool as well as
the drilling depth of single bucket. It displays the actual statuses of the
main/auxiliary woring condition (pressing/luffing), main/auxiliary winch, auxiliary
winch lock and the traveling lock via visual texts.
If the communication between display screen and control unit is disconnected,
the display screen will display a rectangular strip.
5 functional buttons are fitted: Warning, check, setting, button and mast
verticality adjustment. Press to access the warning interface, input/output testing
interface, parameter setting interface, button interface and mast verticality
adjustment interface respectively.
Data display:
X: It displays the lateral (left and right) tilting angle of the mast, with the
display range at ±90º. Among the display range, only the ±5ºrange coincides with
the above-shown coordinate axes and the coordinate axes can only display the
angle within ±5ºrange. If out of above range, the angle displayed shall prevail.
Y: It displays the longitudinal (front and rear) tilting angle of the mast, with the
Actual hole depth: It displays the current depth of the hole drilled. The depth
displayed is also a relative value by taking the reset depth position as zero. A
negative value denotes upward movement and a positive value denotes downward
movement.
Pressure of main and auxiliary pumps: It displays the actual pressures of main
pump 1, main pump 2, and auxiliary pump.
b. Input testing interface
It displays all input signals of the system only for the checking by the repair
personnel and for the operation personnel to understand the working status of the
system.
c. Output testing interface
It displays all output signals of the system only for the checking by the repair
system.
d. Warning interface
The warning interface mainly displays the warning information of the system.
When the audible alarm sounds (in addition, when the warning lock is not locked,
the audible and visual alarm on the panel will flash and sound at the same time), the
user may access this interface to understand the malfunction cause of the warning.
Press button “Return” to return to main interface.
e. Mast verticality adjustment interface
This interface displays and controls the horizontality of the mast. The mast and
leveling angle are displayed by numbers and graphs in the middle portion, of which
the graph can be displayed only within ±5ºrange.
The leveling can be operated by manual mode and inching mode. The 2nd
switch on the right of the interface is used to switch among two working modes.
When it's switched to manual leveling mode, the position of mast can be
operated by the leveling lever.
When it’s switched to inching leveling mode, the leveling lever is not
functioning. The user can operate the inching control on the actions of mast by
means of four arrow buttons on the left of the interface.
f. Button panel interface and parameter setting interface
Press the “Button" under main interface to access the button panel interface.
The buttons Main/Auxiliary Working Condition, Main/Auxiliary Winch, and
Extension/Retraction of Tracks are the functional replication and redundancy of
operation panel buttons and lever buttons. For the buttons Warning Lock Switch
and Limit Switch Enabled, it’s recommended not to turn off the warning, limit
switch and limit switch, unless it’s absolutely necessary.
The paramerer setting interface can only be accesed with correct password. A
four-digit password is provided along with the product service and training.
Caution! The data modification under the interface will cause significant
influence on the system. Any modification by any user not trained by the
administrator is prohibited. Our company will not be liable for any consequence
arising from data modification by any person not trained by the administrator or
any person who doesn’t know the consequences from the modifications, though he
is trained by the administrator. Please modify with great care!
The paramerer setting interface can be used for the setting of parameters for the
following four items:
Depth parameter
Calibration of proportional valve
Calibration of operating lever
Calibration of verticality
Depth setting interface: it displays the position of drilling tool——constantly
changing; depth of single bucket——depth of hole drilled; actual hole
depth——maximum depth of hole drilled; length of wire rope on the
winch——length of the wire rope left on the winch.
The aboave 4 parameters are provided for reference only and the drilling depth
actuall measured shall prevail.
Replace the wire rope accoding to the prompts as shown in the interface.
There are two depth measurement methods available for TR150D rotary drilling
rig, and any one of the following two methods may be applicable to your mahicne.
Please choose the corresponding method under the premise that the depth
measurement method applicable to your mahicne has beedn confirmed.
(I) Absolute Value Encoder Structure
Depth measurement method: after the wire rope is fastened, press button A on
the top left of the left operating lever (the left of rotation button) when you begin to
wind the wire rope, and press the “Null Depth” button B (F1) at the same time, that
is, press the buttons A and B simultaneously. Wait for 2 miutes after confirming that
the two buttons are simultaneously pressed, and then begin to retract the rope. At
this moment, a negative value is displayed only in the “Posiiton of drilling tool”,
and the position of stopping retracting the rope refers to the position from rope end
to the main winch limit switch. After the rope is retracted, press the “Depth Reset”
button (below the left operating lever) to complete the setup of depth and perfom
normal construction! Note: Do not cut off the power during the 2 minutes of
waiting!
Warning! Buttons A and B can only be pressed during the installation of wire
rope! It is not allowed to press simultaneously the buttons A and B at any other
time!
(II) Proximity Switch Structure
The calibration of proportional valve, calibration of operating lever, and
calibration of verticality are properly adjusted during the manufacturing and no
adjustment by the user is required.
g. Functional buttons
The functional buttons are located below the display screen in the following
order from left to right: track extension, track retraction, traveling lock and
auxiliary winch lock.
The track extension and retraction buttons are used to control the movement of
track and can work only when the traveling lock is closed. The traveling lock
switch also controls the traveling of the undercarriage: the undercarriage can travel
when this switch is engaged and is locked against traveling when this switch is
disengaged.
The user can switch to auxiliary winch via the main/auxiliary winch selection
button only after the auxiliary winch lock switch is engaged and the auxiliary winch
cannot work when the auxiliary winch lock switch is disengaged.
h. Main interface (English)
The main interface digitally displays the date, time, pressure of the main and
auxiliary pumps, real-time position and drilling depth of the drilling tool as well as
the drilling depth of single bucket. It displays the actual statuses of the
main/auxiliary woring condition (pressing/luffing), main/auxiliary winch, auxiliary
winch lock and the traveling lock via visual texts.
If the communication between display screen and control unit is disconnected,
the display screen will display a rectangular strip.

5 functional buttons are fitted: Warning, check, button and mast verticality
adjustment. Press to access the warning interface, input/output testing interface,
button interface and mast verticality adjustment interface respectively.
Data display:
X: It displays the lateral (left and right) tilting angle of the mast, with the
Y: It displays the longitudinal (front and rear) tilting angle of the mast, with the
Actual hole depth: It displays the current depth of the hole drilled. The depth
displayed is also a relative value by taking the reset depth position as zero. A
negative value denotes upward movement and a positive value denotes downward
movement.
Pressure of main and auxiliary pumps: It displays the actual pressures of main
pump 1, main pump 2, and auxiliary pump.
i. Input testing interface (English)
It displays all input signals of the system only for the checking by the repair
system.
j. Warning interface (English)
The warning interface mainly displays the warning information of the system.
When the audible alarm sounds (in addition, when the warning lock is not locked,
the audible and visual alarm on the panel will flash and sound at the same time), the
user may access this interface to understand the malfunction cause of the warning.
Press button “Return” to return to main interface.
Press the button Return to return to main interface.
k. Mast verticality adjustment interface (English)
The leveling can be operated by manual mode and inching mode. The 2nd
switch on the right of the interface is used to switch among two working modes.
When it's switched to manual leveling mode, the position of mast can be
operated by the leveling lever.

When it’s switched to inching leveling mode, the leveling lever is not
functioning. The user can operate the inching control on the actions of mast by
means of four arrow buttons on the left of the interface.
1. Button panel interface (English)
Press the “Button" under main interface to access the button panel interface.
The buttons Main/Auxiliary Working Condition, Main/Auxiliary Winch, and
Extension/Retraction of Tracks are the functional replication and redundancy of
operation panel buttons and lever buttons. For the buttons Warning Lock Switch
and Limit Switch Enabled, it’s recommended not to turn off the warning, limit
switch and limit switch, unless it’s absolutely necessary.
Precautions:
①It’s prohibited to knock or impact the display screen with hard object or
heavy weight. Do not apply excessive force while pressing the switches on two
sides of the display screen.

②Guard the display screen against the ingress of water, chemical fluid, and
metal. Avoid the chemical gas, direct exposure to sunlight, and ingress of dust in
the working environment.
③Ensure sufficient heat radiation space for the display screen. Do not block the
radiator holes of the display screen or use out of the working temperature range
(-20~70ºC). Avoid the sudden change of temperature around the touchscreen.
④Do not wipe the display screen holder and the screen with paint thinner or
other chemical.
⑤When the display screen is powered off, wait for several seconds before
power-on again.
2.2.7 Engine monitoring panel
Caution: When the monitor panel alarms, immediately check the monitor
panel and take necessary actions or maintenance instructed by the
monitoring panel.
1) Clock
2) Warning signal indicator
3) Engine speed knob indicator
4) Oil level
5) Oil temperature record
6) Engine coolant temperature
7) Keyboard
Engine speed knob indicator: This number indicates the engine speed. For more
detailed information, refer to the part Operation Control in the maintenance manual.
Fuel level – It indicates the fuel level in the fuel tank. If the fuel level in
the fuel tank is below the specified level, the warning information is displayed on
the display screen. Add the fuel.
Engine coolant temperature – It indicates the engine coolant temperature.
The green zone is the normal working temperature range. The red zone is the
overheating range.
Hydraulic oil temperature – It indicates the hydraulic oil temperature. The

green zone is the normal working temperature range. When the pointer of
instrument reaches red zone, relieve the machine load and find out the cause.
Keyboard – There are 8 keys for information input to the electronic monitoring
system.
Up – This key moves upward the cursor.
Right – This key moves rightward the cursor or reduces the value.
Setting key – This key is used to reset or set value.
Menu – This key is used to access the main menu.
Left – This key moves leftward the cursor or increases the value.
Down – This key moves downward the cursor.
Cancel – This key is used to reject an immediate selection or reject a

design value. Press this key to return to default interface.
OK – This key is used to select the item from the items listed in the
menu.
The electronic monitoring system is used to warn the driver of the current or
imminent malfunction of the machine. The malfunction may occur in multiple
systems of the machine.
Monitoring unit activation function
Rotate the starter switch of engine to position ON.
The CAT logo will appear on the display screen after approximate 1s.
In such case, the coolant temperature, hydraulic oil temperature, fuel level, and
engine speed will be displayed.
Before the start of the engine, the monitoring unit system will check the levels
of engine coolant, engine oil, and hydraulic oil.
Upon detection of low level by the level sensor, the corresponding information
will be displayed and the level will be indicated by graph.
Note: Upon detection of more than one low level, the left and right key symbols
will appear on the right lower corner of the display screen. Press the left and right
keys to observe accordingly. The low level warning will disappear 5s after the
engine is started.
Note: Do not check the level when the machine is on a slope. Make sure to
check the level on a flat ground.
If the engine is started during the level checking, the level checking will be
interrupted automatically.
The system will check the working hours of the filter and the working hours of
fluid. If a filter or fluid is beyond the recommended replacement period, warning
information “CHECK FLTR/FLUID INFO” will appear on the display screen and
will disappear after 5s.
Machine Warnings
The monitoring system can provide 3 types of warnings.
The first type of warnings is the driver’s hint, which will appear on the display
screen.
The second type of warning is about the driving or maintenance of the machine,
which will appear on the display screen. At the same time, the warning indicator
will flash.
The third type of warning requires the immediate stop of the engine.
In event of multiple warnings in the system, the most important warning
information will appear in the first place. Press the left and right keys to observe all
warning information of the machine. If no key is pressed within 5s, the display
screen will return to the most important warning information.
Note: Pressing the menu button can still return to the menu function.
Warning level 1
The warning information of the warning level 1 will only appear on the display
screen. The level 1 warnings are intended to warn the driver of the attention on the
machine system. The level 1 warnings are intended to warn the driver of the
attention on the machine system.
“Unauthorized Key”: Guarantee the system safety under the ready status of
the machine. It indicates that the ignition key is not inserted.
Battery voltage – This warning appears on the display screen to indicate the
malfunction of charging system. This warning will appear during the normal start
procedure. The machine can work when this warning appears. If this warning fails
to disappear, immediately check the electric parts of the charging circuit and take
necessary repair.
Blockage of hydraulic oil return filter – When the hydraulic oil return filter is
blocked, this warning appears on the display screen (4). The blockage of hydraulic
oil return filter will lead to malfunction of hydraulic system. Rotate the starter
switch of engine to position OFF and then rotate the starter switch of engine to
position ON. If this warning disappears, it indicates that the filter is normal. Run the
machine under unloaded condition for at least 10min. If this warning appears again,
replace the oil return filter.
Blockage of air cleaner – When the air cleaner is blocked, this warning
appears on the display screen. The blockage of air cleaner will reduce the power
output of the engine. Check the air cleaner. Clean the air cleaner. Check the status
of air cleaner. Replace the air cleaner when necessary.
Fuel level – If the fuel level in the fuel tank is below the specified level, this
warning will appear on the display screen. Add the fuel.
Fuel-water separator – When the fuel-water separator is full, this warning will
appear on the display screen. Check and drain water from the fuel-water separator.
Low lubricating oil level – This warning indicates that the oil level in the
lubricating oil tank for automatic lubrication system is too low. Add lubricating oil.
Automatic lubrication system error – This warning indicates the malfunction

of automatic lubrication system. Stop the machine and check the malfunction cause.
Warning level 2
High intake temperature – This warning indicates over-high temperature at

the intake port. Stop the machine and check the malfunction cause.
Coolant temperature – This warning indicates the over-high temperature of the

coolant. When this warning appears on the display screen, lower the working speed
of the machine. Idle run the engine, till the engine temperature is reduced. If the
warning still appears after the engine is idling for a period, stop the engine. Check
the engine coolant level and check the radiator for presence of fragments.
Engine stop – The engine is stopped immediately due to an error. Please

contact the supplier.
Acceleration termination warning – This warning indicates that the engine

speed is too fast. Change the operation method. If this status still remains, contact
the supplier.
Over-high hydraulic oil temperature – This warning indicates over-high

hydraulic oil temperature. Stop the operations, adjust the engine to unloaded
condition, and wait for the hydraulic oil temperature to cool down to normal level.
If the warning still appears under unloaded condition of the engine, check the
hydraulic oil level. If the warning still appears under unloaded condition, stop the
engine. Check the hydraulic oil level, check the hydraulic oil cooler for presence of
fragments, and take some necessary measures as far as possible.
Over-high fuel pressure: This warning indicates over-high fuel pressure.

Please contact the supplier.
ECM error – This warning indicates the malfunction of ECM. Please contact the
supplier.
ECM error – This warning indicates the malfunction of ECM. Please contact
the supplier.
Engine ECM error – This warning indicates the malfunction of engine ECM.
Please contact the supplier. Please contact the supplier.
Monitoring unit error – This warning indicates the malfunction of monitoring

unit. Please contact the supplier.
Machine malfunction – This warning indicates that the system detects a

malfunction. Please contact the supplier.
Machine control malfunction - This warning indicates that there is a

