SWDM240英文操作保养手册【802B00000000】-EN DONE 20210508

ROTARY DRILLING RIG
（802B00000000）
OPERATION & MAINTENANCE MANUAL
May, 2021
SUNWARD INTELLIGENT EQUIPMENT CO., LTD.

OPERATION & MAINTENANCE MANUAL SWDM240
Foreword
This manual will help users to operate and maintain the machine correctly.
It is particularly important that the machine operator should read these instructions carefully
not only prior to using the machine for the first time (in order to become acquainted with its
operation and special features), but also to take full advantage of its capabilities during use,
or for lubricating and servicing operations. Otherwise accidents or damage may occur.
The manual should be regarded as the permanent part of machine and kept in the cab for
consultation at any time. And the manual should be attached when the machine is transferred
or sold.
The machine is designed according to the metric system, all the data presented are metric
and only metric parts and apparatus can be used.
Position definition: RIGHT and LEFT always mean the left and right of an operator seated
correctly in the machine. The drive sprockets of undercarriage are located at the rear.
Sunward guarantees to keep machine in good repair in term of service. The service details
are showed in Maintenance Card supplied by distribution.
Maintenance Card guarantees can you get service or not in service period. In some
conditions, even if machine is out of service term, Sunward can also supply the in site free
service in normal. Warranty claims will not be considered provided：1. Reassemble and
repair machine without any notice to Sunward; 2.Disaassemble, welding and add parts in
machine; 3.Use the parts which is not from Sunward or do not get approval by Sunward;
4.Assemble, operate, park the machine which do not follow the operator’s manual; 5. Fuel
oil and lubricating grease is not fit for the manual request; 6.Do not complete routine
maintenance base on the manual.
Possible warranty claims may be considered only provided that all operations are made by
qualified operator and scheduled inspections are made at the specified times by qualified
technician.
Regarding SAFETY in particular, we recommend carefully reading the SAFETY RULES in
this manual and complying with all the safety rules.
The equipment covered by this manual meets the applicable technical specifications
effective as of its date of issue. The manufacturer SUNWARD reserves the right to make
from time to time and without prior notice any modification or amendment of any nature,
deemed useful or necessary, to any machine component, without any obligation to amend
the content of this manual accordingly. Pictures and data contained in this manual are not
binding. Consequently, no claim raised in this respect will be considered.
Sunward Intelligent Equipment Co., Ltd.

TABLE OF CONTENTS
1 SAFETY RULES ............................................................................................... 1

1.1 SAFETY PRECAUTION .............................................................................................. 1
1.2 PREPARATION FOR EMERGENCY .......................................................................... 2
1.3 WEARING SAFETY EQUIPMENT ............................................................................. 2
1.4 CORRECT GETTING ON/OFF MACHINE ................................................................ 2
1.5 ADJUSTMENT OF OPERATOR’S SEAT .................................................................... 3
1.6 CORRECT START-UP OF ENGINE ............................................................................ 3
1.7 BEFORE OPERATING MACHINE.............................................................................. 3
1.8 MACHINE OPERATION .............................................................................................. 3
1.9 NOTES FOR MACHINE HIGH-EFFICIENCY WORK .............................................. 4
1.10 KEEPING MACHINE AWAY FROM POWER TRANSMISSION LINE ................. 4
1.11 MOVING MACHINE SAFELY .................................................................................. 5
1.12 ALLOWABLE TRAVELING GRADE OF SLOPE .................................................... 5
1.13 ALLOWABLE WORK GRADE OF SLOPE .............................................................. 7
1.14 PARKING MACHINE SAFELY ................................................................................. 7
1.15 WINCH WORK ........................................................................................................... 8
1.16 SAFE MAINTENANCE .............................................................................................. 8
1.17 KEEPING MACHINE CLEAN ................................................................................... 8
1.18 PREVENTION OF STORAGE BATTERY EXPLOSION ......................................... 9
1.19 PREVENTING INHALATION OF ASBESTOS DUST ............................................. 9
1.20 BEWARE HIGH PRESSURE LIQUID ....................................................................... 9
1.21 AVOIDING HEATING NEAR PRESSURE OIL PIPES............................................. 9
1.22 AVOIDING HEATING FLAMMABLE LIQUID PIPES .......................................... 10
1.23 PAINT REMOVING BEFORE WELDING OR HEATING ..................................... 10
1.24 SAFE DISPOSAL OF LIQUID ................................................................................. 10
1.25 SAFE DISPOSAL OF CHEMICALS ........................................................................ 10
1.26 FIRE PREVENTION ................................................................................................. 10
1.27 SAFETY FACILITIES ............................................................................................... 11
1.28 PROTECTION AGAINST NOISE ............................................................................ 12
2 OVERVIEW .................................................................................................... 13
2.1 MODEL DEFINITION ................................................................................................ 13
2.2 APPLICABLE RANGE ............................................................................................... 13
3 TECHNICAL CHARACTERISTICS ........................................................... 14
3.1 MACHINE STRUCTURE ........................................................................................... 14
3.2 MAIN TECHNICAL DATA ........................................................................................ 15
4 MAIN STRUCTURAL FEATURES ............................................................. 16
4.1 UNDERCARRIAGE.................................................................................................... 16
4.2 UPPER- CARRIAGE................................................................................................... 18
4.2.1 Swing Platform ............................................. 18
4.2.2 Main Winch and Auxiliary Winch ............................. 18
4.3 POWER SYSTEM ....................................................................................................... 19
4.4 AIR-CONDITIONING SYSTEM ............................................................................... 20
4.4 LUFFING MECHANISM AND DRILL MAST ......................................................... 22

4.6 ROTARY HEAD .......................................................................................................... 23
5 HYDRAULIC SYSTEM................................................................................. 24
5.1 UNDERCARRIAGE HYDRAULIC SYSTEM .......................................................... 24
5.2 UPPER-CARRIAGE HYDRAULIC SYSTEM .......................................................... 24
5.3 PILOT CONTROL SYSTEM ...................................................................................... 25
5.4 OIL FILTER ................................................................................................................. 26
5.5 HYDRAULIC OIL....................................................................................................... 26
6 ELECTRICAL SYSTEM ............................................................................... 27
6. 1 DESCRIPTION ........................................................................................................... 28
6.2 CONSOLE OPERATION INSTRUCTIONS .............................................................. 29
6.3 INTERIOR OPERATION INSTRUCTIONS .............................................................. 36
6.3.1 Operation Interfaces of Display Screen ..................... 39
6.3.2 Membrane Keyboard Panel .................................... 58
6.3.3 Control .................................................... 63
7 OPERATION ................................................................................................... 91
7.1 PREPARATION AND CHECK-UP BEFORE OPERATION ..................................... 91
7.2 OPERATION MECHANISM AND INSTRUMENTS ................................................ 91
7.3 PREPARATION FOR OPERATION ........................................................................... 91
7.3.1 Machine Positioning ........................................ 91
7.3.2 Machine Assembly ........................................... 92
7.4 MACHINE WORK ...................................................................................................... 95
7.4.1 Rig Running-in ............................................. 95
7.4.2 Drill Tools Selection ...................................... 95
7.4.3 Hole Opening and Barrel Installation ....................... 95
7.4.4 Drilling ................................................... 96
7.4.5 Machine Relocation ......................................... 98
7.4.6 LCD Monitor, Warning Icon .................................. 98
7.4.7 Machine Stop and Emergency Stop ............................ 99
7.4.8 Steps from Drilling Mode to Transportation Mode ............ 99
7.5 ENGINE USE ............................................................................................................ 101
7.5.1 Precautions for Engine Use ................................ 101
7.5.2 Precautions for Engine Preheating and Idling .............. 101
7.5.3 Precautions for Engine Shutdown ........................... 101
7.5.4 Correct Filling of Coolant ................................ 102
7.5.5 Other Operation Precautions ............................... 102
7.6 AIR CONDITIONER ................................................................................................. 103
7.6.1 Use of Air Conditioner .................................... 103
7.6.2 Common Failures and Solutions ............................. 107
7.7 Operation and Maintenance of Fuel Pump................................................................. 109
7.7.1 Operational Steps ......................................... 109
7.7.2 Notes for Use ............................................. 109
7.7.3 Maintenance ............................................... 110
7.7.4 Fault Analysis and Troubleshooting for Fuel Pump .......... 110
8. KELLY AND DRILLING TOOLS ..............................................................112
8.1 KELLY ....................................................................................................................... 112

8.1.1 Introduction of Kelly ..................................... 112
8.1.2 Correct Model Selection for Kelly ......................... 114
8.1.3 Correct Operation of Kelly ................................ 114
8.1.4 Kelly Disassembly ......................................... 117
8.1.5 Maintenance for Kelly ..................................... 119
8.1.6 Requirements of Long-time Storage and Transport for Kelly . 120
8.1.7 After-Sale Service Code for Kelly ......................... 120
8.1.8 Simple Repair Technology for Kelly ........................ 122
8.2 DRILLING TOOLS ................................................................................................... 124
8.2.1 Common Drilling Tools and Application ..................... 124
9 SERVICE AND MAINTENANCE .............................................................. 129
9.1 SAFETY INSTRUCTIONS FOR MAINTENANCE ................................................ 129
9.1.1 Overview .................................................. 129
9.1.2 Note for Maintenance ...................................... 129
9.2 REGULAR MAINTENANCE................................................................................. 135
9.2.1 Lubrication Maintenance Chart ............................. 136
9.2.2 Oil ....................................................... 141
9.2.3 Regular Check ............................................. 142
9.3 EVERY 10 HOURS MAINTENANCE ..................................................................... 143
9.3.1 Checking and adjusting track tension ...................... 143
9.3.2 Hydraulic Cylinder Maintenance ............................ 145
9.3.3 Checking oil level in rotary head gearbox ................. 146
9.3.5 Check Track Components for Lost or Damaged ................ 147
9.3.6 Wire Rope Inspection ...................................... 147
9.3.7 Discard Criteria of Wire Rope ............................. 148
9.3.8 Wire Rope Maintenance ..................................... 150
9.3.9 Check Swivel Joint for Flexibility ........................ 150
9.3.10 Wire Rope Swivel Joint Lubrication ....................... 151
9.3.11 Checking Engine Oil Level ................................ 152
9.3.12 Draining Water and Sediment in Diesel Tank ............... 153
9.3.13 Check Hydraulic Oil Level and Quality .................... 154
9.3.14 Checking Gear Oil Level for Reduction Gearbox ............ 154
9.3.15 Checking Coolant Level ................................... 156
9.3.16 Checking Fuel Capacity and Filling Fuel Oil .............. 157
9.3.17 Checking Switches, Buttons and Operating Handles ......... 159
9.4 MAINTENANCE FOR INITIAL 50 HOURS OF OPERATION ............................. 159
9.4.1 Change Engine Oil and Filter .............................. 159
9.4.2 Replacing Fuel Filter ..................................... 161
9.4.3 Changing Oil-water Separator .............................. 162
9.4.4 Cleaning Filter Screen for Fuel Tank ...................... 163
9.5 MAINTENANCE FOR EVERY 50 HOURS ............................................................ 164
9.5.1 Check wire rope retainer and roller for parallel .......... 164
9.5.2 Checking Slewing Bearing Junction Bolts ................... 164
9.5.3 Checking Bolts Tightening for Key Parts of Rotary Head .... 164
9.5.4 Checking and Changing Drive Key Bar for Kelly ............. 165
9.5.5 Checking and Changing Rotary Head Wear Plate .............. 165
9.5.6 Checking Mounting Bolt of Track Shoe for Secure ........... 166
9.5.7 Visual Inspection of Air Intake System .................... 166
9.5.8 Checking Wiper ............................................ 167
9.5.9 Checking Front Window Clean Device ........................ 167
9.5.10 Changing Slewing Bearing of Servo-frame .................. 167
9.5.11 Checking Air Compressor Belt ............................. 168
9.6 MAINTENANCE FOR EVERY 100 HOURS .......................................................... 168
9.6.1 Swing Reduction Gearbox Oil Check ......................... 168
9.6.2 Travel Reduction Gearbox Oil Check ........................ 169
9.6.3 Auxiliary Winch Reduction Gearbox Oil Check ............... 169
9.6.4 Checking Hydraulic Oil Filter Element ..................... 170
9.6.5 Draining Water and Sediment in Hydraulic Oil Tank ......... 172
9.7 MAINTENANCE FOR INITIAL 250 HOURS OF OPERATION ........................... 173
9.7.1 Changing Gear Oil for Main Winch Reduction Gearbox ........ 173
9.7.2 Change Gear Oil for Rotary Head Reduction Gearbox ......... 174
9.7.3 Changing Gear Oil for Swing Reduction Gearbox ............. 174
9.7.4 Changing Gear Oil for Travel Reduction Gearbox ............ 175
9.7.5 Changing Gear Oil for Auxiliary Winch Reduction Gearbox ... 175
9.7.6 Changing Gear Oil for Rotary Head Gearbox ................. 176
9.8.1 Checking and Changing Servo-frame Wear Plate .............. 177
9.8.2 Rotary Head Gear Oil Sample and Inspection ................ 177
9.8.3 Checking and Changing Hoses ............................... 178
9.8.4 Replacing Engine Oil and Filter –see chapter 9.4.4 ....... 178
9.8.5 Cleaning Air Conditioner Condenser ........................ 178
9.9.1 Checking Wire Rope Sheave ................................. 179
9.9.2 Changing Main Winch Reduction Gear Oil- see 9.7.1 ......... 179
9.9.3 Replacing Rotary Head Gearbox Gear Oil- see 9.7.2 ......... 179
9.9.4 Changing Engine Oil and Filter-see 9.4.1 .................. 179
9.9.5 Changing Fuel Filter-see 9.4.2 ............................ 179
9.9.6 Changing Oil-Water Separator Filter –see 9.4.3 ........... 179
9.9.7 Maintenance of Engine Breather ............................ 179
9.9.8 Checking and Changing Air Conditioner Inner and Outer Air Filter
Element ............................................................ 179
9.10 MAINTENANCE FOR EVERY 1000 HOURS ...................................................... 181
9.10.1 Changing Air Filter, Return Filter Element, Pilot Filter Element
see –chapter 9.6.4 ................................................ 181
9.10.2 Changing Swing Reduction Gearbox Oil see-chapter 9.7.3 ... 181
8.10.3 Changing Travel Reduction Gearbox Oil see–chapter 9.7.4 . 181
9.10.4 Changing Auxiliary Winch Reduction Gearbox Oil see–chapter 9.7.5
................................................................... 181
9.10.5 Changing Rotary Head Reduction Gearbox Oil see –chapter 9.7.6
................................................................... 181
9.10.6 Hydraulic Hoses Inspection ............................... 181
9.10.7 Hydraulic Hoses Replacement .............................. 182
9.10.8 Cleanness Control for Hydraulic System ................... 182
9.10.9 Temperature Control of Hydraulic Oil ..................... 182
9.10.10 Use of Battery .......................................... 183
9.10.11 Checking and Changing Air Filter ........................ 185
9.11 Maintenance for Every 2000 Hours ......................................................................... 186
9.11.1 Changing Hydraulic Oil ................................... 186
9.12 Maintenance for Every Two Years or 3000 Hours ................................................... 186
9.12.1 Changing Coolant ......................................... 186
9.13 Machine Storage....................................................................................................... 187
9.13.1 Cleaning Machine ......................................... 187
9.13.2 Storing Machine .......................................... 187
9.13.3 Daily Maintenance ........................................ 188
9.13.4 Maintenance for a Long-term Storage ...................... 189
10 TRANSPORTATION .................................................................................. 190
10.1 Transportation of the Whole Machine...................................................................... 190
10.1.1 Machine Loading and Unloading ............................ 190
10.1.2 Tying Down the Machine ................................... 191
10.2 DISASSEMBLED TRANSPORTATION ................................................................ 191
10.2.1 Rotary Head Parameter .................................... 192
10.2.2 Counterweight Parameter .................................. 193
10.2.3 Kelly Bar Parameter ...................................... 193
11 TROUBLESHOOTING.............................................................................. 195
11.1 COMMON FAILURES AND SOLUTIONS ........................................................... 195
11.2 ACCIDENTS AND SOLUTIONS DURING OPERATION ................................... 197
12 MANUFACTURER INFORMATION ...................................................... 198
1 SAFETY RULES
1.1 SAFETY PRECAUTION
Disobey the safety rules may cause accidents during operation and maintenance. We
recommend that operators should pay much attention to the operation safety,
Before use and maintain machines, please carefully read the SAFETY RULES in this manual
For using machines safely, there are various labels at various places on the machine indicating
various risks, such as Danger, Warning, Attention, etc (right figure), they have the following
meaning:
Danger---indicates an imminently hazardous situation which, if not avoided, will result in

death or serious injury.
Warning---indicates a potentially hazardous situation which, if not avoided, could result in

death or serious injury.
Attention---indicates a potentially hazardous situation which, if not avoided, may result in

minor or moderate injury.
Always keep the safety labels clean. Change any lost or damaged labels with new ones. If the
labels or manual are lost, you can contact the dealer and indicate the model of machine to
purchase.
WARNING: Do not operate and move machine before read and understand the safety
instructions. If you do not follow the safety rules or warnings, accidents or damage may
occur and you should be responsible for the all by yourself.
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1.2 PREPARATION FOR EMERGENCY
All personnel related to operating the machine should pay attention to prevent accidents from
happening, Always keep a first-aid kit and fire extinguisher nearby. Have phone numbers of a
doctor, ambulance, hospital, and fire department with you in case of emergency.
1.3 WEARING SAFETY EQUIPMENT
Before operation, always wear protective gear as the work requires, this includes: Tight work
clothes, Hard hat, Safety gloves, Safety glasses, goggles, or shield, Dust mask or respirator etc.
1.4 CORRECT GETTING ON/OFF MACHINE
◆Check and clean pedals and armrest before enter the machine；
◆Only get up/down the machine by pedal or armrest;
◆Always face the machine when you use the steps and hand-holds to enter or leave machine;
◆Never enter or leave the machine in its working or moving；
◆Use ropes to hoist and fall tools and material from rig, do not try to take them during getting
up and down the machine.
Warning！！
！
Never use any operating rod as armrest in getting up/down the machine.
When the machine is in operation or traveling, no passenger is allowed to stay on or in the machine
except the operator.
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1.5 ADJUSTMENT OF OPERATOR’S SEAT

You may adjust seat to suit yourself, Lean your back on the
back of seat and let your feet reach the pedals.
1.6 CORRECT START-UP OF ENGINE

The operator must sit on cab seat to start engine.
Never start engine by connecting start terminal or accumulator linking to start terminal, which
will seriously damage electric parts. Prevent short-circuit from electrical system damage;
If “No START” is showed in start button or control rod, do not start or operate engine;
Before starting engine, keep all control rod in “HOLD” position; push hydraulic control rod in
“LOCKED” position；
Engine emission gas can cause diseases and even death. If machine is operated at indoor, it’s
necessary to open door and windows to ventilate. Or you can also use lengthened discharge
pipe to discharge exhaust gas to outside.
1.7 BEFORE OPERATING MACHINE
Clean all obstacles in machine running way;
Excepting operators, other person should leave machine and stay far away from running range;
Familiar with complicated terrain, such as cable trench, refill soil etc. dangerous site；
Adjust back mirror to optimum，pay attention to the machine side and rear position；
Ensure horn and all warning devices in machine are in good condition;
Before moving machine, check the position of travel device. Its correct direction: tension roller
is under cab front, drive roller is in the back；
Check controller and safety devices are in good condition;
Make sure to follow all safety rules.

1.8 MACHINE OPERATION
Operator must sit in cab seat to control machine;
Lower mast must be kept in the height 10cm over ground level in rig rotating and mast up；
Pay attention to any failure and solve it in time during rig working;
Please do not drive machine near cliff, collapsing range;
When machine is unbalance in rotary head pressurization or hoisting drill, stop work
3
immediately；
Prevent machine out of control and do not work over rated bearing capacity;
Do not change direction in slope which may make machine tilt or slide；
Machine may sink in loose road, insert wood or steel plate under crawler;
It is better move along longitudinal slope and prevent horizontal direction;
Please obey national and local construction safety regulations for obstacle minimum distance;
After hole forming, fill it or cover and mark it in time.

1.9 NOTES FOR MACHINE HIGH-EFFICIENCY WORK
Generally, the machine can use drill tool and stabilizer to lower casing, and also can be fit
casing driver to fall it; then it can pull out casing by main& service winch or crane. Operate it
slowly and evenly. Do not use winch to hoist and fall casing suddenly and shock which can
damage machine.
If fall and hoist casing by above mentioned methed is difficult, please use special equipment
such as twisting machine, hammer drill etc.
When lower drill rod, operator should always observe lowering depth and extend length for
each section rod to prevent “ rod lock”, “rod loosen” and “rod break”.
During falling drill rod, operator should always observe steel rope stress to prevent over falling
winch steel rope because of drills lock.
Stop falling winch in upper hole base 1-3M , open free fall and make drills touching hole base;
Prevent steel rope over falling.
Before lifting drill rod, anti-clockwise rotate rotary head to delete occlusal between each
section drill rod. Always observe lifting depth and drill rod connection to prevent “rod lock”,
“rod break”.
Choose different drill tools according to different stratums during drilling; Change drill teeth
angle and amount to advance drill efficiency. Please contact our after-sales for technical
support in necessary.
When in-hole collapse accident is occurring, it should lift winch immediately and hoist drill
tool quickly to prevent drills embedding; When drill rod is dropping into hole because of steel
rope cutting, it should pull rod out by other device in time to prevent drills embedding.
1.10 KEEPING MACHINE AWAY FROM POWER TRANSMISSION
LINE
Know your machine maximum height and extend range. Machine and attachment should keep
a safety distance from power line; Keep the machine more than 3 meters away from 50000V
power line；If voltage is over 50000V, safety distance should be increased more.
Warning！！！
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If you do not follow the safety rules or ignore warnings, you should be responsible for all.
1.11 MOVING MACHINE SAFELY
Before the machine travels or swings, warn other people by tapping the horn. Ensure no other
people is in the work range.
Operate the mast backward 10°～15°to prevent machine tilting because of rough terrain.
When traveling and starting in narrow area, hand signal should be used, and agree upon the
hand signals before machine start-up. Before operate machine, make sure helpers is in safety
range. Only know and understand helpers signal, can operate rig.
Enough light should be provided in moving machine.
1.12 ALLOWABLE TRAVELING GRADE OF SLOPE

Warning！The allowable grade of slope is calculated in the rigid ground without any
ascend, so when the machine is in the rough and loosen ground, the valve should be
reduced.
Travel carefully and slowly in falling gradient, and check the ground status before running。
Forbid to travel over the allowable value so as to prevent the tilting danger.
Warning！
When travel in falling gradient，grade of slope in longitudinal must be no more than 5°，
and adjust the mast backward no less than 10°～15°.
When travel in up grade，grade of slope in longitudinal must be no more than 5°, and
adjust the mast backward no less than 10°～15°.
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WARNING!
Grade of slope in cross direction must be no more than 5°in traveling.
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1.13 ALLOWABLE WORK GRADE OF SLOPE
Warning: Forbid work over the allowable grade of slope, so as to prevent tilting danger.
Machine can work in all position of the grade of slope no over 2°in longitudinal.
1.14 PARKING MACHINE SAFELY
When park machine for a short time (such as in rest time), it should be parked in safety range
and lay drill tools down, loosen steel rope.
Stop machine according to the following
steps：
Place machine on flat hard ground, fall drill mast to bracket support position;
Put machine in safety range;
Idle running engine for 5 minutes, cooling machine;
Turn the ignition key to “OFF” position and take off the key.
Switch off pilot control switch.
Clean cab.
Close and lock window, sky window, cabin
WARNING!! Never load in machine when it is in park mode.
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1.15 WINCH WORK
Winch in rig is only used for hole-forming(such as lifting rod，bit and other drills etc.).
If use winch to complete other work (such as lifting heavy load), Sunward will not be
respinsible for it.
Hoisting load, and load is just in front of mast; angle between steel rope and mast should not
over 15°；If load is in front side, rotate rig to prevent tilting.
Warning！！
！
Winch in rig is the special equipment for pore-forming, never use it as crane or other loading device.
1.16 SAFE MAINTENANCE

Before maintenance, stop diesel engine, take off ignition
key, show “Machine out of duty” in control platform.
Before maintenance, cut off power supply and release

pressure in hydraulic system at first. Make sure all parts
temperature is normal. Do safe protection in treating
elastic parts (such as springs).
When technical staff diagnoses and evaluates failure, it needs to operate machine and check its
actions; Technical staff must ensure:
Operators and technical staff can see each other, understand and exchange signal clearly；
Technical staff can hear and reply operator clearly;
Service person must be in safety range before rig running; only operators fully understand
service person, can they operate machine.
In maintenance, enough light must be provided in site.
Wear protective gloves in maintenance.

