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KLEMM KR 806-2 Technical Manual

All hydraulic crawler drill rig
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TECHNICAL MANUAL
All hydraulic crawler drill rig
Description
Operation
Maintenance
for
KR 806 - 2
Zweigniederlassung der
Bauer Maschinen GmbH
Germany
tel:
fax:
++49 (0) 2761 705- 0
++49 (0) 2761 705 - 49
++49 (0) 2761 705 - 50

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  • Page 1 TECHNICAL MANUAL Description Operation Maintenance All hydraulic crawler drill rig KR 806 - 2 Zweigniederlassung der Bauer Maschinen GmbH Germany tel: ++49 (0) 2761 705- 0 fax: ++49 (0) 2761 705 - 49 ++49 (0) 2761 705 - 50...
  • Page 2 Although compiled with all care, the manual may be incomplete. KLEMM Bohrtechnik will not any ac- cept claims resulting from missing data in this manual. Technical specifications and data subject to modifications.
  • Page 3 Bei Anfragen und für schnelle und When making enquiries or orde- reibungslose Ersatzteillieferung ring spares, please specify the fol- bitte stets folgende Informationen lowing data to ensure prompt and angeben: reliable delivery: 1. Maschinennummer 1. Number of Rig 2. Maschinentyp 2.

  • Page 4: Table Of Contents

    Table of Contents Safety instructions ........General safety instructions .
  • Page 5 Recommended Oil- and grease - types for drill rig KR 806 - 2 ..6.1.1 Characteristics of different hydraulic oils for Klemm drill rigs ..
  • Page 6 Rope attachment points (A-D) on the drill rig type KR 806-2 for loading with the help of a crane ... Bridge with rigging (max. 20t) for loading the drill rig KR 806-2 .

  • Page 7: Safety Instructions

    Safety instructions All personnel involved in operating and/or maintaining this equipment must first read and thoroughly understand the operating instructions before attempting to operate or perform maintenance on the drill rig. Non- authorised or untrained per- sonnel must not under any circumstances attempt to operate or repair the machine. Safety first must always be the primary consideration of all personnel while opera- ting or maintaining the drill rig under normal and especially in unusual conditions.

  • Page 8: General Safety Instructions

    General safety instructions Directive of application The KLEMM drill rig must be used only as directed in DIN EN ISO 12100- 1 (safety of machinery), and as described in the operators manual for drilling operations. Another using of the drill rig as directed (e.g. for lifting operations as a crane or ground moving operatios) is striktly forbidden.

  • Page 9: Safety Instructions For Operation The Drill Rig

    Safety devices are e.p. ESS- system (System KLEMM), engine cover doors, protective gratings, coatings. All safety devices and protective equipment must be reinstalled after comple- tion of maintenance service and repairs.
  • Page 10 Transport of persons The transport of persons on the drill rig is strictly forbidden!! Step on the drill rig While operation the drill rig is forbidden to step on the machine. Before step- ping on the machine the engine of the drill rig must be stopped and secured against inadvertent or unauthorised start- up.
  • Page 11 10. Signalling If the operators vision is impaired during tramming and working, someone must give signals for assistance, or the tramming / working area must be cordoned off. Only reliable persons must be designated to give signals. They must be instructed as to their responsibility. Communication must be coordinated and exclusively used between operator and the person giving signals.
  • Page 12 22. Use only the purpose- made craneage lugs when lifting the rig. For loading the drill rig with help of a crane please contact KLEMM comp. 23. Guards and safety devices are for your protection. Do not remove or disable them under any circumstances.

  • Page 13: Safety Instructions For Maintenance Of The Drill Rig

    The setting of pressure limiting valves and safety valves in the hydraulic circuits of the drill rig must be changed only by KLEMM Bohrtechnik approved personnel. Welding of static and bearing components on the machine is to be carried out only by the manufacturer or KLEMM Bohrtechnik approved personnel.
  • Page 14 Safety reqirements for hydraulic lines Markings : a) Hydraulic hoses must carry continuous markings at intervals not greater than 50 cm. These markings must be clearly readable and supply the following data: Name of manufacturer Type Nominal diameter Date of manufacture Example : ”...