malfunction in working device. Stop the machine and check the working
device.
Warning level 3
Crane overload warning – This warning indicates that the load of the machine
is too high and there is a danger of machine rollover. Immediately reduce the load
and look up the operation and maintenance manual.
Low engine oil pressure – This warning indicates low engine oil pressure. Stop
the machine and engine and check for the malfunction cause. It’s prohibited to start
the engine before the problem is resolved.
Operations
Operation of machine
Adjustment of monitoring unit operation position:
1) Loosen the knob on the back of the monitoring unit
2) Adjust the monitoring unit to correct position
3) Tighten the knob
Main Menu
The Main Menu can be used for the driver to observe the machine information and
also for the service personnel to change the settings of the machine.
1) Press the menu button under the default interface.
“MAIN MENU”
“SETTING”
2) There are 4 items in the menu “Main Menu”: Setting, Maintenance
Information, Performance, and Service, of which the detailed descriptions are
given in corresponding submenu.
3) Operate the Left key or Right key to select the menu (highlighted when
being selected) and press OK key to open the submenu.
Caution: Press the Return key or Home key to exit the menu or return to
default interface.
Setting
The menu SETTING is used for the driver to change the settings of the
machine.
1) Press the button Menu
“MAIN MENU”
“SETTING”
2) Press the Right key or Left key to select SETTING and press OK key to
enter submenu.
“ＳＥＴＴＩＮＧ”
“DISPLAY STUP”
“WORK TOOL SELECT”
3) There are two new items under the menu SETTING, of which the
descriptions are given in corresponding submenu.
4) Press the Up key or Down key to select the required item (highlighted when
being selected) and then press OK key to open the submenu.
Caution: Press the HOME key to return to default interface.
Maintenance Information
The menu “MAINTENANCE INFO” is used for the drive to observe the
current usage and interruption variation status for various parts of the system.
“MAIN MENU”
“MAINTENANCE INFO”
2) Press Right key or Left key to select item “MAINTENANCEINFO” and
press OK key to enter submenu.
“MAINTENANCE INFO”
“COOLANT”
“100/1200[HR]”
“HYD OIL”
“100/2000[HR]”
“ENGINE OIL”
“100/500 [HR]”
COOLANT: Coolant
HYD OIL: Hydraulic oil
ENGINE OIL: Lubricating oil
3) The menu lists the current working time for each part of the system. The
driver may scroll by Up and Down keys for observation. In event of
interrupted change of certain system part, the current working time displayed
will also change intermittently.
Note: Press HOME key to return to default interface.
Performance
The menu “PERFORMANCE” is used for the driver to observe the parameters
of all system parts. The following parameters will be displayed under the
menu PERFORMANCE: Battery Voltage, Engine Speed, and Pump Pressure.
“MAIN MENU”
“PERFORMANCE”
2) Press Right key or Left key to select item “PERFORMANCE” and press
OK key to enter submenu.
“PERFORMANCE”
“BATTERY VOLTAGE”
“26[V] ”
“ENGINE SPEED”
“1300[RPM]”
“COOLANT TEMP”
“20[°C]”
BATTERY VOLTAGE: Battery voltage
ENGINE SPEED : Engine speed
COOLANT TEMP : Coolant temperature
3) The menu “PERFORMANCE” includes some system parameters. Press the
Up key or Down key to scroll the menu for observation.
Service
The menu "SERVICE” is used for the driver to change the password and the filter
and flow speeds of the machine.
“MAIN MENU”
“SERVICE”
2) Press Right key or Left key to select item “SERVICE” (highlighted when
being selected) and press OK key to enter submenu.
Caution: The entry of password will be prompted. It’s required to input the
password in “Password Entry” to access the menu.
“SERVICE”
“MAINTENANCE”
“PASSWORD CHANGE”
MAINTENANCE: Maintenance
PASSWORD CHANGE: Change of password
3) After the correct password is inputted, two new items will be displayed
under the menu “SERVICE”, of which the detailed description is given in the
corresponding submenu.
Password Entry
The entry of password is required to access certain submenu. The procedure for
entry of password is as below.
“PASSWORD”
“ENTER PASSWORD”
————————
BCDEF012345
1) Press Right key or Left key to select the numeral or character input.
Caution: The password is composed of numerals and characters. Make sure to
select the numerals 0~9 and characters A~F.
Caution: The default password is 0001 when the machine is manufactured.
2) Press OK key to input the numerals/characters.
Caution: Press the Back key to delete the last character or numeral.
3) After the input of 4 characters or numerals, the system will verify the
password. If the password inputted is correct, this menu can be accessed.
“PASSWORD”
“ENTER PASSWORD”
．．．．．．．．．
‘INVALID PASSWORD’
ENTER PASSWORD: Input of password
INVALID PASSWORD: Invalid password
4) If the password inputted is incorrect, the “INVALID PASSWORD” will
appear. Press OK key to re-input or press Return key to return to previous
menu.
Caution: Please contact the Caterpillar’s dealer if the password is forgotten.
Display Setup
The menu “DISPLAY SETUP” is used for the driver to adjust the display effects of
the display screen.
“MAIN MENU”
“SETTING”
2) Press Left key or Right key to select item “SETTING” (highlighted when
being selected) and press OK key to enter the submenu.
“DISPLAY STUP”
DISPLAY STUP: Setup of display screen
WORK TOOL SELECT: Selection of working condition
3) Press Up key or Down key to select item “DISPLAY SETUP” (highlighted
when being selected) and press OK key to enter submenu.
“DISPLAY SETUP”
“CLOCK ADJUST”
“LANGUAGE SELECT”
“INDICATED ITEM”
“CONTRAST”
“BRIGHTNESS”
“BRIGHTNESS”
CLOCK ADJUST: Clock Setting
LANGUAGE SELECT: Selection of language
INDICATED ITEM: Display of menu items
CONTRAST: Contrast
BRIGHTNESS: Brightness
4) A series of selectable display performances of the display screen are listed in
the menu “DISPLAY SETUP”, of which the detailed description is given in
corresponding submenu.
5) Press Up key or Down key to select the desired item and press OK key to
enter submenu.
Selecting the work tool
WORK TOOL SELECTING is used for the driver to change the setting of
working condition.
Caution: Before the change of the working condition, make sure to place the
hydraulic operating lever to position LOCKED.
“MAIN MENU”
“SETTING”
2) Press Left key or Right key to select item “SETTING” (highlighted when
being selected) and press OK key to enter the submenu.
“DISPLAY STUP”
3) Press Up key or Down key to select item “WORK TOOL SELECT”
(highlighted when being selected) and press OK key to enter the submenu.
“TOOL#01”
“TOOL #02”
“TOOL #03”
“TOOL #04”
Note: If the Work Tools have been set by the electronic technician, the names
of the working tools will be displayed by numerals.
4) The menu “WORK TOOL SELECT” will indicate the currently selected
working tool. Press Up key or Down key to select the required working tool.
Press the OK key.
ADJUSTING THE CLOCK
The operator may set the new time under the menu “CLOCK ADJUST”.
“MAIN MENU”
“SETTING”
b) Press Right key or Left key to select item “SETTING”. Press the OK key.
“DISPLAY STUP”
3) Press Right key or Left key to select item “DISPLAY (SETTING)”. Press
the OK key.
“DISPLAY SETUP”
“CLOCK ADJUST”
“CONTRAST”
“BRIGHTNESS”
“BRIGHTNESS”
4) Press Up key or Down key to select item “CLOCK ADJUST”. Press the OK
key.
“CLOCK ADJUST”
“12 : 00”
5) The menu “CLOCK ADJUST” displays the current time. Press Left key or
Right key to select hour or minute. Press Down key to reduce the value.
6) When the desired time is set, press OK key to save new time.
Caution: Pressing Back key will return to the previously displayed time
without saving.
Caution: Pressing Home key will return to default displayed time.
LANGUAGE SELECTION
The operator may change the language setting under the menu “LANGUAGE
SELECT”.
“MAIN MENU”
“SETTING”
2) Press Right key or Left key to select item “SETTING”. Then press the OK
key.
“DISPLAY STUP”
3) Press the Up key or On key to select item “DISPLAY SETUP”. Then
press the OK key.
“DISPLAY SETUP”
“CLOCK ADJUST”
“CONTRAST”
“BRIGHTNESS”
“BRIGHTNESS”
4) Press the Up key or On key to select item “LANGUAGE SELECT”
(Display Setup). Then press the OK key.
“ENGLISH”
“DANISH”
“FINNISH”
“ICELANDIC”
“NORWEGIAN”
“SWEDISH”
5) The list of available languages will be displayed under the menu
“LANGUAGE SELECT”. Press Up key or Down key to scroll the available
languages. Press Set key to select the desired language.
Caution: Pressing the Home key will return to default language.
INDICATED ITEM
The operator may display the current working tool or the default maintenance
period of the machine via the menu “INDICATED ITEM”. This menu can also
remove these items from the default display.
“MAIN MENU”
“SETTING”
key.
“DISPLAY STUP”
press the OK key.
“DISPLAY SETUP”
“CLOCK ADJUST”
“CONTRAST”
“BRIGHTNESS”
“BRIGHTNESS”
4) Press the Up key or On key to select item “LANGUAGE SELECT”
(Display Setup). Then press the OK key.
Caution: The entry of password is required. It’s related to the “Password
Entry” for entry of password.
“INDICATED
ITEM”
“TOOL NAME”
“SERVICE HR METER”
5) Two items will be displayed under the menu “INDICATED ITEM”. Press
the Up key or Down key to highlight the desired item. Press the OK key to
set the item. Similarly, pressing the OK key can also cancel the item. When a
set item is selected, the item will be displayed in the default value. When a
canceled item is selected, the item will be removed from the default value.
Caution: Pressing the Home key will return to default interface.
ADJUSTING THE CONSTRAST
The operator may adjust the contrast of the monitoring unit via the menu
“CONTRAST”.
Press the button Menu
“MAIN MENU”
“SETTING”
key.
“DISPLAY STUP”
press the OK key.
“DISPLAY SETUP”
“CLOCK ADJUST”
“CONTRAST”
“BRIGHTNESS”
“BRIGHTNESS”
4) Press the Up key or On key to select item “CONTRAST”. Then press the
OK key.
“CONTRAST”
ITEM”
“5”
5) The contrast can be set within the range of 1~10. Press Right key to
increase and press Left key to reduce.
Caution: press Home key to return default interface.
Brightness
The operator may adjust the brightness of the monitoring unit via menu
“BRIGHTNESS”.

“MAIN MENU”
“SETTING”
key.
“DISPLAY STUP”
press the OK key.
“DISPLAY SETUP”
“CLOCK ADJUST”
“CONTRAST”
“BRIGHTNESS”
“BRIGHTNESS”
4) Press Up key or On key to select the item “BRIGHTNESS”. Then press the
OK key.
Caution: There are two items for the “BRIGHTNESS”. One item is intended
for use at daytime and the other item is intended for use at nighttime.
“BRIGHTNESS”
ITEM”
“5”
5) The brightness can be set within the range of 1~10. Press Right key to
increase and press Left key to reduce.
MAINTENANCE
The operator may adjust the accumulative filter and flow time of the machine
via menu “Maintenance”.
“MAIN MENU”
“SERVICE”
2) Press Right key or Left key to select item “Service”. Then press the OK
key.
“SERVICE”
“MAINTENANCE”
3) After the correct password is inputted, press the Up key or On key to
select item “MAINTENANCE”. Then press the OK key.
“MAINTENANCE ”
“FLTR/FLUID INFO”
4) Two new items will be displayed under the menu “Maintenance”, of which
the detailed descriptions will be displayed beneath corresponding item.
CHANGING THE PASSWORD
The operator may change the password via menu “PASSWORD CHANGE”.
“MAIN MENU”
“SERVICE”
2) Press Right key or Left key to select item “Service”. Then press the OK
key.
“SERVICE”
“MAINTENANCE”
3) After the correct password is inputted, press the Up key or Down key to
select item “PASSWORD CHANGE”. Then press the OK key.
“ PASSWORD
CHANG”
“ENTER NEW
PASSWORD”
“---------”
“‹B C D E F 0 1 2 3 4 5›”
4) Press Right key or Left key to select the desired numeral or character.
Caution: The password is composed of numerals and characters. You may
select from “0” ~ ”9” as well as from “A” ~ “F”.
Caution: The initial password is 0001 after the machine is manufactured.
5) Press OK key to input characters.
Caution: Press Back key to delete the last inputted character.
“PASSWORD
CHANGE”
“ENTER
CHANG” NEW
PASSWORD”
“* * * *”
“ARE YOU SURE？”
6) After 4 characters are inputted, you will be prompted to confirm your
choice. Press OK key to save the inputted password and return to menu
“SERVICE”. Press Back key to return to menu “SERVICE” without saving
the inputted password.
FILTER AND FLUID INFORMATION
The operator may adjust the accumulative time for the machine filter and fluid
via the menu “FLTR/FLUID INFO”.
“MAIN MENU”
“SERVICE”
2) Press Right key or Left key to select item “SERVICE”. Then press the OK
key.
“SERVICE”
“MAINTENANCE”
3) After the correct password is inputted, press the Up key or On key to
select item “MAINTENANCE”. Then press the OK key.
“MAINTENANCE”
4) Press the Up key or Down key to select menu “FLTR/FLUID INFO”.
Then press the OK key.
“ENGINE OIL FILTER”

00000/00000 [HR]”
“HYD OIL RET FILTER”
00000/00000 [HR]”
“PILOT OIL FILTER”
00000/00000 [HR]”
5) A series of filters and fluids will be displayed. For any item, the current
working time is displayed on the left side. The recommended adjustment
interval is displayed on the right side. Press Up key or Down key to select the
desired filter/fluid. Then press the OK key.
6) Press Left key to reset the accumulative time of the selected item.
7) Press OK key to save new time.
Caution: Press Back key to return to previous interface without saving the
inputted value.
2.2.8 Working hourmeter
The working hourmeter is located beneath the cab inner seat and the data indicated
is the accumulative working hours of the engine.
2.2.9 Left and right operating levers
The diagrams of the operating levers are shown in Figure 7(b):
Figure 7(b): Diagrams of the Operating Levers
1 Front view of left operating lever
2 Back view of left operating lever
3 Front view of right operating lever
4 Back view of right operating lever
1. Description for front and back views of left operating lever A: Front
top left button C: Front top right button D: Front lower button E:
Back lower button
2. Description for front and back views of right operating lever F: Front top
left button G: Front top right button H: Front lower button I: Back
lower button
The left operating lever, right operating lever, traveling operating lever (pedal),
mast leveling lever, hydraulic system pilot control switch, pressure gauge, display
screen operating panel, and engine monitoring panel are described respectively as
below.
1. Left operating lever:
Layout description: Left operating lever button A: null depth button A
Front top button C: rotation control button
Front botton button D: horn.
Back switch button E: reset of hole depth
Operation description: under the main working condition, pull backward to drive
the main winch for lifting the kelly bar and push forward to lower the kelly bar.
Under auxiliary working condition, push forward to dirve the auxiliary winch for
releasing the wire rope and pull backward to lift the wire rope. Press button A and
push leftward the opertating lever simultaneously to achive leftward swing of
superstructure. Press button A and push rightward the opertating lever
simultaneously to achive rightward swing of superstructure. To ensure the safety of
rotation radius for the drilling rig, a rotation warning indicator is fiited in the rear to
give warning sound during leftward and rightward rotation.
2. Right operating lever
Layout description: right operating lever button F: floating of main winch.
Front top switch button G: standby.
Front bottom switch button H: main/auxiliary winch selection.
Back switch button I: main/auxiliary working condition selection
(pressing/luffing selection).
Under the main working condition, push leftward the right operating lever to
rotate forward the power unit (namely drilling in the stratum) and push rightward to
rotate reversely the power unit (namely unlocking the Kelly kelly bar and closing
the bottom gate of drilling bucket). Under the main working condition, push
forward the right operating lever to extend the pressing cylinder piston rod, press
the kelly bar and pull backward to retract the pressing cylinder piston rod and lift
the power unit. In case of switching to the auxiliary working condition, push
forward the right operating lever to make the mast move forward in a parallel
manner and pull backward to make it move backward in a parallel manner; under
the main working condition, press button F to achieve free floating of the kelly bar.
2.2.10 Limit switches
Location diagram for limit switches of TR150D rotary drilling rig
Luffing rear limit switch: The action of the luffing cylinder will stop
automatically when the boom is lifted to come into contact with the limit switch.
Mast left/right tilting limit switch: When the mast is tilting leftward or rightward,
the action of the mast cylinder will stop automatically after the limit switch is hit.
Main winch upper limit switch: While the main winch is lifting, the action of
main winch will stop automatically when the servo frame hits the limit switch.
Auxiliary winch upper limit switch: The action of auxiliary winch will stop
automatically when the load of auxiliary winch hits the limit switch.
Note: When the above action stops after the limit switch is hit, please operate
the reverse action slowly to restore the normal working of the drilling rig.
2.2.11 Warning device
2.2.11.1 The rotation warning lamp is located on the rear ballast of the drilling
rig. When the driver rotates the drilling rig, the warning lamp will flash
automatically and issue the warning sound to remind the surrounding personnel
of the safety and standing in the safety area.
2.2.11.2 The Caterpillar chassis is fitted with the traveling warning system.
When the driver operates the traveling operating lever of the drilling rig, the
warning system will issue the warning sound to remind the surrounding personnel
of the safety and standing in the safety area.
Note: Upon detection of working failure of warning device under either
condition, please check and repair timely, in order to prevent unnecessary
damages.
2.2.12 A/C System
The A/C control panel is located on the right side of the seat. The A/C can be turned
on only after the start of the engine. Adjust the working mode and temperature
setting of the A/C depending on the needs of the operator.
1) ON/OFF switch
2) Automatic control switch
3) Temperature switch
4) LCD screen
5) Fan switch
6) Compressor switch
7) Defroster Mode
8) Air inlet selection switch
9) Air vent selection switch
2.2.13 Operation description of radio
(A) Display panel (B) Indicator (stereo)
(C) Indicator (music) (1) Power switch
(2) AM/FM band selection (3) Preset button
(4) “Tone” controller (5) Scan and automatic save button
(6) “Tune” button (7) “Tune" button
(8) Volume controller (9) Volume controller
Note: Reduce the radio volume while the machine is working.
Chapter III Basic Operations of Drilling Rig
3.1 Before start of engine
 Before the start of engine, check whether there are bystanders and
maintenance personnel nearby. Ensure all personnel are far away from
the machine. Before the start of engine, sound the horn.
 Check the machine for presence of problems, such as loose bolt, oil
leakage, coolant leakage, and damage or wear of parts.
 Check all parts of the hydraulic system.
 Check the levels of engine oil, coolant, fuel, and hydraulic oil.
3.2 Start of engine
 Rotate the battery switch to position ON.
 Rotate the hydraulic operating lever to position LOCKED.
This machine is fitted with engine neutral start system. This system can start
the engine only when the hydraulic operating lever is at position
LOCKED.
 Rotate the operating lever to position HOLD.
 Rotate the Engine switch (1) to position ON.
 Monitor the system start.
Caution: The prestart checking of the monitoring system will be
activated when the engine start switch is held at position ON for 2s or
longer. Upon detection of low fluid level, the information for the low
fluid level will be displayed on the information display screen. In the
event of too low fluid level, add corresponding fluid to the specified
level. Note: Add the fluid before the start of engine.
Ensure that the information "INTAKE AIR HEATER ON" (The intake heater is
turned on) is not displayed on the information display screen. If this information is
displayed on the information display screen, it indicates that the engine coolant
temperature is too low and the engine can't be started correctly.
Information display screen
Note: The intake heater will be turned on when the engine coolant temperature is
low. The information "INTAKE AIR HEATER ON" (The intake heater is turned on)
will be displayed on the display screen. Start the engine after this information
disappears. (Before starting the engine, sound the horn to alert other working
personnel).
Caution: Do not attempt to start the engine for more than 30s. If the
engine can't be started, cool down the starter for 2min before retry.
Before the retry, make sure to rotate the engine starter switch to
position OFF.
Rotate the engine starter switch (1) to position START.
Release the starter switch key once the engine is started.
Note: Before starting the engine, make sure that the hydraulic system pilot
switch is at position LOCKED (vertical).
This machine is equipped with engine of standard technical specification. After
the engine is started, idle run for at least 5min to ensure the completion of hydraulic
oil preheating. Then, turn on the hydraulic system pilot switch to operate the
drilling rig. This drilling rig can be started in the regions with the temperature as
low as -18ºC. After the engine is started, idle run under unloaded condition for
20~30min. After the engine is sufficiently preheated, operate the drilling rig to
working state.
Note: This drilling rig is fitted with CAT's C6.4 special engine for construction
machinery, which features highest working efficiency and lowest fuel consumption
at 10th gear (engine speed at 1,980). It's recommended to use 10th gear as far as
possible during the working of the drilling rig, in order to realize higher efficiency
and better fuel-saving.
3.3 Stop of Engine
Caution: Stopping the engine immediately after the working under
loaded condition will lead to engine overheating and the accelerated
wear of engine parts. Please cool down the engine with reference to
the following engine stop procedure, in order to prevent the choking
of engine oil due to overheating in turbocharger housing.
Before stopping the machine, idle run the engine for 5min.
Caution: During the running of the engine, it's absolutely prohibited
to rotate the battery cutoff switch to position OFF, or it will lead to
the damage of electric circuit system.
 Rotate the engine starter switch to position OFF and withdraw the
engine start switch key.
 Stop the engine.
 Rotate the engine starter switch to position OFF. If the engine is not
stopped, proceed to the following procedure.
 The emergency stop switch is located beneath the left side of driver
seat.
 Lift the red cap.
 Push down the switch to stop the engine.
Note: Firstly, use the engine starter switch to stop the engine. If the
engine fails to stop normally, use the engine stop controller. This is
another method to stop the engine.
 Push the switch back to original position to get ready for the next
start of engine.
Note: Do not operate the machine before the malfunction is resolved.
 If the engine fails to stop due to electric malfunction, take the
following procedure.
 Rotate the engine starter switch to position OFF. Proceed to the
following procedure.
 Rotate the fuel cutoff valve clockwise to cut off the fuel supply. The
engine will stop after the fuel in the fuel pipe is used up. Note: The
engine will run for further several minutes probably.
3.4 Checking after Stop of Engine
 Inspect thoroughly the drilling, check the working device, rotating
device, exterior, and undercarriage, and check for presence of water
and oil leakage. Upon detection of any abnormality, repair
accordingly.
 Check fuel tank for refueling necessity.
 Check the engine compartment for presence of paper chips and
fragments. Remove the paper chips and fragments to avoid the hazard of
fire.
 Remove the soil adhered on the working device and undercarriage.
3.5 Operations of Drilling Rig
3.5.1 Traveling of drilling rig
Precautions:
 Before moving the machine body, ensure the surrounding safety and
sound the horn for warning.
 Due to limited visual field of the driver within the cab, make sure to
appoint one assistant to assist the driver's observation and send signals
to the driver during traveling of the drilling rig.
 Adjust the superstructure to be paralleling with the tracks and lock the
rotation locking device.
 Adjust the mast position to the minimum working radius.
 Lower the kelly bar and other load to the ground as low as possible.
Before the traveling of drilling rig, firstly check the strength of ground and
bridge to be passed through and ensure the traveling safety.
Before the traveling, determine the maximum exterior sizes of the drilling
rig, in order to prevent the contact with wires and edges of bridges.
While traveling or working in or near the water, in the vicinity of stream
or river, or in muddy place, prevent the ingress of water, mud, sand, or gravel
into the rotating bearings, rotating drive gears, and rotating connectors. In the
event of ingress, immediately add lubricating grease into the rotating bearings,
till the lubricating grease overflows from the outer ring of the rotating
bearings, or it will lead to earlier wear of the rotating bearings.
The following guidelines are applicable for the traveling of drilling rig in the
water, sand and mud, and gravel.
The drilling rig can travel through the river only under the following
conditions:
 Flat riverbed.
 Gentle water flow.
 The water depth shall be no higher than the height of the track carrier
roller center of the drilling rig.
The value A for TR150D rotary drilling rig is 730mm.
 Before the traveling of drilling rig, ensure that the traveling lock is under
unloaded state.
 Choose the level ground as far as possible. Remove all obstacles from
the traveling route of the machine, drive the drilling rig linearly as far as
possible, and change the traveling direction gently and gradually.
 While traveling on a rough ground, lower the engine speed and choose
low traveling speed. The lower traveling speed will reduce the damage
possibility of the machine.
 If traveling is required in working state, first tilt the mast backward by
20°before performing the traveling operation.
 Avoid violent actions during traveling.