Warning!!!
Before maintenance, read and understand the safety and maintenance rules.
Never service and repair machine when it is not safely parked.
1.17 KEEPING MACHINE CLEAN

Keep the engine, radiator, battery, hydraulic line, fuel tank, and cabin clean。
After stopping engine, the engine temperature may rise immediately. Open engine compartment
doors to cool engine as soon as possible and clean engine apartment.
Clean machine at regular intervals, eliminate excess lubricant and other trash.
Do not spray water or vapor into cabin. Do not spray high pressure water to engine, hydraulic
and electric parts.
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Do not put your personal goods, tools in machine cabin and other location.
1.18 PREVENTION OF STORAGE BATTERY EXPLOSION
Battery connection must be correct, incorrect connection will cause explosion and hurt. Battery
liquid is corrosive, please wear protective device in checking and repair accumulator. Only
professional people can complete it. Safety is the most important that operators should be
cared.
Never put metal between terminals to test accumulator charging status. It must be tested by
voltage mater or hydrometer.
Never charge freezing accumulator, otherwise, which will lead to explosion.
Warning!!!
Forbid fire or flame and welding close to the battery. You would bear all responsibility if do not follow
safety rules and warning.
1.19 PREVENTING INHALATION OF ASBESTOS DUST

Prevent inhaling possible asbestos dust. The asbestos fiber may cause lung cancer。
Some seals contain asbestos fiber. In these components, normally, the asbestos is in the resin
or kept closed. If the asbestos containing parts don’t cause dust, there isn’t any danger in
normal disposal.
In order to prevent dust, don’t clean with compressed air, and avoid brushing and grinding
asbestos-contained materials. In maintenance work, wear regulated respirator, and use a
special dust collector to clean asbestos. If dust collector is not available, use a little oil or
water to damp the asbestos-contained material. Comply with working area rules and asbestos
disposal rules. Keep other people from entering in working area.
1.20 BEWARE HIGH PRESSURE LIQUID

Liquids in high pressure can penetrate through skin, causing GBH.
Release pressure before disconnecting any pipes to avoid the danger.
Operate control lever many times to release pressure.
Before pressurizing, tighten all the connections.
Inspect leakage with cardboard. Pay attention to protect your hand and body.
If accident occurs, see a doctor at once.
Any liquid penetrating the skin must be cleaned within a few hours, otherwise it will cause
tissue decay.
1.21 AVOIDING HEATING NEAR PRESSURE OIL PIPES
To prevent severe burns, do not weld or flame cut near pressured oil pipe or other flammable
materials.
A temporary fireproof protection cover should be provided when welding, flame cutting or gas
welding taking place.
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1.22 AVOIDING HEATING FLAMMABLE LIQUID PIPES

Pipes with flammable liquid are not permitted to be welded. Pipes or hoses must be cleaned
completely with incombustible solvent should any welding be required on those pipes.
1.23 PAINT REMOVING BEFORE WELDING OR HEATING

Prevent potential poisonous gas and dust.
When paint is heated up by welding or other methods, it will produce poisonous gas.
Remove paint by the following methods before welding or heating:
 Wear a regulated mask to prevent inhaling dust when removing paint with abrasive
paper or sand wheel.
 Remove paint with solvent or paint remover. Clean paint remover with soap and
water and wait for about 15 minutes for solvent to evaporate before welding.
 Paint removal work should be conducted outdoors or in a well-ventilated area.
1.24 SAFE DISPOSAL OF LIQUID
All fuels, most lubricants, and some coolants are flammable. These flammable liquids should be
stored away from fire. Do not burn or punch any liquid containers.
Dispose of fuel carefully; stop engine before adding fuel; prohibit smoking while adding fuel.
Add fuel outdoors.
Do not put oil-containing rags on the machine to ensure the machine stays clean.
1.25 SAFE DISPOSAL OF CHEMICALS
Touching harmful chemicals directly will cause serious injury to the human body. The
chemicals used in this machine, such as lubricant, coolant, paint, and adhesive may be harmful.
Before using harmful chemicals, check and understand its danger; know how to use them safely.
1.26 FIRE PREVENTION

Following these steps to prevent fire:
Prevent fire caused by leakages of fuel, hydraulic oil and lubricant.
Inspect clamps and ensure they are intact, check hoses and pipes to see they are in the right
position; check hydraulic oil cooler, connections; check leakage using a piece of cardboard;
never check leakage by hand to prevent pressure oil pierce skin and result in injured.
Tighten, repair, or replace any clamps, pipes, hose, oil cooler, and flange bolts of oil cooler.
Do not twist or punch any high-pressured pipe.
Do not use any twisted or damaged pipe or hose.
Inspect short circuits. Short circuiting of the electric system can cause fire.
Check cables and wires before every shift or after 8 hours operation.
Check connectors before every shift or after 8 hours operation.

10
Tighten, repair, or replace any loosened or damaged cables, wires and connectors before
operation. Do not operate the machine if the cables and wires are not in good condition.
Check key switch and engine emergency stop switch before everyday operation. Repair
immediately if they are not functioning.
Fire might be even worse or GBH might happen if engine cannot be stopped in case
Clean out flammable materials
Spilled fuel, excessive coal dust, and other flammable materials may cause fire. Keep the
machine clean every day to prevent fire.
1.27 SAFETY FACILITIES

Emergency exit: There is a small hammer in the left side of operator which will be used in
emergency（see the fig）.Once danger occurs or cab door locked，operator can use the hammer
to crack glass and escape from the window, or open sky window to escape.
Fire extinguisher: The cab is equipped a 1KG extingsuisher.When a fire breaks out,open
the door quicklyand take out the extinguisher,then pull out the hydrant, press down the
handle of the extinguisher and shoot at the root of the flame.
Emergency stop: The control panel within the cab has a emergency stop button,see
following figure.Once it has an emergency,press this button quickly to close all drilling
functions.If you want to resume normal work,be sure to pull the button to the normal
position.
11
1.28 PROTECTION AGAINST NOISE

It should do the noise test in normal running status for the machine.
Engine and other rotating parts should be in high speed.
The noise in operator’s seat meets the standard ISO/DIS11201: LP= 80dB
Machine noise meets standard ISO4872: Lw= 112dB
Attention：
Operator should wear ear shield before work.
12
2 OVERVIEW
SWDM240 rotary drilling rig is designed for cast-in-drilled-hole construction and widely
used in foundation construction of roads, bridges, and high-rise buildings with many features
like high torque, high mobility and high efficiency. Equipped with long or short auger, drilling
bucket, core barrel or hydraulic hammer, it can be used in drilling clay, sand, gravel or medium
weathered rock layers. The machine can be suit for large part of area soil condition in our
country, and can be widely used in the subways, bridges, docks and high building construction.
2.1 MODEL DEFINITION
SWDM240
SW——SUNWARD
DM——Drilling Machine
240——Rotary Head Torque is not less than 240KN.m
2.2 APPLICABLE RANGE
Equipped with a short auger for clayed soil, silty soil, backfilling, medium density sand and
weathered rock layers above water table.
Equipped with a drilling bucket, adopting slurry retaining wall for clayed soil, silty soil, sand,
backfill, gravel and weathered rock layers below water table.
Equipped with a rock auger for gravel, medium hard rock and weathered rock layers.
Equipped with a core barrel for weathered rock layer and cracked rock layer.
Equipped with a hydraulic hammer for construction foundation prefabricate concrete.
13
3 TECHNICAL CHARACTERISTICS
3.1 MACHINE STRUCTURE
FIG. 3-1
①frame ② crawler travel system ③ swing platform ④ shed
⑤counterweight ⑥power system ⑦auxiliary winch ⑧main winch
⑨ cab ⑩ luffing system ⑾ drill mast ⑿ swivel joint
⒀ following frame ⒁ Kelly bar ⒂ rotary head ⒃ drill tool ⒄ tool case
14
3.2 MAIN TECHNICAL DATA
Item Unit Parameter

Max. pile diameter mm 2000
Friction Kelly m 69（5 sections）

Max. pile depth
Inter-locking Kelly m 54（4 sections）
Machine Work mm 9120X4500X22275
dimension Transportation mm 16310X3000X3330
Operating weight (including Kelly bar and
t 76
drilling tools）
Model QSL9-C325
Engine
Rated power Kw/rpm 242/2100
Max. output torque KN.m 245
Rotary head
Rotation speed r/min 6～28
Max. pressure KN 210
Crowd cylinder Max. lifting force KN 240
Max. stroke mm 5000
Max. line pull KN 220

Main winch Max. line speed m/min 72
Wire rope diameter mm 28
Max. line pull KN 80
Auxiliary winch Max. line speed m/min 58
Wire rope diameter mm 20
Lateral  5
Mast inclination Forward  5
Rearward  90
Track shoe width mm 800

Crawler width of retraction
Chassis mm 3000～4500
and extension
Chassis length mm 5755
** As the improvement of the product, technical parameters are subject to change
without notice in advance.
15
4 MAIN STRUCTURAL FEATURES
See Fig 3-1 for machine structure. Main components: under-carriage (frame and crawler travel
system), upper-carriage (Swing platform, main winch, service winch etc.), luffing system, drill
mast, rotary head, Kelly bar, drill tool, cabin, hydraulic system, electrical system etc.
Basic Function and Theory:
Upper-carriage drill work and under-carriage traveling are the main functions for the machine
and the two functions can complete interlock through control system.
When in traveling, engine drives hydraulic pump，high pressure oil passing through main valve,
center swing joint enters travel motor and drives traveling planetary to complete crawlers move
forward/backward, left/right and stop.
Crawlers extend and retract, mast up/down, rotary head pressurization are all driven by related
hydraulic cylinders through control valves.
Kelly bar rotation, main/auxiliary winches lifting and Swing platform slewing utilizes
planetary driven by related hydraulic cylinders through control valves.
Rotary head drives motor and makes Kelly bar rotate, supplying oil to forcing cylinder,
completing drill under rotary head vertical downward pressure.
Total drilling depth and depth of each pass are displayed in the virtual digital display which is
convenient for operator monitoring drill depth.
For transportation, the mast can be boomed down with Kelly bar and Kelly bar bracket
detached. With the cathead and lower mast folded and crawlers retracted, the drilling rig can
move onto tractor and the counterweight can be removed if road condition does not permit.
4.1 UNDERCARRIAGE
Undercarriage is including frame and travel system etc. (Fig 4-1)
Pin shaft
Fig 4-1
16
Frame base is box-type welding structure and two main beams are controlled by hydraulic
cylinder to change crawler gauge. Before work, extend crawler to ensure drilling stability;
retract crawler before shipping to ensure proper shipping width.
Important：Make sure pin shafts in limit link rod of intermediate frame and two main beams are fitted
correctly before extending and retracting crawler before work and shipping.
Crawler travel system (see fig 4-2) is composed of guide wheel, tension device, crawler
assembly, carrier roller, track roller, drive wheel, travel reductor etc. Crawler regulating system
keeps its tension by using high pressure lubricant. Hydraulic system controls travel system to
complete moving forward/backward, left/right, turning etc.
Fig 4-2
① Idler and tension device
② Crawler assembly
③ Track roller
④ Drive sprocket
⑤ Travel reduction gearbox
Crawler tension unit (Fig 4-3) is composed of tension cylinder, tension spring, guide wheel, oil
cup. Track tension is regulated by hydraulic; tension spring must exist precompression which
can make crawler tension and ensure meshing between crawler pin and drive wheel.
Important：Lubricating grease leakage cannot be checked through safety valve.
Fig 4-3 Tension Unit

1. Idler 2. Tension spring 3.Tension cylinder 4. Grease zerk
17
4.2 UPPER- CARRIAGE
Sunward upper-carriage design is considering stability and multifunction application demand,

easy operation and maintenance. Hydraulic and electrical pipelines are arranged in different
layers, beautiful and clear integral layout.
4.2.1 Swing Platform
All parts in upper-carriage（including big roller main winch, service winch, hydraulic oil tank,
power system, air condition etc）are fit under Swing platform. According to rig work condition,
swing platform stress is complicated. Swing platform is a welding part, the 3-D stressed
analysis is showed in fig 4-4.
Fig 4-4
4.2.2 Main Winch and Auxiliary Winch
Main winch adopts a roller with large diameter. The steel wire rope is released in one layer
while working to avoid rope layer change and squeeze and abrasion between the upper and
lower layers. In that case, the service life of steel rope is longer.
Fig 4-5
18
4.3 POWER SYSTEM
Engine is the power source of the whole machine. It’s installed on the machine as shown
in FIG. 4-6, including engine mounting system, main pump system, air intake system, cooling
system, fuel pipeline system and exhaust system. Please refer to electrical system for engine
control system.
This equipment adopts Cummins QSL9-C325-T3, USA, meeting the emission standard of
U.S. EPA Tier 3, CARB Tier 3 and EU Stage IIIA. It has excellent performance with low fuel
consumption. Matching with hydraulic pump precisely, the output power is strong, thus,
making the work efficiency of the machine is high.
FIG. 4-6
1-Air intake system 2-Cooling system 3-Engine mounting
4-Fuel pipeline system 5- Exhaust system 6-Main pump mounting
Please find the use and maintenance of engine system in engine manual.
19
4.4 AIR-CONDITIONING SYSTEM
Electric heating and cooling air conditioning is adopted to improve the indoor comfort of the
cab.
1）System refrigerating capacity: 5 KW±10%
2）System heating capacity：5.81KW±10%
3）System air output: cold air：550 m³/h； warm air：400 m³/h
4）Freezing medium：R-134a
5）Compressor exhaust volume：167.3 cm³/r
6）Power consumption：24V.DC
7）Power consumption： <3 KW
8）Working environment: -25℃～65℃ 20％～90％（Relative humidity）
1. Operating principle of air conditioning:

The compressor compresses the gaseous refrigerant into the refrigerant gas of high temperature
and high pressure, then the refrigerant gas is discharged into the condenser from the
compressor nozzle, and cools down to become the liquid, then flow to the reservoir. High
temperature and high pressure of the refrigerant liquid is flowed into the evaporator after dry
filter within the reservoir, after expansion valve throttling depressurization, become the low
temperature and low pressure gas-liquid mixture, and then be inhaled from the low pressure
intake pipe, it is a constant cycle. Evaporator continuously absorbs heat to send cold air to the
cab, attaining the effect of refrigeration.（as FIG. 4-7）

Heating: Hot water in engine is guided into the evaporator element, on which the cold air is
sent by fan continuously, and then change with hot water, making cold air into hot one. And
the hot air is blown into cab through air pipe of the air conditioner. Above circulation is
repeated continuously, so as to heat.（as FIG. 4-8）
20
FIG. 4-7 FIG. 4-8
2）The composition of the air-conditioning system（as FIG. 4-9）：The air-condition system

consists of compressor, condenser, evaporator and air-conditioning pipeline.
Condenser
Compressor
Drying
bottle
Evaporator
FIG. 4-9
21
4.4 LUFFING MECHANISM AND DRILL MAST
The luffing mechanism is composed of arms, tripod, link rod and luffing cylinders (Fig 4-10).
Luffing uses two-grade cylinders, boom luffing cylinder controls the angle of arms, the mast
tilting cylinders adjusts mast verticality. The mast can tilt 5 degree left/right; 5 degree forward.
The box type drill mast is composed of three sections; each section is fit slide rail. Rotary head
and following frame moves up and down in slide rail. The upper cathead section and the lower
drill mast section can be automatically folded /unfolded, It can complete self-load/unload by its
own power and structure without crane, for example, lower section drill mast can finish
self-load and unload in mast vertical mode（see fig 4-11）. Pulley is mounted in the upper
cathead, and steel rope of main/service winch passes through the pulley.
MAST TILTING
CYLINDER ROCKING
BAR UNIT
1
ROCKING
BAR UNIT 2
BOOM
PULL ROD
LOWER
LUFFING MAST
LINKAGE MAST
CYLINDER
Fig 4-10 Fig 4-11
Service stabilizer cylinder is assembled in lower section drill mast for fitting hole barrel: make
its bottom is level with bottom of drill stool by service stabilizer extension, press barrel two
sides, use stabilizer cylinder to press down one side, fall main winch down and press another
side down by drill tool weight .This barrel fitting method is much faster than only drill tool
22
fitting. Otherwise, service stabilizer makes crawler maintenance safety and convenience.
Rotate the drill mast 90°and raise one side of the crawlers (see fig 4-13).
Fig 4-12 Fig 4-13
4.6 ROTARY HEAD
See Fig 4-14. Rotary head is mainly composed of

sliding frame and gyrator. Sliding frame is used to
support gyrator to make it move in sliding rail and
transfer force; gyrator is mainly composed of two
hydraulic motors、planetary, drive gear, gear box and
drive sleeve etc. The working theory is that the driving
sleeve drives the kelly bar to rotate after speed is
reduced by driving gear and speed reducer. The first
stage lubrication of the gear box adopts circulation
lubrication and the second stage lubrication adopts
oil-bath lubrication. Planetary is imported. When
spinning-off is required, it can exchange rotary head Fig 4-14
or jerk in high speed. The driving sleeve has
rectangle teeth and rotates with the kelly bar when they are engaged the control system is a
variable pump, variable motor system and it can automatically adjust its speed and torque
(power load sensing) according to different soil condition.
23
5 HYDRAULIC SYSTEM
All functions for SWDM240 rotary drilling rig are driven by hydraulic system, such as
machine traveling, Swing platform rotation, boom luffing, mast luffing, main and aux winch,
rotary head swing etc.
The system can be divided into two parts: center rotation body and its under-carriage hydraulic
system, remaining is upper-carriage hydraulic system.
Before operation, press down safety control bar to make pilot pressure oil enter pilot control
valve and related electromagnetic control valves.
Special Explanation: In entering and leaving cab, safety joystick must be pulled up to cut
off hydraulic system to prevent mishandling.
5.1 UNDERCARRIAGE HYDRAULIC SYSTEM
Under-carriage hydraulic system can complete travel and crawler gauge change.
1）Travel system：Through multiple unit valve, main pump supplies oil to two travel motors.
Operate left and right pilot valve to make multiple unit valve change direction and complete
machine move forward, backward and turning.
2）Crawler extend and retract：Press down wane switch “crawler extend/retract”, change valve
Y34 works and crawler gauge changed. Pilot control oil drives change valves, operate right
handle at this moment, cylinder works and crawler extends & retracts. ①Rotates Swing
platform to crawler frame vertical position in track extension; extends stabilizer on ground at
the same time. Make sure that crawler frame extension side is in suspension before track
extension; ②It also can extend and retract crawler during traveling.
For safety, we suggest to use ① for complete crawler extension.
5.2 UPPER-CARRIAGE HYDRAULIC SYSTEM
Upper carriage hydraulic system controls: boom level lifting, mast angle adjusting, pressurized
cylinder forcing and lifting, main/aux. winches, upper structure swing, rotary head rotation etc.
1）Boom level lifting：press down safety button and control pilot right handle forward and
backward，oil flows into boom level lifting cylinder through multiple unit valve, and complete
mast level moving.
2）Mast angle adjustment：operate electrical control handle and press down safety button, oil
from aux pump flows into mast derricking cylinder through multiple unit valve and complete
angle adjustment（Attention! Mast left and right tilt angle must be less than 5°）.
3）Pressurized cylinder forcing and lifting: press down wane switch “adjust/work”，operate
pilot right handle forward or backward，oil from aux pump flows into pressurized cylinder
24
through multiple unit valve and make piston bar extend (or retract)。If presses down “forcing
fast” wane switch at the same time, the piston bar can quickly push downward/upward.
4）Rotary head swing：Press down “adjust/work” wane switch and operate pilot right handle to
left or right，oil from main pump flows into rotary head motor through multiple unit valve and
completes rotary head swing(clockwise or anti-clockwise).
If presses down handle for fast spin-off at the same time, high counterclockwise/clockwise
spinning off speed is achieved. (optional function)
If rotates rotary head control button at the same time, it can adjust rotary head torque changing
function to suit different soil condition and advance hole forming efficiency. (optional
function)
5）Upper-carriage swing：operate pilot left handle to left or right，oil from aux pump flows into
swing motor through multiple unit valve ， upper-carriage completes swing 360 degree
clockwise or anticlockwise.
6）Main winch operation：operate pilot left handle forward or backward，oil from main pump
flows into main winch motor through multiple unit valve and completes load up and down.
When “adjust/work” is switched on, if presses down main winch fast button and operates the
handle at the same time, it can complete load fast upward and downward.
7）Main winch float：press down “ main winch float” wane switch during drilling work.
Special Attention：Never lower Kelly bar through float function in non-drill work.
8）Service stabilizer retract and extend：operate pilot right handle to left or right, oil from aux
pump flows into stabilizer cylinder through aux change valve, valve Y34 and completes
stabilizer retract or extend. (Remark: The design is for matching crawler gauge change and
hole barrel fitting).
9）Auxiliary winch operation：operate pilot right handle forward or backward, oil from main
pump flows into service winch motor through multiple unit valve, and makes load up and
down.
10）System cooling：Whole cooling system is assembled in the upper-carriage hydraulic system.

