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Geax XD5 Operation And Safety Manual

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GEAX
s.r.l.
XD5
J20
OPERATION AND SAFETY
MANUAL
Rev.01/17

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Summary of Contents for Geax XD5

  • Page 1 GEAX s.r.l. OPERATION AND SAFETY MANUAL Rev.01/17...
  • Page 2 Serial number : 020J005X GEAX s.r.l via Campoceraso,13 60027 Osimo (AN) ITALY Tel +39 0717131953 Fax +39 071715199 www.geax.it info@geax.it...
  • Page 3 Foreword This manual provides information to operators on the features and operation of the XD5 track-mounted drilling rig. It also describes the hazards relating to the rig's operation and what to do to minimize the risks. The purpose of this manual is to prepare safety-minded operators;...
  • Page 4 GEAX s.r.l Chapter 1 All protective clothing and devices must be in good conditions and clean enough not to affect their protection capacity or wearing comfort. In particular, heavy clothing must be used as required by the temperature on the jobsite: thermal comfort contributes to keeping the attention threshold high.
  • Page 5 GEAX s.r.l Chapter 1 1.5 Symbols used in this manual Danger (or other) signs are used at various points in the manual to call the reader’s attention to issues regarding potentially dangerous activities. Situation, procedure, context or other factor that can lead to increased risk.
  • Page 6 GEAX s.r.l. Chapter 2 Chapter 2 TRANSPORTING THE DRILLING RIG 2.1 Before/after transporting the drilling rig 2.1.1 Removing the tool If the rig is standing on farmland, proceed as follows: • Lower the tool to the ground and make a small drilling rotation to ensure that the tool remains stable once it is detached from the kelly bar.
  • Page 7 GEAX s.r.l. Chapter 2 Removing the tubular structure for the auxiliary winch 2.1.2 The structure for the auxiliary winch must be folded according to the following procedure: • Place the mast to the necessary height to allow to secure the support rod at both ends;...
  • Page 8 GEAX s.r.l. Chapter 2 • Remove the safety catch and pull the top pin fig.2.1.2.3; fig.2.1.2.3 • Operators at a safe distance fig.2.1.2.4; • Slowly raise the mast, at the same time the structure of the 2nd winch will start to rotate lowering fig.2.1.2.4;...
  • Page 9 GEAX s.r.l. Chapter 2 fig.2.1.2.6 fig.2.1.2.7 • hook the winch rope to the appropriate eyebolt; • lock the oscillatory movements of the structure of the 2nd winch with adequate safety strap belt. The bolts must be replaced in the seats with their nuts and the pin with the...
  • Page 10 GEAX s.r.l. Chapter 2 Installation of the tubular structure for the auxiliary winch 2.1.3 The structure for the auxiliary winch must be positioned according to the following procedure: • Place the mast to the necessary height to allow to secure the support rod at both ends;...
  • Page 11 GEAX s.r.l. Chapter 2 fig.2.1.3.4 fig.2.1.3.5 • Insert the locking pin with its safety catch fig.2.1.3.6; fig.2.1.3.6 • Remove the nuts and remove the shaft by removing the bolts beginning with the lower fig.2.1.3.6. TRANPORTING THE DRILLING RIG...
  • Page 12 GEAX s.r.l. Chapter 2 fig.2.1.3.6 fig.2.1.3.7 In work configuration, the auxiliary winch rope should always be attached to the appropriate eyebolt fig.2.1.3.7. Installing the tool 2.1.4 The steps are as follows: • raise the kelly bar in order to leave enough space below for the tool;...
  • Page 13 GEAX s.r.l. Chapter 2 2.2 Loading, unloading and anchoring the rig on a truck / semitrailer Positioning the truck / semitrailer 2.2.1 The trailer must be placed on level ground, firm enough to allow using the loading ramps and performing the manoeuvres required to align the rig to the ramps.
  • Page 14 GEAX s.r.l. Chapter 2 fig.2.2.2.3 , in particular, show the approximate point where the fig. 2.2.2.3 2.2.2.6 rig changes inclination when passing from the ramp to the deck or vice versa. In this stage the rig should travel at its lowest speed so that the change occurs as gently as possible.