 During long distance traveling, please rest for 5min at interval of 20
traveling minutes, in order to prevent damaging the traveling motor.
 For operation stability, the damper is set on the traveling operating
lever/pedal. Under cold weathers, the operating force of the traveling
operating lever and pedal will increase. In such case, operate the
traveling operating lever for several times when the pilot control switch
is at locked position.
 Whenever the traveling operating lever/pedal is release at any place, the
traveling operating lever/pedal will automatically return to neutral
position and the machine will be automatically under the braked state.
 Do not switch the operating lever suddenly, or it will lead to sudden
movement. Avoid switching the operating lever from forward gear or
reverse gear (or from reverse gear to forward gear) suddenly. Avoid
switching the operating lever suddenly, such as the sudden stop from
high speed.
(A) Rear of drilling rig
(B) Drive wheel
(C) Guide wheel
Note: During the traveling of the drilling rig, ensure that the drive wheels
are beneath the rear of the machine, in order to prevent danger.
When the drive wheels are located on the rear of the operating room, push
forward two operating levers to travel forward the machine and pull backward two
operating levers to travel backward the machine. One operating lever controls the
movement of track on the same side and the other side remains still so that the
machine can make turns (for instance, the machine travels forward for right turn
when the left operating lever is pushed forward and will travels backward for left
turn when the left operating lever is pulled rearward and vice versa). When one
operating lever is pushed forward and the other operating lever is pulled backward,
the machine will rotate in-situ (For instance, the machine rotates in-situ clockwise
when the left operating lever is pushed forward and the right operating lever is
pulled backward and rotates in-situ counter-clockwise when the right operating
lever is pushed forward and the left operating lever is pulled backward).
Travel forward
Travel backward
Turn right rearward
Turn in-situ (leftward)
Turn right rearward
Turn in-situ (rightward)
When the drive wheels are on the front of the operation room, the traveling
directions of the machine are reverse to the above description.
3.5.2 Swing of superstructure
Precautions:
 Before the rotation, ensure that there is no obstacle within the maximum
rotation radius.
 When the operating lever is released at any place, the operating lever
will return to neutral position automatically and the machine will stop
rotation.
 The swing amplitude of the lever controls the rotation speed of the
drilling rig. Avoid the fierce actions.
 Do not switch the direction of the operating lever suddenly. Avoid
switching the operating lever from left to right (or from right to left)
suddenly.
Swing left: Push up (or press down) the button "A" of the left operating lever
to activate the swing. Meanwhile, push the left operating lever leftward to swing
the superstructure to the left.
Swing right: Push up (or press down) the button "A" of the left operating lever
to activate the swing. Meanwhile, push the left operating lever rightward to swing
the superstructure to the right.
3.5.3 Erection/lowering and verticality adjustment of mast
3.5.3.1 Erection/lowering of mast
The erection of mast refers to the process the mast is erected from the horizontal
state to the vertical state.
The lowering of mast refers to the process the mast is lowered from the
vertical state to the horizontal state.
The TR150D rotary drilling rig mainly operates the erection, lowering, and
verticality of mast by manual mode or inching mode.
The leveling can be operated by manual mode and inching mode. The 2nd switch
on the right of the interface is used to switch among three working modes.
When it's switched to manual leveling mode, the position of mast can be operated
by the leveling lever.
When it's switched to inching leveling mode, the leveling lever is not functioning.
The user can operate the inching control on the actions of mast by means of four
arrow buttons on the left of the interface.
3.5.3.2 Verticality adjustment of mast
Access the main interface and press the button F5. The display screen will switch to
mast verticality adjustment interface.
As per the mode for erection/lowering of mast, adjust the angle between the
mast and ground by tuning the manual operating lever or using the inching
buttons, till the black spot in the interface coincides with the center of cross to
complete the verticality adjustment of mast.
3.5.4 Lifting and lowering of luffing
Precautions:
 Ensure there is no obstacle within the luffing range before the luffing
operation.
 When the lever is released at any place, the lever will automatically
return to neutral position and the luffing operation will be stopped.
 The action amplitude of the lever controls the telescoping speed of the
luffing cylinder. Avoid the fierce actions.
Warning
When the kelly bar or drilling tool of the rotary drilling rig is
within a hole, luffing, rotation and traveling operations are
prohibited, in order to avoid accidents.
The functions of buttons on all operating levers are described in details in the
section 2.2.9. Switch the working condition mode (left lower corner) in the main
interface to auxiliary working condition by means of the button on the back of the
right operating lever, push forward the right operating lever to move forward
horizontally the luffing lowering mast, and pull backward the right operating lever
to move backward horizontally the luffing lifting mast.
3.5.5 Operations of main and auxiliary winches
Precautions:
 While releasing the wire rope from the winches, to ensure the safety as
per the relevant standards, make sure that there are at least three turns of
wire rope left on the winch drum.
 When the operating lever is released at any place, the lever will
automatically return to neutral position and the winch will stop action.
 The action amplitude of the lever determines the lifting and lowering
speeds of the winch. Avoid the fierce actions.
 The main or auxiliary winch will hit the upper limit after being lifted to a
certain position. In such case, the winch can't be lifted further. You may
operate the lowering slowly to restore the drilling rig normal. The further
lifting after deactivating the limit will lead to danger.
 The floating function of the main winch is used for the drilling of power
unit, under which the main winch can lower freely along with the kelly
bar. It's absolutely prohibited to operate the floating function of main
winch under any other working condition, or the kelly bar will lower
freely or even fall off and it will lead to serious malfunction of drilling
rig parts.
The functions of the buttons on all operating levers are described in details in
section 2.2.9. The button beneath the front view of the right operating lever is
used to switch between main and auxiliary winches.
Under main working condition, pull backward the left operating lever to drive the
main winch for lifting the kelly bar and push forward the left operating lever to
lower the kelly bar. Under auxiliary working condition, push forward the left
operating lever to drive the auxiliary winch for releasing the wire rope and pull
backward the left operating lever to lift the wire rope.
3.5.6 Operations of pressing cylinder
Precautions:
 The action amplitude of the operating lever controls the pressing/lifting
speed of the pressing cylinder. Avoid the fierce actions.
 When the lever is released at any position, the lever will automatically
return to neutral position and the pressing/lifting operation will be
stopped.
interface to main working condition by means of the button on the back of the
right operating lever. Under main working condition, push forward the right
operating lever to extend the piston rod of the pressing cylinder and press the
kelly bar and pull backward to draw back the piston rod and lift the power unit.
3.5.7 Control of power unit
Precautions:
 The action amplitude of the operating lever controls the pressing/lifting
speed of the pressing cylinder. Avoid the fierce actions.
 When the lever is released at any position, the lever will automatically
return to neutral position and the pressing/lifting operation will be
stopped.
interface to main working condition by means of the button on the back of the
right operating lever. Under the main working condition, push leftward the right
operating lever to rotate forward the power unit (namely drill in the stratum) and
push rightward to rotate reversely the power unit (namely unlock the Kelly kelly
bar and close the bottom gate of drilling bucket).
3.5.8 Depth measuring device
Precautions: To indicate the hole depth accurately, it's required to reset zero the
original depth in the display screen when the tip of the drill bucket comes into
contact with the ground before drilling the hole each time.
The hole depth, the position of drill bucket with respect the ground, and drilling
feed are displayed on the right top corner of the drilling rig main interface.
The functions of the buttons on all operating levers are described in details in
section 2.2.9. The button on the back of the left operating lever is used to reset zero
the original hole depth.
After the drilling rig is working for a period, the measured depth of the hole
becomes inaccurate due to different causes, which is normal. In such case, please
contact the relevant personnel of our company to change the original setting of the
depth measurement, in order to ensure the accurate display of depth measurement.
3.5.9 Extension of tracks
Precautions:
 If it's difficult to withdraw/insert the extension fixing pin, operate
the traveling of machine or extending or retraction of the tracks
repeatedly to help the withdrawal/insertion of the pin.
 The extension of tracks can increase the working stability of the
drilling rig. Ensure that the tracks of the drilling rig are under the
extension status before the operations such as construction,
installation, and disassembly (except the loading to or unloading
from a trailer).
Chapter IV Construction of Drilling Rig
Before using and operating the TR150D rotary drilling rig, you are reminded
once again that all issues in the safety manual and the operation manual must be
strictly followed.
4.1 Construction preparations
 Inject the lubricating grease to all lubricating points. Check the hydraulic
oil level and quality. Check the gear oil level and quality for winches,
power unit, and superstructure swing reducer. Check the engine oil level
and quality of engine. Check the filter for necessity of replacement.
Check the drilling teeth for necessity of replacement. Check the drilling
bucket for normal opening and closing.
 Verify the geological report of the stratum. Depending on the
stratigraphic distribution (such as cement hardened layer, miscellaneous
fill, clay, fine sand, medium-coarse sand, gravel, and intermediately
weathered sandstone), choose appropriate drill tool as per stratum and
establish construction scheme for construction.
 Choose the drilling tool:
Determine the diameter of drilling tool in accordance with the
requirements of the construction drawing. Generally, the diameter of the
drilling tool is smaller than the specified diameter of the hole by 1cm~2cm.
Ensure there is free of excessive interference coefficient. During the
drilling, it's appropriate to choose short auger drilling tool for cement
hardened layer. Choose special drilling bucket drilling tool for sand and
gravel layers. When the drilling bucket can't drill in the intermediately
weathered hard layer, choose short auger drilling tool for crushing and
then dredge the drilling slag with drilling bucket. (Please refer to the
relevant descriptions in Chapter VII for the detailed choice method of
drilling tool).
Check the drilling rig for normal actions.
1. Trial run of main winch
Operate the main winch with relevant operating lever within the cab to
lift a kelly bar (such as drilling tool). When the operating lever is released,
the weight shall stop immediately and shall be locked. Operate the drilling
rig at low speed in order to prevent the action failure from endangering the
safety of the personnel and machine.
2. Trial run of mast
Lift the mast to the vertical position and tilt slowly the mast. The
lateral tilting angle of the mast is 4ºand the forward tilting angle is 4º. If
out of above range, the mast will be mechanically limited. The back
tilting angle of the mast is 90°.Check for normal actions.
3. Trial run of mast luffing mechanism
Lift the mast to the vertical position and lift and lower the mast
luffing cylinder and power unit pressing cylinder. Check for normal
actions.
4. Trial run of auxiliary winch
Operate the auxiliary winch with relevant operating lever within the
cab to lift a weight (such as drilling tool). When the operating lever is
released, the weight shall stop immediately and shall be locked.
Warning
During the trial run, operate the drilling rig at extremely low speed
and conduct the functional tests carefully, in order to prevent the
action failure from endangering the safety of the personnel and
machine.
At completion of the above operations, the working preparations of the drilling
rig are completed.
4.2 Positioning of drilling rig
4.2.1 Measurement and setting-out
In accordance with the red spots and directions given by the theodolite or laser
range finder and ranging rod and the measurement of construction pipe
position layout, calculate the angles and position distances from the red spots
by polar coordinates. Determine the pile positions with theodolite and ranging
rod at the construction site.
4.2.2 Positioning of drilling rig
Ensure the levelness in the vicinity of the pile position, drive the tracks of the
drilling to near the pile position, and align the tip of the auger drilling tool to
the marked point of pile position.
When the drilling rig is stopped and the swing center is 3.1m-3.5m from
the hole, whenever possible, operate the luffing cylinder to retract the mast to
as minimum as possible from the swing center, in order to reduce the influence
of the alternate tension on the hole position during the lifting and lowering of
the drilling rig. Check for presence of obstacle within the swing radius.
4.2.3 Embedment of pile casing:
The pile casing shall be embedded under correct setting-out of the rotary
drilling rig in accordance with the specified methods and requirements.
Generally, the digging method is adopted for drilling on land by the rotary
drilling rig, which is more simple and practicable.
The embedment of the pile casing is just the beginning of the construction
of the rotary drilling rig. The planimetric position and the vertical position of
the pile casing shall be correct, and the periphery and the base corner shall be
tight and impermeable In the case of pile casing embedment, setting-out shall
be conducted based on the control pegs positioned. The position of drilling by
the rotary drilling rig shall be marked on the bottom of the hole. Lower the
pile casing into the hole, locate the central position of the pile casing, backfill
clay or cement mortar around the central position symmetrical with a cross
curve uniformly, and tamp the clay or cement mortar layer by layer to achieve
the goal of fixing the pile casing. Where conditions permit, bind the upper
opening of the pile casing symmetrically with sleeper and tighten it, so as to
protect the verticality and prevent slurry loss, displacement and dropping. In
case that the substrate of the bottom opening of the pile casing is not made of
cohesive soil, dig deeper or replace the soil. After a layer of 300-500mm thick
cohesive soil is backfilled and compacted for the bottom of the hole of the
rotary drilling rig, put the pile casing in place to avoid collapse due to water
seepage of the bottom opening. During backfilling, take measures to prevent
the occurrence of the deflection of the pile casing.
A long pile casing or a full barcer of the pile casing must be used in mucky
clay layer vulnerable to hole shrinkage, loose miscellaneous fill layer and sand
layer, and severe permeable layer. The pile casing may be lowered in two
ways:
(1) With a vibratory hammer. Lift the electric or hydraulic vibratory
hammer with the truck crane or crawler crane to clamp the high-frequency
vibration and enable the pile casing of the rotary drilling rig to smoothly cut
into under the liquidation action of gravity of surrounding sand. This method
boasts high lowering and lifting speed of pile casing. It also can reduce the
mud-making cost with the dry pore-forming method or natural water during
pore-forming. When lowering the pile casing, pay attention to the adjustment
of verticality.
(2) With the power unit driver. Rotate the power unit normally and
reversely and pressurize the pressing cylinder to push the pile casing into soil.
This method features easy operation, guarantee of sufficient backfilling and
compaction of the pile casing, limited time of digging and backfilling, and
improvement in pore-forming efficiency.
4.2.4 Positioning of pile hole
Depending on the conditions of the working site, drive the machine to the
position of pile hole and keep the machine body as level as possible. If the
inclination is high, adjust by cushioning the sand and gravel.
After the rotation unit and luffing cylinder are accurately aligned, press the
rotation reset button on the touchscreen. Turn on the manual adjustment of
mast verticality status. If the drilling tool is too high from the hole center,
lower the kelly bar under the floating condition, which makes the alignment of
hole center easier.
Lower the tip of the drilling tool to be within same plane with the upper
edge of the pile casing and reset the depth gauge.
4.3 Construction of drilling rig
4.3.1 Collaring
After crushing the hardened layer, operate the main winch lever to lift the
drilling tool to be off the hole opening for a distance and then stop. Operate
the superstructure swing switch to swing the machine and stop at the soil
dump position. Press the rapid rotation switch on the power unit rotation lever
and operate the lever to rotate the power unit at high speed for slag ejection.
After crushing the hardened layer, remove the short auger drilling tool and
replace with conventional drilling bucket and reamer for drilling. After a depth
enough for the pile casing is reached, use auxiliary winch to lift the pile casing
and install into the hole. Then, use the theodolite and joint spider to verify
whether the pile position is consistent with the center of the pile casing. If
inconsistent, move the pile casing for correction. After the correction, fill the
periphery of the pile casing with soil. The embedment of the pile casing is
completed.
4.3.2 Drilling
The drilling operation can be conducted after the pile casing is embedded.
While operating the power unit for drilling rotation, lower the drilling pipe
to the bottom of the hole and press the main winch floating button for pressed
drilling. When the drilling slag reaches certain bucket amount (The bucket
amount depends on the geological condition), the drilling tool can be lifted.
To lift the drilling tool, rotate the kelly bar reversely for 2~5 turns to close
the gate of drilling bucket. While lifting the power unit, operate the main
winch to lift the kelly bar and drilling tool off the hole opening, rotate the
superstructure along with the kelly bar to the soil dump position, and lift the
kelly bar and strike open the bucket gate to dump the drilling slag. Rotate the
power unit to close the bucket gate. Rotate the superstructure to the pile
position, reset the rotation angle to zero via touchscreen, and continue the next
cycle. Repeat the above cycles, till the design hole depth is drilled.
a. Drilling of clay
The clay layer features low drilling resistance, high adhesion, and difficult
falloff. Therefore, the torque of the power unit can't be too high. Operate the
lever for high speed drilling. During the drilling, continue the pressing. The
feed rate depends on the height and diameter of the drilling tool. Generally, the
drilling slag can reach 60%~80% of the bucket capacity for the drilling tools
in diameter of 800mm or less and shall not exceed 60% of bucket capacity for
the drilling tools in diameter of above 800mm. If the drilling slag can't be
dumped due to high adhesion of the clay, rotate the power unit forward and
reversely to separate the clay from the drilling tool.
b. Drilling the sand layer
The sand layer, especially the medium-coarse sand layer, is relatively
coarse due to shortage of cementing property. The material loss in the drilling
bucket is relatively high during the lifting and the resistance is relatively high
during drilling. To promote the drilling efficiency, choose appropriate cutting
angles, operate the maximum torque of power unit during drilling, and press
the pressing button during drilling. When power unit reaches the rated value,
lift the power unit for pressure relief and drill repeatedly, till the drilling
bucket is loaded with certain amount of slag. Then, lift the drilling bucket for
slag dump and start the next drilling cycle. 80% of the drilling tool blocking
accidents of the rotary drilling rig occurs at the sand layer. This is intended to
remind us of the special attention during the operations. Especially, the rough
operations are prohibited while drilling large diameter holes. The over-high
drilling depth and the drop of suspension sand solved in the mud will easily
cause blocking of drilling tool. While drilling the sand layer, choose the
drilling bucket with double bottom gate, which can prevent the blocking
accident of drilling tool to a great extent.
c. Drilling the gravel layer
The gravel belongs to rock stratum. The drilling is performed in such
manner that the drilling teeth cut into the gaps between the gravels and load
the gravels into the drilling bucket. While drilling this layer, press the pressing
button continually to output maximum torque and conduct the pressed drilling
rapidly, till the drilling tool can't drill further. Lift the drilling tool for slag
dump and proceed the next cycle. The gravel layer is relatively complicated
and the unexpected condition frequently occurs in this layer. Special attention
shall be paid during the drilling.
Chapter V Disassembly and Installation of
Drilling Rig
5.1 Installation and disassembly requirements
Warning
For the safety of yourself and other personnel, please bear in mind
and abide by all contents in this chapter.
5.1.1 Safety
The installation of the attachments or optional parts not approved by our
company will influence the service life of the drilling rig and lead to safety
issues.
Please contact our company before the installation of the attachments not
listed in this manual.
5.1.2 General precautions
 The attachments are powerful tools. To prevent serious injuries or
damage, please use the attachments in a correct way.
 Carefully read the manual. Do not use the attachment before the contents
of the manual are fully understood.
 If the manual is lost, please timely contact our company and obtain a new
manual.
 Before the operations, appoint an instructor and determine the
commanding signals to be used.
 The rotation radius and gravity center of the machine will change after
the installation of attachment. Make sure to understand the status of the
drilling rig appropriately.
 Before the operations, set up a warning line in the vicinity of the machine
to guard against the access of other personnel.
 To prevent the serious accidents arising from misoperations, keep all
personnel away from the machine, except the operation personnel.
5.1.3 Precautions for installation and disassembly
 Conduct the disassembly and installation operations on a solid and level
ground.
 When the operations are performed by two or more operators, determine
the commanding signals and abide by the commanding signals during the
operations.
 Use the crane while hoisting or handling the heavy objects (more than
25kg).
 While disassembling heavy parts, support the parts before the
disassembly, in order to prevent the unnecessary damages of parts due to
swing or falloff of the parts after being disassembled from the machine.
 While hoisting with a crane, pay special attention to the gravity center of
the weight and keep away from the crane.
 While placing the disassembled parts or installing the parts, ensure that
the parts are under steady state without falloff.
5.2 Installation of drilling rig
The works required for the installation of drilling equipment: Extend the track
shoes, erect the mast from transport status to working status, and install the kelly
bar (During the transport, the kelly bar is disassembled from the drilling rig and
transported separately, in order to reduce the transport height of the drilling rig.)
1. Drive the drilling rig to a level, solid, and spacious ground, withdraw four
track fixing pins, extend the tracks to maximum width, and insert the track
fixing pins.
2. Withdraw the fixing pins between upper mast and middle mast (Under the
transport status, the fixing pins are used to fix the folded upper mast and
middle mast together) and extend the upper mast along with the cathead to be
linear with the middle mast. Connect the upper mast and middle mast reliably
with pins.
3. Connect the cross member of the cathead to the piston rod of the pressing
cylinder with ropes. Disassemble the connecting rod of transportation.
Operate the lever (refer to the operating functions of the lever), and extend
the piston rod of the pressing cylinder to pull up the cathead. Mount the
support of the cathead to the upper face of the upper mast, and connect them
together reliably with pins (as shown in Figure 13).
Figure 13
4. Release the wire rope of main winch to the length enough to hoist the kelly
bar.
5. Operate the luffing operating lever and mast operating lever alternatively
to slowly erect the mast to vertical status. (As shown in Figure 14).
6. During the above process, when the lower face of the middle mast and the
upper face of main winch frame just close together, immediately stop the
operations of the mast operating lever (or it will damage the machine parts)
and then connect two masts reliably with pins. (As shown in Figure 15).
7. Take out the support rod of lower mast.
8. Operate the pressing cylinder to make its piston rod reach the power unit
bracket, and fix the piston rod and the power unit bracket reliably with pins.
9. Adjust the longitudinal axis of kelly bar to be collinear with the mast and
align the top end of kelly bar with the drilling rig.
Figure 14
Figure 15
10. Fix the main winch wire rope and the upper elevator of the kelly bar
reliably with pins and lock the pins with bolts. (As shown in Figure 16).
11. Tilt the mast forward by 3º~4º. Slowly start the main winch to slowly lift
the kelly bar. While lifting the kelly bar, move the drilling rig towards the
kelly bar. When the kelly bar is about off the ground, keep the kelly bar
vertical to the ground, in order to prevent the swing of kelly bar from
colliding with the power unit device while the kelly bar is hoisted off the
ground. (As shown in Figure 17).
Lift the kelly bar to above the height of power unit and slowly adjust the
kelly bar vertical (Caution: Operate extremely slowly, as the swing of kelly
bar will probably damage the machine parts and working personnel). In such
case, appoint an operator on the power unit to assist the installation of kelly
bar. When the power unit is traveled to the middle lower portion of the mast,
lift the power unit to 1/3 height of the kelly bar, adjust the position of the
kelly bar, and lay down the mast. Place the follow-up carrier slide eyes into
the guide rail of mast, insert the connecting pins, fix the follow-up carrier to
the mast guide rail, and erect the mast again to enter the working
condition.
Figure 16 Figure 17
5.3 Disassembly of drilling rig
The disassembly of drilling rig is divided into two steps: Disassembly of kelly bar,
and disassembly of mast to transport status and retraction of the tracks to the width
of transport.
1. Lay down the mast and disassemble the connecting pin between the
follow-up carrier and the mast guide rail to separate the follow-up carrier
from the mast.
2. Operate the main winch to lift the kelly bar separated from the drilling rig,
till its lower end is separated from the power unit and the guide slide eye of
upper bracket is separated from the mast guide rail. Slowly tilt the mast
forward by 4º(Pay attention to operate slowly, in order to prevent the swing
of drill from colliding with the machine parts).(Figures 18 and 19).
Figure 18 Figure 19
3. Continue to slowly lower the kelly bar, till the lower end of kelly bar
comes into contact with the ground. Lower the kelly bar and at the same time
move backward the drilling rig, till the kelly bar is completely laid onto the
ground. (As shown in Figure 19).
4. Disassemble the connecting pin between the wire rope of main winch and
the upper lifter of the kelly bar to separate the main winch wire rope from the
kelly bar.
5. Retract the main winch wire rope to a length appropriate for transport and
fix the rope end.
6. Lower the power unit to the bottom of mast, disassemble the connecting
pin between the power unit and the ressing cylinder, and withdraw the piston
rod of pressing cylinder. (As shown in Figure 20).
7. Adjust the tilting angle of the mast to ease the installation of lower mast
support rod. (As shown in Figure 21).
Figure 20 Figure 21
8. Disassemble the connecting pins between the middle mast and main winch
frame. (As shown in Figure 22).
Figure 22
9. Adjust the mast to horizontal status and lower to the rear mast bracket. (As
shown in Figure 23).
Figure 23
10. Hoist the cathead with a hoisting crane. Disassemble the connecting pins
between the cathead and upper mast. Put down the cathead and secure it to
the upper mast with the connecting rod of transportation.
11. Disassemble the connecting pins between upper mast and middle mast,
disassemble the upper mast along with the cathead to the side face of the
middle mast, and fix both parts with pins. (As shown in Figure 24).
Figure 24
12. Withdraw the track fixing pins, retract the tracks to the width of transport
status, and insert the track fixing pins. The disassembly of the drilling rig is
completed and the drilling rig can be loaded to a trailer.
Chapter VI Transport of Drilling Rig
6.1 Transport parameters
TR150D rotary drilling rig is 3410mm high, 12635mm long and 3000mm wide in
transportation with the transportation weight of 43T (as shown in Figure 25).
Figure 25
6.2 Transport requirements
At the time of transport, firstly understand and abide by all local laws and
regulations.
1. If transported by trailer, firstly verify the length, width, height, and weight
of the trailer used to transport the machine.
2. Investigate the status of transport route, such as the restrictions on
dimensions and weight and the traffic regulations.
3. When necessary, break up the machine to meet the local regulations on
transport size and weight restrictions.
6.3 Loading to or unloading from trailer
6.3.1 Loading to trailer