In normal condition, cooling fan ON/OFF is decided by hydraulic oil temperature, In order to
keep oil temperature in reasonable range, press down “cooling radiating” to start fan and cool
hydraulic oil.
11）Winch balance valve is designed in whole hydraulic system to prevent winch stalling，
cushion valve is used for cushioning，cylinder balance valve is for hydraulic cylinder locking.
5.3 PILOT CONTROL SYSTEM
Hydraulic system with pilot control, safety control pull rod(hydraulic enable switch) controls
pilot pressure oil ON/OFF. Pilot control is easy and flexible. Bagging-type accumulator is fit in
the system to ensure stable pressure.
25
5.4 OIL FILTER
Assemble oil filter in the hydraulic oil circuit to filter the impurity from oil, keep hydraulic oil
cleanly. It is important step to protect hydraulic component normally run and increase its
service life. When the filter have been obstructed to certain degree ,it will alarm to remind
customer clean or change filter in time, to protect hydraulic system.
When replacing filter core, twist off air filter in oil tank, dismount top cover in oil filter, pull
filter drum and filter core out from oil filter, then take old filter core out and clean filter drum
and fit new filter core, reassemble filter drum and filter core, and fit top cover and air filter.
Attention: Before taking out filter drum，it cannot pull oil filter core out to prevent
impurity enter oil tank.
Assemble high pressure oil filter at the out port of pilot pump, ensure pilot oil system cleanly
and work normally.
5.5 HYDRAULIC OIL
Hydraulic oil is the working medium to pass the energy and action within the hydraulic system.
It is high pressure hydraulic system for our machine with high precision hydraulic components.
Thus, it is required for the hydraulic oil to be not only high quality such as anti-wear property,
viscosity, viscosity-temperature index number etc, but also high cleanliness. Any impurity as
dirt, water etc. entering the hydraulic oil would lead to serious consequence even destroying of
entire hydraulic system.
Our machine uses YB-N68 hydraulic oil. In different weather, different hydraulic oil may be
used. For new machine, the hydraulic oil shall be drawn out for filtration after 100 work hours.
Later on, make the hydraulic oil filtered every 500 work hours and replace the oil return filter
on the top of oil tank at the same time, replace hydraulic oil and filters every 2000 work hours.
During filling or replacing, keep hydraulic oil according with the standard: IS04606
17/14-18/15 or NAS1638 level 8—level 9.
★★★Special Attention：Oil pump, motor, cylinder, balance valve, multiple unit valve are very
important and sophisticated, the parameters are debugged elaborately after test by our
company. So dismantling or debugging should be carried under authorization from the sale
Dep. of our company or performed by our service engineer, otherwise we are not responsible
for any serious consequence.
26
6 ELECTRICAL SYSTEM
Special Attention: All the control units and engine ECM sockets should be unplugged in any
welding occur on the machine. Pay attention that all sockets connection is in the proper
position. If sockets cannot be locked in, please check inside cushion washer is in correct
position or not.（see photos as following）
Plug in the correct place Plug out
Plug in the correct place before welding Plug out while welding
27
6. 1 DESCRIPTION
Electrical system for rotary drilling rig is including engine, controller, operating panel, sensor
and display meter etc. It adopts advanced CAN general wire compile procedure controller,
graph transmit and guide display controller etc modules. It is an intelligent control system
which including data acquisition, programmable control, virtuality instrument, concentration
line transmit, fault diagnostics, engine power limit adjusting. Operator presses the buttons and
switches in control panel to send order; sensors test the machine work parameter and limit
parameter; procedure controller treats the order signal to drive motors and valves etc. By this,
machines can finish engine monitor, machine travel, drill work, deviation-rectify, failure
diagnosis and data store. All mode parameters for system running is transferred to graph
transmit and guide display controller by CAN-line and complete hole depth display,
deviation-rectify curve display etc, and also can set parameters and system scaling through
display. Block-diagram and layout see Fig 6-1.
Fig 6-1
28
6.2 CONSOLE OPERATION INSTRUCTIONS
29
Number Name Patterning Function

Check the slope of the ground
Warning
★ When travel in falling
gradient, grade of slope in
longitudinal must be no more
than 5°, and adjust the mast
1 Gradienter
backward no less than 10°～
15°.
★When travelling, grade of
slope in transverse must be no
more than 5°.
This button is used together with the

“Button 2- the suspension switch of main
winch” of the membrane panel; The
Main winch
suspension function of the main winch is
2 suspension
enabled when it’s connected and its pedal is
pedal
treaded. Release the pedal to disable the
function, while there’s a prompt of
suspension status on the main interface.
“Button 1- Working switch” in the

membrane keypad panel is not connected:
Push the two handle forward to advance
the machine.
Push the two handle backward to move
the machine back.
Left/right Push the left handle forward and the right
3-4 travel pedal handle backward to turn the machine to the
valve right in situ.
Push the left handle backward and the
right handle forward to turn the machine to
the left in situ.
When “Button 1- Working switch” in the
membrane keypad panel is connected, there
is no action.
30
5 Pedal Alleviate leg fatigue.
Handle forward, main winch down.

Button 3 Handle backward, main winch up.
Button 1 Handle leftward, main winch turn left
Button 2
Handle rightward, main winch turn
Button 4 right
★Press “Button 2”,the main volume
motor variable, the speed is getting faster.
Left pilot ★Press “Button 3”, the horn control
6
handle button.
★Press “Button 4”,the upper-carriage
rotate automatically.
★When the drill bar is in upper limit, press
“Button 1 +Button 2”and “Button 1-
working switch” in the membrane keypad
panel is unconnected, the upper limit is
cancelled.
B
Control engine speed and output power
a——Low idle position
b——High idle position
When the accelerator knob turns
Accelerator
7 clockwise from “a” to “b”, the engine
knob
speed will increase.
A When the accelerator knob turns

anticlockwise from “b” to “a”, the engine
speed will decrease.
31
The key switch is used to turn on/off the

engine, mainly including three working
positions:（OFF），（ON）,（START）.
OFF: Key can be inserted or pulled out.
Turn the key to this position to cut off the
power of all electrical systems except the
cab lights, and stop the engine.
ON: The position enables all electrical
system to be connected. When the engine is
running normally, the starting switch should
always be in this position. If abnormal,
8 Ignition key check the electrical system immediately.
START: The starting position of the
engine. When starting the engine, keep the
key in the position.
Warming
★ Time for start-up should
not over than ten seconds to
avoid the damage of engine.

membrane key panel is not connected:
★Press “Button 8”,handle forward,
mast forward.
★Press “Button 8”,handle backward,
Electric mast backward.
9
handle
★Press “Button 8”,handle leftward,
mast leftward.
★Press “Button 8”, handle rightward, mast
rightward. When “Button 1- Working
switch” in the membrane key panel is
connected, there is no action.
32
Press down the wiper switch ① and

the wiper will clean the front window.
Press down the wiper switch ② to
open the watering can and spray water onto
the front window.
Rocker
Press down the headlamp switch ③ to
switch
10 turn on the front headlamp at night.
group 1
Press down the dome light switch ④
to turn on the dome light in the cab at night.
Press down the warning light switch
⑤ to turn on the warning light during work.
Press down the horn switch ⑥ to sound the
horn for alarm during working.
Cigar
11 Vehicle-mounted power socket
lighter
USB
12 USB socket.
plug
33
Users can listen to broadcasts from

different channels according to their demand
and hobby to alleviate operation fatigue.
①－Power control
②－Band selection
③－Automatic search
storage/Pre-storage radio
audition
13 Radio
④－Radio presets
⑤－LCD
⑥－Manual sorting table：“∧”
frequency increase，“∨”
frequency decrease
⑦－Clock
⑧－Volume control：“∧”Volume
increase，“∨”Volume decrease
The air conditioning panel is used to switch

on and off the air conditioner in the driver's
cab, adjust the air volume, select the
refrigeration and heating modes, etc.
①－OFF Switch. Fan and air conditioning
stop control.
②－Fan speed setting switch.
14 AC panel
③－Temperature setting switch.
④－Blow out mode setting switch.
⑤－Automatic mode setting switch.
⑥－Internal and external gas mode setting
switch.
⑦－Liquid crystal display unit.
⑧－Air conditioner switch.
34

membrane key panel is not connected:
Handle forward, auxiliary winch down.
Handle backward, auxiliary winch up.
★Press “Button 5”, handle forward, luffer
down.
★Press “Button 5”, handle backward, luffer
up.
Handle leftward, mast support retract;
Handle rightward, mast support extend;
★Button 4- crawler extension switch” in the
membrane key panel is connected,
handle leftward, crawler retract;
★“Button 4- tracks extension switch” in the
membrane key panel is connected,
handle rightward, crawler extend.
Right pilot
15 ★“Button 1- Working switch” in the
handle
membrane key panel is connected:
Push handle forward, pressurized
cylinder extend;
Push handle rearward, pressurized
cylinder retract;
Push handle leftward to rotate rotary
head clockwise;
Push handle rightward to rotate rotary
head anticlockwise;
★Press “Button 6”, rotary head throw soil
quickly
★Press “Button 7” once, push the handle
leftward and rightward to the
end respectively to lock it, press
again to unlock it.
The handle must be locked before the driver

leaves the seat of the cab. All the hydraulic
functions are disabled when the safety
Pilot safety handle is in the “OFF” position.
16
handle Enable the pilot control: the handle is moved
to the position 1.2;
Disable the pilot control: the handle is
moved to the position 1.1.
35
6.3 INTERIOR OPERATION INSTRUCTIONS
36
No. Name Patterning Function

In case of emergency, press
down this button, then all
hydraulic functions are disabled.
Return to normal, rotate the
emergency switch clockwise,
and all hydraulic functions will
be back to normal.
Pilot Warning
emergency ★In case of emergency, this button

1
stop
switch should be pressed down
immediately and stop working.
Operator should report to the safety
supervisor, after-sales people and
technicians immediately. It is
forbidden to operate the machine
U-disk
interface
for
The recorded data copying
2 copying No picture
interface for display screen.
data of
display
screen
Spare
3 rocker No picture Spare
switch
37
Membrane
4 keypad See chapter 3.2.2
panel
Monitors are used for

monitoring the working status of
the machine key parts.
In total, four cameras can be
connected, monitoring main
winch wire rope, left rear of the
5 Monitor machine, right rear of the
machine and the wire rope on
the top of Cathead (optional)
★Notice：According to different
machine models It's optional
to mount wire rope camera
on the top of the Cathead.
Display
6 See chapter 3.2.1
screen
38
6.3.1 Operation Interfaces of Display Screen
6.3.1.1 Main Interface
Figure 3.2.1-1
Operator sets to this interface showing on the display screen while working, in which following
main working parameters of the rotary drilling rig are included. Such as, current rightward
inclination angle (X), forward inclination angle (Y), the swing angle, the depth of last hole,
depth of drilling drum, water temperature, rotation speed and loaded rate of engine, limit mode,
suspension status, swing mode, pressure of rotary head , system and main winch, and the pilot
pressure value etc.
Click "rotation in situ"(Key 1) to reset the current rotation angle, and set the current rotation
angle as zero; When the rotary drilling rig is working, set the current drilling position to zero.
After turning and throwing the soil, press the left handle to lower the key, and the platform will
automatically turn and reset. As long as it returns to zero, it means that it has returned to the
drilling position. The precision error of the rotation Angle is controlled within 0.1, and the
rotary control precision is high.
Click "clear depth"(Key 2) to set the current depth to zero; When the ground height of the
rotary digging and drilling work site is not the same, the drill bit can be conveniently adjusted
by this press group. Put the drill bit on the ground and press the button to set the current depth
to zero.
Click" "(Key 3) to turn off the buzzer.
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Click" "(Key 4), suspension function of the main winch: icon is displayed with "X",
indicates that the control suspension function of the display screen is disabled, enable it to
operate the film operation panel and suspension pedal switch. When the suspension function of
membrane panel and its suspension pedal is treaded, “Enabled” is displayed. After the pedal is
released, “Disabled” is displayed. There’s no “×”is displayed with the icon, that means the
suspension function is controlled by the display screen directly-the suspension valve is opened,
“Enabled” is displayed in the status of suspension.
Click "leveling" (Key 5) ,and enter the " leveling " interface to monitor auxiliary operations
such as mast erection, leveling and rotation.
Click "set" (Key 6) to enter the "setting interface" for parameter setting.
Click "monitor" (Key 7) to enter the "monitoring interface" for instrument and sensor
monitoring.
Click "contact us" (Key 8) to enter the "contact us interface", here are contact information of
company marketing, after-sales service.
Description for Main Interface
Icon on the top:
The left-most part of the line is the system date and time, which can be set in the system
Settings. The far right is the number of working hours of the engine of the equipment.
Icon from left to right:
The left-most part of the line is the system date and time, which can be set in the system
Settings. The far right is the number of working hours of the engine of the equipment.
Icon from left to right:
Fuel level alarm prompt: when the fuel level is too low (generally less than 15%) this
icon will become yellow with red line.
Hydraulic oil temperature alarm prompt: when the hydraulic oil temperature is too
high, the icon will become yellow with red line.
Battery voltage alarm: when the battery voltage is too low (below 25.5V), the icon
will turn yellow and red.
Oil pressure alarm: when the oil pressure is abnormal, the icon will turn yellow and
red.
Warning of engine water temperature: when the engine water temperature is too high,
the icon will turn yellow and red.
Engine failure alarm prompt: this icon will turn yellow and red when the engine has
failure.
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Hydraulic enable prompt: hydraulic system pilot solenoid valve electricity, pilot oil
circuit connected when the icon will become yellow line and red.
Warning of limit position of main winch: when the upper limit position of main
winch hammer is reached, the icon will turn yellow with red line.
Warning for hydraulic oil returning filter element: when the oil returning filter
element is blocked and the return oil pressure is too high, the icon will turn into a red line with
yellow bottom.
Alarm prompt: in addition to the above alarm, if there is any other alarm on the
device, the icon will turn yellow with red line. At this time, you should enter the monitoring
interface to view other alarm prompts.
Gyration and mast Angle:
The red box indicates the gyration Angle; The yellow box indicates the Angle of
the mast X/Y axis.
6.3.1.2 Move Leveling Interface
Click the “Leveling” (key 5) in the “Main interface” (FIG. 6.3.1-1) to enter the “Move
Leveling interface” (FIG. 6.3.1-2).
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Figure 6.3.1-2
Current display is MANUAL mode, press key 2 AUTO key. Auto leveling fails if X and Y
axles show more than 5°and the display goes back to MANUAL mode again and LEVEL
DISPLAY shows “UNEVEN”. If X and Y angles are less than 5°, auto leveling keeps the mast
straight and LEVEL DISPLAY shows “EVEN”. Press Key1 for MANUAL mode if needed.
Adjust X+，X-，Y+，Y- in display for Kelly bar verticality under manual mode.
Click “X＋”（key 3）to increase angle on X-direction（tilting right increase）;

Click “X－”（key 4）to decrease angle on X-direction（tilting left increase）;
Click “Y＋”（key 5）to increase angle on Y-direction（tilting backward decrease）;
Click “Y-” （key 6）to decrease angle on Y-direction（tilting backward increase）.
Click "Debugging" (key 7) to enter the "Debugging" interface (Figure 3.2.1-3);
Click “Return” (key 8) to back to the "Main Interface" (Figure 3.2.1-1).
LEVEL DISPLAY shows “EVEN” when X and Y are within 0.2° range, otherwise the LEVEL
DISPLAY shows “UNEVEN”.
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6.3.1.3 Debugging Interface
Click “Debugging” (key 7) to enter “Debugging interface” in the “Move Leveling”

interface (Figure 6.3.1-2).
Figure 6.3.1-3
The interface is used to debug the mast, whether it's normal.
Click the key 1 "Step length" to enter the interface of "Setting of Step Length" (Figure 3.2.1-4).
Click the key 2 "Left Cylinder Extend" to stretch the left cylinder which is vertical with the
Kelly bar.
Click the key 3 "Left Cylinder Retract" to retract the left cylinder which is vertical with the
Kelly bar.
Click the key 4 "Right Cylinder Extend" to stretch the right cylinder which is vertical with the
Kelly bar.
Click the key 5 "Right Cylinder Retract" to retract the right cylinder which is vertical with the
Kelly bar.
Click the Key 8 "Return" to back to the "Moving Interface"（Figure 6.3.1-2）.
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6.3.1.4 Space Setting Interface
Click the “Space set” (key 1) in the “Debugging” interface (figure 6.3.1-3) to enter the “Space
Setting” interface.
Figure 6.3.1-4
Press the button of left and right (key 1/2) to move the cursor, set the value by the key "+" "_"
(key 3/4) , then input the "9999" and confirm by the key 7, at this time, the limit mode of mast
is disabled.
At the end, press the "Return" button (key 8) to back to the "Debugging" interface (Figure
6.3.1-3).
6.3.1.5 Main Parameter Setting Interface
Click the “Setting” (key 6) in the “Main interface” (figure 6.3.1-1) to enter the “Setting of Page
Password” interface.
44
Figure 6.3.1-5
Press the buttons of left and right (key 1/2) to move the cursor, set the value by the keys "+"
and "_" (key 3/4), then input the correct password and confirm by the key 7, at last, it jumps to
the "Main Parameters Setting Interface “(Figure6.3.1-6).
Figure 6.3.1-6
★Warning: Because the system parameters can be modified in this interface, improper settings of the
parameter will cause the descending using performance of the machine, even the control less of operation
resulting in heavy accidents. Thus, the "Settings" interface only can be modified with the conduction of
45
professional personnel of SUNWARD. Otherwise, SUNWARD will take no responsibility for any
consequence.
6.3.1.6 Main Monitor Interface
Enter the "Main Monitor" interface by clicking the button "Monitor" (key 7) in the "Main
Interface" (figure 6.3.1-1).
Figure 6.3.1-7
All the conditions of sensors and equipment alarms are displayed in this interface: when the
icon is yellow bottom with red line that indicates there is fault or alarm, you need to check the
corresponding part.
Click the "CFA" (key 1) to enter the "CFA Interface" (Figure 6.3.1-8).
Click the "Port" (key 2) to enter the "Port Monitor Interface 1" (Figure 6.3.1-9).
Click the "GPS" (key 3) to enter the "GPS Monitor" interface (Figure 6.3.1-15).
Click the "Record" (key 4) to enter the "Record Interface" (Figure 6.3.1-16).
Click the "Engine" (key 5) to enter the "Engine Malfunction" (Figure 6.3.1-19).
Click the "Work Record" (key 6) to enter the "Work Record Interface" (Figure 6.3.1.20).
Click the button "Record Printing"(key 7) to enter the "Record Printing Interface" (Figure
6.3.1-21).
Click the "Return" (key 8) to enter the "Main Interface" (Figure 6.3.1-1).
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6.3.1.7 CFA Interface (Optional Function)
Click “CFA” (KEY 1) in the “Main Monitor Interface”(figure 6.3.1-7) to enter “CFA”
interface.
Figure 6.3.1-8
This interface shows the parameters that are related with CFA, including: slurry flow, pressure,
winch speed. Click "Return" (key 8) to enter the "Main Monitor Interface"（Figure 6.3.1-7）.
6.3.1.8 Port Monitor Interface
Enter the "Port Monitor Page 1" by clicking the "Port" (key 2) on the "Main Monitor Interface"
(Figure 6.3.1.7).
47
Figure 6.3.1-9
Figure 6.3.1-10
48
Figure 6.3.1-11
Figure 6.3.1-12
49
Figure 6.3.1-13
Figure 6.3.1-14
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In each interface of the "Monitoring Port", follow operations can be done.
Click "Page 1" (key 1) to enter the "Com Monitor Page 1" (Figure 6.3.1-9).
Click "IO Module" (key 5) to enter the "IO Module Monitoring" page (Figure 6.3.1-13).
Click "Membrane" button (key 6) to enter “Membrane Keyboards Monitor" page (Figure
6.3.1-14).
Click "Return" (key 8) to enter the "Main Monitoring" interface (Figure 6.3.1-7).
The "Port Interface" monitors the working value of all the ports, such as equipment controller,
IO module, film button, and also provides the instructions.
There are two kinds of numerical value under detecting:
① The number value is 0/1, 0 showing that input voltage or output voltage of the port is zero,
1 showing that the input or output voltage of the port is 24V. When the value is "0", the
instruction about the port is DI_ or DO_.
② The analog value displays in numeral form, that means the input or output voltage of the
port or the electricity current. There's AI_ or AO_ displays in the port instruction.
In the column of the port, the marked letter, such as “4:AI_P1”, which indicate that the fourth
stitch of the controller (or IO module), the numerical tube is marked with “P1”, which is the
analog value.
6.3.1.9 GPS Status Display Interface
Click “GPS” (key 3) in the “Main Monitor Interface” (figure 6.3.1-7) to enter “GPS Status
Display Interface”.
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Figure 6.3.1-15
Click "Return" (key 8) to enter "Main Monitor Interface" (Figure 6.3.1-7).
In this interface, following information can be found.
If the icon behind the item become " ", which means the corresponding item is locked.
When the direction of locking is sent out: the icon behind the relay become " ", the icon
behind the main controller become " ".
★Warning: Human-caused damage of GPS may result in system stoppage.
6.3.1.10 Record Interface
Click “Record”(key 4) in the “Main Monitor Interface” (figure 6.3.1-7) to enter the “Record”
interface.
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Figure 6.3.1-16
This interface records the accumulated drilling depth and accumulated working hours, total
engine consumption, and the recorded information about the machine, such as the maintenance
information of each key parts of structure, the version of controller and displayer etc.
Enter the "Service Page" by clicking the "Service" (key 2). (figure 6.3.1-17).
Enter the "Port Monitoring Page 3" by clicking the "Version Information" (key 3). (figure
6.3.1-18).
Enter the "Main Monitor Interface" (Figure 6.3.1-7) by clicking "Return" (key 8).
Figure 6.3.1-17
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Instructions about this interface: This interface is used for equipment maintenance information,
the followed icon become red when "Service Cycle" approaches since "The maintenance of last
time", which means that the specified item should be maintained. After finishing the
maintenance, press key 1/2 to move the cursor to the correct item, press the key 3 "Confirm",
then the record will keep this maintenance: when the time counting from the last maintenance
become zero, while the times are one more than the original one.
Click “Return” (key 8) to enter the “Record Interface” (figure 6.3.1-16).
Figure 6.3.1-18
Version information includes the information of controller, IO module, GPS and monitor.
Enter the "Record Interface" (figure 6.3.1-16) by clicking the "Return" (key 8).
6.3.1.11 Engine Malfunction Interface
Click “Engine” (key 5) in the “Main Monitor” interface (figure 6.3.1-7) to enter “Engine
Malfunction” interface.
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Figure 6.3.1-19
Above interface is used for checking the engine fault information: Enter this interface, you'll
find the details about the engine fault when the indicator light of the engine becomes yellow or
red.
Enter the "Record Interface" (Figure 6.3.1-16) by clicking "Return" (key 8).
6.3.1.12 Work Record
Enter the "Work Record” interface by clicking the "Work Record"(key 6) in the "Main Monitor
Interface" (Figure 6.3.1-7).
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Figure 6.3.1-20
Follow below steps to record the data.
①Set the pile number, pile diameter, recording time;
②Press down the starting record button (key 6) to enable the system data recording.
③After finishing the pile, press down the record button (key 7) to disable the system
recording.
④Copy the data out to a U disk by pressing down the U disk button (key 5).
⑤The data in the recorded file consist of time, date, pile number, pile diameter, depth, vertical
angle of the mast, the flow and pressure of slurry, the pressure of rotary head, the rotation
speed of engine.
Enter the "Record Interface" (Figure6.3.1-16) by clicking "Return" (key 8).
56
6.3.1.13 Record Printing
Enter the "Record Printing" interface by clicking the "Record Printing"(key 7) in the "Main
Monitor Interface (Figure 6.3.1-7).
Figure 6.3.1-21
The real-time recorded information can be printed out in this interface (Special printer must be
connected).
Enter "Record Interface" (Figure 6.3.1-16) by clicking the "Return" (key 8).
6.3.1.14 Company Information Interface
Enter the "Company Information Interface" by clicking "Contact Us"(key 7) in the "Main
Interface" (Figure 6.3.1-1).
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6.3.2 Membrane Keyboard Panel
58
No. Name Patterning Function
1 Working switch Exchange machine work mode
Main winch Press down this switch, and tread down the suspension
2
suspension switch pedal switch to enable the suspension function.
Manually turn on the hydraulic oil cooling motor

★Notice: When the oil temperature exceeds 50℃，the
3 Oil cooling switch
system shall automatically open the hydraulic oil
cooling motor.
When “Button 1-Working switch" is disconnected:
Crawler extension "Button 4—Crawler extension switch” is connected,
4
switch right pilot handle leftward, crawler will be retreated.
Right pilot handle rightward, crawler will be extended.
When “Button 1-Working switch” is disconnected:
“Button 5—Tension switch of crowd switch wire

Tension switch of
5 crowd switch wire rope” is connected, right pilot handle leftward,
rope crowd switch wire rope cylinder will be retreated.
Right pilot handle rightward, crowd switch wire
rope cylinder will be extended.
When “Button 1-Working switch”is disconnected:
“Button 6—Cathead cylinder switch”is connected,
Cathead cylinder right pilot handle leftward, crowd switch wirerope

6
switch cylinder will be retreated. Right pilot handle rightward,
crowd switch wirerope cylinder will be extended
★Notice: This feature is not currently configured on
this model.
Rotary head
7 In no-load condition, the rotary head rotates slowly.
low-speed switch
Pressurization and The pressurization and high-speed switch of rotary

8
high-speed switch head.
59
Walking speed of equipment crawler.
9 Fast travel ★Notice: This feature is not currently configured on
this model.
Mode L switch for

10 Rotary head rotates at normal speed.
rotary head
Mode M switch for

11 Rotary head rotates at low speed 1.
rotary head
Mode H switch for

12 Rotary head rotates at low speed 2.
rotary head
Rotary head torque

13 Reduce the rotary head rotary pressure.
limit switch
Reduce the rotary head pressurized pressure
14 Pressure limit switch ★Notice: This feature is not currently configured on
this model.
Centralized
15 lubrication power Centralized lubrication system will be opened.
switch
Fan switch of Electric control cabinet cooling ventilation fan.