  • Page 15 GEAX s.r.l. Chapter 2 show unloading operation. fig.2.2.2.6 fig.2.2.2.6 Always keep perfect alignment with the ramps. Going down from the truck did not proceed as . This configuration is fig.2.2.2.7 less stable. fig.2.2.2.7 To climb the slope use the ramps supplied, placing them so that their length and rigidity are compatible with the rig's gradeability and weight.
  • Page 16 GEAX s.r.l. Chapter 2 rubber tires provide insulation from the ground and allow very high voltages. This risk remains even on the ground when the tracks are covered by insulating material (rubber tracks). Non-electric cables pose risks of a mechanical nature. They might be strong enough to topple supporting structures before breaking, causing danger to bystanders.
  • Page 17 GEAX s.r.l. Chapter 2 at a speed that is compatible with the conditions of the road and such as to not compromise the stability of the load at any time. TRANPORTING THE DRILLING RIG...
  • Page 18 GEAX s.r.l. Chapter 3 Chapter 3 DRILLING RIG JOBSITE OPERATIONS 3.1 Moving the rig in the jobsite Pre-planning the route 3.1.1 Before moving the drilling rig in the jobsite you should survey (on foot) the area where the rig is to be placed, and plan the path of travel by which to get there.
  • Page 19 GEAX s.r.l. Chapter 3 • Maximum upward slope 12° (20% gradient) with cabin aligned with the direction of travel, facing forward fig. 3.1.1.2 slope fig.3.1.1.2 Climb the slope along the line of maximum gradient (<20%). This will prevent the rig from tilting sideways.
  • Page 20 GEAX s.r.l. Chapter 3 • Maximum lateral slope 7° (12% gradient), with extended undercarriage and cabin aligned with the direction of travel, (both directions); fig. 3.1.1.3 • Maximum lateral slope 3° (5% gradient) with close undercarriage and cabin aligned with the direction of travel (both directions); to be used only to cross narrow passages.
  • Page 21 GEAX s.r.l. Chapter 3 • Maximum lateral slope 5° (9% gradient) with cabin turned sideways to the direction of travel and unstable centre of gravity fig. 3.1.1.4 slope fig.3.1.1.4 Drive the rig at a low, steady speed. The recommended gradient limits must never be exceeded.
  • Page 22 GEAX s.r.l. Chapter 3 • Maximum lateral slope 12° (20% gradient) with cab turned sideways to the direction of travel and stable centre of gravity fig. 3.1.1.5 slope fig. 3.1.1.5 Bear in mind the protruding counterweight at the back. DRILLING RIG JOBSITE OPERATIONS...
  • Page 23 GEAX s.r.l. Chapter 3 In general, when the rig is moving, the bucket should be held as low as possible (as shown in the figures), but not so low as to risk scraping on uneven ground. This might damage the rig structure or make the rig unstable.
  • Page 24 GEAX s.r.l. Chapter 3 Borehole drilling hazards 3.3.2 Consult the worksite supervisor or chief of operations to make sure: • that no underground distribution networks (gas, power, telephone, water, sewage, etc.) are present in the planned drilling sites; • that drilling a borehole in the vicinity of a structure will not affect its stability;...
  • Page 25 GEAX s.r.l. Chapter 3 3.5 Risk management in case of unexpected obstacles inside borehole Damaging buried installations 3.5.1 In case the bucket hits and damages a buried installation, due to wrong information received, proceed as follows. 1. If the buried object is a power cable, pull the bucket out of the hole to eliminate the contact.
  • Page 26 GEAX s.r.l. Chapter 3 3.6 Hazards posed by boreholes inside work area Operation in the presence of boreholes 3.6.1 As soon as the borehole is completed and the required depth is reached, it must be made safe by setting up barriers preventing access to the hole.
  • Page 27 GEAX s.r.l. Chapter 3 • When shifting the rig, the operator should be able to see vertical points of reference standing out of the ground (buildings, poles, etc.) in order to prevent alterations of his sense of balance. • When shifting the rig, the operator should be able to view the planned route and have perfect visibility of the ground around the rig.
