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Geax EK75CFAJ160 Operation And Safety Manual

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GEAX
s.r.l.
EK75CFA
J160
OPERATION AND SAFETY
MANUAL
Rev.01/17

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Summary of Contents for Geax EK75CFAJ160

  • Page 1 GEAX s.r.l. EK75CFA J160 OPERATION AND SAFETY MANUAL Rev.01/17...
  • Page 2 Serial number : 160J075E GEAX s.r.l via Campoceraso,13 60027 Osimo (AN) ITALY Tel. +39/0717131953 Fax. +39/071715199 www.geax.it info@geax.it...
  • Page 3 GEAX s.r.l Chapter 1 Chapter 1 OPERATOR TRAINING Foreword This manual provides information to operators on the features and operation of the EK75 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 Operations preparing transportation Removing the tool 2.1.1 The auger tool (two parts + the tip) can only be disassembled with the mast upright. Disassemble the tip, the lower part and then the upper part.
  • Page 7 GEAX s.r.l. Chapter 2  Hook the tool (lower element) to the rope of the secondary winch.  Command a slight tensioning of the rope.  Loosen the recessed safety bolt and slip the pin off.  Climb down the ladder and remove it.
  • Page 8 GEAX s.r.l. Chapter 2 fig.2.1.1.1 fig.2.1.1.2 Disassembly of mast support extension. 2.1.2 Before folding the mast, the support extension must be disassembled TRANSPORTING THE DRILLING RIG...
  • Page 9 GEAX s.r.l. Chapter 2 Closing mast for travel configuration 2.1.3 Proceed as follows to fold the mast: Lower the rotary to the point indicated in fig.2.1.3.1. Position the pin V on the rotary guide to block downward sliding fig.2.1.3.2 Deactivate the down limit switch of winch 1°.
  • Page 10 GEAX s.r.l. Chapter 2 Remove the bolts and two pins B between the two parts of the mast fig.2.1.2.3 fig.2.1.3.3 Make sure no one is in the trajectory of the folding mast fig.2.1.3.4. Act on the selector D3 to fold the mast.
  • Page 11 GEAX s.r.l. Chapter 2 2.2 Setting up drilling rig at jobsitesite Opening mast for work configuration 2.2.1 Proceed as follows to open the mast:  Remove the bolt A between the two parts of the mast.  Make sure no one is in the trajectory of the opening mast.
  • Page 12 GEAX s.r.l. Chapter 2  Align the mast vertically by acting alternately on the joystick D1 and on the selector D2, being careful not to scrape the base of the mast against the ground.  Act on the joystick D1 to achieve the perfect upright position of the mast.
  • Page 13 GEAX s.r.l. Chapter 2 Hook the tool (upper element) to the rope of the secondary winch. Go to a safe area. Lift the tool until the two parts of the joint are aligned. Lean the ladder against the mast. When a second operator at the base guarantees the stability of the ladder by holding it with both hands, climb up to the height of the rotary joint and secure the safety belts to the eyebolt on the mast.
  • Page 14 GEAX s.r.l. Chapter 2 Proceed as follows to assemble the tip: Hook the tip to the rope of the secondary winch. Lift the tip a bit off the ground. Rest the tip on the ground so that the parts of the joint are aligned both axially and with the surfaces of the hexagon.
  • Page 15 GEAX s.r.l. Chapter 2 Fig. 2.2.3.1 2.3 Loading, unloading and anchoring the rig on a semitrailer Positioning the semitrailer 2.3.1 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 16 GEAX s.r.l. Chapter 2 fig.2.3.2.1 fig.2.3.2.2 show the approximate point where the rig changes Figures 2.3.2.2 2.3.2.11 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 17 GEAX s.r.l. Chapter 2 fig.2.3.2.4 fig.2.3.2.5 fig.2.3.2.6 TRANSPORTING THE DRILLING RIG...
  • Page 18 GEAX s.r.l. Chapter 2 show the unloading operation sequence. Figures 2.2.2.7 -8-9-10-11 fig.2.3.2.7 fig.2.3.2.8 fig.2.3.2.9 TRANSPORTING THE DRILLING RIG...