16 electric control ★Notice: This feature is not currently configured on
cabinet this model.
Rotary brake The rotary brake cylinder retracts.

17 cylinder retraction ★Notice: This feature is not currently configured on
switch this model.
The rotary brake cylinder extends.
Rotary brake
★Notice: This feature is not currently configured on
18 cylinder extension
this model. Figure 6.3.1-12
switch
Press and hold the left handle button 1, and press the
rotary head speed-increasing switch. The electric
19 Rotary head speed
up button + current of solenoid valve Y52 for controlling rotary
head increases by 10mA after every pressing. (It can be
observed from the port monitor interface 4 (figure
6.3.1-12) of the monitor interface for display screen.
60
Press and hold the left handle button 1, and press the
rotary head speed-increasing switch. The electric
20
Rotary head speed
down button ˉ current of solenoid valve Y52 for controlling rotary
head decreases by 10mA after every pressing. (It can
be observed from the port monitor interface 4 (figure
6.3.1-12) of the monitor interface for display screen.
Press down auto idle switch, when handle is in
medium position，system no work. Engine will adjust

21 Auto idle switch
rev to 1000rmp after 4 seconds. This function disables
after the switch is disconnected.
If engine failure indicating light in panel flashes, press
Failure diagnosis down failure diagnosis switch, to get the engine failure
22
switch indicating light flash status and refer to manual for
failure cause and easy maintenance.
Press down engine medium speed switch， engine

Engine medium
23 keeps in setting speed running （ setting speed is
speed switch
1600rpm）.
Press down “up” failure diagnosis page-up switch，

Failure diagnosis
24 failure diagnosis light flash shows the last failure code
page-up switch
of the engine.
Crowd switch suspension will be opened.

Crowd switch
25 ★Notice: This feature is not currently configured on
suspension switch
this model.
Press down “down” failure diagnosis page-up switch，

Failure diagnosis
26 failure diagnosis light flash shows the next failure code
page-down switch
of the engine.
61
Casing oscillator mode is on.

Casing oscillator
mode switch
this model.
When the red light is flash，stops engine at once

and check the failure.
Engine stop failure Warning

28
warning ★When the red light is
flash，stops engine at once and
contact the manufacturer.
Engine failure When the yellow light is flash, engine has common
29
warning failure.
Engine write waiting When the write light is flash，it needs to wait start,
30
start light starts engine after write light closing.
If there has the failure and alarm, the buzzer alarm.
Warning
31 Buzzer alarm switch ★When the buzzer alarm, the monitor
screen should be checked for alarm
reasons.
32 Horn switch Start electric horn
Mast mode switch.

33 Mode switch ★Notice: This feature is not currently configured on
this model.
CFA-construction method is on.
CFA-construction
method switch
this model.
62
6.3.3 Control
6.3.3.1 Travel
★Note: Prior to operate all actions, please make sure that pilot handle is open.
● Place the pilot handle to position 1.2;
● “Button 1- Working switch” in the thin membrane keyboard panel is not connected(The
light above the key is off):
63
●Push the left and right pedal valves：
Foot Valve On 1 Foot Valve on 2
Position 2.1 Position 2.2
64
●Corresponding action schematic：
The left and right pedal The left and right The right pedal The left pedal valves are
valves are pushed to pedal valves are valves are pushed pushed to position 2.1
position 2.1 pushed to position to position 2.1
2.2
The right pedal valves The left pedal The left pedal The left pedal valves are
are pushed to position valves are pushed valves are pushed pushed to position 2.1 and
2.2 to position 2.2 to position 2.2 and the right pedal valves are
the right pedal pushed to position 2.2
valves are pushed
to position 2.1
6.3.3.2 Crawler Extension and Retraction
●"Button 1- Working switch" in the membrane keyboard panel is not connected(The light
above the key is off).
●"Button 4- Crawler extension switch" in the membrane keyboard panel is connected(The
light above the key is on).
65
● Push the right pilot handle leftward/rightward:
66
●Corresponding action schematic:
Push the right pilot handle rightward Push the right pilot handle leftward
6.3.3.3 Upper-Carriage Slewing
● Push the left pilot handle leftward/rightward:
67

Push the left pilot handle rightward Push the left pilot handle leftward
●Press and hold“Button 4”, upper-carriage rotation will automatic reset.
●When machine is in drilling operation and drilling depth reading is greater than zero, the
system considers that the Kelly bar is inside hole and accidents may occur if upper-carriage
swings and the program restricts this operation. If the drilling depth proximity switch is
damaged and the drilling depth reading is less than zero, set the “Button 1- working switch" in
the membrane keyboard panel to disconnect (The light above the key is off) before swinging
upper carriage.
68
6.3.3.4 Boom Luffing
●“Button 1- Working switch" in the membrane keyboard panel is not connected(The light
●Press and hold“Button 5", push the right pilot handle forward/rearward.
69
● Corresponding action schematic

Press and hold "Button 5", push the right Press and hold "Button 5", push the right
pilot handle upward. pilot handle downward.
6.3.3.5 Mast Erecting
●"Button 1- working switch" in the membrane keyboard panel is not connected (The light
70
above the key is off):
●Press and hold "Button 8", push the right electric handle leftward/rightward.
71
●Corresponding action schematic

Press and hold Press and hold Press and hold
Press and hold“Button
“Button 8”, push “Button 8”, push “Button 8”,push
8”,push the electric
the electric handle the electric handle the electric handle
forward backward handle rightward leftward.
●When the mast deflects leftward (or rightward) to a certain degree and touches the mast
stroke limit switch, stroke switch will send signal to controller, then controller will cut off the
mast movements which including rightward (leftward) deflection, forward extension, rearward
retraction to protect machine from damage.
●If the mast limit function needs to be canceled, the step length should be set at“9999”.
6.3.3.6 Main Winch
●Push the left pilot handle forward/backward.
72
Push the left pilot handle forward Push the left pilot handle rearward
●The main winch provides high-speed function: press “Button 1”, the speed of main winch
will be faster. Corresponding action schematic:
73
Press and hold“Button 1", push the left Press and hold“Button 1", push the left
pilot handle forward pilot handle backward
●Main winch is equipped with suspension function: When feeding, open the main suspension
function to make the drill bar following feed, there is no need to lower the winch manually.
①In the "Main Interface" of the monitor: click the " " (key 4), following steps ②③
should be done while there's "×" followed with the icon. While there's no
"×", following operations are not needed.
②The "Button 2- Suspension Switch of Main Winch" in the "Membrane Panel" is connected
(the indicator light is on):
74
③Tread down the suspension pedal of the main winch, its suspension function is enabled, after
the pedal is released, the function is closed. There's a prompt about the suspension status:
●In order to protect cathead from being hit by Kelly bar when main winch pulls up, the stroke
switch is activated when Kelly bar reaches to the top and the main winch only can descend but
not ascend. Follow below steps to cancel the limit when the Kelly bar needed to change under
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some special conditions:
The "Button 1-working switch" in the Membrane Keypad Panel is not connected, pull left pilot
handle rearward, press down two buttons on the left pilot handle together, operate the main
winch to rise the Kelly bar by crossing the limit, much attention should be paid to do above
operations.
6.3.2.7 Auxiliary Winch
●“Button 1- Working switch" in the membrane keyboard panel is not connected (The light
76
●Push the right pilot handle forward/backward:

77
Push the right pilot handle forward Push the right pilot handle backward
6.3.2.8 Rotary Head Rotation
●"Button 1- working switch" in the membrane keyboard panel is connected (The light above
the key is on):
●Push the right pilot handle leftward and rightward:
78

●In order to alleviate the labor intensity of the operator, the left/right direction of the handle is
built-in locking function: Press on the "Button 7" one time, push the handle to the end of right
and left, and the handle is locked. Press it again, the locking is cancelled and the handle
bounces back to the middle position.

Corresponding action schematic
79
●Rotary head throwing function: Press down "Button 6", rotary head is high-speed throwing.
●Rotary head torque limit function: Turn on feed torque limit switch in complex soil
condition and slow drilling to protect rotary head.
80
●Rotary head low-speed function: Turn on rotary head low-speed switch to rotate the rotary
head slowly.
6.3.2.9 Pressurization
●“Button 1- working switch" in the membrane keyboard panel is connected(The light above
the key is on).
81
●Push the right pilot handle forward/backward;
82
Push the right pilot handle forward Push the right pilot handle backward
●Pressure and the limit function: Open pressure limit switch in complex soil condition when
lower pressure is needed.
★Notice: This feature is not configured on this model.
83
● Pressurization high-speed function：This function can be turned on when the drill string
needs less pressure and the pressure action needs to be faster in complicated geological
conditions.
●Pressurization suspension function: Pressurization winch float, enable this function to float
the rotary head. ★Attention: This mode is not equipped this function currently.
84
6.3.2.10 Mast Outrigger
●“Button 1- working switch” in the membrane keyboard panel is not connected(The light
above the key is not on).
●Push the right pilot handle leftward/rightward:
85

6.3.2.11 Crowd Switch Wire Rope Tension
● “Button 1- Working switch” in the membrane keyboard panel is not connected (The light
above the key is not on)
● “Button 5- Crowd switch steel wire rope tension switch” in the membrane keyboard
panel is connected(The light above the key is light)
86
●Push the right pilot handle leftward/rightward:
87
6.3.2.12 Cathead Lifting Cylinder
●“Button 1- working switch” in the membrane keyboard panel is not connected (The light
above the key is off);
●“Button 6- crowd switch wire rope extension switch” in the membrane keyboard panel is
connected (The light above the key is on).
★Notice: This feature is not currently configured on this model.
●Push the right pilot handle leftward/rightward.
88

Push the right pilot handle leftward
Push the right pilot handle rightward
6.3.2.13 Movements of Rotary Brake Cylinder
● “Button 17- Rotary brake cylinder retract” in the membrane keyboard panel is connected
(The light above the key is on). Press and hold the button to connect, release it to disconnect;
★ Notice: Rotary brake cylinder action function is only available for large models
89
（SWDM520/600W）, except this model.
● “Button 18- Rotary brake cylinder retraction switch” in the membrane keyboard panel is
connected(The light above the key is on). Press and hold the button to connect, release it to
disconnect;
★ Notice: Rotary brake cylinder action function is only available for large models
（SWDM520/600W）.
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7 OPERATION
Distinguished users, we kindly remind you that all the safety rules and attentions mentioned in
the chapter one of this manual should be strictly followed prior to operating the machine.
7.1 PREPARATION AND CHECK-UP BEFORE OPERATION

1. Choose different drilling tool based on different soil condition. Attention: Even if in the
same hole drilling, bits of different kinds may be used for operation in turn.
2. Check hydraulic oil, no oil leakage.
3. Check fuel oil level.
4. Check steel wire rope.
5. Check tools.
6. Check bolts and nuts
7. Check joysticks, levers and gauges.
8. Check engine coolant (see engine operation manual).
7.2 OPERATION MECHANISM AND INSTRUMENTS
See Fig 6-14 for names and codes of operational instrument in the cab;
See Fig 6-2 to 6-13 for LCD display of working modes and switches function.
7.3 PREPARATION FOR OPERATION
1. Open Main Power switch and start engine (see engine manual)
Special Attention: Please follow the Engine Manual to start and stop engine.
2. Move fuel control lever to “Mid” position and hydraulic enable switch OFF before engine
start-up.
3. Run engine at low rpm for 5 minutes after engine start-up.
4. Circumstance temperature is low in winter, hydraulic oil must be pre-heated in load

working.
5. After engine starting, engine oil pressure mark turns red. It should stop engine and solve
related failure at first, then start engine.
7.3.1 Machine Positioning
Rig can be transported by flatcar to job site, after entering job site, choose smooth and
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compacted ground, put down gangplank (angle between gangplank and ground≤15°, start
engine, control travel joystick and aim crawler to gangplank, drive rig down to ground slowly.
Fig 7-1.
Special Attention：Always adjust mast height during rig running from flatcar to prevent touching ground
and damaging rig parts.
Fig 7-1
7.3.2 Machine Assembly
7.3.2.1 Crawler Extension/Retraction
Attention：For the safety and stability of the machine, the crawlers must be fully extended before drilling
operation.
1. Choose a firm, flat and wide ground;
2. Press down the switch for crawler extension, push right joystick to right for fully extend
crawler;
3. Pull out locking pin for upper-carriage and under-carriage.
7.3.2.2 Mast Assembly and Disassembly
1. Reconnect pressurized cylinder if it has been disconnected or not loaded;
2. Loosen fixing pin between upper mast and mediate mast( the pin is for fixing upper mast
and main mast in shipping），extend upper mast with cathead to make main mast and upper
mast in one line, fixing them by bolts.
3. Use crane or rope to connect pressurized cylinder (extend) to pull cathead until locating pin
shaft is fixed;
4. Pull out main winch steel rope to the length for hoisting kelly bar;
5. Push “Move/Work” wane switch to move，push right joystick backward to extend boom
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level lifting cylinder and lift boom, push Electric Handle (with button SB5 in joystick pushed)
forward and the luffing cylinders extend, take turns to operate the two joysticks until drill mast
up slowly, then connect main drill mast and lower mast by bolts.
Special Attention: Do not make lower mast touch ground during mast up，Stop electric handle operation
when the lower mast and main mast are fully connected (otherwise components may be damaged). Mount
two sides bolts in mast connecting surface, then take off the pull rod between the triangle frame and drill
mast.
6. Take off supporting pull rod for lower mast.
7. Push “Move/Work” wane switch to Work ， push right joystick forward to extend
pressurized cylinder, connect cylinder piston bar and rotary head sliding frame by pin shaft.
8. Mast disassembly process is vice versa to the process above.

Special Attention:
1）A helper is required during mast assembly/disassembly.
2）Use proper length of wire rope during the mast assembly/disassembly process. No wire rope
overlapping is permitted to happen in the main/aux winches.
7.3.2.3 Mounting the Kelly Bar
1. Connecting following frame and kelly bar by bolts at first
2. Taking out following frame pin shaft. Open two clamping claws and put pin shaft to original
position (see fig 7-2).
3. Fully extending forcing cylinder to make rotary head in the lowest position.
4. Adjust rig longitudinal axial line and Kelly bar in one line, and aim Kelly bar upper end to
rig.
5. Operate joystick to make mast forward tilt 5°.
6. Operate pilot left joystick forward to make main winch down，main winch steel rope falling
to connection position, Make sure steel rope inclination angle is less than 10°. Then mounting
pin shaft (see fig 7-3).
7. Operate pilot left joystick backward , main winch up. Press down up limit switch, lift Kelly
bar slowly and drive rig to Kelly bar at the same time, make Kelly bar vertical with ground to
prevent it from swinging in lifting Kelly bar.
8. When Kelly bar lower end over rotary head, stop lifting, then adjust Kelly bar in vertical
mode slowly; make following frame guide face connect with mast guide rail. A helper is
needed to stand in rotary head for Kelly bar fitting, Kelly bar is inserted into rotary head.
Special Note：Operation should be very slow, otherwise, swinging Kelly bar may damage rig parts and
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hurt operators.
9. Retract crowd cylinder slowly and lift rotary head, adjust rotary head in Kelly bar mediate
position.
10. Operate electric joystick backward (with button in joystick) to lower mast in level position，
taking out following frame pin shaft and close claws, then fitting pin shaft again(see fig 7-4).
Fig 7-2 Fig 7-3
Fig 7-4
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7.4 MACHINE WORK
7.4.1 Rig Running-in
Main winch test running：Operate left joystick forward or backward to make Kelly bar up and
down, once release control joystick, Kelly bar stops to work and can be locked immediately.
Auxiliary winch test running：Operate right joystick forward or backward to make load up and
down, once release control joystick, heavy load stops to run and can be locked immediately.
Drill mast tilting test running: Lift mast to vertical position, operate electric handle to adjust
mast tilting. Drill mast side tilting and forward tilting angle are 5°; Once over the angle, tilt
sensor will limit. Mast backward tilting angle is 90°，check its work.
Luffing system test running：Lift mast to vertical position, control right joystick (with button
SB5) to make luffing cylinder extend& retract, confirm tripod moving status.
Special Note：Running rig slowly in testing, and do function test carefully to prevent out
of control and accidents.
7.4.2 Drill Tools Selection
In construction, choose different drill tools base on due soil condition, which can advance work
efficiency and save cost. Main drill tools features and suitable stratum are showed in table 4-1.
Confirm bit diameter according to construction drawing. Normally, bit diameter is smaller
1cm～2cm than hole diameter.
7.4.3 Hole Opening and Barrel Installation
1. Measuring
Measure and calculate for the construction piles layout drawing by theodolite or laser distance
measuring meter and ranging rod according to pre-setting red line points and direction. Use
polar coordinate to calculate angle and distance. Use altometer and ranging rod to confirm pile
location in site.
2. Rig positioning
Drive rig in pile side，aim bit top to pile location mark. If possible, maximum retract mast, and
check whether existing barrier in swing radius.
3. Hole opening
After aiming hole location, use reamer bit to drill hole, hole diameter should match barrel.
4. Barrel installation
Use main winch and stabilizer to install barrel, and also can fit barrel driver to install it. Use
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main and service winch to pull up barrel. But when it is difficult to lower/pull up barrel by
above mentioned method, please use special equipment to do it. Such as rubbing machine,
vibrator hammer etc.
Special Note：When use stabilizer and rotary head to press down barrel, operate slowly;
Do not use winch emergency stop to attack barrel which will badly damage machine.
When open hole to suitable depth, use service winch to move barrel to hole location, then use
bucket and service stabilizer to press barrel into ground. It should keep barrel pressed vertically,
barrel surrounding is fully filled soil. Confirm barrel length and embedded depth according to
soil condition and underground water condition. In normal，barrel diameter is bigger 20cm than
pile diameter.
7.4.4 Drilling
Caution：During the construction, it is strictly forbidden to open the engine hood!!
There are following common drill tools for rotary drilling machine：
1. Short auger drilling
Push “Move/Work” to Work, push right joystick to left and make rotary head clockwise
rotation; press down winch free suspension switch to make main winch free fall. Push right
joystick to left front tilt and make pressurized cylinder down for machine drilling.
Special attention：No free fall is permitted if machine is not in drilling process.
Drilling depth of each pass will be displayed on the LCD monitor.
1) Control right joystick to make rotary head anti-clockwise rotation; the kelly bar and rotary
head sleeve disengage.
2) Control left joystick to make main winch lift Kelly bar; control right joystick at the same
time to retract pressurized cylinder and rotary head can raise. Fast lifting can be used for saving
time.
3) After short auger up, control left joystick to make upper-carriage swing to crawler side,
control right joystick and press down button SB5 to make rotary head rotate fast and spin-off.
Special Note：Generally, it is better do not use winch emergency stop to vibrate and unload soil, which will
badly effect winch and steel wire rope service life, even lead to rope break and accident occur.
4) Swing platform anti-clockwise rotate to original position after spinning-off. Operate left
joystick to lower main winch to the position of last hole depth 1 meter.（Attention：Do not use
Free Fall to lower kelly bar）
5) Repeat above procedure to complete drill, soil catching, drill tool hoisting, spin-off, return &
lowering.
6)Clean hole after drilling to due depth and protect hole port。
Pay attention during drilling process:

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●Keep kelly bar vertical and in correct position. Keep kelly bar from wobbling.
●When lowering kelly bar, pay attention to the corresponding relation of falling depth and the
extension of each section kelly bar in order to prevent accidents from “rod lock”, “rod
wobbling” and “rod cracking”.
●Drill slowly at the beginning, speed up after auger goes inside soil; slow down when drilling
soft-hard soil junction layer.
●Handle with soil near hole port and barrel in time, an abnormality like high ground water
level, hole collapse or hole shrinking happen should be discussed and treated..
●Do not push to drill when clean hole; do not rotate drilling tool when pulling drilling tool up.
●Before lifting Kelly bar, anti-clockwise rotate rotary head to delete occlusion because of
torque transferring .During kelly bar hoisting, check corresponding relation of lifting depth and
each section Kelly bar retraction order to prevent “rod lock”, “rod cracking”.
2. Rotary bucket
1) Install barrel. Barrel imbedded length is based on soil condition and water table level. Barrel
diameter should be bigger 20cm than pile diameter
2) Normally use stabilizing liquid (mainly composed of bentonite) to prevent hole wall from
collapse.
3）Bucket operation is the same as short auger drilling，except discharging soil, lifting bit to
rotary head lower baffle plate, strike lower baffle plate to open rotary bucket base cover,
spin-off by swing emergency stop.
Special Note：Generally, it is better do not use winch emergency stop to vibrate and
unload soil, which will badly effect winch and steel wire rope service life, even lead to
rope break and accident occur.
4) Put down the drilling bucket on the ground quickly after dumped, enable the drilling bucket
bottom plate closed by opening mechanism reacted.
5) Repeat above procedure until reach to the design depth or need change bit.
Attention：
 It may use stabilizing liquid instead of barrel when drilling in normal soil layer。
 Prepare some stabilizing liquid for drilling hole, the ratio according to soil condition, N
value, drilling dia. and water level and so on.
 Confirm water level condition, testing piles.
 Remove slurry and stabilizing liquid mixture in hole bottom after hole drilling.
 When drill in the layer without underground water, it can be compacted by hammer or
fill cement and mix it with hole bottom less settlement.
 When lowering Kelly bar, pay attention to the corresponding relation of falling depth
and each section Kelly bar extension order to prevent “rod lock”, “rod wobbling” and
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“rod cracking”.
 Before lifting Kelly bar, anti-clockwise rotate rotary head to delete occlusion because of
torque transferring .During kelly bar hoisting, check corresponding relation of lifting
depth and each section Kelly bar retraction order to prevent “rod lock”, “rod cracking”.
3. Core Drill
1) Drilling procedure is the same as short auger.
2) Pay attention to drilling speed and pressure; keep kelly bar from jumping up and down.
3) Slow down drilling with low pressure before core barrel enters rock; increase speed and
pressure when core barrel enters rock layer.
4) Slow speed with low pressure to prevent core barrel from sliding when inclined rock face is
encountered. Crooked hole may break kelly bar.
7.4.5 Machine Relocation
After drilling one hole, it needs to move machine to next ready pile hole. It should check the
ground status between two holes to prevent mushy road, collapse and cross tilt angle over 5°
ground. After moving, repeat above mention drilling procedure.
7.4.6 LCD Monitor, Warning Icon
Check LCD monitor and alarm warning icons during machine work. Take necessary measures
when alarm beeps.
Attention: When Alarm icons in Fig 6-6, 6-7 turn red or flash, please check the machine.
1) When 1 # icon turns red, it means the engine oil pressure is low. Do not start engine before
the problem is eliminated.
2) When 2# icon turns red, it means the coolant temperature is too high. Slow down until the
coolant temperature drops down. Or stop engine.
3) When 3# icon turns red, it means the hydraulic oil temperature is too high. Slow down until
hydraulic oil temperature drops down to normal temperature.
4) When 4 #icon turns red, it means the fuel is not sufficient.
5) When 5# icon turns red, it means battery charger failure (or low battery). Engine can work
but battery discharges quickly.
6) When 6# icon turns red, it means the main winch hoist has reached to the limit. Stop main
winch.
7) When 7# icon turns red, it means the hydraulic enabling switch is OFF.
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8) When 8# icon turns red, it means hydraulic filter is plugged and needs to be cleaned or
replaced.
7.4.7 Machine Stop and Emergency Stop
7.4.7.1 Machine Stop
1) Lower drilling tool and rotary head down for short time engine shut down; set the mast
down as in Fig. 3 for long time engine shut down.
Attention: Switch off hydraulic enable switch SQ3+SB0 before exit the driver’s cabin for short time to
prevent mis-operation.
2) In long term stop, run engine at low speed for 5 minutes to cool engine down.
3) Switch the ignition key to “OFF” position, pull ignition key out, switch off the main power.。
4) Lock cab door and all canopy doors.