Adjust the drilling rig to be on one same axis with the platform vehicle. Position
the drilling rig in such manner that its guide wheels are near to the platform vehicle
and its drive wheels are far from the platform vehicle. Adjust the power unit and
drive wheels to be the same side so that the drilling rig can drive backward onto the
platform vehicle (As shown in Figure 26).
Note: Securely lock the wheels of platform vehicle and place the ramps. The
inclination angle between the ramps and the ground shall be no more than 15º.
Under the instructions of the instructor, slowly drive the drilling rig onto the
platform vehicle. Make sure to operate slowly and carefully for this process. Make
sure to park the drilling rig in the middle of the platform and never offset from the
central axis of platform vehicle. After parking on the vehicle, secure it with ropes.
While driving up the trailer, adjust the mast height at all times, in order to change
the height of the lower mast and prevent the power unit from touching the ground
and damaging the machine parts.
6.3.2 Unloading from trailer

The drilling rig is transported to the working site via the platform vehicle.
After the drilling rig is transported to the working site, choose a level and solid area
and place the ramps (the inclination angle between ramps and ground shall be no
more than 15º). Start the engine, operate the traveling operating lever to align the
tracks with the ramps, and drive the drilling rig down the platform vehicle slowly.
While driving down the drilling rig, adjust the height of mast at all times, in order
to prevent the power unit from damaging the parts due to ground contact.
Figure 26
6.4 Marine transport requirements
The key for the marine transport is the anti-corrosion treatment of the rotary drilling
rig against the seawater and salt fog.
6.4.1 Choice and basic usage of protective materials
1. Protection for non-coated parts (plated parts and phosphating treated parts)
Apply anti-rusting oil 377-HF uniformly for two times.
Pack with polyethylene film (bag) or wrapping film and seal with
polyethylene tape.
2. Protection for coated surfaces
For exposed coated surfaces, wrap and pack with air-cushion film and then
seal with anti-rusting wrapping film. The overlapped portion shall be no less
than 150mm during the wrapping and the surfaces shall be wrapped tightly
for 3 layers before fixing. The surfaces of the covering parts (including the
external coated surfaces of the cab) shall be sealed by TESA (50530) paint
protective film.
The internal trim surfaces, coated surfaces, seat, floor, operating levers, and
operating panels of the cab shall be packed by TESAS1136 internal
protective film.
3. Protection for reducer, exposed oil pipe connectors, bolts, and end faces of
pins
Apply the 377-HF anti-rusting oil uniformly for two times and seal by three
layers of anti-rusting wrapping film (The assembled subassemblies may be
sealed by the entire wrapping of the subassembly with anti-rusting wrapping
film).
4. Protection for glass windows
Seal with TESA (51136) transparent glass protective film. Apply the
protective film from the outer surface of the glass and scrape along one same
direction with rubber scraper. The protective film shall stick tightly to the
glass surface, without damage or clear air bubble.
6.4.2 Hoisting of machine
1. Pull the pilot control switch to locked position.
2. Stop the engine and withdraw the key from the key switch.
3. Use long enough wire ropes and support rods to prevent collision with
machine during the hoisting.
4. As necessary, wind some protective materials to the wire ropes and support
rods to prevent damaging the machine.
5. Drive the crane to an appropriate hoisting position.
6. Pass the wire rope beneath the track frames on two sides, support securely
with support rods, and install the wire rope onto the crane.
Chapter VII Kelly bar and Drilling tool
7.1 Types and choice of kelly bar
7.1.1 Types of kelly bar
Depending on different pressing modes, the kelly bars are classified into three
types: Friction kelly bar, interlock kelly bar and composite pressing kelly bar.
7.1.2 Choice of kelly bar
The choice of kelly bar mainly takes the stratum, type and depth of hole,
maximum output torque of drilling rig, and pressing force into consideration.
Friction kelly bar: The external key for each segment of kelly bar adopts
complete straight plate structure in full length of the kelly bar. During the drilling,
the axial pressing force is the circumferential positive pressure conveyed between
the internal and external keys among the segments of the kelly bar by the rotating
torque, which is converted to axial friction force by means of the friction resistance
between the internal and external keys to realize the axial pressing feed action. The
advantage of this kelly bar is that there is free of unlocking problem among the
segments of the kelly bar when the kelly bar is lifted so that the kelly bar can be
lifted smoothly.
Interlock kelly bar: The external key for each segment of kelly bar is fitted with
multiple recessed pressing points, instead of the straight plate structure in full
length, so that the kelly bar can convey the complete axial force. It can fulfill the
drilling operations under harder geological condition.
7.2 Use of kelly bar
7.2.1 Use of friction kelly bar
1. Rotate the superstructure to align the drilling tool with the hole position
and ensure that the mast is vertical during the entire drilling process.
2. Run the power unit at appropriate speed so that the kelly bar drives the
rotation of drilling tool for drilling, till the drilling bucket is full.
Depending on different geological conditions, for pressed drilling of power
unit, do not continue the pressing for more than 1m. The friction kelly bar
applies the pressing via the slide friction force so that there will be easily
relative slide among the middle segments of the kelly bar, which will lead to
certain segment hanging in the air. When the power unit stops rotation or
rotates reversely, the segment hanging in the air will drop and reset to cause
falloff and damage of kelly bar. To prevent the falloff of kelly bar, when the
drilling is pressed for nearly 1m, halt the power unit and lift slightly or rotate
reversely for a while to reset the kelly bar. Then, continue to rotate forward the
kelly bar, till the drilling bucket is full.
3. Lift out the kelly bar and drilling tool with main winch.
4. Dump the soil.
5. A working cycle is completed. Repeat the above cycles, till the hole is
drilled.
Note: In the event of feeding failure and slip when the friction kelly bar is
used, avoid or reduce the above problem through the following methods:
 The drilling bucket shall not be tool full (preferably 70%~80%)
during the drilling.
 Weld spring plate to the worn bucket teeth to lengthen the bucket
teeth.
 Replace the drilling tool, such as the adoption of auger drilling tool.
The above methods can be adopted appropriately depending on the specific
conditions, in order to find out the appropriate method.
7.2.2 Use of interlock kelly bar
1. Rotate the superstructure to align the drilling tool with the hole position
and ensure that the mast is vertical during the entire drilling process.
2. While placing the kelly bar, make sure to rotate reversely the power unit
at low speed, in order to prevent the collision between hole walls and
drilling tool from causing falloff during lowering.
3. After the drilling tool reaches the bottom of the hole, place all segments
of interlock kelly bar to locked position, and start the pressed drilling. Run
the power unit at appropriate speed so that the kelly bar drives the rotation
of drilling tool for drilling, till the drilling bucket is full.
4. Unlock and lift the kelly bar, as per the operation method below:
Note: While lifting the kelly bar, pay special attention to the pressure variation
of the winch main pump, listen to the power variation of the engine, and
judge for presence of clear overweight. In the event of clear overweight, it
indicates that the kelly bar is incompletely unlocked. In such case, lower the
kelly bar to the bottom of the hole once again and unlock again as per the
unlocking procedure.
5. Lift the drilling tool out of the hole and complete the soil dump.
6. Repeat the above cycles.
7.3 Structural types of drilling tool
The common rotary drilling bits include auger drilling tool, rotary drilling bucket,
barrel-type coring bit, under-reaming bit, and chopping bit.
7.4 Connection types between drilling tools and kelly bar
The connection types between drilling tool and kelly bar mainly include Bauer
square type and Sanyi square type. The main difference is the different number of
connecting pins.
7.5 Choice of drilling tool
Choose the drilling tool based on the geological condition:
 Clay: Choose the rotary drilling bucket with single bottom. If the diameter
is small, choose two-half drilling bucket or drilling bucket with dump
plate.
 Sludge, weak clay, sandy soil, and gravel layer with poor adhesion and
small grain size: Choose the drilling bucket with double bottom.
 Hard plaster: Choose the rotary drilling bucket with single inlet (and
single bottom or double bottom) or toothed straight auger drilling bucket.
 Frozen soil layer: Choose toothed straight auger drilling bucket and rotary
drilling bucket for the soil with low ice content and choose tapered auger
drilling tool for soil with high ice content. It shall be pointed out that the
auger drilling tool is effective for all soil layers (except the sludge).
However, make sure to use the auger drilling tool under the conditions
without underground water, in order to prevent the blockage due to
pumping action.
 Cemented gravel and intensely weathered rock: Choose tapered auger
drilling tool and rotary drilling bucket with double bottom (single inlet for
large grain size and double inlet for small grain size).
 Moderately weathered bed rock: Choose cutting tooth barrel-type coring
bit – tapered auger drilling tool – rotary drilling bucket with double
bottom or cutting tooth straight auger drilling tool – rotary drilling bucket
with double bottom.
 Weakly weathered bed rock: Choose cone barrel-type coring bit – tapered
auger drilling tool – rotary drilling bucket with double bottom. For
over-large diameters, adopt the stepped drilling process.
Part II Maintenance Manual for Rotary Drilling
Rig
Profile
 This manual is applicable for TR150D rotary drilling rig of Beijing CSR Times
Locomotive & Rolling Stock Machines Co., Ltd. Please confirm your chosen
machine model and fulfill the maintenance as per the following instructions.
 This manual includes the data for product structure of rotary drilling rig,
replacement of wearing parts, and periodical maintenance.
 Some photos and graphic details or optional parts in this manual may differ
from your machine.
 This manual may not include the modifications of the machine due to continual
improvement and upgrade of the product design. Please carefully read and
research this manual and properly preserve this manual.
Chapter I Maintenance Safety Instruction
1.1 Maintenance Preparation
 For proper operation and long life, inspection and maintenance should be
regularly carried out following specified rules. Parts shall be replaced as
planned.
 Unauthorized personnel are not allowed to approach the machine during
lubrication and maintenance.
 Any operator should be guarded by proper equipment such as safety overall,
goggle and helmet etc.
 When cleaning machine, please take necessary measures to keep electrical
elements and joints dry rather than spray water to them.
 Keep the vehicle body clean to easily check abnormal phenomenon, such as
oil leakage, crack and looseness etc. Especially to keep the grease nozzle,
breather and dipstick clean to prevent dust from getting in.
 Only spare parts approved by the company are allowed for maintenance.
 Any modification to this vehicle without manufacturer’s approval is
prohibited.
 Abide by the maintenance rules of the third party part manufacturer.
 If there is any doubt during maintenance, please timely contact with our
company.
Note: Care must be taken to avoid any casualty during maintenance. Special
instruction should be given for engine startup during maintenance.
1.2 Precautions for Maintenance
 Unauthorized personnel are not allowed to approach the equipment during
lubrication, inspection and maintenance.
 Any operator should be guarded by proper equipment such as safety overall,
goggle and helmet etc.
 Before maintenance, remove the ignition key of the drilling rig, and hang a
warning sign labeling "under maintenance" or other markers at an apparent
position in the cab to alert the operator.
 Only spare parts approved by the company are allowed for maintenance.
 Any modification to this vehicle without manufacturer’s approval is
prohibited.
 In case of need to move the security-related functional units, install them in
place after the maintenance in a timely manner.
 Abide by the maintenance rules of the third party part manufacturer of the
drilling rig.
 If welding is required during the maintenance, disconnect the positive and
negative connections of the battery, and remove the ignition key of the drilling
rig. Meanwhile, in the case of welding, fix the earth wire as close as possible
to the welding point to avoid damage of welding current to other parts (such
as bearings, bushings, shafts, etc.), especially in the case of superstructure
welding, the earth wire must be connected to the superstructure, to the
undercarriage in the case of undercarriage welding, and to the mast in the case
of mast welding.
 If there is any doubt during maintenance, please timely contact with our
company.
 Assembling and disassembling operations are strictly prohibited on rough and
soft ground or at night with poor light under non-drilling conditions.
Chapter II Routine Inspection for Rotary Drilling
Rig
2.1 Daily Maintenance
During drilling, the following maintenance should be done at any time.
1. Before operation each shift, add grease to the Kelly bar elevator (Kelly bar swing
connector);
Caution: While adding grease to the grease nipple of elevator, be
sure to discharge all dirt containing tiny sand from the
connections, which will otherwise wear the bearing, thereby
reducing the sensitivity of the elevator.
2. Check the slewing bearing for flexible rotation before the operations of each
work shift, and add lubricating grease to the follow-up carrier pivotal bearing every
week;
3. Frequently check the intactness of wire ropes;
4. Frequently check the damages of oil pipes and seal rings, and in case of
damage, replace in a timely manner.
5. Frequently check the circuit relays for presence of aging, and prepare the
spare parts timely;
6. Check the bearings of kelly bar elevator (kelly bar swing connector) for
flexible rotation, and immediately replace any damage bearing;
7. Frequently check the bolts and hinges if there is any wear, looseness, and
breakage and immediately replace any damaged one.
2.2 Lubrication on all Lubricating Points
Fig. 1 Location Diagram of Lubricating Points