  • Page 15: Preface

    Your KLEMM KR 806- 2 drill represents ”State of Art” in mobile drilling equip- The drill mast is fitted in guiding strips ment. Apart from a pressurized water or...
  • Page 16 90_. EMERGENCY switches fail and show no function. The KLEMM KR 806 - 2 has 2 EMER- GENCY switch - off buttons. The power pack is fitted with a sound One EMERGENCY switch off is moun- prooved cover to meet current noise le- ted on the slewable control panel.

  • Page 17: Technical Description

    The mast car- rier acts as support and guide for the drill mast. KR 806-2 07/2004 KR 806 - 2 / Serial No. 64004...

  • Page 18: Engine And Central Hydraulics

    3.1.1 Engine and central 3.1.2 Crawler Undercarriage hydraulics Each crawler consists of base frame, The main power source is an fluid- coo- track chain, sprocket drive wheel, guide led 6- cylinder four- stroke diesel en- wheel and seven idlers, two support gine with an output of 129,5 kW at 2300 wheels, as well as a track tensioning rpm (for details see engine manual).

  • Page 19: Boom Assembly

    Boom Assembly The boom assembly features allow for A hydraulic cylinder is used to tilt the as- perfect setting- up and alignment of the sembly in the desired position. drill mast, and consist basically of sle- This swivel head arrangement allows wing table, slewing column, boom arm, the entire drill mast to be slewed from swivel head and mast carrier, complete...

  • Page 20: Drill Mast Type 202 With Attachments

    Drill mast type 202 with attachments The drill mast consists of square sectio- ned steel profiles. The bottom end is fitted with a centrali- ser, a twin clamp / breaking device and a toothed support plate. The drill mast Feed gear is attached to the mast carrier.

  • Page 21: Safety Instuctions For Roller Chains For Drill Feed System

    3.3.1 Safety Instuctions for roller chains for drill feed system (only for drill masts with feed chain) CAUTION ”The 3,5- time security factor versus rupture of the roller feed chain, according to the machine guide line DIN EN 791, is only ensured when the feed chain will be regularly controlled.

  • Page 22: Operation

    Operation Prior to start-up Be sure that all operating levers Absolutely ckeck before the START: are in neutral ”OFF” position a) Ball- valve in pump suction line opened? Check that EMERGENCY OFF switches on the slewable control panel and tramming console are b) All control levers in inactive .

  • Page 23: Operating Instructions

    Operating Instructions Control elements for tramming func- CAUTION tions are placed on left side at the back of the rig. Controls for setting - up and alignment IN CASE OF DANGER ALL OF THE of the boom, and all controls for drilling RIG FUNCTIONS CAN BE STOPPED BY ACTIVATING ONE OF THE functions are mounted on the slewable...

  • Page 24: Engine Control Box Kr 806

    4.2.1 Engine control box KR 806 - 2 Counter for working hours Display Ignition lock It is forbidden to clean the start and control element with strong water pressure or with a high pressure cleaner Indications and diagnostic oppotunities on the display of the engine control box Normal Indication: - first line:...
  • Page 25 Diagnostic oppotunities: By simultaneous operating of button no. 2 + 3 the diagnostic oppotunities can be selected All inputs and outputs of the ECM- computer and different engine data can be interrogated. The buttons no. 2 + 3 on the engine control box are cursor buttons. The butten no.
  • Page 26 Input 6 = Start: If the start button or the ignition lock to start the engine is activated, the input set- ting is “1”. If non of these conditions is fulfilled, the input stays in “0” setting. Input 7 + Input 8: Option Analogue input 3 = fuel tank level: The indicator for the fuel tank level has an output signal from 4..20mA.
  • Page 27 Error messages: In the left part of the display different error messages can be indicated. This error messages can not be recieped. After error correction and a new start of the diesel engine, the messages are distinguished. The following errors can be indicated: 1.

  • Page 28: Engine Control System Kr 806 - 2

    4.2.2 Engine control system KR 806 - 2 Cause of errors Reaction of the engine control system S Warning in the display (text), Lack of cooling fluid S Switching - off hydr. pilot control S Switching - off diesel engine S If temperature of cooling fluid >= 111_C, warning To high cooling fluid temperature...