Attention:
Stop machine on a flat ground.
Daily clean machine, crawlers, rollers, carriers after work.
Drain off any coolant which is easily to be frozen in winter, such as coolant.
7.4.7.2 Emergency Stop
1)Emergency switch in cab：
Once emergency switch is pressed down, machine all action will be stopped.
2) Emergency switches beside counterweight（2 pcs）

Once emergency occurs, press down two sides jerk switch, engine will be stopped.
7.4.8 Steps from Drilling Mode to Transportation Mode
1. Stop drill rig on a flat ground, lower mast, dismount pin shaft between following frame and
mast guide rail;
2. Mast up, move rotary head to mast lower. Hoist Kelly bar(without drill tool) to make it leave
rotary head, upper claw disconnects with mast guide rail.
3. Let mast tilt forward until kelly bar away from mast and rotary head；Lower Kelly bar
slowly until it touching ground.
4. Lower Kelly bar and travel backward slowly until kelly bar is put down the ground.
5. Disconnect main winch steel wire rope from kelly bar.
6. Lower rotary head to mast bottom, dismount connecting pin between rotary head and
pressurized cylinder, retract piston bar for pressurized cylinder.
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7. Adjust mast tilt angle to mount pull rod between lower mast and tripod.
8. Dismount connecting bolt between main mast and lower mast.
9. Retract drill mast to level condition, and support it in mast bracket.
10. Mount front shipping frame.
11. Lower cathead by crane and similar equipment, dismount connecting bolt between pulley
frame and upper mast, lower pulley frame and hang it by back shipping frame.
12. Dismount connecting bolt between upper mast and mediate mast, fold upper mast with
pulley frame to main mast side, fix them by pin shaft.
13. Control crawler extension cylinder to retract crawler.
14. Pin upper carriage and undercarriage together.

Special Attention:
1）A helper is required during mast assembly/disassembly.
2 ） Use proper length of wire rope during the mast assembly/disassembly process. No wire rope
overlapping is permitted in the main/aux winches.
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7.5 ENGINE USE
7.5.1 Precautions for Engine Use
1. When air temperature is over -12℃, engine can start without starting auxiliary device
(such as air intake preheater); When air temperature is lower than -12℃,engine will preheat
automatically, after that it’s able to start. Air intake preheating can be used with the
temperature over than -31℃.
2. Check coolant level, engine oil level and fuel level.
3. Starting time should not over than 30s. The interval between twice starting should more
than 2 minutes. If fail three times continuously, inspection should be done prior to next
starting.
4. Within 15 seconds after starting, pay attention to check the prompt of engine oil
pressure alarm icon on the monitoring interface. If there’s an alarm, please stop the machine to
check causes immediately.
5. When air temperature is low, the machine should be preheated after initial starting, and
it should be operated till engine water temperature up to 60℃.
6. If there’s air in the fuel system, that may result in difficulty for starting. Restart after air
is exhausted completely.
7.5.2 Precautions for Engine Preheating and Idling
1. It’s forbidden to run engine at fast speed when the machine is not warmed up. When
starting at low temperature, engine speed should be increased gradually.
2. Don’t run engine at idling speed more than 10 minutes. If too long time for idling, oil
nozzle may be clogged by the carbon deposition and cause the sticking of piston ring and air
valve, affecting engine performance.
7.5.3 Precautions for Engine Shutdown
After running for a long time or with large load, the machine should be idled for 3 to 5
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minutes before shutdown. Failure to comply may result in engine component overheating,
damaging the bearing of supercharger.
7.5.4 Correct Filling of Coolant
1. Don’t fill in coolant too rush. Failure to comply, air in the engine water sleeve may
can’t be exhausted.
2. After filling, check expansion tank level after idling for 1 minute, and then fill it up to
the limit.
3. After filling, tighten up the cap of expansion tank. Change the expansion tank cap when
change coolant regularly. The coolant of same type should be used.
7.5.5 Other Operation Precautions
1. Check water temperature in the monitoring interface, if coolant is still lower than 60℃
or 100℃, stop the machine and find causes.
2. Always check engine oil value, prohibit engine running when engine oil pressure is too
low. Engine oil pressure should be not lower than 69 Kpa while idling, and 426Kp when at
rated rotation speed. The minimum engine oil pressure for protection at idling speed is 55 Kpa.
3. Always check engine oil level, coolant level and fuel level.
4. Avoid running engine when there’s a failure. Pay attention to engine performance,
sound and some predictable changes. If there’s any abnormal condition, stop the engine to
check.
5. It’s not allowed to run engine at peak speed with full load for 30 seconds. Failure to
comply may damage the engine.
6. It’s not allowed to run engine beyond maximum rotation speed. Failure to comply may
damage the engine.
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7.6 AIR CONDITIONER
7.6.1 Use of Air Conditioner
1. Auto-running
1. The auto mode setting switch ⑤ is on and the temperature, air flow rate, auto switch, and
A/C switch indicator lights on the LCD screen are on.
2. Adjust the temperature switch and set the temperature to a comfortable value. Set the
temperature accordingly, and the air conditioner automatically switches in the air flow rate, air
outlet, and internal/external circulation. The air conditioner runs automatically to reach the set
temperature.
Remarks: in the auto mode, the air flow rate is automatically limited to prevent the cool air
from flowing out and the engine coolant temperature is flow.
2. Auto-Running Stop
Press down the OFF switch ①

The set temperature and air flow rate indicators on the LCD screen as well as the auto switch and A/C
switch lights are off and the air conditioner is stopped.
3. Manual Control Running
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1. Press down the fan regulation switch ② to regulate the air flow rate. In addition, confirm
the set temperature and air flow rate by checking the information shown on the LCD screen.
2. It is possible to check whether the A/C switch ⑧ is switched on by checking the light on it.
3. Set an appropriate temperature by regulating the temperature regulation switch ③.
4. Adjust the blowing mode toggle switch ④ to enable the required air outlets.
5. Select the required internal/external air mode by using the internal/external switching button
⑥.
4. Manual-run Stop
Press down the OFF switch ①

The set temperature and air flow rate indicators on the LCD screen as well as the auto switch and A/C
switch lights are off and the air conditioner is stopped.
5. Running in cool head and warm feet mode
1. Press down the fan switch ② to adjust the air flow rate. The set temperature and air flow
rate are confirmed through the LCD screen.
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2. Press down the air outlet mode setting switch ④ to select an air outlet mode.
3. Allow the air conditioner ⑧ in the On state. The light on switch can be used to confirm
this.
4. Adjust the fan speed setting switch ②, temperature setting switch ③, and internal/external
air mode switching switch ⑥to the appropriate positions respectively.
6. Defrosting running
1. Press down the fan switch ② to adjust the air flow rate. The set temperature and air flow
rate are confirmed through the LCD screen.
2. Adjust the air outlet mode switching switch ④.
3. Select the external air import state by pressing down the internal/external air switching
button ⑥.
4. Adjust the temperature adjustment switch ③ to set the temperature to 32℃ (maximum
heating capacity)
In order to allow the air to be blown onto the glass, adjust the shutter directions of the air
outlets.
In addition, if the glass is covered with moisture or dehumidification is required in the plum
rain season, simply start the air conditioner ⑧ for dehumidification.
7. Self-diagnosis function
Implement the fault check of the air conditioners sensors and parts.
1. Press down the OFF switch ①. The set temperature and air flow rate indicators on the LCD
screen disappear and the air conditioner stops running.
2. Simultaneously, press down the control button of the temperature setting switch ③ for
three seconds or above, and there will be a trouble code on the LCD screen.
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8. Conversion between ℃ and ℉

To press down the temperature setting switches and simultaneously for 5 seconds
while the fan operates can realize the conversion between ℃ and ℉.
9. Reset
Applicable for the newly installed air conditioner or erasing the trouble codes after the
troubleshooting.
Simultaneously pressing down the internal and external switches for three seconds or above
can erase the trouble codes.
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7.6.2 Common Failures and Solutions
1. Failure of Controlling Circuit and

Component Failure Cause Solution
Bad contact of connector；bad contact Check and

of ground wire repair
Fan not work No pull-in of relay; Temperature

Change
controller not work
Damage of temperature controller
Change
package
Condensor
fan Wrong wiring of temperature
Repair
Fan work but controller
can’t stop
Relay can’t be turn off Change
Stuck of
Burnout ; stuck of fan fin Change
condenser fan
Burnout of
Rubedo of speed regulating resistor Change
evaporator fan
Small air volume Check and

Evaporator Impeller looseness; impurity clogging
of evaporator fan repair
fan
Evaporator fan Invalid third gear switch; bad contact

Repair
doesn’t turn of ground wire
Low rotation
Repair or
speed of Looseness of belt; belt abrasion
change
compressor
Compressor Uneven gap of clutch Adjust

doesn’t run
normally Pressure switch work unstable Change
Compressor
Burnout of clutch solenoid coil Change
Compressor Pressure switch not work(open

Change
doesn’t turn circuit)
Repair or
Too large gap of clutch
change
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2. Common Failure and Causes of Refrigeration System

Item Failure description Causes Solution
Frost on the pipe orifice of Too large opening of

Repair
low pressure expansion valve
Too high temperature package of

Outlet pipe of condesor is
pressure of expansion valve and bad Repair
cool
low contact of evaporator
pressure
gauge
Damage of expansion valve
Change
temperature package
Overfill of fluorine Drain fluorine
Low pressure gauge

Impurity in low pressure pipe
Too low sometimes indicate Change pipe
or pipe orifice is clogged
pressure of negative pressure
low pressure
gauge Inlet of expansion valve is
Clogging of expansion valve Flush
cool or attached by frost
Condenser surface is clogged Clean condenser

Condensor surface too hot
by impurity. surface
Too high
pressure of
Stuck or bad contact of
high Condensor fan not work Change
condenser fan
pressure
gauge Compressor too hot and
pipe orifice of high Air is mixed. Adjust
pressure too hot
Pressure on high and low Compressor doesn’t work Change

pressure gauge are both too
Too low
low
pressure of Lack of fluorine Fill fluorine
high
pressure Pressure of high pressure
Ice clogging or impurity
gauge gauge too low, negative
clogging Change
value of low pressure
check from sight glass
gauge
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7.7 Operation and Maintenance of Fuel Pump
Attention: The fuel pump of this machine is added with diesel, not water, gasoline or other
media.
7.7.1 Operational Steps
1. Dismantle the hose winding in the storage position of the machine.

2. Plug the hose with bottom valve into the diesel drum completely.
3. Press down the START button (open).
4. Diesel is pumped from the barrel into the diesel tank.
5. The pump will stop till the diesel drum is empty. You also can stop the pump by
pressing the button at any time.
6. The START button should be pressed down again while changing another barrel.
7. Pull out the hose after oil filling is finished under the allowance of oil droplets. Make
sure all the remains and impurity are cleaned off before storing. Roll up the hose (the min.
diameter is 150 mm) to put it back to the storage place.
7.7.2 Notes for Use
1. Only diesel is allowable, it’s forbidden to pump up the fluid with low flashing point
(lower than 38℃) and other chemical fluid, such as gasoline, hydraulic oil, water or others.
The hydraulic pump is not allowed for high pressure using.
2. Don’t use it when the machine is running.
3. Make sure the check filter is used during the process; clean the filter net when there’s
obvious impurity.
4. Do not dismantle or refit the product without authorization, otherwise the warranty of
quality for this machine is not provided.
5. This manual should be read carefully and understood completely prior to operation. Any
disoperation may cause machine fault and leakage prematurely.
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7.7.3 Maintenance
Check hoses for damage and leakage before every operation.

Warning!!! All the necessary precautions should be observed while handling the fuel to avoid leakage.
7.7.4 Fault Analysis and Troubleshooting for Fuel Pump
Indicator
Fault Cause Solution
light
Press the START button to check the

indicator light, if no responding, connect the
Disconnection of
fuel pump with electricity alone, if it’s the
Power line
same, there must be the problem of the
electrical line which should be repaired.
System No Press the START button to check the

is not respondin indicator light, if no responding, connect the
running Fault of Intelligent g fuel pump with electricity alone, if it works
controller normally, there must be the fault of the
intelligent controller which should be
changed.
Intelligent controller Press the STRART button to check the
starts protection for indicator light, if no responding, reset the
the wrong connection positive and negative anodes connection of
of the power line the power supply and then check again.
Voltage too low/too Press the START button to check the
high, the voltage indicator light, if the fuel pump doesn’t work,
protection of test the voltage of the power supply by
intelligent controller is external-use meter, reset if the voltage is
enabled. lower than 16V or higher than 32V.
Press START button to check the indicator
Rotor is stuck by light; open its front cover to check the rotor
No oil
impurity; the for blocking in the chamber, if the fuel pump
ejected Red light
overloaded protection doesn’t work; if there’s any impurity, clean it,
from the flashing
of the intelligent polish the rotor and the places of cover with
system
controller is activated. scratch and burr by sandpaper, install after
cleaning.
Oil drain tube is Press the START button to check the
blocked, the indicator light; If fuel pump starts and stops
overloaded protection immediately, check the oil drain tube, make
of the intelligent sure the valve switch is turned on or there’s
controller is activated. no blocking of the oil drain tube causing by
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twisting.
Disconnection
between the fuel pump Press the START button to check the
and controller, the indicator light; if the fuel pump doesn’t work,
empty rotation of the check the connection wiring harness for
intelligent controller is abrasion; Change if there’s any damage.
activated.
Green
There’s 3 meters from
light is
the installation Press the START button to check the
always on,
position of fuel pump indicator light; check if there’s any diesel in
then red
to the bottom of the oil the suction tube and not enter into the pump if
light
barrel, the empty the fuel pump works normal; If so, please
flickers for
rotation of the reset the position between the equipment and
5 seconds.
intelligent controller is the oil drum to minish the drop.
activated.
Oil drum is empty, the Press the START button to check the
empty rotation of the indicator light, if the indicator light of the fuel
intelligent controller is pump flickers in red after working for a while,
activated. therefore, the oil drum should be changed.
The wiring harness of
the fuel pump is Green Check whether the wiring harness connection
connected reversely, light is between the fuel pump and intelligent
motor rotates always on. controller is correct or not.
reversely.
The wiring harness of
liquid level is Press the START button to check the
Green
cutting-out, the liquid indicator light; check the liquid level wiring
light
level protection of the harness for short circuit, if there is, change to
flickers.
intelligent controller is open circuit.
activated.
Increase voltage of the power supply but
Power voltage too low
within the allowable range.
Check the oil tube for flattened place, recover
Oil Oil tube is flattened.
and make it smooth.
ejected Green
Check the filter which is equipped on the
from the light is
suction tube for blocking, clean on time if
system Filter is blocked. always on.
there’s any impurity, please make sure the oil
is little.
tube is unblocked.
Check the blade for abrasion, change a new if
Blade wore out.
it’s damaged.
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8. KELLY AND DRILLING TOOLS
8.1 KELLY
8.1.1 Introduction of Kelly
Telescopic Kelly is to lift or lower the drill bit, drill and dump by the extension and retraction
of itself. This way reduces assistant working time and improves drilling efficiency. It mainly
consists of two to six sections, including following structure: junction pin shaft, spring seat,
cushion spring, outlet pan, outer arc plate, drive sleeve, outer key bar, steel pipe, O-ring,
positioning ring, shock absorbing parts, center flange, triangle plate, top end flange and flat
head. For a machine-lock kelly, pressure table and inclined plate are included. (as following
figure)
During drilling, Kelly delivers swing torque and axial pressure to the drill bit.
Kelly bear the compound stress, such as pull, press, twist and bend. According to different
axial pressure and structure features, there are two kinds of Kelly, machine-lock Kelly and
friction Kelly.
Friction Kelly delivers swing torque by outer key and inner spline. When key is pressed
tightly on the side to deliver swing torque, the friction is transmitted to crowd cylinder or
crowd winch via the pressure enforced by rotary head. The characteristics of friction kelly is
that simple structure, easy operation and less strength transmission, besides, it’s one more
section than the machine-lock kelly, and deeper drilling.
Machine-lock Kelly meets for the requirements of large torque and large axial pressure. It can
deliver strong axial pressure via crowd steps. It features in more suitable for drilling into hard
layer comparing with friction Kelly. Meanwhile, the more sections the harder operation and the
higher requirements for the operator.
The Kelly rotation and downward pressing of rotary drilling rig is driven by inner spline,
which is adopted quick-change technology with patent, besides, its material is matched with
the pressurized block. The rotary head inner spline and kelly have long service life, thus, low
cost.
Sections among Kelly deliver torque and axial pressure via inner and outer spline by layers.
Each section of machine-lock Kelly has 3 to 5 pressure steps, for which position in the hole,
the operator should remember, in this case, improving the working efficiency.
Below figure is the illustration of shape and parts of normal machine-lock Kelly.
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8.1.2 Correct Model Selection for Kelly
Below figure is the relation of Kelly and depth and weight of main frame, please choose
carefully.
Select main frame model according to the working conditions.
Select section quantity according to construction depth. The less Kelly sections, the more
strength, the lighter weight, thus, save fuel.
Weight
Pile depth Machine-lock Pile depth Weight of Kelly
Model Friction Kelly of Kelly
（m） Kelly （m）（kg）
（kg）
MZ440-5X15m 69 10200 JS440-4X15m 54 9090
SWDM240
MZ440-5X11.5m 52 9000 JS440-4X11.5m 41 8000
8.1.3 Correct Operation of Kelly
8.1.3.1 Correct Operation
Before working, follwing procedures should be done, check, install, lift, cross, assemble, adjust,
align, lower, find and retract.
Check: check construction ground for main frame, if the ground is soft, cushion thick steel
plate on the ground.
Install: install servo-frame and elevator.
Aim the slewing bearing of servo-frame at the flange on the top end of Kelly and insert into
bolts with the tightening torque standard refer to “Rotary Drilling Rig Operation &
Maintenance Manuual”, tighten the mounting bolts of slewing bearing once every 50 hours or
every week.
Pay attention to not leave bolt spacer in the Kelly when assembly and disassembly, failure to
comply may result in Kelly stuck or follow.
Before work every day, visually check mounting bolts on the slewing bearing of servo-frame
for looseness or loss, if found, repair that first.
Lift：lift the kelly, pay attention to the inclination direction , which should be adjusted to
vertical with the ground to avoid the deformation of Kelly caused by the leader while lifting.
Meanwhile, ensure that servo-frame aims at the mast sliding track.
Cross：Aim the Kelly with rotary head, buckle the servo-frame to the sliding track of upper
mast, and rotate Kelly to the same direction of rotary head inner spline and cross through
Kelly.
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Assemble：Assemble with the kelly, plug the pin shaft and lock.
Adjust：Adjust mast to vertical with ground, put drill bit on the ground with pressure, observe
perpendicularity display, and adjust the mast cylinder till the pointer aiming at the scale. If not
adjust perpendicularity before piling, the Kelly will bearing force at the inclined status for a
long time, it’s easy to result in inclined pile hole, broken spline bar or pipe casing crack
extending to Kelly breakage. Thus, mast perpendicularity should be adjusted before piling to
ensure Kelly in the center position of rotary head.
Aim：aim Kelly at the barrel center.
Lower：lower rear main winch rope, and then lower Kelly section from outer to inner
successively, observe the display distance and decrease the lowering speed till 3 meter to the
hole bottom, not colliding drill bucket with the hole bottom.
Find：After drill bit touches with the bottom, lift and rotate rotary head anticlockwise slowly to
adjust the height, then find pressure steps, and rotate it clockwise making inner spline of every
section entering into the range of pressure steps, press it down and lock, at last rotate rotary
head clockwise downward to drill.
Retract：After grabbing soil, keep the drill bucket close to the bottom surface and lift and
rotate rotary head clockwise at small range, then rotate anticlockwise to separate pressure table
and drive sleeve inner spline of each layer, making the inner spline entering into the sliding
groove of Kelly and close the bucket, confirm unlock completely, keep rotary head
anticlockwise rotation, lift main winch, at last retract the core bar. When retracting each section
completely, the disc always collide with the end surface of the drive sleeve slightly, causing
slight nodding to the rotary drilling rig, and winch tension increase in a sudden then back to
stable, thus, the operator should be familiar with that nodding depth.
8.1.3.2 Ten Forbidden Operation
One：It’s forbidden to operate ignoring the abnormal conditions on the working site.
If any abnormality is found, stop work at once to check problem, avoiding accidents in the hole.
The serious accident is to smash the Kelly caused by Kelly following.
Two: It’s forbidden to refit Kelly.
It’s forbidden to operate baking, spot welding, welding and grinding freely by non-professional
personnel.
Three: It’s forbidden to pressurize the machine-lock Kelly freely at any position and use it as a
friction Kelly.
Pressurize the Kelly directly without finding pressure point, this will result in the abrasion,
stuck or rolling spline for the Kelly caused by too much pressure with small contacting area on
the pressure side surface or inclined plate.
Four: It’s forbidden to tilt the front end of track and mast rearward.
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The front end of track tilt when drilling, that will not increase any effective pressure but
increase lateral force to the Kelly and lead to crack and even breakage. Any problem is found,
release the pressure at once replacing with intermittent pressure.
Five: It’s forbidden to loosen main winch excessively.
If main winch rope is loosened excessively, the elevator will fall. After Kelly rotates, elevator
and flat head will deform and break, even cut off the wire rope.
Six: It’s forbidden to place rotary head too high or too low when throwing soil.
Rotary head too low will cause incomplete contact of inner spline and Kelly key bar on which
impact increased partly and leading the crack of key bar or lower pipe.
Rotary head too high will cause excessive impact for outer lower crowd block while throwing
soil breaking Kelly and damaging rotary head.
Seven: It’s forbidden to use the Kelly to press pile casing, stir soil, and mix slurry.
Because these operations may make Kelly core bar to bear force partly, resulting in the crack
or break-off near the junction position of square head and core bar steel pipe.
Eight: It’s forbidden to operate with unsuitable Kelly and drill bit.
An open bucket (two half bucket) should be used when the hole diameter is small or soil
viscidity is high. The type of Kelly is precise for a small piling hole. Thus, it’s forbidden to
install a small drill bit onto the Kelly resulting in outer Kelly scratching on the hole wall.
Nine: It’s forbidden to drill too deep with a single bucket.
For a piling hole with small diameter or a auger bit, too deep drilling over than spring seat may
result in Kelly stuck caused by soil squeezed into the gap for a long time.
Ten: It’s forbidden to swing the upper-carriage with the bucket door open.
Avoid the crack, deformation and break-off caused by the collision of track and bucket door.
8.1.3.3 Cause and Prevention for Followed and Smashed Kelly
Followed Kelly:
When retraction, the fourth section retracts completely, collide and nod, at this moment
somewhere of the third section stuck at the second section which is driven to move up in
advance, this is called as followed Kelly. At this time, nodding also happens. If followed Kelly
is not found at once and lifted to a certain height, the stuck position will be loosened caused by
shock or collision, the second Kelly will be dropped to collide the disc or on the inner spline of
the first section drive sleeve, this is called as smashed Kelly, which may result in positioning
ring damage, bulge of drive sleeve, Kelly lock, rotary head falling and even Kelly falling into
the hole caused by rope breakoff.
Prevention Measurements
1. Operator should know the crowd length of outer rod of Kelly and inner rod of each section,
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remember the piling depth for the position of pressurization and machine nodding depth caused
by lifted disc colliding with drive sleeve of each section.
2. When nodding at abnormal depth, operator should lift rotary head slowly till fitting with the
Kelly absorber to prevent rotary head falling down, and then rotate anticlockwise to lower the
Kelly and loosen it out completely, and retract the Kelly again.
Causes of Followed Kelly：
1. Kelly bend caused by various reasons.
2. Inclined piling hole
3. Tiny sediment in the Kelly
4. Collision of edge curl in the Kelly and inner wall of steel pipe
5. Lift before confirmation of complete unlocking and no continuous anticlockwise rotation
during lifting
Lift while keeping rotation anticlockwise: While lifting, negative pressure is easy to form on
the hole bottom or drill bucket collides with the hole wall, thus, causing Kelly rotates
clockwise at small extent. If it’s right on the pressure area, the inclined key bar will be
withstood by the drive sleeve inner spline and leading to Kelly lifted in advance.
8.1.4 Kelly Disassembly
Disassembly：
1. Place the Kelly on the crosstie.
2. Remove bolts on the clamp plate, separate the plate and pull out the core pin set ring, clean
out small parts, such as nut spacer, don’t leave them in the Kelly.
3. Insert a pin shaft ( diameter 25) into the Kelly drive sleeve and fix the 1st, 2nd and 3rd section
Kelly.
4. Reeve wire rope through Kelly square head and install bucket teeth on two ends of the rope.
5. Travel excavator rearward to pull out the core bar.
6. Withstand the 3rd drive sleeve with one end of a rebar, and the other end is withstood by the
excavator, and then push the 3rd section of Kelly for half a meter to one meter with the bucket.
7. Twine the set ring with a cotton tape and drag out with the excavator.
8. Use above same procedures for the 2nd section.
9. Don’t place the parts of Kelly freely after disassembly to avoid damaged or buried while
taking out.
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Method for disassembly and assembly is the same,