  • Page 19 GEAX s.r.l. Chapter 2 fig.2.3.2.10 fig.2.3.2.11 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. Place the trailer on a sufficiently wide, flat area, free from overhead cables (power lines or other) that might interfere with loading/unloading.
  • Page 20 GEAX s.r.l. Chapter 2 structures before breaking, causing danger to bystanders. After breaking, they might whip around violently as they release the elastic energy accumulated. During loading and unloading, persons on the ground should stay at a safe distance. Anchoring 2.3.3...
  • Page 21 GEAX s.r.l. Chapter 2 fig.2.4.1.2 Clockwise rotation A to B Before taking on transport configuration with mast in the rear Anticlockwise rotation B to A Before starting unloading fig.2.3.2.1 Centre of gravity 2.4.2 In the transport configuration the rig’s centre of gravity is located approximately 60-70 cm in front of the fifth wheel-cab axis.
  • Page 22 GEAX s.r.l. Chapter 2 Replacing extension shaft and relative support rod Disassembling extension shaft 2.5.1 Do as follows to disassemble the extension shaft: Place the rotary as low as possible. Move the hook of the winch 2° near the eyebolt at the top of the extension shaft (slightly below).
  • Page 23 GEAX s.r.l. Chapter 2 fig.2.5.2.1  Fold the mast forwards by acting alternately on the lever D1 and selector D2 fig. 2.5.2.2  An operator must be at the end of the support ready to sustain the weight (40 kg.) to pull the first bolt off fig.2.5.2.2...
  • Page 24 GEAX s.r.l. Chapter 2 fig.2.5.2.2  Loosen the upper bolt 1 and remove it.  Rest the end of the support on the ground.  Support the weight of the rod and remove the second bolt 2.  Place the support on the ground and move it.
  • Page 25 GEAX s.r.l. Chapter 2 fig.2.5.4.1 Push the lower part of the shaft to align it with the pass-through hole of the drag device. Align the shaft so that the sliding guide can be inserted onto the support rod. Turn the shaft so that it blocks on the inserts of the rotary (detail of fig.2.5.4.1...
  • Page 26 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 27 GEAX s.r.l. Chapter 3 • Maximum downward slope 6° (10% gradient), with mast held vertically and cab aligned with the direction of travel, facing forward (fig. 3.1.1.1). • Maximum upward slope 6° (10% gradient), with mast held vertically and cab aligned with the direction of travel, facing forward (fig.
  • Page 28 GEAX s.r.l. Chapter 3 • Maximum upward slope 18° (30% gradient), with mast lowered and cab aligned with the direction of travel, facing forward maximum (fig. 3.1.1.3); downward slope 18° (30% gradient), with mast lowered and cab aligned with the direction of travel, facing backwards (in reverse) (fig.
  • Page 29 GEAX s.r.l. Chapter 3 • Maximum lateral slope 5° (8% gradient), with mast held vertically and cab aligned with the direction of travel, facing either way (fig. 3.1.1.4). fig.3.1.1.4 Drive the rig at a low, steady speed. The recommended gradient limits must never be exceeded.
  • Page 30 GEAX s.r.l. Chapter 3 When travelling in reverse, use the rear-view mirrors and check both sides frequently. In case of poor visibility, stop the rig and inspect the path from a better viewpoint. • Maximum lateral slope 9° (15% gradient), with mast lowered...
  • Page 31 GEAX s.r.l. Chapter 3 • Maximum lateral slope 5° (8% gradient), with mast held vertically, cab turned sideways to the direction of travel and unstable centre of gravity (fig. 3.1.1.6) fig.3.1.1.6 Drive the rig at a low, steady speed. The recommended gradient limits must never be exceeded.
  • Page 32 GEAX s.r.l. Chapter 3 • Maximum lateral slope 5° (8% gradient), with mast held vertically, cab turned sideways to the direction of travel and stable centre of gravity Along the way maximum slope could rise up to 10° (18% (fig. 3.1.1.7).
  • Page 33 GEAX s.r.l. Chapter 3 • When travelling over flat areas, use the configuration shown in ; do not use the configuration shown in except for fig.3.1.1.1-2 fig. 3.1.1.8 very short transfers (i.e., getting over an obstacle). This configuration applies a heavy stress on the crawler's front drive wheels and on the mast guides.