  • Page 29: Electronic Engine Regulator (Ecm)

    4.2.3 Electronic engine regulator (ECM) The electronic engine regulator (ECM) is located on the rear side of the diesel en- gine and can be reached through the rear engine cover door (see pic. 1). At the engine control distribution there is a error control lamp (1), a battery charge lamp (2) as well as a busser (4) for tramming signal and error signal.

  • Page 30: Engine Start - Up

    4.2.4 Engine start - up Set rpm control porentiome- If the engine does not fire, ter to approx. quarter speed repeat starting procedure (on the left side at the back of after 1 minute. the rig or on slewable control panel).

  • Page 31: Operating Instructions Crawler Drill Rig Kr 806- 2

    4.2.6 Operating instructions crawler drill rig KR 806 - 2 General instructions START - UP (with diesel engine) This operating manual and spares list is Check filling level of hydraulic valid for different configurations of the oil tank (on level indicator) as drill rig.

  • Page 32: Release Switch For Oscillating Undercarriage / Oscillating Automatic

    4.2.7 Release switch for oscillating undercarriage / oscillating automatic General terms The location of the center of gravity in relation to the tipping edges is the main indicator for the stability of the drill rig. Tipping edges are the connection lines between the track chain guide rollers and the sprocket wheel in tramming direction.
  • Page 33 CAUTION! In care the drill mast with slide and drill head unit is slewed far to the side, the point of gravity is in an inconvinient position. It is strictly prohibited to activate the release switch of the oscillating automatic. The following sketch showes the starting position in the lower section and the according rig position in the upper section.

  • Page 34: Tramming The Crawler Drill

    4.2.8 Tramming the Crawler Drill Activate control levers Do not apply levers fully to begin with, 1 + 2 in corresponding but activate as if accelerating a car. Le- direction. ver position determines the degree of opening of the control valves, and the- The crawler drill rig is rewith the quantity of oil supplied.

  • Page 35: 1Tramming The Drill Rig On Slopes

    While tramming the rig, be sure to align the drill mast horizontally, resting on the mast support bracket. The drill head unit must be positioned between mast carrier and mast support bracket. Never attempt to turn the drill rig on the spot in swampy muddy or any soft ground conditions.

  • Page 36: Setting Up And Alignment Of The Boom

    4.2.9 Setting up and alignment of the boom The control console for the boom alignment is located on the right side of the slewa- ble control panel, and consists of six adjacent operating levers. These can be activa- ted forward or backward from the centre setting. Push or pull the levers to activate the corresponding hydraulic cylinders.
  • Page 37 Symbols Push: Push: lower boom swivel head to the left around Pull: its axle lift boom Pull: swivel head to the right around its axle Push: Push: slew boom right drill mast displacement to the front Pull: slew boom left Pull: drill mast displacement to the back...

  • Page 38: Drilling Controls On Slewable Control Console

    4.2.10 Drilling controls on slewable control console The controls for drilling functions are located on l.h. side and in the middle of the slewable control panel Symbols Manually adjustable Push: hydraulic pressure close breaking regulator for feed clamp Press pressure Pull: open breaking clamp...
  • Page 39 17/18 20/21 22 23 24/25 27 ESS- box (see page 42) Symbols manually adjustable manually adjustable hydraulic pressure drifter percussions regulator for outer frequency drill string rotation (only for double head (only for hydr. drifter Press unit operation) operation) Frequency Manually adjustable Push: pressure regulator...
  • Page 40 Symbols Push: Push / Pull: fast feed rotation of forward outer drill string left / right Pull: fast feed (only for double backward head unit operation) Push: Manual Valve: additional drill string RPM regulation for rotation drill string (l.h. and r.h. rotation) right <...
  • Page 41 Hold - back device feed / fast feed (mounted on the lifting arm of the control panel) ATTENTION ! DRUCKWAAGE After every adjustment of the drill mast, you press. maintaining valve must regulate the pressure maintaining valve! A to low regulation of the pressure maintaining valve can result damages and danger for persons.

  • Page 42: Ess Control Box On Slewable Control Panel

    4.2.11 ESS control box on slewable control panel Functions on the electr. ESS -Box RPM regulation for diesel engine Horn Start - button Feed gear switching normal/fast EMERGENCY- switch off 07/2004 KR 806 - 2 / Serial No. 64004...