Kelly disassembly
the order as below:
procedure
Kelly assembly
Clamp plate
Square head pin shaft
Positioning ring
Front three sections
4th section ⑤ spring ⑨Disc
3rd section
Kelly assembly
1st section 2nd section
process
Assembly:
1. Check each section of steel pipe center for foreign objects before installation
2. The procedures for Kelly assembly and disassembly are opposite. Pay attention to align two
sections. When the 2nd section is close to the drive sleeve of the first section, observe carefully
whether the sliding groove is aligned, and adjust slightly via excavator drive cotton driving the
set ring of the 2nd section. The steps can be found as below:
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The 1st Kelly assembly process

section The 2nd section
The 3nd section
Note
Front three
sections The winch should be used to
assemble Kelly.
Step 1: Cushion the 1st section with crosstie on
the ground, assemble the 2nd section through the
1st section center, and then assemble the 3rd Step 2: Cushion the 4th section with
section through 2nd section. crosstie on the ground, pull the
spring and disc through the 4th
The 4th Spring section successively.
section Disc
Step 3: Assemble Clamp plate

the 4th section Square head pin
through the 1st shaft
section, 2nd section
and 3rd section,
then install Kelly assembly
positioning ring,
clamp plate and
square head pin
8.1.5 Maintenance for Kelly
Maintenance can help users to find problem in advance, reducing the possibility occur in the
operation. It’s really an effective measure for ensuring construction efficiency.
After Kelly has been used for 50 hours or piled for 150m, please disassemble it to take the
initial maintenance. After used for 200 hours, take the maintenance for the second time, and
after that maintain it once every 500 hours. Any abnormal is found during operation, stop
working at once and disassemble the Kelly to repair. Besides, maintenance should be done
after changing the working site.
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Nine Rules for Maintenance and Inspection:

1. Check key bar, crowd block, lower end of drive sleeve for burr, edge curl and grind it
smooth.
2. Check end surface of drive head for abrasion and grind it smooth.
3. Check movable disc for unsmooth abrasion and weld in time or change with a new one.
4. Replace the spring with spot-welding, defects or breakage at once.
5. Check Kelly section surface for crack, if found, stop work at once and ask professional
personnel to repair that.
6. Check Kelly section key bar or steel pipe surface for scratch or abrasion, if found, stop work
at once and ask professional personnel to repair that.
7. Check and tighten servo-frame and bolts at the connection place of shock-reducing rubber.
8. Check whether the drill bit is matched with machine Kelly, and repair or change drill bit in
time.
9. Change lower briquetting of rotary head.
8.1.6 Requirements of Long-time Storage and Transport for Kelly
1. When the Kelly is stored for a long time, wide firm level ground is needed, on which three
crossties should be padded. Don’t allow to place it on the ground directly. Don’t keep it
together with soil slag, broken stone and other tiny objects. Don’t place it in wet area, such as
in water.
2. After working in alkaline slurry, seawater and clay, wash the Kelly with plenty of clean
water before long-time storage, disassemble it to dry, then assemble to avoid corrosion or stuck.
If the Kelly have been used in the seawater, check each Kelly section surface before reuse,
polish its surface to avoid breakage caused by shocking tiny crack during construction and
resulting in Kelly breakage accident.
3. It’s forbidden to place the servo-frame vertically for a long time, this may result in the
suspension of Kelly middle part, and Kelly deformation caused by the long-time effect of
gravity.
4. When transport, the Kelly should be placed on the crosstie, with anti-extend device installed
on the flat head, and then tied down to avoid accidents caused by Kelly across the machine
body.
8.1.7 After-Sale Service Code for Kelly
After-sale deadline: effective time starts from the shipping day, repair or change according to
the serial number on the Kelly nameplate.
1.Within 2000 hours or one year since the day of purchase (whichever comes first), the Kelly
should be repaired without charge when it can be operated normally but with function failures.
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2. For non-standard Kelly (as below table), within 2000 hours or one year since the day of
purchase (whichever comes first), it should be repaired without charge when it can be operated
normally but with function failures.
3. For the Kelly used in abnormal working environment, such as long time working in seawater
or inclined working, within 1000 hours or half a year since the day of purchase (whichever
comes first), it should be repaired without charge when it can be operated normally but with
function failures.
4. Within 1000 hours or three months since the day of purchase (whichever comes first), the
machine can be operated but with function failures. For the quick-wear parts, such as spring,
rubber shock absorber, movable disc and pin shaft, these should be replaced without charge.
The after-sale service should be cancelled for following operations.
1. The damage of Kelly caused by above forbidden operations and requirements and smashed
rod.
2. Don’t maintain, keep and transport Kelly according to above requirements.
List and Illustration about Kelly with Standard Specification
Machine Model Kelly Note

MZ273-4X7.5m 1. If the Kelly is installed to a larger machine model, it
SWDM60
JS273-3X7.5m should be regarded as non-standard Kelly. E.g. 377
MZ299-4X9.60m Kelly original for SWDM160, but install it to
SWDM100
JS299-3X9.60m SWDM220
MZ355-5X10.1m 2. MZ is for friction, JS is for machine lock. The most
SWDM120 sections and largest length for friction Kelly and
JS355-4X10.1m
inter-lock Kelly is indicated on the left. If the Kelly
MZ377-5X11.5m
SWDM160HⅡ exceed that, it should be regarded as non-standard Kelly.
JS377-4X11.5m
E.g. JS377-4X11.5m, now the Kelly of
MZ440-5X15m
SWDM240 JS377-5X11.5m or JS377-4X13m are regarded as
JS440-4X15m non-standard Kelly.
MZ470-5X16m 3.If equipped with lower length and less section for
SWDM260
JS470-4X16m friction Kelly or inter-lock Kelly of every model, that
MZ508-6X17m are regarded as standard Kelly. E.g.
SWDM300H MZ377-5X11.5m，the Kelly of MZ377-4X11.5m is a
JS508-4X17m
MZ575-6X22.0m standard one.
SWDM450 4. If inter-lock Kelly is refit to friction one with the
JS575-4X22.0m
same sections and length, it should not be regarded as
MZ630-6X24.5m
non-standard one. But if friction Kelly is refit to
inter-lock Kelly with same sections and length, it should
SWDM550 be regarded as non-standard one. E.g. JS377-4X11.5m
JS630-4X24.5m is changed to MZ377-4X11.5m, not as non-standard,
MZ377-5X11.5m is changed to JS377-5X11.5m, as
non-standard.
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8.1.8 Simple Repair Technology for Kelly
Purpose: make sure there’s repair value ad corresponding repair technology for Kelly
according to criteria.
Range：This guideline specifies the repair value and corresponding repair technology.
Preparation：Assemble the second-hand Kelly to wash it with clean water. If it’s stuck, please
check any sand or foreign objects for clogging and Kelly locking.
1. Silt clogging: wash with clean water, and take out after it’s soften.
2. Impurity jamming: find out the jamming position, make a gas-cut tetragon at the pipe wall
position, and take out. If it’s hard to find, create a gas-cut ring at drive sleeve and inspect.
3. Kelly locking: check steel pipe outer wall for deformation, do a gas-cutting at the
deformation position.
4. Wash each section of Kelly to ensure its surface can be seen clearly for easy analysis.
Criteria Judgment for Kelly Repair Value
Discard Criteria
1. Whole Kelly twist and deformation.
2. Too much spline crack on the whole Kelly, the length of new steel pipe is also as the same as
the original size.
3. The use time is too long, the value of parts required to be changed, is almost 80% of the new
manufacturing ones.
Repairable Criteria:
Each section of Kelly can be repaired at one or two positions at most to ensure the use. The
repair cost is less than the sale value after remanufacturing.
Methods of Repair Technology
Square-head repair:
1.Connect 1.5m steel pipe at square head for gas cutting, cut spline at surplus place for
180mm-250mm to make every it form 45 bevel edge, mutually staggered, not damaging the
steel pipe, polish that after gas-cutting.
2. Determine whether the square head can be used repeatedly, if OK, gouge square head and
steel pipe welding groove, and polish to shine.
3. Cover the square head on the spring seat to connect 1.5m new steel pipe, open grooves on
two end of new pipe to guarantee the same axial less than 1.5mm, do that according to the heat
preservation requirements for preheating and welding.
4. Install spring-stiffened arc plate and do that according to the heat preservation requirements
for preheating and welding.
5. Measure the length of key bar which required to be arranged, weld that completely,
remembering that welding should be done one step by one step. After welding, polish the
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groove to avoid interference.

Positioning ring repair:
1. Do gas-cutting for the positioning ring, and remove the damaged part without breaking the
steel pipe and polish it to shine.
2. If it’s a structure of two positioning rings, do ring gas-cutting on the steel pipe between two
rings, and then install the new positioning ring.
3. Mount the new part, don’t weld the O-ring, which is a movable part, weld the kidney slot of
the positioning ring together with the other side.
4. If the steel pipe has been cut with gas, it should be weld together again for the same axial
less than 1.5mm.
Repair for the crack of Kelly center pressurized block or inclined plate:
1. Find the crack position to determine whether the steel pipe body is damaged.
2. If the crack doesn’t damage the pipe body, change or weld on the spline or pressurized block
directly.
3. If the crack damage the pipe body but the distance is not over than 1/5 circle, the operation
should be done skillful professional personnel. Figure out the crack source on two ends,
eliminate the crack source completely, repair the crack into a V-shaped groove, and then weld it
again and polish the surface.
4. The middle part of steel pipe and accessories should be changed if the crack is too long, cut
the damaged part with gas and weld it.
Repair of Kelly Drive Sleeve
1.If the end surface is uneven, rub it down to flat.
2. If then end surface is too rough, cut it with gas into a plane, open a ring groove, and then
weld it with a special part for drive sleeve end surface.
3. Change the drive sleeve and arc plate spline if it’s damaged severely.
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8.2 DRILLING TOOLS
8.2.1 Common Drilling Tools and Application
Type of Drill Bit Features Suitable layer

Cone single head single Cone teeth drill Gravel-cobble layer,
auger bit successively, that reduce gravelly soil, especially for
load greatly; Cone auger the layer with much and
pilot drilling prevent or big gravel-cobble and a
reduce the possibility of weathered rock formation
inclined hole; big screw with joint fissures
pitch distance, strong
capacity for conveying
soil slag, but small
intensity; low performance
Cone double head dual During drilling, dual teeth Suitable for drilling under
auger bit work simultaneously, thus big pressure, used for
high efficiency and stable intermediary weathered
drilling; Cone structure for sandstone and slightly
good guide performance; weathered bed rock, and
Small screw pitch gravel ground with small
distance, conveying particle size
channel for soil slag is
small but with high
intensity, and good
performance in guiding
and carrying rock.

Small screw pitch in the front Suitable for all kinds of
part, high intensity; the screw bedrock, pebble layers
pitch is double in the rear with medium size
part, the conveying channel
for soil slag increase.
Big screw pitch, large soil Suitable for frozen soil
slag conveying channel, but without water, cohesive
small intensity, bucket teeth soil, sand layer, gravel
(V20, 25T, BZ80) layer with partial
cementation difference
medium particle size
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Double head double screw Small screw pitch, small Suitable for
straight auger bit channel for conveying soil unconsolidated layer
slag, bucket teeth (V20, 25T, without water, sand layer
BZ80) to enable cutter teeth with much sand, small
drilling into extreme soft diameter gravel layer with
rock poor cementation, strongly
weathered and extremely
soft rock
Double bottom and double It’s one of the most common Suitable for layer of silt,
opening bailing bucket drilling tool, it’s suitable for sandy soil, gravel. This
the construction of rotary cutter teeth type bucket
drilling rig with the also suits for hard layer
technology of static mud and complex layer, such as
retaining wall. High slag moderately weathered
capacity and well sealed. bedrock.
Bucket tooth type soil has
high adhesion efficiency. The
cross-cut teeth improve the
drilling ability. Its diameter is
large and equipped with vent
hole.

Double bottom and single Large inlet area for slag, Suitable for gravel layer
opening bailing bucket especially for gravel; As with large diameter;
single opening, the drill teeth Slippery mudstone, plastic
is reduced, torque load is soft rock; or heaving soil
decreased, the cutting ability which is required to
is improved. But inclination prevent the suction, sand
is easy to occur. layer.
Single bottom and double Drilling resistance is small, Suitable for non-loose soft
opening bailing bucket so as to enable drilling and layer, such as silty clay,
digging at high speed, but clay, plastic frozen soil,
with loose muck falling massive sandy soil,
weathered soft rock.
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Tooth-socketed cylindrical Straight barrel design, Medium hard core drilling
drill lower part is open for slag
inlet. Lower part of the
barrel with annular edge is
equipped with different
cutting teeth. Drilling
method is ring cutting with
high efficiency into the
rock. Rock enters the
barrel in columnar during
drilling.
Cone-socketed cylindrical Straight barrel design, Slightly weathered and
drill lower part is open for slag unweathered hard bedrock
inlet. Lower part of the
barrel with annular edge is
equipped with cone.
Drilling method is ring
cutting with high
efficiency into the rock.
Rock enters the barrel in
columnar during drilling.

Tooth alloy rock-socketed Straight barrel design, lower part is open Slightly weathered and
cylindrical drill for slag inlet. Lower part of the barrel unweathered hard bedrock,
with annular edge is welded with carbide large boulders
tooth. Drilling method is ring cutting
with high efficiency into the rock. Rock
enters the barrel in columnar during
drilling.
Clamped rock-socketed Straight barrel design, lower part is open Bedrock and large gravel
cylindrical drill for slag inlet. Lower part of the barrel layer
with annular edge can be equipped with
cutting teeth, cone and lumpy alloy. A
grab mechanism is installed in the inner
part. Drilling method is ring cutting with
high efficiency into the rock. Rock enters
the barrel in columnar during drilling.
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Mechanical bottom The open mechanism is a four link rod, Soil layer, highly
reaming bit which includes expansion arm and link weathered layer,
rod. A bearing bottom plate is installed moderately weathered
on the bottom of drill bit, of which two layer and hard bedrock
reamed blade spread out symmetrically
to expand bottom pile of different
diameters. It mainly includes two types:
upper open and lower open; Simple
structure, easy operation and
maintenance. It can be installed with
normal alloy bit tool, cutter teeth, cone
and hob.
Hydraulic bottom reaming Hydraulic cylinder controls the extension Soil layer, highly
bit and retraction of reamed blade, it should weathered layer,
be retracted downward when work. moderately weathered
Hydraulic power station and pipe reeling layer and hard bedrock
equipment should be placed on the
ground. But the ability to expand is very
strong. The reamed pile wall has high
intensity, not easy to collapse;
meanwhile, it can be reamed at any
position of the pile hole. It also can take
the construction for bamboo pile.

Hole cleaning bit Welding continuous type, Remove sediment from the bottom of
detachable scraper the hole
Open bucket Semiclosed type, cutting tool Suitable for layer with large
is cutter tooth or bucket viscosity, such as pure clay, old clay
tooth. and silt. The work efficiency is not
quicker than bucket tooth
semiclosed, but its application is
wider, such as high work efficiency
for pebble bed.
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Refer to below table to select.

Rock quality designation is the ratio of the accumulated length of columnar core which
greater than 10cm per run to footage per drilling return (shown in percentage).
Rock compressive
strength Cone Cylindrical
drill
Cylindrical
Drilling
drill
teeth
designation
Rock
Drillin Short auger

g tool
Rotary drilling bit
quality
Uniaxial compressive strength
1. For rock uniaxial compressive capacity more than 70Mpa and RQD value more than 60%,
cone teeth cylinder drilling core should be used.
2. Cone cylindrical drill should be used if the drilling efficiency is lower than 10cm/hour when
using cutter teeth cylinder.
3. When cutter teeth cylinder is used to drill at speed lowering than 15cm/hour, besides,
machine vibration is very large, and the cutter teeth is consumed obviously, thus, the cone teeth
cylinder drilling core should be used.
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9 SERVICE AND MAINTENANCE
Special note：
Regular and rigorous maintenance is essential to personal safety, the normal operation of the
machine and the extension of machine service life.
9.1 SAFETY INSTRUCTIONS FOR MAINTENANCE
9.1.1 Overview
In this chapter, it emphasizes some risks that may happen during maintenance for the drilling
machine.
Related details about safety information can be found in the corresponding chapter.
Check and maintain the machine as specified requirements in regular interval, and change parts
in comply with the replacement schedule.
Keep all handles, pedals and stairs without dust, snow, ice and oil.
Never allow unauthorized people to get close to the drilling machine during lubrication and
maintenance.
Wear specified safety device, such as safety clothes, protective goggles, and safety helmet.
Never spray water onto the electrical parts and joints while washing the machine, and take
measures to keep them dry.
Keep the machine body clean so as to find oil leakage, crack, connection parts loosen and other
abnormality, especially keep grease nozzle, breather hole and oil dipstick clean to avoid dust.
Only use parts specified by the manufacturer.
Never change, retrofitting or modify the drilling machine without the authorization from the
manufacturer.
Please contact with SUNWARD after-sales department when you have any questions about
lubrication and maintenance.
9.1.2 Note for Maintenance
9.1.2.1 Maintenance Personnel
Maintenance personnel should be professional for maintenance work, especially for electrical
system, hydraulic system, engine and each transmission system.
9.1.2.2 Risks during Service and Maintenance
The requirements in the chapter of lubrication and maintenance should be strictly observed.
Much attention should be paid for some dangerous parts during lubrication and maintenance.
The risk level is raised successively from “Note, warning and danger”, you should note that.
Risk caused by swing: Stay in the range of swing radius may cause collision and injury.
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Potential Parts: counterweight, upper carriage.

Maintenance: Grease refilling for upper carriage swing gear ring
FIG. 9-1-1
Measures：Honk the horn before work and never allow anyone stay within the range of swing
radius.
Risk of hands involved and dragged: Be careful of hands involved. All rotating and moving
parts may cause hands, body involved or dragged.
Related parts: steel ropes, pulleys, winches, crawler travel mechanism, swing mechanism and
luffing mechanism.
Maintenance: Change steel ropes, apply lubricating grease for crawler tension cylinder, check
and replace transmission gear oil.
Measures: When changing steel ropes, a specified person is needed to assistant a person to
wind and a person to operate.
FIG. 9-1-2
Falling risk: Incorrect getting on or off the machine is easy to cause falling.
Related parts: high position and travel parts
Maintenance: maintenance for the upper carriage.
Measures:
 Only get on/off the machine by stairs or handrails, which should be checked and
cleaned before using.
 Always face the machine to get on or off it with handrails and stairs.
 If you should travel on the mast, before that, please make sure the mast is lowered
to the proper position and take effective measures to avoid slipping and falling.
130
FIG. 9-1-3
Scald risk： High temperature may scald the maintenance personnel.
Related parts ：Engine exhaust system, water tank, engine housing, hydraulic system during
working.
Maintenance：Maintain the engine and hydraulic system and change coolant.
Measures: Don’t maintain the engine immediately after a long time running, wait till it cools
down and can be touched by hands.
FIG. 9-1-4
High pressure risk: If sprayed out by high pressure, diesel oil, hydraulic oil and lubricant
penetrate or inject into eyes, serious injury, blindness or even death may be resulted in.
Related parts: Hydraulic components and crawler tension cylinder.
Maintenance: Maintain hydraulic system and crawler tension cylinder.
Measures:
 Tighten all connections before pressurization.

 Release pressure before dismantling the hydraulic lines.
 Check the leakage with a cardboard, pay attention to protect your hands
and body to avoid touching with high pressure liquid. Wear face shield or
protective goggles.
FIG. 9-1-5
131
FIG. 9-1-6
FIRE ：Leakage of fuel, hydraulic oil and lubricant may cause fire.
Maintenance：Hydraulic oil tubes, hydraulic system and electrical system
Measures：
 Clean spilled fuel, hydraulic oil, rubbish, lubricant, scrap and other flammable objects
after maintenance, and do the inspection and cleaning every day to remove any
accumulated flammable objects.
 Clean and tighten electrical connections, check cable and wire for loosen, twist,
hardness or crack, and handle that immediately.
 Prepare a fire extinguisher on the site.
FIG. 9-1-7
9.1.2.3 Before Maintenance
Inform the operator and assign a supervisor.