01: Connecting shaft on two ends of boom 3 places Add lubricating
grease once a
week
02: Outer bearing of main winch drum 1 place Add lubricating
grease each day
03: Connecting shaft between middle mast and 2 places Add lubricating
winch frame grease each day
04: Rotary plate and triangular connecting shaft 1 place Add lubricating
grease once a
week
05: Lock block of rotary plate and rotary plate 14 place Add lubricating
grease once a
week
06: Outer bearing of auxiliary winch drum 1 place Add lubricating
grease once a
week
07: Connecting shaft between upper mast and middle 2 places Add lubricating
mast grease every
shift
08: Follow-up carrier pivotal bearing 2 places Add lubricating
grease once a
week
09: Elevator bearings 1 place Add lubricating
grease once a
week
10: Connecting shaft between cathead and upper 1 place Add lubricating
mast grease once a
week
11: Cathead small pulley shaft 2 places Add lubricating
grease once a
week
12: Cathead large pulley shaft 2 places Add lubricating
grease each day
2.3 Scheduled maintenance for Initial 50 Working Hours of Rotary
Drilling Rig
Scheduled maintenance for Initial 50 Working Hours of Rotary Drilling Rig

No. Maintenance description
1 Add lubricating grease to the required lubricating points, with reference to
lubrication diagram of rotary drilling rig
2 Check tightening status of all connecting bolts of the drilling rig and when
necessary tighten to required torque.
3 Check the battery for sufficient power and when necessary charge the
battery
4 Check the wear status of power unit sliding plate and when necessary
replace
5 Check wear status of power unit key board and when necessary adjust
vertically or replace key board
6 Check track tension and when necessary adjust the track tension cylinder
7 Check the wiper for normal functioning and good wiping effect
8 Check the front windscreen washer
Caution: Frequently check the tightening status of connecting bolts of drilling rig
and tighten timely. When necessary, replace the fasteners.
Drilling Rig
Maint No. Maintenance description
enanc
e
categ
ory
1 Replace engine oil and engine oil filter element in engine oil sump, fuel
filter element, and fuel-water separator
2 Check the bolts of fuel pump, A/C compressor, drive pump, and water
Regular maintenance
pump for presence of looseness

3 Check and adjust tension of fan belt.
4 Check and adjust the tension of A/C compressor belt
5 Check the blades of after-cooler for blockage of dirt and fragment and
check after-cooler for presence of cracking, void, and other damage.
6 Check the bolts of fuel pump, A/C compressor, drive pump, and water
pump for presence of looseness
7 Check the gear oil level of traveling reducer
8 Replace gear oil of main winch reducer
9 Replace gear oil of power unit reducer
Chain wheel/guide wheel/track roller/carrier roller
Track shoe/connecting bolt/pin
Track tension
Structural Connecting bolts
1
parts Structural parts
Mandatory maintenance
Cylinder piston rod

Kelly bar
Elevator
Replace engine oil/filter element
Replace fuel/filter element
Check coolant/filter element
Check hydraulic oil/filter element
Check or Check swing reducer and gear oil
2
replace oil Check traveling reducer gear oil
Replace gear oil of main winch reducer
Check gear oil of auxiliary winch reducer
Replace gear oil of power unit reducer
Check gear oil of power unit reducer
Main pump/hose
Auxiliary pump/hoses
Gear pump/hoses
Main valve/hoses
Auxiliary valve/hoses
Solenoid valve group/hoses
Telescoping cylinder/hoses
Hydraulic Luffing cylinder/hoses
3
system Mast cylinder/hoses
Pressing cylinder/hoses
Traveling motor/hoses
Swing motor/hoses
Main winch motor/hoses
Pressing winch motor/hoses
Auxiliary winch motor/hoses
Power unit motor/hoses
Undercarriage monitor warning
Display screen warning
Wiper motor
Check air conditioner (electric/fan) and clean A/C air filter
Electric
4 screen
system
Operating levers
Leveling system
Depth measurement system
Superstructure swing system
Check running performance
Clean external filter element of air cleaner, check safety
Engine filter element, and when necessary replace all filter
5
system elements
Check starter/alternator
Check charging status of battery
Drilling Rig
No. Maintenance description
1 Replace air cleaner element
2 Replace hydraulic oil tank oil return filter element, oil suction filter
element, pilot oil filter element, and auxiliary pump filter element
3 Check coolant level
Caution: While replacing the filter element of air cleaner, make sure to replace both
external and internal filter elements
2.6 Scheduled maintenance for Initial 1000 Working Hours of

Rotary Drilling Rig
Mainte No. Maintenance description
nance
categor
y
1 Replace antifreeze
maintenance
Regular
2 Clean air blower of turbocharger

3 Adjust intake/exhaust valve clearance
4 Check fuel injector nozzle pressure
5 Check and replace gear oil of auxiliary winch reducer
Chain wheel/guide wheel/track roller/carrier roller
Track shoe/connecting bolt/pin
Structural parts
Track tension
Connecting bolts
1
Structural parts
Cylinder piston rod
Kelly bar
Elevator
2 Replace engine oil/filter element
Mandatory maintenance
Replace fuel/filter element

Check or replace oil
Check coolant/filter element

Check hydraulic oil/filter element
Check swing reducer and gear oil
Check traveling reducer gear oil
Replace gear oil of main winch reducer
Check gear oil of auxiliary winch reducer
Replace gear oil of power unit reducer
Check gear oil of power unit reducer
Main pump/hose
Hydraulic system
Auxiliary pump/hoses
Gear pump/hoses
3 Main valve/hoses
Auxiliary valve/hoses
Solenoid valve group/hoses
Telescoping cylinder/hoses
Luffing cylinder/hoses
Mast cylinder/hoses
Pressing cylinder/hoses
Traveling motor/hoses
Swing motor/hoses
Main winch motor/hoses
Auxiliary winch motor/hoses
Power unit motor/hoses
Replace hydraulic oil suction filter screen
Undercarriage monitor warning
Display screen warning
Electric system
Wiper motor
Check air conditioner (electric/fan) and clean A/C air filter
4 screen
Operating levers
Leveling system
Depth measurement system
Superstructure swing system
Check running performance
Engine
system
5 Air cleaner/filter element

Check starter/alternator
Caution: After the rotary drilling rig is working for 1000 hours, conduct the
maintenance once every 1000 hours as per the items listed in the table.
Chapter III Checking and Maintenance of
Critical Parts
3.1 Engine
For the drilling rig, in addition to the daily maintenance works during the
construction, make sure to fulfill the periodical maintenance works for the critical
parts as per the requirements.Among the maintenance works, please abide by the
repair instructions of Caterpillar C-6.4 electronic injection diesel engine for the
maintenance periods and requirements for the minor, intermediate, and major
maintenances of the diesel engine.Please refer to Table 1 for the maintenance
periods for other critical parts of the drilling rig.Please arrange the maintenance
plan as per the following requirements and strictly fulfill the maintenance works
for various parts as per the scheduled maintenance.
Table I
Oil replacement period of CAT323D engine(1)
Working condition
Multi-grade oil Fuel high-load Sulphur Altitude

type Normal coefficient (3) content in higher than
(2)
higher than fuel 1830m
29.4L(7.8US gal) 0.3%-0.5%(4) （6000ft）
Preferred CAT
500hr 500hr 500hr 250h(6)
DEO
Preferred CAT
ECF-1
500hr 500hr 500hr 250hr(6)
TBN Mini.
11.0
Preferred CAT
ECF-1
500hr 500hr 250hr 250hr(6)
TBN min. less
than 11.0
API CG-4 250hr 250hr(5) 250hr(5) 250hr(6)
(1) Engine oil-change cycle is normally 250 working hours. If engine operation
conditions are in line with the fuel type suggested in table, the standard fuel-change
cycle can be 500h.
(2) The normal working status includes the following factors: <0.3% sulphur
content of fuel, <1830m (6000ft) altitude, and good maintenance of air cleaner and
fuel filter. The normal working status does not include high load factor, abnormal
working period, or harsh environment.
(3) The high load factor will shorten the working life of engine oil. The continuous
high power working and few idling will increase the fuel consumption and oil
contamination. These factors will rapidly consume the oil additives. If your
CAT323D average fuel consumption exceeds 37.8L (9.8US gal) every hour, please
observe the suggestions of high-load factor in Table 4.2.1. To acquire the average
fuel consumption, please regard the 50-100h as a cycle. If the application of this
machine changes, the average fuel consumption will also change.
(I) Engine cooling system
1. Change coolant
Note: before delivery, this machine has already filled with CATERPILLAR
long-lasting coolant.
(1) Open and then lift the engine hood.
(1) Slowly loosen the pressurized cap on the radiator to release the inside
pressure in cooling system.
(2) Remove the pressurized cap.
(3) Remove the access cover beneath the radiator.
(4) Open the drainage valve to drain the coolant into an appropriate container.
The drainage valve is located on the bottom of the radiator.
(5) Flush the cooling system. Correctly flush the cooling system as per step a to
h.
a. Close the drain valve
b. Fill the cooling system with clean water.
c. Install the pressurized cap.
d. Start engine and let it run to reach work temperature.
e. Shut off the engine and let it cool down.
f. Slowly loosen the pressurized cap on the radiator to release the inside
pressure in cooling system.
g. Open the drain valve beneath radiator to let the coolant be drained into a
proper container.
h. Flush the radiator until the drained water is clean.
(6) Close the drain valve and then install the access cover beneath the radiator.
(7) Replenish the long-lasting coolant. Refer to the following chapters.
(8) Start the engine.Start the engine. Let engine run without pressurized cap on
radiator until the coolant temperature regulator is turned on and coolant level
is steady.
(10) Keep the coolant level within a height of 13mm (5inch) from the bottom of
filling pipe.
(11) Check the pressurized cap gasket in cooling system. Replace any damaged
pressurized cap.
(12) Install the pressurized cap onto the radiator.
(13) Shut off the engine.
(14) Open the left access cover.
(1) Full level (2) Low level
(15) Check coolant tank. Keep the coolant level stay between Full and Low.
(16) To fill the CATERPILLAR coolant, remove the pressurized cap.
(17) Install the coolant tank.
(18) Close and lock the engine hood.Close the left access cover.
2. Add coolant extending agent
When the CATERPILLAR long-lasting coolant (ELC) is used, 119-5152
coolant extending agent should be added into the hydraulic system.
Use 8T=5296 coolant anti-rust agent testing device to test the coolant
concentration.
Note: before delivery, this machine has already filled with CATERPILLAR
long-lasting coolant.
(1) Park the machine on the flat ground.
(4) Ensure the cooling system has already cooled down. Slowly loosen
the pressurized cap on the radiator to release the inside pressure in
cooling system. Remove the pressurized cap.
(5) Some coolant should be drained from the radiator so that the
CATEERPILLAR extending agent can be filled into the cooling
system.
(6) Fill the cooling system with 119-5152 coolant extending agent.
(7) Check the pressurized cap gasket in cooling system. Replace any
damaged pressurized cap.
(8) Install the pressurized cap onto the radiator.
(9) Close and lock the engine hood.
2. Check or replace hose
(2) Check all hoses if there is any leakage, and if the hoses next to clamp
is softened or if the clamp is loose.
(3) Replace the cracked or softened hose, tighten the loose clamp.
(4) Slowly loosen the pressurized cap on the radiator to release the
pressure. Remove the pressurized cap.
(5) Drain the coolant until the level is less than position where the hose is
to be replaced.
(6) Loosen the hose clamp and then disconnect the damaged hose.
(7) Replace the hose with a new one.
(8) Replace with a new clamp and then tighten it.
(9) Fill the cooling system with proper coolant.
(10) Close and lock the engine hood.
4. Check the coolant level
(1) Full level (2) Low level
(2) Check the coolant level in tank. Keep the coolant level stay between
Full and Low.
a. Open and then lift the engine hood.
b. Slowly loosen the pressurized cap on the radiator to release the
pressure. Remove the pressurized cap.
c. Fill the cooling system with proper coolant.
d. Start the engine.Start the engine. Let engine run without
pressurized cap on radiator until the coolant temperature regulator
is turned on and coolant level is steady.
e. Keep the coolant level within a height of 13mm (5inch) from the
bottom of filling pipe.
f. Check the pressurized cap gasket in cooling system. Replace any
damaged pressurized cap.
g. Install the pressurized cap onto the radiator.
h. Shut off the engine.
i. Close and lock the engine hood.
(3) To fill the CATERPILLAR coolant, remove the pressurized cap.
(4) Install the coolant tank cover.
(5) Close the left access cover.
5. Clean/ replace the strainer of air cleaner
In case of warning or image showed on the display, or block smoke from the
exhaust device, please check the strainer.
(2) Gently squeeze the outlet pipe to remove the dust.
(3) Loosen the four buckles on the cover of air cleaner to remove the air
cleaner.
(4) Remove the strainer from the air cleaner housing.
(5) Clean the cover of air cleaner and inside of air cleaner housing.
(6) Check the O-ring on the cover of air cleaner. Replace any damaged or
worn O-ring.
Caution: Never clean the air filter element by means of impacting or
knocking. Do not use the element already pleated or with gasket or seals
damaged. That will damage to engine. Before putting the element into filter
housing, make ensure to keep the cleaned filter element dry. Moisture in
element will lead to wrong contamination indication by scheduled sampling
analysis.
(7) Clean the strainer. Check the strainer. Strainer can be cleaned by
low-pressure compressed air.
(8) Guide the airflow along the inside and outside of wrinkle on strainer of
air filter. Do not let the air nozzle directly contact with the wrinkle.
(9) Check the strainer after being cleaned. Do not use the element already
pleated or with gasket or seals damaged.
(10) Pack the cleaned strainers and then store them in clean and dry room.
(11) Install the clean strainer.
(12) Install and then lock the air cleaner cover.
Note: air filter cover should be correctly installed, with arrow face upward.
(13) In case of following items, replace the air filter.
● Air filter clogging indicator on monitoring panel is constant ON.
● After the strainer is well installed, black smoke still emerges from the exhaust
device.
(14) Close the access cover.
6. Replace fine element of air filter
(1) Open the left-front access cover.
(2) Remove the fine element.
(3) Cover the air inlet. Clean the inside of air cleaner housing.
(4) Remove the cover from air inlet.
(5) Install the new fine filter.
(6) Install the strainer.
(7) Install and then lock the air cleaner cover.
(II) Engine lubricating system
I. Check Engine Oil Level
Check engine oil level when engine is switched off. Do not check engine oil level
with engine running.
1. Open and then lift the engine hood.
2. Take out the oil dipstick.Wipe out the oil on dipstick, and then reinstall it again.
3. Take out and then check the oil dipstick. The engine oil level should be kept
within FULL and ADD.
Caution: The engine oil level should be kept within FULL and ADD.
If the oil level exceeds FULL, crankshaft will immerge in oil during
engine running. That will raise oil temperature and hence reduce the
oil lubricity.
4. If necessary, remove the lubricant filler cap to replenish lubricant.
Note: if the lubricant is deteriorated or badly polluted, change the lubricant
whenever the maintenance cycle arrives.
5. Clean the lubricant filler cap. Install the lubricant filler cap.
6. Close and lock the engine hood.
II. Replace Engine Oil and Oil Filter
1. Oil-change cycle
Note: Only if the operation conditions are in line with the multi-grade oil
grade, can the oil-change cycle be 500h. Otherwise, the oil-change cycle
should shorten to 250h. The acceptable oil-change cycle can be acquired by
SOS sampling and analysis degree. Too long replacement cycle for oil and
filter will damage the engine. The suggested multi-grade oil is already listed
in table. Do not use the single-grade lubricant.
(1) Engine oil-change cycle is normally 250 working hours. If engine
operation conditions are in line with the fuel type suggested in table, the standard
fuel-change cycle can be 500h. If the engine running operation is changed,
oil-change cycle will also change.
(2) The normal working status includes the following factors: <0.3% sulphur
content of fuel, <1830m (6000ft) altitude, and good maintenance of air cleaner and
fuel filter. The normal working status does not include high load factor, abnormal
working period, or harsh environment. Normal conditions exclude: high-load factor,
abnormal work cycle or harsh environment. High-load factor will shorten the
working life of engine oil.
(3)The continuous high power working and few idling will increase the fuel
consumption and oil contamination.These factors will rapidly consume the oil
additives. If your CAT323D average fuel consumption exceeds 37.8L (9.8US gal)
every hour, please observe the suggestions of high-load factor in the table below. To
acquire the average fuel consumption, please regard the 50-100h as a cycle. If the
application of this machine changes, the average fuel consumption will also change.
Table II
Oil replacement period of CAT323D engine(1)
Working condition
Multi-grade oil Fuel high-load Sulphur Altitude