  • Page 43: Operation The Drill Rig With Single Hydr. Drifter Or Double Head Unit

    (no. 1) must be plugged. Now the drifter pre- line filter is out of function. For operation the drill rig in double head mode the pressure setting for the function “Inner rotation” must be changed. Please consult your Klemm Bohrtechnik Ser- vice to get informations about the right pressure setting.

  • Page 44: Operational Instructions For Dhd Application In Combination With Hydr. Hammer

    Klemm declines all claims, if the hydr. hammer is abused in above mentio- ned way. Very important for safety reasons: The DHD must be operated with fully operational hydr.
  • Page 45 Exemplary setup of a DHD system on drill rigs hydr. hammer flushing head drill rod shock - absorber 07/2004 KR 806 - 2 / Serial No. 64004...

  • Page 46: Drilling Operation

    4.2.13 Drilling operation Use boom control levers to align the drill mast in the required position. Mast has to be pressed against object to drill. Check mast inclination with angle indi- cator. Adjust the feed pressure setting using the adjustment valve on the slewable control panel.

  • Page 47: Drilling Method

    After having chosen the accessories (of which Klemm offers a wide range off all diffe- rent kinds) the operator has to determine the right feed pressure and R.P.M.

  • Page 48: Preventative Maintenance

    Preventative Maintenance Adjusting Track Chain Tension Adjusting Track Tension Park the crawler drill rig on levelled and bearing ground. Place a straight edge on the grousers between the front idler and the top carrier roller. Measure the distance between the bottom of the straight edge and the top of the track plates.

  • Page 49: Repairs And Replacement Operations On Crawler Chains

    Repairs and Replacement Operations on crawler chains ATTENTION The Chains are under tension !! Tensioned by a high pressure grease cylinder ATTENTION Before removing or repairing crawler chains, the drill rig must be shut - off and firmly stabilised. Before repairs and replacement operations are executed, it is absolutely necessary to reduce the chain tension.

  • Page 50: Care And Maintenance Of The Klemm Crawler Drill Rig Type Kr 806-2

    Care and maintenance of the KLEMM crawler drill rig type KR 806 - 2 General remarks Cost consciousness and the call for greater efficiency have led to an ever increasing use of machinery in the Construction Industry. This has enabled Contractors to dis- pense of expensive man- power, while at the same time reducing the time spent on- site.
  • Page 51 (e.g. Stability), are to be effected only after consultation and with the written permission of KLEMM Bohrtechnik and under the supervision of a KLEMM Bohrtechnik Specialist Expert. Changes without consultation of the manufacturer result in a total loss of warranty.

  • Page 52: Recommended Oil- And Grease-Types For Drill Rig Kr 806-2

    Recommended Oil- and grease-types for drill rig KR 806-2 Fields of use Oil- and grease-type Quantity (liters) Diesel engine SAE 10 W- 30 approx. 13,1 ** CAT 3056 EATAAC SAE 10 W- 40 Mineral hydraulic oil: VG 32: for winter conditions in...

  • Page 53: Characteristics Of Different Hydraulic Oils For Klemm Drill Rigs

    6.1.1 Characteristics of different hydraulic oils for Klemm drill rigs The selection of the right hydraulic - oil and the ambient- outside - temperature - ranges have important influence on hydraulic functions and speeds of the drill rig. The max. permissible viscosity- range for the hydraulic components is 1600mm only for engine start- up (cold start).
  • Page 54 These facts can create malfunctions and damages of the hydr.system. Caution! Mineral oils and synthetic oils can not be mixed. Therefore please refer always to page 52 (original Klemm oil fill). 07/2004 KR 806 - 2 / Serial No. 64004...