Shut down the engine, only start it when needed during the lubrication and maintenance.
Stop the drilling machine on firm level ground and take measures to avoid moving.
Make sure unauthorized people is not able to start the drilling machine (lock the cab’s door),
and place a warning sign.
Lock the power switch of electrical system and starting switch before lubrication and
maintenance.
Clean the machine and remove lubricating oil on the joints and couplers, fuel or addictive
before maintenance. Don’t use erosive detergent and clean with non-fiber cloth.
Cover parts which may be affected by water, vapor or detergent before cleaning.
Remove all the cover after cleaning to check these parts.
Check fuel lines, engine oil lines and hydraulic oil lines for leakage, joints for loosen, crack or
damage after cleaning.
A suitable container should be prepared for the oil spill during the maintenance and installation
process.
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9.1.2.4 During Maintenance
A suitable place and the auxiliary equipment should be prepared for the maintenance.
Lock down the working area carefully.
When changing a part or a larger assembly, it should be placed on an auxiliary equipment and
make sure there’s no damage risk.
Only use a auxiliary equipment with enough load capacity with proper functioning.
Don’t stand, walk or work under a suspended heavy part.
Only specify personnel with rich experience to command, who should always stay within the
range of visibility of the operator, and send signals to the operator through voice, gestures or
telecommunication.
Before maintenance, fix the loosened bolts.
If the safety device is dismantled during the maintenance, reinstall that after finishing the work.
Make sure working media, consumption parts and replaceable parts meet the requirements and
standard of environment-friendly and safety.
Store the oil cloth and flammable material away from places where with the fire risk.
The electrical device should be checked regularly. Repair or replace loosened joints or burned
cables immediately.
Only a qualified electrician or a trained personnel under the supervise of a qualified electrician
can repair the electrical system in accordance with the technical regulation.
Only original fuse with specified current intensity can be used.
Release pressure for related parts before maintaining the electrical system.
Regularly check hoses for the hydraulic system and joints for any leakage and damage, repair
or change if any damage is found.
Only professional personnel with the knowledge and experience in hydraulic can lubricate or
maintain the hydraulic parts.
Related safety regulations should be observed when handling with the lubricating oil, grease or
other chemicals.
Pay attention to handle hot parts. (the risk of scald or burn).
Avoid excessive lubrication, which is not only wasteful, but also harmful.
1）Excessive lubrication may permeate the lubricating grease or oil into the friction surface and
resulting in operational failure.
2）Dropped lubricating oil or grease on the walkway may make people slip and hurt.
3）Oil level is too high, lubricating oil may bubble, overflowing from the oil tank.
4）When the pressure is large, too much lubricating grease may lead to the bearing sleeve is
pushed out.
After work, make sure there’s no tools left on the equipment, if failure to comply, dropped or
bulged tools may cause danger.
If parts should be transported, pay attention to protect pipe end, joints or harness to avoid oil
leakage.
When maintenance, pay attention to keep small parts to avoid pollution.
Welding or grinding should be taken after getting the permission.
Before welding on the drilling machine, cut off the battery connection and pull out the starting
key, failure to comply may result in harness burn, battery explosion and electrical parts burnout
133
and others serious accidents.

Before welding or grinding, clean dust and flammable materials away from the drilling
machine and ventilate for it.
9.1.2.5 Note for Hydraulic Components Maintenance
After replacing hydraulic main pump and motor, it must be filled with oil in the casing for
main pump or motor in first, then you can run it, otherwise it will cause early damage, even
immediately damage if serious.
A11V/D1P pump
exhaust method:
Loosen the top T
slot of the main
pump casing, and
fill up the pump
casing with
hydraulic oil by
perfusion.
FIG.9-1-8
The exhaust method of rotary head

motor:
Filling with hydraulic oil from
motor T slot, the hose is attached,
and the tubing is always higher
than the motor shell or plug the
other end of the hose when it is
installed, preventing the motor oil
leaking out. Install the motor and
134
FIG. 9-1-9
The exhaust method

for travel motor:
Disassemble the T
joint, fill the motor
casing with hydraulic
oil by perfusion.
FIG. 9-1-10
Main winch motor exhaust

method:
Perfusion. The port T is located
on the motor bottom. Loosen
motor drain joint to pour hydraulic
oil from the high place of drain
pipe till oil flows out from the
drain outlet. Then start the
FIG. 8-1-11
machine, operate the main winch
for 3 to five minutes without load.
Note: Loading is not permitted. If
the motor is damaged by loading,
our company will not take any
responsibility
9.2 REGULAR MAINTENANCE
After used for a long time, the rotary drilling rig may abrade and loosen, and severe working
condition may make the machine condition even worse. Thus, regular check, service and
135
maintenance can reduce machine failure, extend the service life, shorten the stoppage time and
improve work efficiency, making the machine in the best condition.
9.2.1 Lubrication Maintenance Chart
Main lubrication and maintenance of SWDM240 rotary drilling rig is as figure 9-2-1,
lubricating points illustration, in which show main lubrication positions, lubricating interval
and oil replacement interval. Lubricating oil, please refer to table 9-2-1.
FIG.9-2-1 Lubricating Points Illustration
136
FIG. 9-2-1 Lubrication Illustration of Rotary Drilling Rig
137
Table 9-2-1 Maintenance or Lubrication Content and Cycle

No. Part Measures Maintenance Cycle
1 Steel rope Check abrasion 10 hours or every day
2 Drill tool Install and wear 10 hours or every day
3 Swivel joint regular lubrication ， check joints, 10 hours or every day
mounting pin shaft for tightness, split
pin for wear
4 Transmission pulley shaft regular lubrication 10 hours or every day
and bearing
5 Servo-frame swing bearing Regular lubrication and tightness 10 hours or every day
6 Cathead main sliding frame Regular lubrication 10 hours or every day
shaft, bearing
7 Hydraulic oil check oil level and hydraulic oil quality 10 hours or every day
8 Rotary head gearbox gear check oil level 10 hours or every day
oil
9 Rotary head reduction check oil level 10 hours or every day
gearbox gear oil
10 Crowd winch reduction check oil level 10 hours or every day
gearbox gear oil (none)
11 Main winch reduction check oil level 10 hours or every day
gearbox gear oil
12 Fuel tank check oil level 10 hours or every day
13 Coolant Check liquid level 10 hours or every day
14 Engine oil level check oil level 10 hours or every day
15 Oil-water separator Check 10 hours or every day
draining
16 Air intake pipe, water pipe Check 10 hours or every day
for loosen
17 Crankcase breather Check 10 hours or every day
18 Drive belt, fan and bolts Check 10 hours or every day
19 Control mechanism and Check mechanical gear or meter 10 hours or every day
meter function
Each shaft, bearing, sliding regular lubrication 50 hours or every week
20
rail and etc.
21 Cathead auxiliary pulley 50 hours or every week
Regular lubrication
frame shaft and bearing
22 Auxiliary winch end 50 hours or every week
regular lubrication
bearing
23 Platform swing bearing regular lubrication and bolts tightness 50 hours or every week
24 Crowd winch end bearing regular lubrication 50 hours or every week
(none)
25 Rotary head sliding rail regular lubrication and bolts tightness 50 hours or every week
bracket check or replace wear plate
26 Drive sleeve or key bar check abrasion 50 hours or every week
138
27 Main winch rope retaining check abrasion, rope retaining roller and 50 hours or every week
roller roller for parallel
28 Drill mast sliding rail regular lubrication 50 hours or every week
29 Drill mast each section Bolts tightness 50 hours or every week
flange
30 Undercarriage and crawler visual check crawler tension 10 hours or every day
Check crawler mounting bolt tightness 50 hours or every week
and loaded structural parts
31 Engine oil change oil at initial maintenance 50 hours or every week

32 Engine oil filter element change element at initial maintenance 50 hours or every week
33 Oil-water separator filter change element at initial maintenance 50 hours or every week
element
34 Fuel filter element change element at initial maintenance 50 hours or every week
35 Kelly Check 100 hours or every 2 weeks
36 Swing reduction gearbox check oil level 100 hours or every 2 weeks
gear oil
37 Auxiliary winch reduction check oil level 100 hours or every 2 weeks
gear oil
38 Travel reduction gearbox check oil level 100 hours or every 2 weeks
gear oil
39 Hydraulic oil filter element
Check 100 hours or every 2 weeks
40 Hydraulic oil tank Hydraulic oil tank, pollutant discharge 100 hours or every 2 weeks
and water draining
41 Servo-frame friction plate Check or replace 250 hours or every month
42 Rotary head reduction change oil at initial maintenance 250 hours or every month
gearbox gear oil
43 Crowd winch reduction change oil at initial maintenance 250 hours or every month
44 Main winch reduction change oil at initial maintenance 250 hours or every month
gearbox gear oil
45 Rotary head gearbox gear change oil at initial maintenance 250 hours or every month
oil
46 Travel reduction gearbox change oil at initial maintenance 250 hours or every month
gear oil
47 Auxiliary winch reduction change oil at initial maintenance 250 hours or every month
gearbox gear oil
48 Swing reduction gear oil change oil at initial maintenance 250 hours or every month
49 Engine oil Regular maintenance and change engine 500 hours or every 3 months
oil
50 Regular maintenance and change 500 hours or every 3 months
Engine oil filter element
element
51 Oil-water separator filter Regular maintenance and change 500 hours or every 3 months
139
element element
52 Regular maintenance and change 500 hours or every 3 months
Fuel filter element
element
53 Regular maintenance and clean 250 hours or every month
Air filter element Regular maintenance and change 500 hours or every 3 months
element
54 Water filter element Regular maintenance and change 1000 hours or every half a
element year
55 Oil filter element change element at initial maintenance 250 hours or every month
56 Pilot filter element change element at initial maintenance 250 hours or every month
57 Air breather initial element replacement 250 hours or every month
58 Pulley rope grooves wear or deformation 500 hours or every 3 months
59 Rotary head reduction regular maintenance and change gear oil 500 hours or every 3 months
gearbox gear oil
60 Crowd winch reduction regular maintenance and change gear oil 500 hours or every 3 months
61 Main winch reduction regular maintenance and change gear oil 500 hours or every 3 months
gearbox gear oil
62 Rotary head gearbox gear regular maintenance and change gear oil 1000 hours or every half a
oil year
63 Travel reduction gearbox regular maintenance and change gear oil 1000 hours or every half a
gear oil year
64 Auxiliary winch reduction regular maintenance and change gear oil1000 hours or every half a
gearbox gear oil year
65 Swing reduction gearbox regular maintenance and change gear oil 1000 hours or every half a
gear oil year
66 Cooling fan belt tensioner Check 1000 hours or every half a
year
67 Oil filter element Regular maintenance and change 1000 hours or every half a
element year
68 Pilot filter element Regular maintenance and change 1000 hours or every half a
element year
69 Air breather Regular maintenance and change 1000 hours or every half a
element year
70 Fan ，belt Check 1000 hours or every half a
year
71 Battery Check 1000 hours or every half a
year
72 Track roller Regular maintenance, change gear oil 2000 hours or every year
73 Carrier roller Regular maintenance, change gear oil 2000 hours or every year
74 Hydraulic tank Clean hydraulic oil tank 2000 hours or every year
75 Hydraulic oil fine filter Change filter element 2000 hours or every year
76 Hydraulic oil Change hydraulic oil 2000 hours or every year
140
9.2.2 Oil
Oil use for SWDM240 can be found in the table 9-2-2.

Table 9-2-2 Oil capacity and type
Capacity
No. Components or system Oil type Remark
（L）
The diesel for lower
0# diesel（4°above） environment temperature
1 Fuel tank 523
-10# diesel（-5°-4°） can be selected for real
condition.
1.Viscosity: 15W-40
2.Choose oil of suitable
viscosity according to
CH-4 environment temperature
2 Engine oil capacity 22.7
15W-40 3. The filling capacity
depends on the scale of
engine oil dipstick(between
LOW and HIGH)
3 Engine coolant 11 1. Don’t mix antifreeze of
Antifreeze ： 50% different types.
Ethylene glycol or 2. The filling capacity of
4 Radiator water tank 19 Propylene glycol +50% antifreeze is up to the upper
purified water sight glass of radiator or the
filler.
Cylinder (luffing, mast,
crowd, track extension &
Forth, Total or retraction etc.), fill up to the
6 Hydraulic oil tank 535 International 68 ＃ upper scale line of tank level
antiwear hydraulic oil gauge; Fill up to the lower
scale line when the cylinder
extend and retract fully).
6 Swing reduction gearbox 5.5 Industrial gear oil220 In the reduction gearbox
7 Travel reduction gearbox 2×8.5 Industrial gear oil 220
8 Rotary head housing 35-40 Industrial gear oil 220
Rotary head reduction
9 2×8 Industrial gear oil 220
gearbox
Main winch reduction
10 9 Industrial gear oil 220
gearbox
Auxiliary winch
11 4 Industrial gear oil 220
reduction gearbox
12 Swing gear ring 30kg Lithium base grease
Left & right crawler As Adjust track tension to
13 Lithium base grease
tension cylinder required specified requirements.
141
Note：
 The oil capacity in above table is only for reference, please see the standard at the oil
filler. When cylinder is fully retracted or extended, hydraulic oil should be at upper
scale or lower scale on the level gauge.
 Any changes in places and times, please consult SUNWARD after-sale service
department.
 When the drilling machine is operated in the environment under 0℃, warm-up
operation should be done as below to ensure the safety of hydraulic system:
 Idle engine for 7 to 10 minutes, increasing rotation to 1000～1700r/min, don’t
operate the drilling machine, idle the machine for 30～40 minutes or longer to
heat up the hydraulic oil above 20℃.
 After finishing above operations, normal work can be started. Besides, adjust the
heating time according to the environment temperature.
 During normal operation, the control lever and pedal should be operated slowly
and system running should be observed.
Warning！
The risk of losing claim right！
If the drilling rig is not serviced and maintained as specified time, it may be damaged.
Maintenance personnel for the machine should record every maintenance in the Maintenance
Log, for which should be signed by the person and the supervisor. When there’s claim dispute,
SUNWARD INTELLIGENT EQUIPMENT CO., LTD. has the right to check the Maintenance
Log.
9.2.3 Regular Check
Purpose：
 Prepare for operation.

 Maintain the machine performance.
 Shorten stoppage time.
 Maintain the using performance of the drilling rig.
 Reduce repairing cost.
9.2.3.1 Note
 Check and maintain hydraulic components in a room or a clean place; Pay attention to
keep clean to avoid impurities when maintaining hydraulic system; Check seal parts to
prevent leakage from missing installation or damage.
 It’s dangerous to check and maintain when maintaining with load. The engine should be
stopped without load. Hang a sign with “Checking and Maintaining” on the cab’s door.
142
 It’s forbidden to dismantle or adjust hydraulic components in the hydraulic system without
the authorization of SUNWARD, such as the pump, valve and motor.
 Observe the safety instructions for maintenance.
9.2.3.2 Regular Maintenance
 Below listed maintenance interval is suitable for “normal operation condition”. It should
be shortened on some severe conditions, such as too much dust, corrosive air, abnormal
low temperature, large load, very frequent or long-time operation circulation. Before
accumulating much experience for the maintenance, please observe the time interval in
this chapter.
 If found that bearing and bushing is too hot, excessive loosen and rust for transmission
during the regular inspection, that means lack of lubrication, the lubrication cycle should
be shortened for the unusual parts.
 Besides checking the reduction gearbox oil level in accordance with the maintenance time,
the lubricating oil also should be added on following two conditions:
-Before the first time startup
-Storage for over than three months
Note：
 Inspection should be done as required hours or specified time interval, whichever

comes first.
 Maintenance time interval is accumulated, e.g. when 1000 hours interval comes, the
maintenance work for 10 hours, 50 hours, 100 hours, 250 hours and 500 hours should
be done together.
 The maintenance should be more frequently when the machine is operated in the
moist or dusty area.
 Details about service and maintenance of engine should be referred to the manual
made by the manufacturer.
9.3 EVERY 10 HOURS MAINTENANCE
9.3.1 Checking and adjusting track tension
Danger: When releasing pressure, sprayed-out lubricating grease with high pressure can
penetrate into human body causing death.
Note：
1）Pressure relief valve only can be loosened for one circle. If track is unable to loosen, turn off
the vale and consult SUNWARD after-sale service department.
2）Don’t check overflowed lubricating grease by pressure relief valve. Check track or tension
cylinder for track sag.
143
Pin shaft
Grease filler
FIG.9-3-1
FIG. 9-3-2
（1）Idler （2）Carrier roller （3）Ruler （a）Track sag
1. Operate the machine according to the direction of idler, place the drilling rig on firm level
ground and place the track pin shaft (1) right on the carrier roller (2).
2. Put a ruler (3) on the track, and it should be long enough to measure from idler (1) to carrier
roller (2).
3.Measure the maximum sag for track, which is measured from the lowest point to the bottom
of the ruler and adjust the track correctly. The track sag “a” is about 20mm to 35mm.
FIG. 9-3-3
① Idler ② Cushion spring ③ Tension cylinder ④ Grease nozzle
Tension device includes tension cylinder, cushion spring, idler and grease cup. If the track is
too tight or loose, please refer to below procedures “track tension tightening or loosening” to
adjust.
Track tension tightening
1. Wipe out the grease nozzle before adding lubricating grease.
2. Fill lubricating grease through the nozzle till proper track tension is reached.
3. Travel the machine forward to balance the pressure.
4. Check track sag and adjust according to requirements.
Track tension loosening
144
1. Loosen the pressure relief valve till the track starts to loose, with one circle at most.
2. When track tension is proper, tighten the pressure relief valve according to torque.
3. Travel the machine rearward to balance the pressure.
4. Check track sag and adjust according to requirements.
9.3.2 Hydraulic Cylinder Maintenance
Table 9-3-1 Cylinder Inspection

Cylinders Qty. Function Inspection method
in the chassis frame, it’s used When extending or retracting
Track extension
1 to extend or retract the track track, oil cylinder should be
cylinder
frame on two ends. operated slowly.
Support the parallelogram in
When luffing is operated, two
Boom luffing the luffing mechanism and
2 luffing cylinders should be
cylinder lift and lower the luffing by
operated synchronously.
the extension and retraction
When operating the drill mast,
two mast cylinders should be
operated slowly. After the
Support the drill mast to
leveling button on the lower
Drill mast move forward or rearward
2 mast is pressed down, the drill
cylinder and adjust the mast
mast inclined correspondingly.
inclination angle laterally.
When inclining forward or
rearward, two cylinders should
be operated synchronously.
When operating rotary head,
Lift and lower the rotary
crowd cylinder move
head and increase pressure
Crowd cylinder 1 correspondingly. After the
for the rotary head while
crowd button is pressed down,
drilling.
rotary head falls slowly.
1. Daily maintenance for hydraulic cylinder

 Check bearing on the two ends of hydraulic cylinder for lubrication every day, and
apply lubricating grease once every one working hour.
 Visual check structural parts of hydraulic cylinder for crack regularly, repair or
replace when necessary.
 Apply hydraulic oil onto piston rod once or twice a week, and extend or retract piston
rod for several times.
 Before long-time storage, apply acid free grease to protect piston rod.
 Don’t clean piston rod with high-pressure water gun, sharp tools, corrosive alkaline
water or grinding materials.
2. Check seal for hydraulic cylinder
145
 Every time, before or after work, check junction oil tube joints which link with
cylinders for looseness, fasten immediately when necessary.
 Check hydraulic cylinder for leakage before or after work, change damaged seal parts
in the cylinder when necessary.
 If cylinder tubing is damaged, change hydraulic cylinder if necessary (if hydraulic
cylinder is used in a set, the whole cylinder set should be changed at the same time).
3. Note for cylinder maintenance
 Check hydraulic cylinder motions whether it’s correct during operation, if hydraulic
cylinder work slowly, without strength, or no motion, shut down the machine to check
immediately.
 The cylinder is loaded, attention should be paid to safety when repairing or replacing
it.
 The cylinder piston rod should be retracted completely when repairing or maintaining
the balance valve on the cylinder.
 If any questions, please contact with the after-sale service department of SUNWARD
INTELLIGENT EQUIPMENT CO., LTD.
9.3.3 Checking oil level in rotary head gearbox
Note：
 If the color of gear oil has changed, indicating that water has mixed into oil, change
gear oil immediately. Drain up the used oil before refilling and wash the reduction
gearbox with new oil for times.
1. Keep liquid level on proper position.
2. Check oil level when rotary head is still.
3. The oil level should be at the 1/2-2/3 position of view glass.
Oil level sight glass
FIG. 9-3-4o Check oil level for reduction gearbox

9.3.4 Check cushion device of rotary head
Check cushion device of rotary head and key bar every day, figure out the abrasion condition
of the machine; especially, after smashing the rod, inspection is necessary, and replace related
parts.
146
Rotating disk
Spring
Cushion seat
FIG. 9-3-5 Cushion device

1）Check rotating disk for abrasion, deformation or damage, replace it if necessary.
2）Check spring for deformation or damage, replace it if necessary.
3）Check thread on spring guide pin, especial after smashing rod, if transformed or damaged,
repair or change cushion seat.
9.3.5 Check Track Components for Lost or Damaged
1）Keep upper-carriage vertical with the track and clean mud on the track completely.
2）Check joint bolts for drive sprocket, reduction gearbox, track shoe and chain rail.
3）After extending the track, apply grease onto the telescopic beam of the track to avoid rust.
4）Take walk-around inspection for the machine to check abrasion, damage and oil leakage,
especially for parts as below:
FIG. 9-3-6 Track Components

（1）Track shoe（2）Chain rail section（3）Carrier roller（4）Driver sprocket
（5）Reduction gearbox（6）Track roller（7）Rail-clamp bracket（8）Idler
9.3.6 Wire Rope Inspection
Note：
 When handling the wire rope, it’s possible to be hurt by broken part, thus, gloves
should be put on as an protective measure.
 Much attention should be paid for maintenance, inspection and installation. Be
careful not to be involved in or pinched.
Wire rope is a quick-wear and vital part of the drilling rig. Correct selection, reasonable
use and regular maintenance as required can extend the service life and avoid accidents.
The type of wire rope should be specified by SUNWARD when changing wire ropes for
147
the main winch and auxiliary winch, any problem caused by failure to comply, that
SUNWARD will not take any responsibility.
 Regular inspection should include following aspects:
 State regulatory requirements.
 Equipment work level.
 Previous test results and problem.
 Used time of wire rope.
 Much attention should be paid to following parts:
 Beginning and end for wire rope movable and fixed part
 Strands on rope sheave
 Rope sections may be abraded by some factors.
 Check the location of wire rope for secure.
 Check joint nearby for broken strand, crack and wire rope diameter.
 Visual inspect the overall length of wire rope for damage and deformation. When
broken wire, abrasion, corrosion and deformation is found, determine whether it’s
discarded or not in accordance with “GB/T5972 Inspection and Discard Regulation
for Wire Rope used by Crane Machinery”.
 Inspect the section of wire rope which is draw forth from the fixed end, the fixed
device for deformation or abrasion, and internal and rope end for broken wire or
corrosion, meanwhile, ensure wedge joints and rope clamp are secure (dismountable
device: wedge joint, rope clamp, press plate and etc.).
 Check rope end device for requirements of related standard, visual inspect joint for
broken wire, if found near or in the rope end device, shorten the wire rope and then
install it onto the fixed device. Keep in mind that the length of wire rope should long
enough to wind on the drum at least for 1.5 to 2 circles, normally 3 circles.
9.3.7 Discard Criteria of Wire Rope
Following rules should be observed to determine the problem of wire rope:
 The wire rope without load is straight, with load is twisted: the problem of wire rope.
 The wire rope with load is straight, without load is twisted: the problem of the
machine.
 Generally, the serious damaged section is only the shorter part after the first layer and
the second layer of wire rope wind together on the drum. The left part of wire rope is
OK to use, though, the whole rope should be discarded.
 Determine to discard the wire rope according to the broken wire, abrasion and
corrosion, replace the rope immediately if one of following conditions occurs.
148
FIG. 9-3-7 broken wire
 Broken wire exists most within the rope range of 6d (d for wire rope diameter).
 Broken wire occurs after used for a while and increase gradually, the wire rope should
be discarded in time according to the criteria.
 The whole strand of wire rope is broken.
 Rope diameter is decreased by damaged rope core.
 Determine to discard the wire rope according to the criteria, such as reduction in rope
elasticity etc.
 When the outer layer of wire rope has been abraded for 40% of rope diameter, the
diameter has reduced 7% or more.
FIG. 9-3-8 deformation
 Various deformation of wire rope.

 Determine to discard the wire rope according to the criteria, such as reduction in rope
elasticity etc.
 When the outer layer of wire rope has been abraded for 40% of rope diameter, the
diameter has reduced 7% or more.
 Outer wire rope is corroded with deep kinks.
FIG. 9-3-9 rope diameter reduction
 Rope diameter reduction.