  • Page 28 4.1 Inspecting the drilling rig Periodic inspections 4.1.1 Inspect the drilling rig following the instructions in Manual No. 2 (XD5 Drilling Rig Service Manual), which describes the frequency of the inspections to carry out depending on the operating hours, the work environment and the rig’s age.
  • Page 29 4.3.1 For information on scheduled maintenance and repairs, please consult Manual No. 2 (XD5 Drilling Rig Service Manual). On the worksite, any emergency repair equipment should be kept on service vehicles and not on the drilling rig. Simple inspection equipment (e.g., electric torch, paper towels for cleaning, etc.) can be stored in the compartment on the rig.
  • Page 30 GEAX s.r.l. Chapter 5 Chapter 5 CONTROLS 5.1 Description of drilling rig controls General information on drilling rig controls 5.1.1 The drilling rig is equipped with hydraulically servo-assisted electric controls that require very little effort to be operated, i.e., just enough to win the resistance of the return spring and actuate the electric contact.
  • Page 31 GEAX s.r.l. Chapter 5 fig.5.1.2.2 Joystick. Backwards-forwards controls the main winch; left-right controls cab swing. Joystick. Left-right controls the movement of the mast, forward increases the winch speed. Panel. Depending on its position enables main or aux winches, depth meter.
  • Page 32 GEAX s.r.l. Chapter 5 Acoustic alarm control: 5.1.4 Pressing button P1 on joystick A sounds the acoustic alarm. Rotary and mast controls 5.1.5 The operating controls of the rotary head are two: • pedal R activates rotary rotation clockwise-counterclockwise: • button P2 increases rotation speed.
  • Page 33 GEAX s.r.l. Chapter 5 Move joystick B to the left to lower the rotary and apply a downward thrust on the kelly bar and tool. Move joystick B to the right to lift the rotary and cancel the thrust on the kelly bar and tool.
  • Page 34 GEAX s.r.l. Chapter 5 Main winch and slew controls 5.1.7 The main winch and turret controls are grouped together on joystick A, located on the left-hand side: Push joystick A forward (black arrow) to unwind the main winch and thus lower the Kelly bar and the bucket inside the borehole.
  • Page 35 GEAX s.r.l. Chapter 5 Move joystick A to the right (towards the seat) to make the turret turn clockwise. Move joystick A to the left to make the turret turn counterclockwise. Dozer blade and extending undercarriage controls 5.1.8 Lever L has the double function of positioning (lift-down) the blade and to vary (enlarge-tighten) the undercarriage.
  • Page 36 GEAX s.r.l. Chapter 5 Switch position: TRACK: • Pushing the lever L, the undercarriage extends (black arrow); • Pulling back the lever L, the undercarriage tightens (white arrow). Throttle 5.1.9 The throttle control of the diesel engine is mechanical. • Pushing the lever M, the engine speed and power go down up to the minimum;...
  • Page 37 GEAX s.r.l. Chapter 5 Emergency stop button Using the emergency stop button 5.2.1 The emergency button is installed on the front of the machine which can be easily accessed by an external operator. Pressing down the red mushroom-shaped button stops the engine and consequently all moving parts.
  • Page 38 GEAX s.r.l Chapter 6 Chapter 6 OPERATING THE DRILLING RIG 6.1 Getting Started Positioning on the ground of the drilling machine 6.1.1 The machine must operate on a flat surface. The ground contact of crawlers must be uniform. For this purpose, the dozer blade can be used for leveling the ground when present small irregularities.
  • Page 39 GEAX s.r.l Chapter 6 temporarily, bearing in mind that the final stages of the kelly bar’s descent should be done at a particularly slow rate and immediately releasing the descent control as soon as the tool touches the ground. Behaviour of the winch when rising 6.1.4...
  • Page 40 GEAX s.r.l Chapter 6 fig.6.2.1.2 Stop the rotary, releasing the pedal R, and stop the crowd force moving joystick B to its central (neutral) position; Make rotary head rotate anticlockwise to unlock the kelly bar; Pull back joystick A to lift the tool to the max download height, slightly before the mechanical stop;...
