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Geax XD5 Maintenance Manual

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GEAX
s.r.l.
XD5
MAINTENANCE MANUAL
Rev. 01/17

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Summary of Contents for Geax XD5

  • Page 1 GEAX s.r.l. MAINTENANCE 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 The personnel in charge must have previous experience in the field of mechanical maintenance and know the general safety regulations. Before performing any operation on the drilling unit of the machine one must read the “XD5 MAINTENANCE MANUAL ” and only then, after having understood the contents, one can proceed.
  • Page 4 GEAX s.r.l. Chapter 1 Situation, procedure, context or other factor that can lead to increased risk of intoxication or poisoning by harmful substances. Situation, procedure, context or other factor that can lead to increased risk of intoxication or poisoning by harmful substances.
  • Page 5 Interventions to adapt the drilling machine to special work requirements. 1.2.1 Interventions to adapt the drilling machine to special work requirements must GEAX s.r.l.. necessarily be implemented by Any changes made by the customer to the machine will void any warranty GEAX s.r.l..
  • Page 6 GEAX s.r.l. Chapter 2 Chapter 2 DRILLING MACHINE SCHEDULED MAINTENANCE 2.1 General information concerning scheduled maintenance Scheduled maintenance operations 2.1.1 This refers to periodic maintenance operations with or without replacement of parts or fluids. The frequency is related either to the period of effective operation of the machine, marked by the relevant "hour counter"...
  • Page 7 GEAX s.r.l. Chapter 2 2.2 Scheduled lubrication Scheduled lubrication operations with grease 2.2.1 The machine features a series of isolated points where lubrication must be made manually, as they are not equipped with pressurised circuits. These points feature a connection for the lubricator.
  • Page 8 GEAX s.r.l. Chapter 2 fig.2.2.1.2 LUBRICATION INTERVENTIONS FREQUENCY NOTES DESCRIPTION OF INTERVENTION POINTS Swing post (2 point) Swing post cylinder (2 points) Pull-push hydraulic cylinder (2 points) Rotary slewing ring (2points) Rotary gears (2 points) + every wash with Sliding guides (8 points)
  • Page 9 GEAX s.r.l. Chapter 2 Operations relating to the replacement of lubrication / hydraulic oils 2.2.2 First of all: • operate when the components are not hot; • provide a container to collect the lubricant drained from the machine and for any leakage during the loading stage;...
  • Page 10 GEAX s.r.l. Chapter 2 Management of all waste fluids drained from the machine 2.2.6 Such fluids cannot be disposed of in the environment and should be taken to waste collection centres in compliance with the regulations in force in the country where the machine operates.
  • Page 11 GEAX s.r.l. Chapter 2 Inspection of the auxiliary winch rope Diameter 7 mm Operation Frequency Diameter [hours] [mm] at the Inspection with the mast in transport position of the section of beginning rope from the winch to the rope terminal.
  • Page 12 GEAX s.r.l. Chapter 2 Pulleys scheduled inspection 2.3.2 The pulleys are made of synthetic composite material and are subject to wear. The table indicates the inspection frequency. tab.2.3.2.1 Pulleys inspection Operation Frequency [hours] Inspection, with the mast tilted, of the integrity of the pulleys of...
  • Page 13 GEAX s.r.l. Chapter 2 2.4 Scheduled inspection of bolts tightness Inspection of tightness torque of component bolts. 2.4.1 Due to the vibrations and adjustments that may cause loosening, should periodically check the tightening of the bolts of the main components. The table supplies the indications and frequency.
  • Page 14 GEAX s.r.l. Chapter 2 FREQUENCY OF BOLT TIGHTENING OPERATIONS DESCRIPTION Slewing ring fixing bolts (outer side) 10.9 Slewing ring fixing bolts (inner side) Main Winch fixing bolts 10.9 Main Winch fixing bolts 10.9 Auxiliary Winch fixing bolts 10.9 Auxiliary Winch fixing bolts 10.9...