  • Page 55: Filter And Filter Inserts For Drill Rig Kr 806 - 2

    Filter and Filter inserts for drill rig KR 806-2 ATTENTION! Always stop the diesel engine of the drill rig before maintenance or repair work is being done !! Hydr. circuit Return-line filter (mesh size: 10 micron) Part no. filter cpl. (1 piece) .
  • Page 56 Changing filter insert of return-line filter KR 806-2 Pic. 1- 7: Changing hydr. filter insert Pic. 8- 11: Changing ventilation filter insert Filter insert ATTENTION: The cage must be reused! 07/2004 KR 806 - 2 / Serial No. 64004...
  • Page 57 Supply-line filter for hydr. drifter The hydr. oil filter of hydr. drifter supply line is mounted on the base frame near the hydr. oil tank on right side of the drill rig (see picture below). The first filter change of the element must be done after 50 working hours. The same procedure has to be carried out all further 250 working hours, or sooner in case the dirt indicator needle moves up.
  • Page 58 Diesel engine filter for Caterpillar 3056 EATAAC Engine oil filter Part no. oil filter (2 pieces) ....400090 The engine oil filter (see photo) must be changed every 250 hours or all three month.
  • Page 59 Fuel filter Part no. fuel filter (1 piece) ..400762 The fuel filter is mounted on the right - back side of the engine and can be reached through the rear engine cover door. The fuel filter must be changed every 250 hours. Fuel filter Filter water separator Part no.
  • Page 60 Engine air filter The engine air - filter is mounted on the r. h. side of the diesel engine, inside theen- gine cover. It consists of a housing and 2 filter elements (inner and outer elements). The air filter elements must be changed every 250 working hours . ATTENTION: Never run the diesel engine without properly mounted air filter because the motor will be damaged by abrasive airborne particles.
  • Page 61 - and all steps that must be followed up for the 8 hours service interval The first service has to be carried out by a KLEMM expert or an autorized distribu- tor. Non - compliance with these instructions results in a loss of warranty.

  • Page 62: Lubrication Chart Maintenance And Service Intervals

    Service Intervals in Operting Hours Lubrication Chart Maintenance and Service Intervals 8 16 40 100 200 500 1000 2000 1. Diesel Engine Caterpillar 3056 EATAAC Check oil level in engine Clean fuel filter in fuel - pumps Change engine oil - Volume = Litres Please refer Please refer Clean cooling fans...
  • Page 63 Service Intervals in Operting Hours Lubrication Chart Maintenance and Service Intervals 8 16 40 100 200 500 1000 2000 7. Undercarriage Check track tension Grease idlers 8. Drill mast Grease Nipple - Check filling level - regrease Check Feed Chain tension Check Bearings and Bushings Check wear of rod centralizer (approximate max.

  • Page 64: Special Instructions For Caterpillar Diesel Engine 3056 Eataac

    Special instructions for Caterpillar Diesel Engine 3056 EATAAC In order to get a long operational life of the Caterpillar engine, you strictly have to follow manufactures instructions for the cooling medium. Please refer to the enclo- sed Caterpillar engine manual percentage of cooling percentage of water: temperature range:...

  • Page 65: Hydraulics

    Hydraulics 6.4.1 Hydraulic oil Optimum transmission can be only assured, if operating temperature, viscosity and quality are right. for detales see ”Recommanded Oils and Lubricants” - page 52. Old oil, or oils having been subjected to temperatures in excess of 70_ C lose important operating characteristics and reduce the service life of seals, hoses, pumps and cylinders.

  • Page 66: Oil Changes

    Let the fluid settle and cool down. Drain the oil/water mixture and dispose of in accordance with anti - pollution stipulations. PLEASE NOTE Do only use the hydr. oil according to original Klemm hydr. oil filling! 07/2004 KR 806 - 2 / Serial No. 64004...

  • Page 67: Repairs

    6.4.4 Repairs Service Intervals PLEASE NOTE To ensure the reliability of the drill rig, maintenance and service intervals must be adhered to. Be sure to close ball - valves on pump suction lines before The specified intervals are adequate replacing pumps. for machines being subjected to ave- Disconnect pump bearing flush line and rage usage and conditions.

  • Page 68: Special Remarks (Welding Instructions)

    Those cast steel constructions do not accept weldings, because the metallurgical struc- ture of steel will be disturbed, prudurcing stress areas with possible failure. Please contact KLEMM Bohrtechnik Techni- cal Services, if you should repair or fix items on cast steel components! ATTENTION!

  • Page 69: Battery

    Battery Service Life The battery’s operational readiness is subject to constant recharge from the dynamo. The installed batteries are of the maintenance - free type. 6.7.1 Cold start PLEASE NOTE Store the battery at room temperature during the winter months The capacity of the battery will be greatly reduced at low ambient temperatures.

  • Page 70: Accumulators

    6.8.1 Introduction and precaution instructions Klemm accumulators are in accordance the european regulation 97/ 23/ EG (Pres- sure Equipment Directive), article 3, chapter 3. If an accumulater will be detached and repaired the accumulator has to be checked by an authorised person, according to the operational dependability regulations §10 before it’s sent back to site.