  • Page 34 GEAX s.r.l. Chapter 3 3.3. Prior safety assessment of working conditions Manoeuvring space 3.3.1 Make sure there is a safe distance between the drilling rig and nearby structures or non-removable objects, in order to prevent possible contacts. Check the distance from overhead cables; no rig manoeuvre –...
  • Page 35 GEAX s.r.l. Chapter 3 Removing excavated material 3.4.2 When unloading the excavated material, the person in charge of removing it should wait at a safe distance and move in to remove the material only when the rig, completed the bore, extracts the tool (without rotating it).
  • Page 36 GEAX s.r.l. Chapter 3 the extent of the damage. As a rule, the voltage circulating through telephone cables is not high enough to represent a hazard for operators. As a precaution, however, avoid touching the conductors in the cable or the rig while the contact lasts. Inform the telephone company and move the rig to make room for repairs to be carried out.
  • Page 37 GEAX s.r.l. Chapter 3 The suspended load should never come into contact with the rig itself, to prevent either or both from being damaged or dangerously tangled to each other. When lifting a load, the cab operator should bear in mind that once the load gets off the ground it might begin to sway and injure the ground operator.
  • Page 38 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 39 GEAX s.r.l. Chapter Chapter 4 INSPECTIONS AND IRREGULAR RIG BEHAVIOUR 4.1 Inspecting the drilling rig Periodic inspections 4.1.1 Inspect the drilling rig following the instructions in Manual No. 2 (EK75 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 40 GEAX s.r.l. Chapter Ambient temperature Advanced turning on Working mode [min] -10°<temp.<0° Turning off after the engine starts -15°<temp.<-10° Working simultaneously temp.< -15° Working simultaneously Then, move the rig from its parking area or from the place where it was unloaded from the transport vehicle (see chapter 2) to the drilling site (see chapter 3), then straighten the mast (see chapter 5).
  • Page 41 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 42 GEAX s.r.l. Chapter 5 Symbols identifying the controls 5.1.2 Fig. 5.1.2.1 Joystick. Backwards-forwards controls the main winch; left-right controls cab rotation. Button. Emergency stop Joystick. Backwards-forwards controls the movements of the mast or of the rotary head or of the auxiliary which; left-right controls rotary head rotation.
  • Page 43 GEAX s.r.l. Chapter 5 fig.5.1.2.2 fig.5.1.2.2 Button. Enables manual controls D1 and D2, as well as the automatic alignment of mast P6 and Pr. Selector. Allows associating mast or rotary table movements to joystick B. Selector. In central position enables the 'floating' of winch 1, Set to On (with further clockwise rotation) locks the rotary to the mast (remaining floating active).
  • Page 44 GEAX s.r.l. Chapter 5 Control-lock lever 5.1.3 Lifting lever E will disable all the controls except for the mast alignment controls, (D1-D2) which remain enabled. Pressing button C1, located on panel C on the left, will enable the mast alignment controls D1-D2 and the automatic mast alignment.
  • Page 45 GEAX s.r.l. Chapter 5 Acoustic alarm control 5.1.4 Pressing button P1 on joystick A sounds the acoustic alarm. Mast opening controls 5.1.5 Turn knob D3 anticlockwise to fold mast laterally transport position. This operation must be done only when the mast is in a horizontal position.
  • Page 46 GEAX s.r.l. Chapter 5 Mast alignment controls 5.1.6 The mast alignment control are on panel D, located on the right, and is labelled D1; the control is enabled only when simultaneously pressing safety button C1 on panel C, located on the operator’s left side (regardless of the...
  • Page 47 GEAX s.r.l. Chapter 5 Move lever D1 to the left to make the top of the mast tilt to the left. (tilting). Move lever D1 to the right to make the top of the mast tilt to the right. (tilting).
  • Page 48 GEAX s.r.l. Chapter 5 Mast boom movement control 5.1.7 The mast movement control is on panel D, located on the right, and is labelled D2; the control is enabled only by pressing simultaneously safety button C1 on panel C, located on the operator’s left hand side (regardless of the position of lever E).