  • Page 15 GEAX s.r.l. Chapter 2 Screws tightening torques DIN 267 10.9 12.9 thread hexagon Ø screw pitch  1,25 1,75 1,004 1,204 1,181 1,418 1,050 1,477 1,772 1,146 1,611 1,933 1,429 2,009 2,411 1,549 2,179 2,614 1,941 2,729 3,275 1,997 2,809...
  • Page 16 GEAX s.r.l. Chapter 2 2.5 Mast guide clearance inspection Mast guide slide consumption check. 2.5.1 fig.2.5.1.1 DRILLING MACHINE SCHEDULED MAINTENANCE 2-11...
  • Page 17 GEAX s.r.l. Chapter 2 Tolerance notes Measurement in points A+A’ 0÷1 [mm] 1,2,3 and 4 B+B’ 0÷1 [mm] Measurement in points 1,2,3 and 4 tab.2.5.1.2 The measurements indicated in can be verified using a thickness tab.2.5.1.2, gauge. One must not measure close to the edge (where consumption is higher) but at a certain depth (dotted area fig.2.5.1.1...
  • Page 18 GEAX s.r.l. Chapter 3 Chapter 3 MAINTENANCE ACCORDING TO THE CONDITIONS OF THE DRILLING MACHINE 3.1 General information concerning maintenance according to the conditions of the drilling machine. Non-scheduled maintenance operations 3.1.1 This refers to the operations that are carried out when certain situations/conditions occur on the drilling machine, regardless of the work time.
  • Page 19 GEAX s.r.l. Chapter 3 cc) if cases such as those below occur, according to standard ISO 4309/90;  the pictures are taken from the Teci manual MAINTENANCE ACCORDING TO THE CONDITIONS OF THE DRILLING M.
  • Page 20 GEAX s.r.l. Chapter 3 MAINTENANCE ACCORDING TO THE CONDITIONS OF THE DRILLING M.
  • Page 21 GEAX s.r.l. Chapter 3 MAINTENANCE ACCORDING TO THE CONDITIONS OF THE DRILLING M.
  • Page 22 GEAX s.r.l. Chapter 3 MAINTENANCE ACCORDING TO THE CONDITIONS OF THE DRILLING M.
  • Page 23 GEAX s.r.l. Chapter 3 Characteristics of the ropes used 3.2.2 The tables below illustrate the characteristics of the ropes used. tab.3.1.3.1-2 MAIN WINCH ROPE Characteristics data Nominal diameter [mm] Min. breakage load 6670 Strength class daN/mm Total length 17* (standard kelly)
  • Page 24 GEAX s.r.l. Chapter 3 Replacement of the main winch rope 3.2.3 The main winch rope must be replaced as follows: • configure the drilling machine in the transport configuration, placing the Kelly stub on a support such as to have the swivel as close as possible to the pulley;...
  • Page 25 GEAX s.r.l. Chapter 3 • Release the cable gland springs fig. 3.2.3.5; fig.3.2.3.5 • prepare the new rope according to fig.3.2.3.6 fig.3.2.3.6 • Secure the end of the new rope to the winding drum by wrapping it around the "A" thimble , clamping it inside the pocket using a copper or fig.3.2.3.2...
  • Page 26 GEAX s.r.l. Chapter 3 • Replacement of the bearing when replacing the rope for excessive wear is advisable; • when rewinding is almost complete, position the rope on the return pulley and constrain the ends of the rope to the swivel using the fig.
  • Page 27 GEAX s.r.l. Chapter 3 • • release the insert "A" which secures the rope to the drum fig.3.2.3.2 fig.3.2.3.3 • Release the cable gland springs fig. 3.2.3.5; • prepare the new rope according to fig.3.2.3.6 • Secure the end of the new rope to the winding drum by wrapping it around the "A"...
  • Page 28 GEAX s.r.l. Chapter 3 3.3 Adjusting the limit switch mechanisms. Adjusting the main winch limit switch 3.3.1 The limit switch of the main winch is sensitive to rope loosening when the tool touches the ground (limit switch in descent): fig. 3.3.1.1 •...