  • Page 41 GEAX s.r.l Chapter 6 Repeat from step 2 if the bottom of the borehole has not been reached obviously jumping point 12; The kelly bar block is used to prevent the tool, in the early stages of fig.6.2.1.1 excavation, can twirl the axis of the kelly bar, enlarging the diameter of excavation fig.6.2.1.4...
  • Page 42 GEAX s.r.l Chapter 6 Operations forbidden when drilling a borehole 6.2.2 During actual drilling (bucket rotating) it is strictly forbidden: • to move the rig • to rotate the pivot cab Precautions when drilling a borehole 6.2.3 During the operations described in , care Par.
  • Page 43 GEAX s.r.l Chapter 6 fig. 6.3.1.1. fig. 6.3.1.2 When the winch is not in use, the hook of the rope must be securely fastened to the eye bolt and the rope should be subjected to slight tension. This procedure ensures that the hook is not swinging bumping into ruin someone or something and that is not going to get caught in rotating parts with devastating results.
  • Page 44 GEAX s.r.l Chapter 6 • to enable the management of the rope (winding) in the phase of folding the aux winch tubular structure, thus avoiding to work with hands on the switch and thus remain at a safe distance from the pulley;...
  • Page 45 GEAX s.r.l Chapter 7 Chapter 7 CONTROLLING GENERAL HAZARDS 7.1 Fire prevention Refuelling 7.1.1 The following precautions should be applied to reduce fire hazards during refuelling. Use type-approved dispensing systems when refuelling the drilling rig. Stop the engine when refuelling.
  • Page 46 GEAX s.r.l Chapter 7 Checking other fluids 7.1.3 Checking or topping up other fluids (e.g., lubricating oil, hydraulic oil) should be done when the rig is cold, before the start of a work shift (see Maintenance chapter). Leaking of flammable liquids 7.1.4...
  • Page 47 GEAX s.r.l Chapter 7 Hydraulic actuating circuits 7.2.3 The hydraulic fluid is pressurized hydraulic oil. When the rig is working, the hydraulic oil can reach high operating temperatures that make it dangerous in case of contact. Before servicing a hydraulic device in any way, it should be left to rest until it cools down, then depressurized and emptied of oil.
  • Page 48 GEAX s.r.l Chapter 7 Checking tubes and hoses 7.3.3 Regardless of the inspections carried out at the start of the work shift, the cab operator and ground operator – each from their own point of observation – must have an overall view of the drilling rig in order to warn one another of any change in configuration.
  • Page 49 GEAX s.r.l Chapter 7 7.5 Additional equipment Jobsite arrangement 7.5.1 All the equipment required for work must be arranged in an orderly manner, if possible in a single place and outside the area occupied by the rig when in operation. The reason for this is that a ground operator who is busy preparing equipment cannot pay attention to the rig and all its moving parts.
  • Page 50 GENERAL DESCRIPTION OF DRILLING RIG 8.1 Description of drilling rig The XD5 is a machine designed to drill boreholes using rotary-driven tools. The machine architecture is innovative and patented. The vertical alignment is automatic by gravity, and the kelly bar is round telescopic and interlocking.
  • Page 51 GEAX s.r.l Chapter 8 8.3 Technical data Mechanical specifications 8.3.1 Rotary head Max. torque [kNm] Max. drilling depth: circular section interlocking kelly bar 11,5 Bucket diameter  Max.  Min. Winch  Max. pull [kN] Mass (without accessories) 2400 [Kg]...
  • Page 52 GEAX s.r.l Chapter 8 8.4 Dimensions Working order 8.4.1 Symbol Dimension [mm] / [ft] Note: Max (Min) working height 2900 (2300) Rear radius (distance from the cabin slewing ring axis) 1059 Front radius from the cabin slewing ring axis to the tool axis...
  • Page 53 GEAX s.r.l Chapter 8 8.4.2 Transport configuration Symbol Dimension [mm] / [ft] Note: Max longitudinal dimension 2690 Max cabin height 2320 Min drilling equipment height 2320 Resting point of kelly bar on loading deck fig. 8.4.2.1 Motor vehicle regulations require the topmost point of the drilling rig, when arranged on the transport vehicle, to be <4m (13.1 ft) from the ground (see...