  • Page 71: Works At Accumulators

    6.8.2 Works at accumulators Use only original Klemm parts! If not, you’ll loose warranty claim.! For ordering spare parts there are adequate part- numbers available in our part lists. This is also valid for repair works! Watch the indicated torques for tensioning the screws!

  • Page 72: Assembly Of Cpl. Accumulator

    Works have to be executed in clean environmental areas! Hydraulic fittings and hoses have to be tighten properly! Check the specified filling pressure of the accumulator! Seals and screws have only beused in accordance to the Klemm parts lists and shall be bought from Klemm only! 6.8.4...

  • Page 73: Accumulators Option For Hydr. Drifter Kd 1624

    ATTENTION: adjusting must be done only with an ap- The charging pressure of the percus- proved charging kit from Klemm, sion mechanism nitrogene accumula- Part - no.: 40753 tor is that pressure must be maintained...

  • Page 74: Repairs And Maintenance

    Repairs and Maintenance 6.9.1 Trouble shooting No oil supply and unusual noise characteristics from pump Cause Reason Remedy Local restriction in Open ball - valve fully Cavitation in pump suction line, e.g. partially closed ball- valve Fluid too cold Heat fluid to recommended tempera- ture Damaged tube, or...
  • Page 75 No Pressure build - up Cause Reason Remedy Air intake on suction line Tighten and seal connec- Pump not working tions correctly Damaged pump Repair or replace Pump running hot Viscosity of fluid too low Replace with fluid of the right viscosity Coupling faulty, or Repair defect Pump RPM too low or...
  • Page 76 Pressure or flow fluctuations Cause Reason Remedy Valve seat damaged Repair or replace Knocking of pressure limiting or safety val- Fluid contaminated Drain fluid. Clean tank Valves sticking and system. Refill with new fluid. System not properly Bleed system. Air pockets in the sy- ventilated See also Start- up in- stem, causing irregular...

  • Page 77: Special Guarantee Remarks

    The system pressure of the drill rig is fix adjusted by valve blocks, which are secured against inexpert regulation. An adjustment of the system pressure during the guarantee is only allowed with explicity permission of the KLEMM Bohrtechnik. Non - compliance leads to immediate loss of all warranty entitlements. 6.9.3...

  • Page 78: Conservation Of Hydraulic Piston Rods And Machine Components

    6.10 Conservation of hydraulic piston rods and machine components external conservation procedure Important: Before parts are mounted and used which were treated with external conservation additives on metal surfaces, these corrosion inhibitors must be removed with special solvents, fuel , petroleum or wax- containing solvents. Gear Parts, spline shafts and driving shafts which were preserved with corrosion in- hibitors must be washed/treated with the same solvents/chemicals mentioned above.

  • Page 79: Attachment Points For Truck Transport

    Attachment points for truck transport A - D Attachment points to lash the drill rig for truck transport 07/2004 KR 806 - 2 / Serial No. 64004...
  • Page 80 Rope attachment points (A-D) on the drill rig type KR 806-2 for loading with the help of a crane ATTENTION: Loading the drill rig with the help of a crane is only allowed after consultation with company KLEMM Bohrtechnik! right...
  • Page 81 Bridge with rigging (max. 20t) for loading the drill rig KR 806 - 2 For loading KLEMM drill rigs with drill mast in transport position with help of a crane, you have to use a bridge with two riggings (see sketch).
  • Page 82 Technical Data KR 806 - 2 (with drill mast type 202 and drill head unit) Power source: Caterpillar diesel engine Typ 3056 EATAAC ....129,5 kW ........... 2300 min certified by .
  • Page 83 10.1 Technical data of sound level measurement acc. to DIN EN 791 and 2000/14/EC (Outdoor- Noise - Directive) A -registered sound power level (L ) in different operating modes Measured sound power level L without loading (idle running of engine) .
  • Page 84 KR 806 - 2 basic version Kinematic possible mast movements KR 806 - 2 basic version. For special- and additional equipment differences must be discussed with KLEMM BOHRTECHNIK! (see example a) 07/2004 KR 806 - 2 / Serial No. 64004...

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