type Normal coefficient (3) content in higher than
(2)
higher than fuel 1830m
29.4L(7.8US gal) 0.3%-0.5%(4) （6000ft）
Preferred CAT
500hr 500hr 500hr 250h(6)
DEO
Preferred CAT
ECF-1
500hr 500hr 500hr 250hr(6)
TBN Mini.
11.0
Preferred CAT
ECF-1
500hr 500hr 250hr 250hr(6)
TBN min. less
than 11.0
API CG-4 250hr 250hr(5) 250hr(5) 250hr(6)
(4) To Test the oil-change cycle of 500h, please refer to the following
“Procedure A”.
(5) Use the following “Procedure B” to confirm the proper cycle.
2. Oil-change cycle adjustment
(1) Procedure A
Test of 500h of oil-change cycle
This procedure includes three oil-change cycles of 500h. During three
oil-change cycles of respective 250h and 500h, sample and analyze the engine oil.
Hence, there are total six samples. This analysis includes the oil viscosity and IR. If
all results are satisfying, 500h of oil-change cycle is acceptable. If the application of
machine is changed, please repeat the procedure A.
If the sample is not analyzed, please take one of the following methods:
● Shorten the oil-change cycle to 250h.
● Perform the procedure B.
● Change the preferred oil type.
(2) Procedure B
Optimize oil-change cycle
From the beginning of 250h, gradually prolong the oil-change cycle. Each
cycle should increase by 50h. Regular oil sampling and analysis should be done in
each cycle. This analysis includes the oil viscosity and IR. If the application of
machine is changed, please repeat the procedure B.
If the oil sample fails to be analyzed, please shorten the oil-change cycle or
select the preferred multi-grade oil type listed in above table.
3. Procedures to change engine oil and oil filter.
(1) Check the oil filter
Check the used filter for presence of fragments.
Cut the filter element with cleaner cutter or oil filter cutter. Unfold the
corrugations and check the filter element for presence of metal particles and other
fragments. The presence of excessive fragments in the filter element indicates the
possible malfunction of the parts.
Upon detection of metal in the filter element, use a magnet to separate the
ferrous substance and non-ferrous substance.
The non-ferrous metal is probably worn from the aluminum parts of the
engine.
The ferrous metal indicates the wear of steel or iron parts.
A small amount of fragments detected is probably caused by normal wear and
friction.
(2) Replace engine oil and oil filter
Note: If the sulphur content in fuel exceeds 1.5% by weight, please adopt the
oil with TBN of 30, and then shorten the oil-change cycle to half.
Park the machine on the flat ground.Shut off the engine.
Note: Before the oil cools down, drain the oil in crankcase. That could drain
the particle suspended in oil. If oil cools down, these particles will subside to the
bottom of crankshaft rather than be drained together with oil. Besides, they will
recycle together with the new oil in lubrication system.
1) Drain valve of engine crankcase is located beneath the rear of upper
structure.
2) Open the drain valve of crankcase to drain the used oil into a proper
container.
3) Close the drain valve
4) Open the right access cover.
5) Use a wrench to remove the oil filter.
6) Clean the base of air cleaner housing. Ensure all old filter gaskets are
removed.
7) Apply a thin engine lubricant on the new filter gasket.
8) Manually install a new filter .When the gasket contacts with the base of
filter, continue to rotate the filter by 3/4 circle to fully tighten the filter.
9) Rotation indexes with interval of 1/4 circle on each new oil filter could help
you tighten the oil filter.
10) Close the access cover.
11) Open and then lift the engine hood.
12) Remove the lubricant filler cap. Fill the crankcase with new oil.
Caution: Too much/ little oil is not allowed to be filled into the
crankcase, which will damage to the engine.
13) Start engine to slightly heat the lubricant. Check the engine parts for
leakage. Stop the engine.
14) Wait for 30min to let the lubricant return back to crankcase. Use an oil
dipstick to check lubricant level. The engine oil level should be kept within
FULL and ADD. If needed, replenish the lubricant.
15) Close and lock the engine hood.
Engine fuel system
1. Replace fuel filter
Warning!
Fuel leakage or splashed to hot surface or electrical elements will catch a fire,
leading to casualty.
Hence, all leaked or splashed fuel should be cleaned.
No smoking during operation around fuel system.
To replace the fuel filter, please switch the circuit breaker to OFF or
disconnect the battery.
Caution! Before installing the fuel filter, do not add fuel. Contaminated fuel
will speed up the wear of fuel system.
Open the left access cover.
(1) Place a proper container beneath the drain hose (1) to collect the used liquid.
(2) Open the drain valve (2). Drain the fuel in filter (3) into the container.
(3) Close the valve.
(4) Remove the fuel filter (3).
(5) Open the fuel filter cap to check whether there is scrap in fuel filter.
Note: this kind of filter is of drum-type paper filter that can not be used repeatedly.
(6) Clean the base of air filter. Ensure all used seal rings are removed from the base.
(7) Apply a layer of clean fuel on the new sealing surface of fuel filter.
(8) Manually install a new filter .When the gasket contacts with the base of filter,
continue to rotate the filter by 3/4 circle to fully tighten the filter.Rotation indexes
with interval of 1/4 circle on each new oil filter could help you tighten the oil filter.
(9) Refill the fuel system.
(10) Close the left access cover.
2. Drain the water in oil-water separator.
(1) Open the front access door at the left side of the machine.
(2) Prepare a proper container for collecting the used fluid.
(3) Check the cup (2) at the base of oil-water separator. Open the drain valve (1).
Pour the water and sediment into the cup.
(4) Close the drain valve
(5) Close the front access cover.
(1) Drain valve (2) Cup
3. Replace oil-water separator
(2) Open the drain valve (1) by anticlockwise rotating it, which is located
beneath the oil-water separator.
(3) Drain the water and sediment into a proper container.
(4) Close the drain valve (1).
(5) Remove the filter (3) from its base (4). Use the filter wrench (if possible) to
loosen the oil filter.
Note: this kind of filter is of drum-type paper filter that can not be used repeatedly
(1) Drain valve (2) Cup (3) Filter (4) Base
(6) Remove the filter (3) from the cup (2). Dispose the used filter.
(7) Clean the inside of filter base (4) and cup (2).
(8) Remove the cover (5) from the base of new filter r(3). Remove the seal (6)
from the cover (5).
(9) Install the seal (6) into the groove of cup (2).
(10) Put the cup (2) onto the new filter (3), and then lock them.
(11) Put the new filter (3) onto its base (4), and then lock them.
Note: Do not start engine before fuel system maintenance is completed.
4. Clean the fuel tank cap and strainer.
(1) Remove the fuel tank cap.
(2) Check the seal ring (4) for damage. Replace the seal ring if necessary.
(3) Remove the screw (1), filter assembly (2), drain valve (3) and gasket.
(4) Remove the strainer at the filler cap.
(5) Use the clean and uninflammable solution to clean the strainer and fuel tank
cap.
(6) Install a set of new filter cap, and then the gasket, drain valve (3), filter
assembly (2) and screw (1).
(7) Place the strainer into the filler of filter.
(8) Install the fuel tank cap.
5. Drain the accumulated water and deposition in fuel tank.
(1) Drain valve of fuel tank is beneath the fuel tank.
(2) Open the drain valve by anticlockwise rotating it to drain the water and
sediment into a proper container.
(3) Close the drain valve by clockwise rotating it.
6. Fill the fuel
If necessary, refill the fuel tank. Remove the fuel tank cap, and then fill the
fuel through filler.
After the filling is over, ensure the fuel tank cap is well locked.
● Check the valve clearance of diesel engine.
If the measured valve clearance is within the limit shown below, adjustment is not
needed.
Adjustment of valve clearance
Intake
0.30 to 0.46 ㎜ (0.012 to 0.018inch)
valve
Exhaust
0.56 to 0.72 ㎜ (0.022 to 0.028inch)
valve
If the measured value is not within stipulated range, adjust them if needed.
Please refer to “Adjustment of valve clearance” to obtain the correct procedures.
● Adjustment of valve clearance
Adjustment of valve clearance
Intake 0.38 ㎜ (0.015inch)
valve
Exhaust
0.64 ㎜ (0.025inch)
valve
Use the following procedure to adjust the valve clearance:
1. Place the 1st piston to the TDC of compression stroke.
2. Adjust the intake valve clearance of 1, 2, 4 cylinders.
Use a soft hammer to gently tap the rocker to ensure the tappet roller aligns
with the basic circle of camshaft.
Loosen the adjustable nut (2).
Place a proper feeler between intake rocker (1) and cross member of intake
valve. Then clockwise rotate the adjusting screw. Slide the feeler between the
rocker and cross member of valve. Continue to rotate the screw 2 until you feel
slight tension on feeler. Take out feeler.
Tighten the adjustable nut (2) to 29±7N·m (21±51b ft). Keep the adjustable
screw stay still when tightening the adjustable nut. After the adjustable nut is well
adjusted, recheck the valve clearance.
4. Remove the timing bolt, and then rotate the flywheel along the engine by
360°.Place the 6th piston to the TDC of compression stroke. Install the timing bolt
into the flywheel.
Tighten the adjustable nut (2) to 29±7N·m (21±51b ft). Keep the adjustable screw
stay still when tightening the adjustable nut. After the adjustable nut is well
After all valve clearances are well adjusted, remove the timing bolt from the
flywheel. Reinstall the timing cover.
● Replace the auxiliary cylinder for diethyl ether starting.
Diethyl ether cylinder is in partition of radiator.
(1) Open the left-rear access cover.
(2) Loosen the clamp of cylinder
(3) Loosen and then remove the auxiliary cylinder for diethyl ether starting
(4) Remove the used gasket.
(5) Install the new gasket.
Note: Each diethyl ether cylinder is equipped with a new gasket.
(6) Install a new auxiliary cylinder for diethyl ether starting
(7) Manually tighten a new auxiliary cylinder for diethyl ether starting
(8) Tighten the clamp of cylinder.
3.2 Rotary Mechanism
(I) Lubrication of rotary bearing
Before lubricating the rotary bearing, clean the lubrication nozzle. Rotary
bearing is located beneath the base of upper structure, which is lubricated through
the nozzle, until the lubricant overflows from the seal ring.
(II) Replace the lubricant in rotary drive.
1. Remove the access cover beneath the swing drive.
2. Take out the oil dipstick.
3. Fill quantitative oil by using of oil dipstick.
4. The engine oil level should be kept within FULL and ADD.
5. Check the drained oil for metal scrap or particle.
6. The drained fluid should be properly disposed according to the local
regulations.
● Check the lubricant level in rotary drive.
1. Take out the dipstick located on the upper side of turntable behind the
base of upper structure.
2. Check the oil dipstick. The engine oil level should be kept within FULL
and ADD. If needed, replenish the lubricant by use of dipstick.
3. Insert the oil dipstick.
● Lubricate the rotary bearing gear.
Caution: incorrect lubrication may damage to the machine. Hence,
ensure the amount of grease in rotary drive is proper. Too much grease
in rotary drive will increase the stir difficulty, and then accelerate the
grease deterioration. Deteriorated grease will damage to pinion and gear
ring in rotary drive. Insufficient grease will deteriorate the gear.
1. Remove the access cover around the base of boom. Check the grease.
2. Check the grease for pollution or discoloration.
3. Change any contaminated or discolored grease.
3.3 Rotary Reduction Gear
3.3.1 Check the gear oil level
Except for the normal inspection of oil, in following two cases, check the
oil level in reduction gear, fill the lubricant if needed:
 Before the first startup;
 More than 3 months of rotary drilling rig resting time.
Inspection methods:
1. Stop the rotary drilling rig on the flat ground, and then let it stay for 10
min.
2. Take out the oil dipstick, use clean rag to clean it and then reinsert the
dipstick.
3. Take out the dipstick again to check the oil level. If needed, fill the gear
oil.
Oil filler
Dipstick
4. After that, replace the dipstick.
3.3.2 Change of gear oil
Note: to thoroughly change the gear oil, please let the machine run for a
while. If operator directly contact with hot oil or structure, he/she will be burnt
by it.
3.4 Winch
Note: As the main and auxiliary winches may bear the load, please
demount the Kelly bar and other loads before maintenance.
3.4.1 Inspection of gear oil level in reducer.
Except for the normal inspection of oil, in following two cases, check the oil
level in reduction gear, fill the lubricant if needed:
 Before the first startup;
 More than 3 months of rotary drilling rig resting time.
Spection methods:
1. Park the rotary drilling rig on the flat ground; adjust the mast to let it
be perpendicular to ground.
2. Remove the oil-level plug on the reducer.
3. After the plug is removed, if oil emerges, it indicates the oil is
sufficient, otherwise, refill it.
3.4.2 Change of gear oil in reducer
1. Place the container to the proper location for collection oil.
2. Open the drain plug;
3. Thoroughly drain the oil in reducer.
4. Properly reinstall the drain plug;
5. Open another oil-level plug; replenish the new oil until you see it
flows out from the oil-level access hole.
6. Properly install the oil filler plug and oil –level plug.
Note: The used oil should be environmental-friendly disposed
according to local regulations.
3.4.3 Inspection of winch rope guider
1. Daily check the operation of rope guiders of main and auxiliary rope
guiders. Timely apply the grease if needed.
2. If the rope guider does not move flexibly, which is no caused by lack of
grease, please timely repair or replace the rope guider to avoid any damage to wire
rope.
3. Before operation each time, check the spring pressure of rope guider, and
replace it if necessary.
3.5 Wire Rope
As wire rope belongs to wear part, correctly choose, operation and
maintenance can prolong the wire rope life.
3.5.1 Replacement of wire rope
Method one: During work, surveying and setting out should be done to confirm a
pile location. Rotary drive should be at the bottom of mast, at the same time, the
upper end of Kelly bar should just contact with rotary drive. A person should stand
on the rotary drive, take down the wire rope (with roller) from the elevator, then
lower it to ground by releasing it. At last use a gas cutting machine to cut off the
end of wire rope.
The new wire rope should be butted and then welded to wire rope with end cut (as
shown in Figure 2). Cut off the wire rope according to the depth of drilling hole.
Slightly uplift the winch handle to winch position by large sheave of cathead. Then
cut off the abovementioned welding points, at last reversely rotate the winch to pull
out the used wire rope. Fix the new wire rope onto the winch, operate the handle,
and rotate the winding drum, till the other end of the wire rope is approximate 2m
length left on the ground. Fix the end of wire rope with the connecting roller bush
of elevator with rope clamp (as shown in Figure 3). Install onto the elevator, attach
the connecting pin, fix with cover plate, and lift the kelly bar to complete the
replacement of wire rope.
Method Two:Drive the drilling rig onto flat and solid ground, so that the mast is in
the horizontal position; with the luffing cylinder piston rod extending to 200mm,
stand on the ladder, remove the wire rope from the elevator and draw out the old
wire rope.
The new wire rope runs through the rope groove of the cathead large pulley and is
then pulled to the winch position; fix it with the drum using a wedge, and then
operate the main winch to retract the wire rope, during which the wire rope shall be
in the rope groove of the cathead large pulley; fix the new wire rope onto the winch,
operate the handle to rotate the winding drum, till the other end of the wire rope is
approximate 2m length left on the ground. Fix the end of wire rope with the
connecting roller bush of elevator with rope clamp (as shown in Figure 3). Install
onto the elevator, attach the connecting pin, fix with cover plate, and lift the kelly
bar to complete the replacement of wire rope.
Fig 2
Caution! The welds must be secured.
Fig. 3
3.5.2 Initial use of wire rope
To start the use of wire rope after installation, it’s preferable to firstly
trial run the wire rope under unloaded condition for multiple times and
then use under light load (10~20% of usage load) for multiple times.
During the initial use of wire rope, single wire and strand should be
well arranged to prevent against the wire rope distortion and looseness,
which can be helpful for prolonging its useful life.
3.5.3 Inspection of wire rope
3.5.3.1 If possible, daily check the visible part of wire rope for inspection of
deterioration and deformation. Pay special attention to the parts connected
to equipment. Any minor change of rope should be reported and then
inspected by qualified personnel.
3.5.3.2 For inspection cycles of wire rope, please take into the followings
consideration:
a. Regulations requested by nations where rotary drilling rigs are
used.
b. Working environment of rotary drilling rig
c. Last inspection result;
d. Years of wire rope already used.
3.5.3.3 During inspection of wire rope, pay attention to the fixing positions
of beginning end and tail end, as well as the rope susceptible to foreign
factors.
3.5.3.4 At any case, if a rotary drilling rig has been stored for 3 months or
more, inspect the wire rope before work.
3.5.4 Maintenance of wire rope
1. After operation of each shift, timely clean the mud or other dirt
attached to the wire rope to avoid corrosion.
2. During operation, wire rope should be frequently lubricated to
prevent against any corrosion.
3. The selected grease should be one recommended by wire rope
manufacturer.
4. Use a brush to lubricate it. The useful life can be prolonged by 3
times or more if wire rope is in use under lubricated conditions.
5. Any fracture of wire should be cut off during inspection, as the
fractured wire will damage to the adjacent wire.
3.5.5 Replacement standard for wire rope
Table III
Shortcoming Replacement standard Remarks