  • Page 49 GEAX s.r.l. Chapter 5 Mast movement control 5.1.8 The control to move the mast up and down is joystick B; this control is multifunctional; therefore, it must be set by selectors F1 and D7 (Pay attention to the position of...
  • Page 50 GEAX s.r.l. Chapter 5 Rotary head controls 5.1.9 The main controls of the rotary head are grouped together on the multifunction joystick B, located on the right-hand side. Selector D4 and button P3 allow selecting the rotation speed and the corresponding torque.
  • Page 51 GEAX s.r.l. Chapter 5 By using button P3 joystick together increase rotary head's rotation speed (V3). This is useful when unloading the tool. In CFA mode, do not use to download the auger. Main winch and turret controls 5.1.10 The main winch and turret controls are grouped together on joystick A,...
  • Page 52 GEAX s.r.l. Chapter 5 Pedal switch P5 activates the floating of the main winch; this way the tool lowers at the set speed. The button works only when enabled with selector F1 Move joystick A to the right (towards the seat) to...
  • Page 53 GEAX s.r.l. Chapter 5 BPS control: mechanical locking system between rotary and mast. 5.1.11 This system is to be used when compact or hard soil occurs. Selector F1 in left position enables mast movement. Selector central position shown) enables winch 1 floating.
  • Page 54 GEAX s.r.l. Chapter 5 Auxiliary winch controls 5.1.12 The auxiliary winch is controlled by joystick B. This control is multifunctional; therefore, it must be set by selector D7 (A beep confirms the choice). Button P2 on joystick B sets the system to a higher speed when lowering and raising...
  • Page 55 GEAX s.r.l. Chapter 5 Depth Meter 5.1.13 Press Pr to reset the depth meter. The instrument measures the depth of the borehole by measuring the length of rope deployed by the main winch. The measure is not affected by the movements of the mast when applying thrust.
  • Page 56 GEAX s.r.l. Chapter 5 Pump selection 5.1.14 The number of hydraulic pumps that feed the hydraulic system can be selected: selector D6 allows choosing 1 or 2 pumps. By varying the capacity, the rotary head basic speed also varies: • for normal foundation drilling operations two pumps are used;...
  • Page 57 GEAX s.r.l. Chapter 5  winch 2 UP limit switch can be disabled only to easily wind the winch safely when the machine is placed in transport configuration;  winch 1 UP limit switch can be disabled only to easily place the machine in safety conditions when it is locked due to a limit switch malfunction;...
  • Page 58 GEAX s.r.l Chapter 6 Chapter 6 OPERATING THE DRILLING RIG 6.1 Raising the mast Vertical mast alignment 6.1.1 To set the mast up vertically, press lever D1 on panel D with your right hand while pressing button C1 with your left hand. The purpose is to...
  • Page 59 GEAX s.r.l Chapter 6 6.2 Testing the safety devices Testing the main winch (1) up limit switch 6.2.1 At the start of the work shift, check that the warning light indicating disengagement of the limit switch is off, and then move the rotary up.
  • Page 60 GEAX s.r.l Chapter 6 6.3 Drilling a borehole Control sequence for making the borehole 6.3.1 Make sure that the mast is vertical. Turn selector D5 to lock the undercarriage. Place the rotary head at the maximum height on the mast (joystick A).
  • Page 61 GEAX s.r.l Chapter 6 to the top of the extension rod; in this position the rod has a step on the guides which discharges the weight of the rotary onto the tool. fig.6.3.1.3 fig.6.3.1.3 The rotary starts to turn once again (joystick B to the left), pressing the P5 button to ensure floating.
  • Page 62 GEAX s.r.l Chapter 6 fig.6.3.1.4 The tool is removed from the hole by commanding the upward movement (joystick A back). The operation consists in two phases: during the first phase, stop when the auger protrudes about 1 m from the ground; in this phase the rotary is lowered (the tool remains still due to friction with the ground) to be hooked to the base of the extension rod (inverse operation than point 9);...
  • Page 63 GEAX s.r.l Chapter 6 Using thrust device (BPS) to drill hard soil 6.3.2 Referring to the previous chapter, during point 7, the auger should move forward, screwing into the ground, pushed by the force of its weight. At times, this forward-screwing movement does not occur due to the firmness of the ground.