  • Page 29 GEAX s.r.l. Chapter 3 Adjusting the auxiliary winch limit switch 3.3.2 The auxiliary winch limit switch is sensitive to the hook approaching the pulley (limit switch in ascent): • when the rope, while rewinding, moves the hook near the return pulley, the latter comes into contact with the collar, lifting it, and via the lever recalled by the spring, it closes the contact inside the limit switch;...
  • Page 30 GEAX s.r.l. Chapter 4 Chapter 4 MAINTENANCE ON URGENT FAULTS OF THE DRILLING MACHINE 4.1 General information Classification of urgent faults 4.1.1 Urgent faults entail immediate machine stop, and can be characterised as follows: • a malfunction generated by a fault does not allow machine activity;...
  • Page 31 GEAX s.r.l. Chapter 4 • loosen the cable further so that the kelly bar reaches a safely stable position inside the hole; • release the cable by pulling out the pin 2 fig.4.2.1.1 fig.3.2.3.1 • remove the kelly bar from the hole and put it in a horizontal position on the ground using the auxiliary winch;...
  • Page 32 GEAX s.r.l. Chapter 4 Telescopic kelly bar assembly 4.2.2 To mount the telescopic kelly bar one must prepare a hole (preferably coated) in the ground, at least 0.5 [m] deep, which must be closed appropriately when it is not used.
  • Page 33 GEAX s.r.l. Chapter 4 4.3 Lubricant leaks from the gear unit. Lubricant leaks from the rotary gear unit. 4.3.1 The fault is indicated with leaks that develop on the sealing ring of the gear unit output shaft. The oil leak wets the kelly bar and leaks out of the mast base.
  • Page 34 GEAX s.r.l. Chapter 4 Lubricant leaks from the winces gear units. 4.3.2 One must disassemble the winch to have it serviced by the manufacturer. Follow this procedure: • wear work gloves; • disengage the limit switches; • activate the winch and unwind the cable, winding it onto a wooden support spool;...
  • Page 35 GEAX s.r.l. Chapter 4 fig.4.4.1.1 • switch the engine off; • make sure that the hydraulic oil is at room temperature; • depressurise the hydraulic circuit by loosening the hydraulic pipes downstream the block valve (provide a suitable oil collection container);...
  • Page 36 GEAX s.r.l. Chapter 4 • pull out the second pin, getting ready to support the weight of the hydraulic cylinder with a suitable hoisting means; To assemble repeat the operations in the reverse order. Oil leaks from a hydraulic system hose.
  • Page 37 GEAX s.r.l. Chapter 4 • If the solenoid valve is on a hydraulic cylinder circuit, follow the instructions in paragraph 4.4.1 Hydraulic control component malfunction 4.5.2 Before replacing the component, one must exclude the presence of a fault on auxiliary/nearby devices that may be causing the malfunction. Refer to the hydraulic circuit diagram in annex C and to the crawler manufacturer manual.
  • Page 38 GEAX s.r.l. Chapter 5 Chapter 5 MAINTENANCE ON NON-URGENT FAULTS OF THE DRILLING MACHINE 5.1 General information Classification of faults 5.1.1 The faults listed below do not require an immediate machine stop: • the malfunction generated by the fault allows machine activity by adopting specific measures;...
  • Page 39 GEAX s.r.l. Chapter 5 Fault on the auxiliary winch limit switch system in ascent 5.2.2 The malfunction of the limit switch system can be caused both by an unsuitable adjustment of the limit switch and by a fault on the electric- solenoid valve circuit.
  • Page 40 GEAX s.r.l. Chapter 5 Fault or inaccuracy on the electronic measurement device 5.3.2 If the device has to be programmed (after a replacement), one can follow this procedure: DEEP METER Red Lion Cub-5 0.00 [m].[cm] Display: Pulley diameter Dg=173 [mm]...
  • Page 41 GEAX s.r.l. Chapter 5 KELLY SPEED METER 00 [m] / [minute] Display:  denti   • 1000   • Rope Diam. Df (mm) N° teeth /m Pulley Diam. Dg (mm) 25,3 25,2 25,0 25,2 25,0 24,9 25,0 24,9...