Item Problem
Fract Distribution Quantity of wire fracture up to One lay length is defined as wire
ure of wire 10% of total in one lay length rope distance by rotating the
of fracture(one steel core by one circle.
wire lay length)
Quantity of wire fracture up to
10% of outer strands in one lay
length
Distribution Quantity of wire fracture up to
of wire 20% of outer strands in five lay
fracture(five lengths
lay lengths)
Centralized 5% of total outer strands occur
fracture of to one strand.
wire
5% of total outer strands occur
to one strand.
Wire fracture The wire fracture of strand will The wire fracture of strand
of strand increase the quantity of wire valley happens to the connection
valley fracture of strand.
Fracture of Fracture of wire caused by
wire caused corrosion has been inspected.
by corrosion
Fracture of Fracture of wire end will If the wire rope nearby cord,
wire end accelerate the whole wire anchorage, or clamp is fractured,
fracture. other parts can still be used.
Wire nearby Fracture happens around the This kind of fracture will
ring rope is bend of rope ring. Other parts of accelerate the whole wire
fractured wire fracture should be disposed fracture.
according to "Centralized
fracture of wire".
Wear Entire wear As the wire wears, the diameter
reduced to 93% of initial one.
Local wear As the wire wears, the local
diameter reduced to 93% of
initial one.
Corr Outer Pitted corrosion; the reduction
osio corrosion ratio of breaking force is
n 15-20% of initial one
Inside Inside corrosion may lead to
corrosion wire “swelling”.
Minor rust happens between
strands.
Defo Kink Negative kink will loosen the
rmed strand.
Positive kink will “sprain” the
strand
Defo Wave Height of wave is 4/3 or more
rmed within 25times of wire rope
diameter.
Squeeze Min. diameter of squeezed wire
section is 2/3 or less of max.
diameter.
Squeeze of Min. diameter of squeezed wire
ring rope section is 1/2 or less.
Rope core Inside steel core extruding
extruding outside of outer strand.
Rope core Timely replace it
extruding
(around the
rope ring)
Bent Bend or kink
Strand Strand extruding
extruding
“Birdcage” Extruding of strand,
phenomenon: like ”birdcage
Othe High-temperat Fresh gray without metal color Wire lost of strength and
rs ure damage hardness due to heat or burn.
Green or key blue Wire or corrosion leading to
damage or wire fracture.
Electric effect Arc-type discharge or spark.
If a wire rope complies with any replacement standard listed in above table,
timely replace it. Wire rope diameter of main winch is φ26 and auxiliary
winch is φ16. (wire rope structure: 6*19S+IWR (GB 8918-2006), strength
of extension is 1770 MPa)
3.6 Hydraulic oil cylinder
1. Frequently carry out visual check on all parts (cylinder block, steel tubes)
of the hydraulic oil cylinder for cracks or leakage, and repair or replace the oil
cylinder timely if necessary.
2. Apply hydraulic oil on the piston rod at least once a week or stretch out
or draw back the oil cylinder several times.
3. Do not clean the piston rod with sharp tools, corrosive liquid or
abrasives to avoid scratching the piston rod and causing internal leakage of the
oil cylinder.
4. Before and after operation of every shift, check the oil pipe joints
connected with the oil cylinder for looseness or leakage. In case of any, please
tighten the joints timely and replace the damaged parts if necessary.
5. When the kelly bar is running, pay attention to whether the oil cylinder
works normally. If the oil cylinder movement is slow or weak or even with no
movement, please stop the machine immediately for check, continue running
the machine after troubleshooting.
6. The oil cylinder of the rotary excavation kelly bar is a load-bearing part,
take care for safety during repair or replacement, and use other external reliable
structure for supporting if necessary.
7. When the balance valve on oil cylinder is faulty, draw back the piston
rod of the oil cylinder completely, then carry out the repair or replacement.
3.7 Elevator
3.7.1 Check of elevator
Check the elevator flexibility every shift before working, if it is normal, it
can be rotated easily by hands.
a. Descend the mast flat, please observe the operation steps in the
operating manual for descending the mast with kelly bar;
b. Rotate the main winch, so that the steel wire rope connected with the
elevator can be loosened and the elevator can rotate freely. During the
rotation, keep proper tightness of the steel wire rope to avoid the main
winch twisting the rope;
c. Fix one end, if the other end can rotate freely, it indicates that the
elevator performance is good. If the elevator still cannot rotate normally
after applying the grease, it must be repaired timely or even replaced.
Note: during hole drilling operation of the kelly bar, when pulling the
elevator out of the hole, the elevator always rotates at high speed. At this
moment, take care and observe; if the elevator cannot rotate or is rotating
unsmoothly, please stop the machine for check.
3.7.2 Maintenance of elevator
1. Apply grease on the elevator bearing during every shift.
2. During operation of the kelly bar, fine sands easily enter the elevator,
wear the bearing and reduce the sensitivity of the elevator, thus reducing its
reliability.
3. Every time when adding the grease, check whether the stop screw on
the elevator is loosened or not, if so, please retighten it.
4. Every time after adding the grease, check the stop bolt on the hinge pin
connecting the steel wire rope and kelly bar, if the bolt is loosened, please
retighten it timely.
3.8 Servo Frame
3.8.1 Maintenance of servo frame
Before construction, observe the coverage degree of grease on the guide
rail, ensure the uniform grease application to prolong the service life of the
nylon board.
Lubricate the swing support on the servo frame ever week. apply the
grease on the swing support until it flows out from the periphery.
When adding the grease, check the connecting bolts on the servo frame for
looseness, and retighten them timely if necessary.
If the swing support is damaged or cannot rotate freely, please replace it
timely.
3.8.2 Replacement of swing support on the servo frame
1. Remove the kelly bar from the kelly bar according to the requirements
of safety operation manual.
2. Remove the servo frame from the kelly bar and keep it flat.
3. Unscrew the connecting bolts of the servo frame, kelly bar and the
swing support via a tool and keep them properly.
4. Take off the swing support, pay special attention to safety at the
moment.
5. Correctly install the new swing support on the servo frame, tighten the
bolts, and see the attachment for specific tightening torque.
6. Before initial use of the newly installed swing support, it is
recommended to apply some grease.
3.8.3 Replacement of nylon board on the servo frame
Before kelly bar construction, observe the wear condition of the nylon board
on the servo frame, if the wear is very serious, please replace it timely.
1.Take off the bolts, gaskets and nuts which are used for fixing the nylon
board to be replaced.
2.Take off the nylon board to be replaced.
3.Clean and wipe the hole and faying surface for fixing the nylon board.
4.Install the new nylon board, and fix it with bolts, gaskets and nuts.
3.9 Pulley
When the kelly bar is working, pay attention to the main/auxiliary winch
sheaves for rotation flexibility at all times. If there is any unsmoothness or
swing phenomenon, stop the machine immediately for check. Carry out the
troubleshooting according to the related contents in safety manual and operation
manual and then continue working.
3.10 Mast
The mast is a main load-bearing part of the rotary excavation kelly bar, pay
attention to the lubrication of the mast guide rail when the kelly bar is working.
If the guide rail is insufficiently lubricated, please apply the grease timely, or
remove the old grease on the guide rail and then apply the new grease if
necessary.
Before and after every construction work, check whether the connecting
bolts of the mast assembly are loosened, if so, please retighten them according
to the tightening torque in the attachment.
As the mast is the main load-bearing part, please pay attention to
phenomena such as distortion, deformation, or cracks at all times, in case of any,
please feel free to contact with our company timely.
3.11 Kelly Bar
3.11.1 Scheduled maintenance of kelly bar
Maintain the kelly bar according to the time listed below.

Interval (h)
Machine locked Friction kelly bar
Working condition
kelly bar
Initial use 50 100
Normal use For every 200h For every 400h
(Based on the record of engine working hours)
3.11.2 Check and maintenance contents of kelly bar
No. Part Damage Diagram
1 External External
spline spline edge
warped or
worn
External
spline
Steel tube
1. Protrusion of the warped edge is 1-3mm,
the protruded part shall be grinded flat in
time;
2. Maximum wear: 5mm, if worn, carry out
surfacing with hard surfacing electrodes to
90°. Replace the part if it is seriously worn.
2 Pressurizat Pressurizati
ion point on block
worn
Pressurizati
on block
Pressurization block
Tube body
Maximum wear: pressure bearing surface
5mm; if worn, carry out surfacing with hard
surfacing electrodes to 90°. Replace the part
if it is seriously worn.
3 Externalsp The
line, tube external External spline or External support

tube body cracked plate
(three pieces)
body spline or the
External spline
tube body is
cracked. Steel tube
1. use an angle grinder, grind the cracked
part to 60° double groove to the root part
(grind the steel tube through), weld by the

J506 electrodes, and then grind it flat.
2. In the peripheral direction, add three
external support plates (tailor-welded to the
non-sliding rail part, place the cracked point
to the middle of the support plates) for high
tailor point welding to support and protect
the cracked part (note that the upper and
lower end surfaces shouldn’t be welded).
4 Divide The drive
plate plate is
worn.
If worn, carry out surfacing with hard
surfacing electrodes to 90°. Replace the part
if it is seriously worn.
5 Spring Broken Replace
6 Bolt Damaged Replace
7 Upper Damaged Replace
cushion
8 Pin Damaged Replace
9 Kelly bar Deformatio Repair or replace
joint n, cracks
3.12 Rotary Drive
3.12.1 Name diagram of main parts
Oil cylinder
Guardrail
base plate
Buffer disc
Buffer casing
Connecting plate
Upper oil seal box
Lug
Front lifting eye
Sliding Tank cover
guide
Tank body
Platen
Oil window
Lower oil seal box
Soil ejecting plate
3.12.2 Maintenance and lubrication
1. The device adopts the power box oil sump lubrication, and the oil level
shall not be lower than the upper 2/3 scale mark of the oil window. It is not
allowed to use with insufficient oil.
2. It is recommended to use grade N150 lubricating oil in the power box,
and the temperature scope is -8~80℃.
3. When runs for the initial 240~360h, please change it for new oil (and
empty the dirty oil in the box), change the oil every half a year (8h working
system). If the working condition is bad, the oil change interval shall be
shortened properly.
4. Frequently add the lubricating oil during use. Take out the
precompressed air filter at the upper part of the chassis before oil adding.
Before draining the oil, unscrew the oil drain plug at the lower part of the
chassis.
5. There is no lubricating oil in the power device when it leaves the
factory.
6. During every shift, after removing the mud on the sliding part of the
sliding guide of mast guide rail, please apply proper grease for prolonging the
service time of the sliding board of the sliding guide.
7. During every shift, remove the mud accumulated on the power device to
prevent the muddy water from entering the sealing part of the upper oil seal.
8. Periodically check the connection status for all fastening bolts and
hinges and the wear status for wearing parts. Replace the keys if the keys are
worn to the edge.
3.12.3 Check the lubricating oil of power unit drive unit
Caution: The incorrect lubrication will probably lead to the damage of
machine parts. To prevent the damage, ensure that the lubricating
grease amount added to the power unit drive unit is correct. If the
lubricating grease amount in the power unit gear box is excessive, it
will increase the rotation loss and thus speed up the deterioration of
the lubricating grease. The deteriorated lubricating grease will damage
the gear of the power unit drive unit. The insufficient lubricating
grease will deteriorate the lubrication of gears.
1. Observe the access panel of power unit reduction box. Check whether the
lubricating oil level is within the markings.
2. Check the lubricating oil for presence of contamination and
discoloration.
3. Change any contaminated or discolored lubricating oil.
3.12.4 Replace lubricating oil of power unit gear

1. Rotate the power unit gear oil drainage plug on one side to the bottom
position.
2. Remove the drainage plug and oil level plug. Drain the lubricating oil of
power unit gear into an appropriate container.
3. Clean the plugs and check the O-rings. Upon detection of clear wear or
damage, replace drainage plug, oil level plug, or O-ring.
4. Install the drainage plug.
5. Add lubricating oil to the empty chamber of power unit gear, till the oil
level reaches the middle portion of the oil level window.
6. Install the oil level plug.
7. Thoroughly clean the lubricating oil splashed on various surfaces.
8. Start the power unit and run the power unit gears for several turns.
9. Stop the engine.Check lubricating oil level.
10. Check the drained oil for presence of metal particle or grain.
11. Dispose the drainages correctly.
3.13 Crawler Traveling
● Check of crawler
Check the crawler for wear and excessive contaminations.
● Measure the tension of crawler.
1. Place a ruler on the crawler. The length of the ruler shall be larger than
the distance between the guide wheel and the carrier roller of the crawler.
2. Measure the maximum sag of the crawler. The measurement method for
the sag is to measure the highest point of the crawler grouser to the bottom
of the ruler. Correctly adjust the crawler in such a manner that the sag is
approximately 40~55mm.
● Adjustment of crawler
1. Adjustment of crawler
Note: Make sure to properly adjust the crawler tension as per the
current working conditions. For thick soil layer, loosen the crawler
as much as possible.
2. Tension the crawler
Wipe the oil nipples clean before adding the lubricating grease.
(1) Add lubricating grease via oil nipples (as shown below), till the
correct track tension is reached.
(2) Drive the machine forward and backward to balance the track
pressure.
(3) Check the track sag. Adjust the tracks as necessary.
3. Loosen the tracks.
(1) Carefully loosen the relief valve, till the track starts to loosen.
Loosen only for up to one turn.
(2) When the required tension of the track is reached, tighten the relief
valve to 34N.m (25 1b ft).
(3) Drive the machine forward and backward to balance the track
pressure.
(4) Check the track sag. Adjust the tracks as necessary.
3.14 Air Cleaner in the Cab
The air cleaner is located on the back of the cab.
(2) Loosen the bolts (1) and open the cleaner cap (2) and air cleaner (3).
(3) Disassemble the air cleaner (3) from the cleaner cap (2).
(4) Clean the air filter with compressed air of which the pressure shall be no
higher than 200KPa (2bar).
(5) Check after cleaning the air filter. If the air filter is damaged or seriously
contaminated, please replace it with a new one.
(6) Install the air filter and the filter cover.
Note: make sure that the top arrow of the air filter points to the front.
● Indicators and Instrument test
(1) Observe the instruments for presence of broken glass cover, broken indictor
lamp, and damaged switch and check within the cab for presence of other
damaged part.
(2) Start the engine.
(3) Find the instrument that has problems.
(4) Turn on all lamps on the machine and check for normal working.
(5) Drive the machine forward. The machine shall stop when the traveling
operating lever and traveling pedal are released.
(7) Carry out any required repair before the operation of machine.
3.15 Hydraulic System
● Oil level check of hydraulic system
Caution: if the hydraulic oil is hot, do not remove the oil filler plug/air
bleed plug on the hydraulic oil tank. Otherwise, the air may enter the
hydraulic system and cause damage of the oil pump.
(2) Open the right access cover.
(3) The temperature of the drilling rig hydraulic oil is low in non-operating state
and becomes higher in normal operation.
(4) Close the access cover.Note: if the oil level is low, please carry out step 5-7.
(5) Slowly loosen the oil filler plug/air bleed plug to release all pressure.
(6) Check the O-ring of the filler plug/air bleed plug. Replace the damaged
O-ring.
(7) Clean and install the oil filler plug/air bleed plug.
● Replacement of hydraulic oil filter
1. Replacement of tank oil drain filter
(2) Turn the hydraulic activation operating lever to the UNLOCKED (on)
position.
(3) Turn the engine starting switch to the ON position.
(4) Move the operating lever and traveling operating lever/pedal to the full-travel
position to release the pressure in the pilot pipeline.
(5) Turn the engine starting switch to the OFF position, and return the hydraulic
activation operating lever to the LOCKED position.
(6) Slowly loosen the oil filler plug/air bleed plug at the top of the hydraulic oil
tank to release the internal pressure.
(7) Tighten the oil filler plug/air bleed plug after releasing the pressure.
(9) Clean this area to prevent contaminations from entering the oil filter base.
(10) Remove the used tank oil drain filter from the oil filter base.
Note: this is a filter with a filter cartridge which cannot be reused.
(11) Clean the oil filter base.
(12) Apply clean hydraulic oil on the seal ring of the new oil filter. Install the new
tank oil drain filter on the oil filter base and tighten it by hands.
(13) Restore the filter to the state before the disassembly. Check the machine for
oil leak.
(14) Start the engine, run the machine slowly for 10~15n. Through several cycle
operations, each oil cylinder shall be able to move stably.
(16) Keep the oil level of the cooled machine within the low temperature scope.
Keep the oil level of the normal working machine within the high
temperature scope.
(17) Slowly loosen the oil filler plug/air bleed plug to release all pressure.
(18) Clean the oil filler plug/air bleed plug.Install the oil filler plug/air bleed plug.
2. Replacement of pilot system oil filter
(2) Turn the hydraulic activation operating lever to the UNLOCKED (on)
position.
(3) Turn the engine starting switch to the ON position.
(4) Move the operating lever and traveling operating lever/pedal to the
full-travel position to release the pressure in the pilot pipeline.
(5) Turn the engine starting switch to the OFF position, and return the
hydraulic activation operating lever to the LOCKED position.
(6) Slowly loosen the oil filler plug/air bleed plug at the top of the hydraulic
oil tank to release the internal pressure.Tighten the oil filler plug/air bleed
plug after releasing the pressure.
(8) Clean this area to prevent contaminations from entering the oil filter base.
(9) Remove the used pilot oil filter from the oil filter base.
(10) Clean the oil filter base.
(11) Apply clean hydraulic oil on the seal ring of the new pilot oil filter.
Install a new pilot oil filter on the base of the oil filter, and tighten by hands.
● Change of hydraulic oil
1. Precautions for change of hydraulic oil.
Replace the oil after 800 hours for the first time and afterwards replace the oil
once every 2000 hours. The oil replacement interval may be prolonged if the
imported high quality hydraulic oil is adopted.
2. Oil instructions
Working viscosity scope
To realize the optimum efficiency and service life, the working viscosity shall
be chosen within the scope below:
Vopt=optimum working viscosity 16-36mm2/s
Viscosity limit scope Vmin＝5mm2/s
Temporarily maximum allowable temperature T＝115℃
Please note that: the temperature in partial area (for example, the bearing area)
shall not exceed 115℃
Vmax-1600mm2/s
Temporarily cold start (n<1000r/min, Tmin=-40℃)
4. Precautions for selection of hydraulic oil.
In order to select the correct oil, it is necessary to know the working
temperature in the circuit (closed circuit) related to ambient temperature.
For selection of hydraulic oil, within the working temperature scope, the
working viscosity shall be within the optimum scope (Vopt). We recommend that
oil of high viscosity grade shall be used.
Caution: due to the influence of pressure and pump speed, the leaked
oil (leakage from housing) temperature is always higher than the
circuit temperature. However, the temperature at any point of the
circuit shall not exceed 90℃.