  • Page 64 GEAX s.r.l Chapter 6 Operations forbidden when drilling a borehole 6.3.3 During actual drilling (tool rotating) it is strictly forbidden: • to move the rig by switching selector D5 • to rotate the pivot cab • to modify the mast’s vertical alignment, especially when the mast rests on the ground.
  • Page 65 GEAX s.r.l Chapter 6 fig. 6.4.1.1. fig. 6.4.1.2 Simultaneously pressing button P2 increases the rope's rate of descent. This function should be used only when lowering a reinforcement cage inside the borehole to increase its downward speed and get past narrowings where the cage might get stuck.
  • Page 66 GEAX s.r.l Chapter 6 When the winch is not in use, the hook at the rope’s end must be secured to eyebolt B (Fig. 2.1.2.2) and the rope itself kept slightly tensioned. This will ensure that the hook does not sway around with the risk of hitting persons or objects, and will prevent it from getting tangled in moving parts with disastrous results.
  • Page 67 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 68 GEAX s.r.l Chapter 7 The metal contact between the nozzle and the filler prevents sparking caused by electrostatic discharges. Do not carry fuel cans in or on the drilling rig. Pay attention to the hot parts of the rig and be careful not to splash them with fuel that may be accidentally spilled during refuelling.
  • Page 69 GEAX s.r.l Chapter 7 7.2. Preventing burns from hot surfaces or toxic substances General information 7.2.1 When the rig is working, certain parts reach high operating temperatures that can cause burns if touched. In descending order of danger, the hot parts to be careful of with reference to the internal combustion engine are: the exhaust, the lubrication circuit, the cooling circuit and the cylinder head.
  • Page 70 GEAX s.r.l Chapter 7 7.3 Pressurized devices Hydraulic actuating circuits 7.3.1 The parts of the rig that are hydraulically actuated are driven by pressurized oil. Before servicing any such device it must be depressurized, without loosening the fittings but following the instructions in the service manual.
  • Page 71 GEAX s.r.l Chapter 7 7.4 Entering and exiting the drilling rig cab Proper position and movements 7.4.1 Do not get on or off the machine when it is moving. Do not get on or off the machine when the hydraulic lock (E) is not activated.
  • Page 72 GEAX s.r.l Chapter 7 7.6 Using the emergency stop button Handling a dangerous situation 7.6.1 The emergency button should be used only when the ground operator realizes that the cab operator may not be quick enough to act on the controls in the presence of a dangerous event.
  • Page 73 GEAX s.r.l Chapter 8 Chapter 8 GENERAL DESCRIPTION OF DRILLING RIG 8.1 Description of drilling rig The EK75CFA is a machine designed to drill boreholes using a continuous flight auger known as "CFA". The drilling rig presents an innovative articulation of the mast that allows a wide range of operative positioning.
  • Page 74 GEAX s.r.l Chapter 8 8.3 Technical data Mechanical specifications 8.3.1 Rotary head Max. torque 7500 [DaNm] Max. drilling depth: 16,5 Tool diameter  Max. 0.75  Min. Mast adjustment in working position:  Rotation on transverse plane ±5 [°]  Rotation on longitudinal plane ±5...
  • Page 75 GEAX s.r.l Chapter 8 8.4 Dimensions Working order 8.4.1 Symbol Dimension [mm] Note: Max height in working conditions 19600 Extension kelly stroke 5000 Tail swing 2740 Front radius fifth–wheel axis – bucket axis 2300-3800 Rotary stroke along the mast 11000 Distance of auger axis from frontmost point of mast fig.
  • Page 76 GEAX s.r.l Chapter 8 8.4.2 Transport configuration Symbol Dimension [mm] Note: Typical height (not including flexible parts). Horizontal position with mast 3100 entirely lying on loading deck is also acceptable. Length 10500 Cab height (including safety guards) 3100 Resting point of mast bottom on loading deck (inside crawler tracks perimeter) fig.
  • Page 77 GEAX s.r.l Chapter 8 8.4.3 Spatial requirements during positioning manoeuvres fig. 8.4.3.1 The unbroken red line shows the maximum reach of the top of the rig during the positioning manoeuvres. The dashed line shows the positions that must not be assumed, as they would not be visible to the operator and are not needed for any operation.