Viscosity (㎜ 2/s)
Vopt.
Tmin＝－40℃ Hydraulic oil temperature scope Tmax＝＋115℃
5. Commercially available lubricating oil
The diesel engine lubricating oil (used for heavy machine) with minimum zinc
content of 900ppm can be used.
Caution: it is not allowed to mix the hydraulic oil of

different brands and grades.
● Clean the radiator core
(2) Lift up the engine hood and open the access door at the left side of the
machine.
(3) Check whether there are chips on the radiator fins.
(4) Remove the dust and chips on the radiator fins.
(5) When removing the dust and common chips on the radiator fins, compressed
air is preferred.
(6) Cover the engine hood and close the access door.
● Rapid coupler - Lubrication
Wipe all oil nipples clean before applying the lubricant.
Apply the lubricant through the four oil nipples on the rapid coupler,
respectively two at each side.
Note: do not lubricate the wedges and wear plates. When plugging back, the
wedges shall be fixed in place. The friction force is essential.
3.16 Electric System
● Clean and replacement of battery and recovery of used battery

1. Battery-cleaning
Clean the battery surface with a piece of clean cloth. Keep the terminals clean
and apply Vaseline on the terminals. Then install the terminal cover.
2. Battery-recovery
Make sure to recover the battery. Do not discard the battery.
In general, the used batteries shall be returned to one of the following places:
(1) Battery supplier; (2) authorized battery collection center; (3)recovery plant.
3. Battery retaining clip-fastening
Fasten the battery retaining clip to prevent the battery from moving during
machine running.
4. Battery, battery cable and battery circuit-breaking switch-replacement
Warning!
The vapor or explosion of battery will lead to personal injuries. The
battery will discharge flammable vapor that will probably lead to
explosion. The electrolyte is an acid substance that may cause
personal injuries if splashed on the clothing and skin. Keep the
spark away from battery as it will lead to vapor explosion. It’s
prohibited to contact the ends of the jumper cable with each other
or contact the ends of jumper cable with engine. Incorrect
connection of jumper cable will lead to explosion. Always wear
goggles during the operations of battery.
(1) Turn the engine starting switch key and all switches to the OFF position.
(2) Turn the battery circuit-breaking switch to the OFF position and take down
the key.
(3) Disconnect the battery negative cable.
(4) Disconnect the battery positive cable.
(5) Disconnect the battery cable on the battery circuit-breaking switch which is
connected to the machine frame.
(6) Carry out necessary repair or replace the battery.
(7) Connect the battery cables to the circuit-breaking switch.
(8) Connect the battery positive cable.
(9) Connect the battery negative cable.
(10) Insert the circuit-breaking switch key and turn the battery circuit-breaking
switch to the ON position.
● Reset of circuit breaker
Alternator circuit-this circuit breaker is used for protecting the engine. If

the polarities of battery sets are installed reversely, the circuit breaker can prevent
the alternator from damaging the rectifier.
The capacity of circuit breaker is 80amp.
Reset of circuit breaker-press the button to reset the circuit breaker.If the
electrical system works normally, the button will keep at the position where it is
pressed to. Otherwise, check the corresponding circuit. Repair the circuit if
necessary.
● Replacement of fuse
Open the front access door at the left side of the machine.
The fuse panel is no the circuit breaker panel. Open the fuse access cover to
check the fuse.
Fuse- the fuse protects the circuit system against damages due to overloading.
If the fuse is blown out, please replace it and check and/or repair the circuit.
Caution: during replacement, fuses of same type and capacity shall be used;
otherwise, it will damage the circuit system.
Caution: if the fuse is frequently blown out, there may be faults in the
circuit system.
In order to replace the fuse, the fuse puller stored on the fuse panel shall be
used. There are totally 3 fuses of 5amp, 4 fuses of 10amp, 2 fuses of 15amp and 1
fuse of 30amp on the fuse panel for reserve.
The fuses used for protecting the circuits are listed below. The fuse ampere
values are marked on each circuit.
(1) Standby－5Amp
(2) Standby－10Amp
(3) Standby－10Amp
(4) Standby－10Amp
(5) Standby－15Amp
(6) Standby－30Amp
(7) Standby－30Amp
(8) Engine control unit－15Amp
(9) Horn－10Amp
(10) Timing relay－10Amp
(11) Cab lamp－10Amp
(12) Engine starter switch－10Amp
(13)Boom indicator－10Amp
(14) Engine control unit and pump control unit－10Amp
(15) Attachment valve control unit－15Amp
(16) Roof lamp and memory－10Amp
(17) A/C fan－15Amp
(18) Electric refueling pump－30mp
(19) Standby－5Amp
(20) Standby－5Amp
(21) Standby－10Amp
(22) Standby－10Amp
(23) Fuel pump－10Amp
(24) Windscreen washer and wiper－10Amp
(25) Undercarriage lamp－10Amp
(26) Standby switch and monitor－5Amp
(27) Heater base－5Amp
(28) Lower windscreen washer and wiper－10Amp
(29) Cigarette lighter－10Amp
(30) Switch control board and radio equipment－5Amp
(31) Attachment solenoid coil－10Amp
(32) 12V, 7V rectifier 1－10Amp
(33) 12V, 7V rectifier 2－10Amp
(34) A/C－15Amp
(35) Rapid coupler－5Amp
(36) Signal lamp－10Amp
(37) Cab fan－10Amp
(38) Auxiliary circuit－10Amp
3.17 A/C
Warning!
Inhaling the refrigerant through smoking or through smog emitted
by comburent containing refrigerant gas will lead to personal
injuries or even death. When repairing the A/C or in places with
refrigerant gas, it is not allowed to smoke.
Caution: when adding or replacing the refrigerant, only those
recommended by CATERPILLAR can be used. Otherwise, the
system may be damaged.
(2) Start the engine, and turn the engine speed knob to the MEDIUM SPEED
position.
(3) Open the left front access door.
(4) Observe the liquid reservoir-dryer sight glass and record the refrigerant
quantity.
①There are very few air bubbles in the sight glass (A), and this indicates that
the refrigerant is sufficient.
②There are many air bubbles in the sight glass (B), and this indicates that the
refrigerant is insufficient.
③There are a few air bubbles in the sight glass (C), and this indicates that
there is almost no refrigerant.
④Run the A/C which lacks of refrigerant may damage the compressor.
⑤Keep the A/C in good condition throughout the year. Run it a few minutes
every week so that the compressor can rotate. In this way, refrigerant leakage can be
prevented. Dry seal on the compressor will cause leakage.
● Check and replacement of A/C and cab heater filter.
Caution: if the filter cartridge of air circulating filter is blocked by dust, the
performance of A/C or cab heater will be lowered and their service life be
shortened. To avoid this, please clean the filter cartridge of air circulating
filter as necessary.
The circulating filter is located at the lower part at the left side of the cab.
(2) Pull the filter cartridge upward to remove it.
(3) Clean the filter cartridge with the compressed air of which the maximum
pressure is 200Kpa (2bar).
(4) After cleaning the filter cartridge, please check it. If the filter cartridge is
damaged or seriously contaminated, please replace it with a new filter
cartridge. Make sure that the filter cartridge is dry.
Chapter IV Storage of Kelly Bar
4.1 Cleaning of kelly bar
Before cleaning the kelly bar, clean the whole machine thoroughly. Before
cleaning, remove the kelly bar battery first or carry out sufficient waterproof
treatment to prevent battery short circuit.
When cleaning the kelly bar, do not use the corrosive liquid, otherwise, the
machine surface or other elements and hydraulic components may be corroded.
When cleaning using high-pressure water gun, please protect the electric
equipment and hydraulic components.
After cleaning at low temperature environment, dry the kelly bar
immediately by blowing or wiping to avoid surface freezing.
4.2 Maintenance during Long Term Storage
4.2.1 Kelly bar maintenance during storage
1. Check the machine, and repair the worn or damaged parts. If necessary,
replace the parts.
2. Clean the filter cartridge of the air filter.
3. Retract the telescopic hydraulic cylinder. Apply grease on the exposed
part of the hydraulic piston rod.
4. Lubricate all lubricating point.
5. Place the kelly bar on the solid and flat ground. If necessary, place thick
steel plates or boards with large enough area under the crawler.
6. Clean the kelly bar. Especially when stored in winter seasons, all parts of
the kelly bar, particularly the crawler, must be cleaned.
7. After charging the battery, remove it and store in a dry and safe place. If
the battery is not removed, disconnect the battery negative cable from the (-)
terminal.
8. In winter seasons, antifreeze shall be use, or drain out the water
completely. The freezing point of antifreeze used by Beijing CSR Times
Locomotive and Rolling Stock Mechanics Co., Ltd. is -35℃, if the ambient
temperature is below -35℃, the cooling water shall be drained out. If the
cooling system is emptied, make sure to put a warning sign of “no water in the
radiator” at a conspicuous place.
9. Loosen the belts of the alternator and the cooling fan.
10. Paint at essential places to avoid rusting, such as protect the surface of
telescopic beam and mast guide rail with grease.
11. Store the machine at a dry and safe place. If it is stored outdoor, a
tarpaulin shall be used.
12. If the machine will be stored for a long time, operate and run it at least
once a month.
13. During the storage, frequently remove the dust on the surfaces of gear
ring and driving wheel and check if there is corrosion, and clean and apply the
grease for lubrication if necessary.
4.2.2 Maintenance when moving the kelly bar out of garage
Caution: only start the engine at the ventilated places.
If the machine is stored for a long time, the thin oil layer on the sliding
surfaces may be damaged. Therefore, it is necessary to circulate the hydraulic
functions of the traveling, swing and operating hydraulic systems for 2-3 times
to lubricate the sliding surfaces.
1. Before storage, if the hydraulic cylinder piston rod is applied with grease,
the grease must be removed.
2. Adjust the belt tension of the alternator and the fan.
3. Check all the hoses and their connections.
4. Install the new fuel filter. Replace the engine oil filter and inject the oil
into the engine oil tank.
5. Fill the fuel tank, and exhaust the fuel system.
6. Check all liquid levels and oil quality.
7. Start the engine.Before full-load operation, run the engine for a few
minutes at half speed.
8. Circulate all hydraulic functions several times.
Description: after long-term storage of the machine, the following steps
must be carried out.
1) Check all the hoses and their connections.
2) Preheat the engine.
3) Stop the engine.
4) Install the new fuel filter. Replace the engine oil filter and inject the oil
into the engine oil tank.
Annex I Tightening Torques for Bolts (from GB/T 5000.10-2007)
Bolt Nominal diameter mm

perfor 6 8 10 12 16 20 24 30 36 42 48 56 64 73
mance Tightening torque N.m
rating
5.6 3.3 8.5 16.5 28.7 70 136.3 235 472 822 1319 1991 3192 4769 6904
8.8 7 18 35 61 149 290 500 1004 1749 2806 4236 6791 10147 14689
10.9 9.9 25.4 49.4 86 210 409 705 1416 2466 3957 5973 9575 14307 20712
12.9 11.8 30.4 59.2 103 252 490 845 1697 2956 4742 7159 11477 17148 24824
Note:
1. Applicable to coarse teeth bolts and screws;
2. Tightening torque tolerance of ±5%;
3. Preload is calculated based on σs of the material;
4. Coefficient of friction μ = 0.125;
5. The given value is applicable to the bolts lubricated, while for the un-lubricated bolts, the tightening torque shall be 133% of the value
in the table.
Annex II Lubricant Viscosity Table
Lubricant viscosity table at ambient temperature
Chamber or ℃ ℉
Oil viscosity
system Mini. Maxi. Mini. Maxi.
SAEOW20 -40 +10 -40 +50
SAEOW30 -40 +30 -40 +86
Engine SAE5W30 -30 +30 -22 +86
crankcase SAE5W40 -30 +40 -22 +104
SAE10W30 -20 +40 -4 +104
SAE10W40 -15 +50 +5 +122
SAEOW20 -40 +40 -40 +104
SAEOW30 -40 +40 -40 +104
SAE5W30 -30 +40 -22 +104
SAE5W40 -30 +40 -22 +104
SAE10W -20 +40 -4 +104

Hydraulic
SAE30 +10 +50 +50 +122
system
SAE10W30 -20 +40 -4 +104
SAE15W40 -15 +50 +5 +122
Biodegradable
hydraulic oil -25 +43 -13 +110
(HEES)
SAEOW20(1) -40 0 -40 +32

Final drive,
SAEOW30(1) -40 +10 -40 +50
rotary table
SAE5W30(1) -30 10 -22 +50
driving device,
SAE10W -30 0 -22 +32
track roller
SAE30 -25 +25 -13 +77
and carrier
SAE50 -15 +50 +5 +122
roller
SAE60 -10 +50 +14 +122
Note: these are special lubricating oils containing synthesis basic materials,
and the basic materials do not contain polymer viscosity index improver. High
viscosity index of synthetic oil provides the inherent thickening property.
Beijing CSR Times Locomotive & Rolling Stock Machines Co., Ltd.
Annex III Table for Amount of Solvents and Oil
Approximate refueling amount
Reco
mme
Part or US
ndati
Liter Recommendation and type
system gallon on
and
type
Cooling CATERPILLAR extended life coolant
35 9.2 7.7
system (ELC)
CATERPILLAR extended life coolant

Coolant tank 1.5 0.4 0.3
(ELC)
Fuel tank 400 109 91 Grade 1 or 2 diesel fuel
Engine
CAT diesel engine oil (DEO) multi-grade
crankcase
35.5 9.4 7.8 API
equipped
CH-4, API CG-4 or API CF-4
with filter
CATERPILLAR hydraulic oil (HYDO) or

Hydraulic
315 83 69 CATERPILLAR biodegradable hydraulic
oil tank
oil (HEES)(1)
Hydraulic CATERPILLAR hydraulic oil (HYDO) or

410 108 90
system CATERPILLAR biodegradable hydraulic
oil (HEES)(1)
Rotary table CATERPILLAR transmission drive train

19 5.0 4.18
driving oil (TDTO)
Each final CATERPILLAR transmission drive train

15 4.0 3.3
drive oil (TDTO)
Rotary table
29 7.7 6.4 Multipurpose lithium grease NLG12 grade
gear
Rotary drive
Mboil automotive gear oil MobilVBE
motor 18 4.8 3.95
HD80w-90
reducer
Mboil automotive gear oil MobilVBE

Rotary drive 138 48 39．5
HD80w-90
Annex IV Warranty List of Main Parts of TR150D Model Rotary
Drilling Rig
1. Warranty List of Main Parts
Name Warranty cycle Remarks
Chassis One year
Kelly bar Six months Exclusive of rubber
vibration damping ring
Rotary drive One year Exclusive of rotary
drive sliding lug nylon
board and rotary drive
internal spline bushing
Elevator Six months
Drilling bucket Six months Exclusive of bucket
teeth
All hydraulic motors One year
All reducers One year
Hydraulic oil cylinder One year
Hydraulic valve One year
2. Wear part list:
1. Nylon board for rotary drive sliding lug;
3. Rotary drive spline bushing;

4. Rubber vibration damping disc for Kelly bar;
5. Bucket teeth for drilling bucket;
6. Large/small pulley for cathead;
7. Nylon board for servo frame sliding lug;
8. Oil seal and seal ring for hydraulic components;
9. Seal rings for hydraulic rubber hose joint connection;

Operation Manual of TR150D Rotary Drilling Rig

Uploaded by

Copyright:

Available Formats

Operation Manual of TR150D Rotary Drilling Rig

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Operation Manual of TR150D Rotary Drilling Rig

Uploaded by

Copyright:

Available Formats

What is the purpose of the company?

What is the purpose of the company?

What are the main components and features of the TR150D rotary drilling rig?

What are the main components and features of the TR150D rotary drilling rig?

Operation Manual of TR150D Rotary

1.1 Application Scope of Drilling Rig ................................................................................................ 11

1.2 Technical Specification ................................................................................................................. 11

Chapter II Introduction of Structure and Functions ....................................................................................... 13

2.1 Structure of Rotary Drilling Rig ................................................................................................... 13

2.1.1 Over dimensions ................................................................................................................... 13

2.1.2 Introduction of drilling rig structure and functions............................................................... 14

2.2 Function Description .................................................................................................................... 17

2.2.1 Cab layout ............................................................................................................................. 17

2.2.2 Hydraulic system pilot control switch .................................................................................. 18

2.2.3 Pressure gauge ...................................................................................................................... 18

2.2.4 Mast leveling lever ............................................................................................................... 18

2.2.5 Traveling operating lever (pedal).......................................................................................... 19

2.2.6 Display screen ....................................................................................................................... 19

2.2.7 Engine monitoring panel....................................................................................................... 34

2.2.8 Working hourmeter ............................................................................................................... 70

2.2.9 Left and right operating levers .............................................................................................. 70

2.2.10 Limit switches ....................................................................................................................... 72

2.2.11 Warning device ..................................................................................................................... 74

2.2.12 A/C System ........................................................................................................................... 74

2.2.13 Operation description of radio .............................................................................................. 75

Chapter III Basic Operations of Drilling Rig .................................................................................................. 77

3.1 Before start of engine.................................................................................................................... 77

3.2 Start of engine ......................................................................................................................................... 77

3.3 Stop of Engine .............................................................................................................................. 79

3.4 Checking after Stop of Engine ...................................................................................................... 81

3.5.1 Traveling of drilling rig ........................................................................................................ 81

3.5.2 Swing of superstructure ........................................................................................................ 88

3.5.3 Erection/lowering and verticality adjustment of mast .......................................................... 89

3.5.4 Lifting and lowering of luffing ............................................................................................. 91

3.5.5 Operations of main and auxiliary winches............................................................................ 92

3.5.6 Operations of pressing cylinder ............................................................................................ 94

3.5.7 Control of power unit............................................................................................................ 94

3.5.8 Depth measuring device........................................................................................................ 95

3.5.9 Extension of tracks ............................................................................................................... 95

Chapter IV Construction of Drilling Rig ......................................................................................................... 97

4.1 Construction preparations ............................................................................................................. 97

4.2 Positioning of drilling rig.............................................................................................................. 99

4.2.1 Measurement and setting-out ................................................................................................ 99

4.2.2 Positioning of drilling rig...................................................................................................... 99

4.2.3 Embedment of pile casing: ................................................................................................. 100

4.2.4 Positioning of pile hole ....................................................................................................... 102

4.3 Construction of drilling rig ......................................................................................................... 102

4.3.1 Collaring ............................................................................................................................. 102

4.3.2 Drilling................................................................................................................................ 103

Chapter V Disassembly and Installation of Drilling Rig.............................................................................. 106

5.1 Installation and disassembly requirements ................................................................................. 106

5.1.1 Safety .................................................................................................................................. 106

5.1.2 General precautions ............................................................................................................ 106

5.1.3 Precautions for installation and disassembly ...................................................................... 107

5.2 Installation of drilling rig ............................................................................................................ 108

5.3 Disassembly of drilling rig ......................................................................................................... 113

Chapter VI Transport of Drilling Rig ............................................................................................................ 118

6.1 Transport parameters .................................................................................................................. 118