 Broken wires are caused by internal corrosion, gap reduction among strands and
increased rope diameter.
149
9.3.8 Wire Rope Maintenance
 Clean up mud on the wire rope after work to avoid corrosion.

 Lubricate the wire rope frequently during use, especially the bended part.
 Shorten the lubrication interval of wire rope when used in the corrosive environment.
 The type of lubricating grease should be recommended by the wire rope
manufacturer.
 Choose lubricating grease which is as the same as the one recommended by the wire
rope manufacturer.
 Lubrication methods include: apply with a brush or a grease gun.
 Only lubricated by a grease gun can penetrate the grease into the gap of the wire rope
at the greatest extend.
 Wash the wire rope regularly, especially used in a corrosive or chemical environment.
 If broken wire is found during inspection, it should be cut to prevent damage wire
nearby when reeving a sheave.
 The best method to remove broken wire is to bend wire rope forward and rearward till
the wire break in the gap of two strands.
Note：
 In some occasion, fatigue is the main cause of a damaged wire rope. Even if no
defective part can be found on the appearance, maybe internal broken wire exists.
Above inspection is qualified, and it’s the replacement time, so change the wire rope
with a new one.
 When discarding a wire rope, figure out whether the damage is caused by the
mechanism, eliminate these defects before changing a new wire rope.
9.3.9 Check Swivel Joint for Flexibility
Check swivel joint for flexibility before or after work every day. A swivel joint with good
performance can be turned by hands easily.
1）Lower the drill mast to level position. Pay attention to rotary head and Kelly to avoid
difficulty in erecting mast caused by gravity rearward, or rotary head slipping out caused by
rearward inclination.
2）Turn main winch to loose the end of wire rope linked with swivel joint rotating the swivel
joint freely. During the turning process, keep the wire rope with proper tension to avoid rope
disturbing for the main winch.
3）Secure one end and turn the other, if turning freely, the performance is good. After the swivel
joint is greased, it still doesn’t turn, repair or change it.
Note：
During operation, after swivel joint is lifted out from the drilling hole, it always rotates in
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high speed, observe this carefully. If it doesn’t rotate, shut down the machine to check.
9.3.10 Wire Rope Swivel Joint Lubrication
Note：
 Dirty objects containing fine sediment is easy to enter into the swivel joint, that will
abrade bearing, reduce swivel joint in flexibility, use performance and stability.
 Regularly check swivel joint for oil leakage, if found, change seal.
 Accidental Kelly dropping occur, the swivel joint should be checked immediately.
The swivel joint structure include following two types, please maintain it properly according to
the actual shape.
Structure one is shown as below:
1）Lubricating method:
Unscrew the plug on two ends of swivel joint, inject lubricating oil into grease cup as shown in
following figure till it flows out from the other end.
Overflow port
Oil filling port
FIG. 9-3-10 Swivel Joint Structure

Special note: The plug M10X1 on the other side should be unscrewed when injecting grease
into the grease cup from one end of the swivel joint. In this way, the used lubricating grease
can be squeezed out. Failure to comply may damage the oil seal of the swivel joint, mix
impurity into grease, such as fine sediment, and lead to the reduction in flexibility, using
performance and stability of the swivel joint.
2）If swivel joint is still difficult to rotate after lubrication, repair or change it.
3）Replace parts or swivel joint with original specification for safety.
Lubrication requirements：
1）Apply lubricating grease once every day. Use #2 lithium base lubricating grease in summer
151
and #1 lithium base lubricating grease in winter.

2）Check swivel joint for secure when applying lubricating grease at every time, if loosened,
fasten in time.
3）Check upper and lower pin shafts which link with the swivel joint when applying lubricating
grease at every time, if loosened, fasten in time.
4）After applying lubricating grease, rotate the upper end of the swivel joint when there’s no
load, if it can’t swing or is blocked, repair or change at once.
5）When working on the area with the temperature under 0℃, clean swivel joint in time, wipe
with clean cloth and apply anti-freeze grease on the junction surface to avoid rotary junction
surface freezing on the ground. Before next shift, turn the upper end of swivel joint with hands
to check for freeze. If frozen, thaw with hot water and wipe out, and then check the flexibility
before operation.
9.3.11 Checking Engine Oil Level
After engine shut-down, check engine oil level. Never check the oil level when the engine is
running.
1）Open side seal plate or extract directly.
Note: When checking oil level, the drilling machine should be on level ground. As heat makes
something expand and cold makes it contract, thus engine oil level should be checked after
about 30 minutes and the measurement is correct.
FIG. 9-3-12 Engine oil dipstick position

2）Pull out dipstick. Wipe off oil on the dipstick and insert it again.
FIG. 9-3-13 Engine oil dipstick

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3）Take out the dipstick and check, the oil level should be within the range of “FULL” and
“ADD”.
4）If the oil capacity is not enough, remove the filling plug to add lubricating oil. The engine oil
filler is figure 9-3-14.
FIG. 9-3-14 Engine oil filler position

5）Clean lubricating oil filling plug and install it.
Warning！
Don’t take out the oil dipstick or filling plug when the engine oil is hot, because hot oil and
components is dangerous and easy to get people hurt.
9.3.12 Draining Water and Sediment in Diesel Tank
1）Open the drain valve by rotating it with a wrench anticlockwise to discharge water and
sediment into a suitable container (drain valve is underneath the fuel tank).
2）Close the drain valve by rotating it clockwise.
FIG. 9-3-15 Drain valve
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9.3.13 Check Hydraulic Oil Level and Quality
Warning!
 If hydraulic oil is hot, please don’t remove the filling plug, air outlet plug on the
hydraulic tank, failure to comply may result in the damage of oil pump caused by air
entering into the hydraulic system.
 If air enter into the hydraulic system, it will damage the oil pump.
 Hot oil and component may get people hurt, thus, please don’t allow that to touch
your skin.
1. Park the machine on level ground, open the side door to visually inspect the hydraulic
level gauge and check hydraulic oil level and quality:
(1) The hydraulic oil level should not lower than the indicate line of red zone during operation;
(2)The hydraulic oil level should not lower than the indicate line of yellow zone during
transport;
(3) Visually check the hydraulic quality, if it turns to black or white, please change it at once.
FIG. 9-3-16
9.3.14 Checking Gear Oil Level for Reduction Gearbox
■ The machine should be shut down when checking gear oil level for reduction gearbox;
■ Any one of following methods can be used:
（1）Visual inspection for reduction gearbox sight glass, the oil level should be above 1/2 of
the sight glass;
（2）Take out gear oil dipstick to measure oil level, which approaches to the highest scale;
（3）Screw off the inspection hole plug to check oil level, and gear oil flows out.
■ The machine should be parked on level ground to check gear oil for main winch reduction
gearbox; Erect the drill mast vertical to check gear oil level for rotary head reduction gearbox
and crowd winch reduction gearbox.
■ Inspection after running, the machine should be shut down for over than 30 minutes to cool
down. If plug should be screwed off or the level dipstick should be taken out, wear protective
gloves when checking oil level, beside, unscrew the plug slowly to release inner pressure in the
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tank to avoid scald caused by spray-out of gear oil.

（1）Gear oil level inspection for rotary head reduction gearbox
FIG. 9-3-17 Reduction gearbox with sight glass FIG. 9-3-18 Reduction gearbox with oil
scale
（2）Check gear oil level for reduction gearbox
FIG. 9-3-19 Main winch reduction gearbox
FIG.9-3-19-2 Main winch reduction gearbox
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9.3.15 Checking Coolant Level
Warning！
 Hot coolant and vapor will cause personal injury.

 Engine coolant is hot with pressure at the working temperature. In the pipes of
radiator and heater contain hot coolant and vapor, which can cause serious scald if
being touched.
 Dismantle pressure cap slowly to release pressure only when the engine is shut
down and the pressure cap of cooling system cools down that can be touched by
hands directly.
 Don’t attempt to fasten hose joint when the cooling system is heating, in that case,
hose may drop off causing scald.
 It’s forbidden to taste the additive of coolant, because it contains cancerogenic
substance. And avoid touching with skin and eyes, if infected, please wash with clean
water at once, for a serious case, go to a doctor.
1. The coolant level is measured by a level sensor, and a warning light is set on the monitor in
the cab.
FIG. 9-3-20 Warning light location

2. Procedures for filling coolant as below:
FIG. 9-3-21 Radiator coolant filler

1）Screw off cover plate on the radiator filler.
2）Release the pressure cap slowly to discharge pressure and remove it.
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3）Fill coolant into the cooling system with proper capacity.

4）Start the engine and run it without pressure cap till thermostat is turned on and coolant level
is still.
5）Check pressure cap spacer and replace it if damaged.
6）Install the pressure cap for the radiator.
7）Shut down the engine.
8）Cover the plate and fasten bolts.
9.3.16 Checking Fuel Capacity and Filling Fuel Oil
Note：
 Please handle fuel oil carefully.

 The engine should be shut down before filling fuel oil.
 Prevent anything, such as dust, water or other foreign objects entering into fuel
system.
Filling fuel oil by oil gun：
FIG. 9-3-22 Main Monitor Interface

1）When the fuel level is low （<5%）on the monitor, please add fuel oil in time.
2）Before filling fuel oil into the tank, let it rest completely (no less than 48 hours), and filter it
with special fuel charger.
3）Discharge water and sediment in the fuel tank every month or in accordance with the actual
use condition.
4）Fuel is flammable, thus, eliminate any possible causes for a fire when filling oil.
5）Take full preparation for maintenance.
6）Open the lock cap for fuel tank.
157
FIG. 9-3-23 Fuel tank cap

7）Pay attention to not spill fuel on the machine when filling oil, and keep the fuel gun nozzle
fix to avoid it damaging fuel tank filter.
8）Stop oil filling when the warning line is higher than the oil filler. Don’t fill too much for the
fuel tank.
9）Install the oil cap and lock it with the key to avoid lose or damage.
Warning！
Smoking is forbidden when refilling oil, failure to comply may cause fire, result in
property loss and personal injury.
Filling Fuel Oil by Fuel self-suction pump:
FIG. 9-3-24 Fuel self-suction pump

1）Clean oil inlet filter screen and pipe port before using.
2）Insert oil inlet filler under the oil level of fuel reservoir.
3）Start the motor switch ( red button), the fuel pump suck oil to oil tank automatically.
4）If the oil pump sucks too slow or there’s loud noise during work, please change filter
element.
5）After motor is started, pump buzz but doesn’t suck, please open the mounting plate on the
oil pump base to check vane and rotor for abrasion or stuck by impurities. And clean the pump
chamber with diesel oil and change O-ring.
6）Turn off the motor after filling up the fuel.
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9.3.17 Checking Switches, Buttons and Operating Handles
1. Start the engine and pull the pilot control switch to LOCK position.
2. Operate all switches, buttons and handles in the cab and check whether the motion is
corresponding with the function. If not, take maintenance for the machine.
9.4 MAINTENANCE FOR INITIAL 50 HOURS OF OPERATION
9.4.1 Change Engine Oil and Filter
Warning！
Hot oil and hot components may result in injury, thus, don’t allow these to contact with skin
directly.
Note：
 Please shorten the oil replacement cycle accordingly if the machine working
condition and using environment is severe.
 Lubricating oil should be changed no matter when the maintenance cycle is if it goes
bad or is polluted seriously.
 Drain the oil in the crankshaft tank when it’s warm. In that case, the suspended
waste article can be discharged out.
1. Park the machine on level ground and start the engine to increase its
temperature to about 80℃. ( Shut down the engine after work to cool the
engine to 80℃).
FIG. 9-4-1 drain valve on the engine oil pan
2. Open drain valve on the engine oil pan to discharge engine oil into a container
with enough capacity (engine oil drain valve is located on the bottom of the
platform, bottom of the oil pan)
3. Close the drain valve.
159
4. Open the covering parts door on the left of the machine.

5. Dismantle the engine oil filter with a special wrench.
FIG. 9-4-2 dismantle engine oil filter
6. Clean filter base and remove all filter spacers.

7. Apply a layer of engine lubricating oil on the new filter spacer.
FIG. 9-4-3 Apply lubricating grease
8. Install the new filter with hands. After spacer contacts with filter base, turn filter
3/4 circle to screw down the filter.
9. Close the covering parts door.
10. Open and lift up the engine cover.
11. Remove filling plug to inject lubricating oil into the new machine.
FIG. 9-4-4 Lubricating oil filling plug
160
Note！
Less oil or too much oil in the engine crankshaft case both can result in the damage of the
engine.
12. Start engine to heat up the lubricating oil. Stop the engine to check engine for oil
leakage.
13. Wait for 30 minutes to let lubricating oil flows to crankshaft case. Check
lubricating oil level with oil dipstick and keep the oil level between the scale
“FULL” and “ADD”. Add or drain lubricating oil if the scale is exceeded.
Note：
The engine is forbidden to start when discharging or adding engine oil, failure to comply may
result in serious damage to the engine.
FIG. 9-4-5 Dipstick
14. Cover the engine.
9.4.2 Replacing Fuel Filter
Warning！
 Fire may result in personal injury or death.

 The leakage or spill of fuel on hot surface or electrical parts may result in fire.
 Clean off leaked or spilled fuel. It’s forbidden to smoke when working on the fuel
system.
 Turn off the cut-out switch or storage battery when changing fuel filter.
FIG. 9-4-6 Fuel filter

（start from left）1. Oil-water separator 2. Fuel primary filter 3. Fuel main filter
161
This machine is equipped with fuel filter of three levels. Grade one is oil-water separator (1),
grade two is fuel primary filter (2), grade three is main fuel filter (3). Three grades in total,
these filters should be changed at the same time.
Details about changing filter core for primary filter and main filter.
1. Open platform cover on the left and side plate.

2. Remove primary filter and main filter according to the arrow direction on the
filter casing, there’s no order to follow.
3. Clean left fuel in the inner chamber, that can be drained in advance if possible.
4. Change filter element.
Note！
 Don’t fill fuel into the filter before installation.

 Polluted fuel may accelerate the abrasion of hydraulic components.
 Don’t use such simple paper filter repeatedly.
5. Apply a layer of clean diesel oil on the seal surface of new filter.
FIG. 9-4 -7 Apply diesel oil
6. Install new fuel filter. When seal ring contacts with the filter base, tighten up the
filter 3/4 circle. For a filter with turning mark, the space between marks is 1/4
circle.
9.4.3 Changing Oil-water Separator
1. Turn drain valve (1) anticlockwise, which is underneath the oil-water separator.
2. Discharge water and sediment into a suitable container.
3. Switch off the drain valve（1）。
4. Remove filter （4）from the base，unscrew filter with a filter wrench.
5. Remove filter （4）from the water cup.
6. Clean the inner surface of filter base（3）and water cup（2）.
7. Remove cover from the bottom of the new filter and take out the seal from the
cover.
162
8. Install the seal into the groove of water cup（2）.

9. Assemble water cup（2） to the new filter（4） and lock it .
10. Install filter （4）onto the base（3）and lock it.
11. After three filter elements have been replaced, open the exhaust bolt on the black
main filter element, press to discharge the air in the fuel pipelines.
12. Close platform parts cover and install side plate.
FIG. 9-4 -8 Oil-water separator

1.Drain valve 2.Water cup 3. Filter base 4.Filter
Note！
 Don’t fill fuel into the oil-water separator before installation. Polluted fuel may
accelerate the abrasion of hydraulic components.
 Don’t use such simple paper filter repeatedly.
 Don’t start the engine before finishing the maintenance for fuel system.
9.4.4 Cleaning Filter Screen for Fuel Tank
1. Remove tank cap.

2. Check seal ring for damage, change it if necessary.
3. Remove screw, filter assembly, drain valve and spacer.
4. Remove the filter screen from the filter filler.
5. Cover with clean diesel filter screen and fuel tank cover, wipe it with cotton.
6. Install a whole set of filter cover, including spacer, drain valve, filter assembly
and screw.
7. Install the filter screen onto the filter filler.
8. Mount the fuel tank cap.
163
FIG. 9-4 -9 dismantle filter screen and fuel tank cap
9.5 MAINTENANCE FOR EVERY 50 HOURS
9.5.1 Check wire rope retainer and roller for parallel
 Check wire rope retainer for abrasion and normal function

 Check whether rope retainer is parallel with roller
 Check rope retainer mounting bolt for secure
 Adjust tension adjustment shaft to have the same pulling force for all springs. Change
worn spring instead of more tension.
 Change rope retaining roller, shaft, sleeve and retaining ring if gap is too large.
 Change rope retaining roller if serious abrasion is found on its surface.
9.5.2 Checking Slewing Bearing Junction Bolts
●Slewing bearing junction bolts are applied with anti-loose glue. Normally, no need to tight up,
visual inspection is enough.
●Bolts with looseness, crack or defects, should be changed. If there’s one loosened, broken or
defective slewing bearing bolt, two bolts on both left and right side should be changed
simultaneously.
● Anti-loose glue should be applied under the surface of lower part of new bolt head.
9.5.3 Checking Bolts Tightening for Key Parts of Rotary Head
Clean rotary head with clean water after work to avoid the damage of inner oil seal and other
parts caused by debris or mud attaching on the rotary head and penetrating into the internal
with the rotation, and shorten the service lift of rotary head.
Check bolt and pin shaft for looseness at initial 10 hours and after that every 50 hours.
Note：
 Risk of damaging rotary head!

164
 Don’t unscrew these bolts unless necessary, failure to comply may result in bolt
looseness caused by seal glue breakage during operation. Visual inspection is enough.
 Visually check cushion device mounting bolts for secure and tank cover
mounting bolts.
 Unscrew loosened mounting bolts, apply thread glue onto changed bolt thread
and then tighten with specified torque.
 Check rotary head housing for bolt breakage when replacing oil.
9.5.4 Checking and Changing Drive Key Bar for Kelly
Note：Check rotary head key bar for loose and damage every 50 hours.
1）Clean drive key bar to avoid mud attaching on it and weaken use performance.
2）Check Kelly drive key bar for abrasion.
3）If abrasion exceeds 8mm, change Kelly drive key bar with a new one. Any abrasion is found,
briquetting block and mounting bolts should be changed together.
FIG. 9-5-1
（1）Remove junction bolts for platen and gear.
（2）Uninstall platen and lower briquetting block in order, take out key bar.
（3）Install new key bar.
（4）Install new briquetting and platen successively.
9.5.5 Checking and Changing Rotary Head Wear Plate
Check wear plate on the rotary head sliding frame. Replace it when any one of following
occurs:
1）Crack or deformation
2）From friction surface of wear plate to fixed screw is less than 2mm,
Replace it when value a is less than 17mm.
165
Replace it when value b is less than 7mm.
FIG. 9-5-2
9.5.6 Checking Mounting Bolt of Track Shoe for Secure
 Check bolts of drill mast flange and undercarriage for secure.

 Tighten loosened bolts.
Table 9-5-1
Thread
Component Standard Maintenance interval
specification
Track shoe GB10677-89 LS201.5 50
Travel reduction gearbox GB/T5782 M20X1.5X50 250
Drive sprocket GB/T70.1 M20×75 250
GB5782 M24×160
Slewing bearing 50 hours at initial, every 2000 hours
GB5782 M24×110
9.5.7 Visual Inspection of Air Intake System
Observe engine air intake & exhaust system for black smoke or other abnormality, if found,
maintain this system.
FIG. 9-5-3 Air intake/ exhaust system

166
9.5.8 Checking Wiper
1）Check wiper every week.

2）Check wiper brush. Replace immediately if abrasion or damage is found.
9.5.9 Checking Front Window Clean Device
1）Check liquid level in windshield wash tank. If it’s low, open the cap to add detergent.
2）In winter, anti-freeze detergent for windshield should be used.
9.5.10 Changing Slewing Bearing of Servo-frame
1）Uninstall Kelly from the drilling machine, remove servo-frame from the Kelly, place the
frame as the figure.
2）Rotate thin thread (1) and nut(2) with open wrench and pneumatic wrench anticlockwise to
loosen about one circle.
3）Uninstall thin thread (1), nut (2), washer (3) and bolt (4), then put it together safely. And
remove other tightening parts successively.
4）Remove slewing bearing (5), pay attention to fixed protection of servo-frame body.
5）Erect the servo-frame and fix it.
6）Install new slewing bearing along with the level direction and servo-frame body (6) to the
correct position.
7）Fix slewing bearing (5) and servo-frame body at three places, among which is 120°, with nut
（1）, nut (2), washer (3), bolt (4).
8）Install nut (1), nut (2), washer (3), bolt (4) onto other mounting hole and tighten as required
torque.
9）Rotate slewing bearing (5) by hands to check abnormality or stuck, if not smooth, apply
grease to the oil filler.
10）Keep the used servo-frame to a designated place, or install onto the machine.
FIG. 9-5-4 Servo-frame
1. Thin nut 2. Nut 3.Washer 4.Bolt 5.Slewing bearing 6.Servo-frame body
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9.5.11 Checking Air Compressor Belt
After working for a certain time, air compressor belt will be slack, that will reduce the rotation,
resulting in bad refrigeration. Thus, it should be checked or changed regularly.
Manual inspection method: Press down with fingers (strength about 6kg) at the belt center of
drive pulley and air compressor pulley (FIG.8-5-5), deformation is about 5 to 8 mm.
FIG. 9-5-5 Air compressor belt

Tensiometer: check the air compressor belt with a tensiometer. The tension of a new belt is
637±108 N, a used belt is 441±88.2 N .
If only looseness is found, please adjust the tension device for the belt. If damage is found,
please replace with a new belt of the same specification.
Note is as the same as in chapter 9.3.14.
9.6.1 Swing Reduction Gearbox Oil Check
FIG. 9-6-1
Open oil level plug on the reduction gearbox to check gear oil which should be not lower 5mm
than the inner chamber top.
168
9.6.2 Travel Reduction Gearbox Oil Check
FIG. 9-6-2
Rotate travel reduction gearbox to the position as above figure, open reduction
gearbox oil plug to check whether there’s flowing gear oil.
9.6.3 Auxiliary Winch Reduction Gearbox Oil Check
Examin
e hole
Oil
drain
FIG. 9-6-3-1
1） Rotate the roller;

2） Aim the observation hole at upper oil discharging port, and this hole is on level
position;
3） Open oil discharging port to check whether there’s flowing gear oil.
169
FIG. 9-6-3-2
1）Turn the roller to the position as shown in figure, and open the roller plug;
2）Open the oil outlet through the roller plug to discharge clean gear oil after rotating the
roller for 180°。
3) Open the oil level plug after the roller is turned to the position as shown in above figure;
4）Inject gear oil from the oil inlet port till it flows out from the position of oil level plug.
9.6.4 Checking Hydraulic Oil Filter Element
FIG. 9-6-4 FIG. 9-6-5
FIG. 9-6-6 FIG. 9-6-7
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FIG. 9-6-8 FIG. 9-6-9

Note
■ Exhaust the inner pressure air from the oil tank through air filter top rod before
maintaining filter element.
■ Pay attention to tighten fixed bolts with proper strength to avoid over torque causing
thread damage when dismantling or mounting return filter cover plate.
■ The filter cartridge should be taken out from the oil tank when maintaining the return filter
element, so as to avoid impurity mixing into the hydraulic tank.
■ Check seal rings for damage, replace immediately if found.
■ When installing filter elements, seal rings should be check to avoid dropping or loss.
■ Return filter element and filter cartridge should be checked at the same time. If much
visible scrap iron and copper, please check hydraulic oil pump, hydraulic motor and other
hydraulic components for damage or abrasion at once.
Clean oil tank air filter, according to FIG. 9-6-5 , dismantle filter element, blow it from inner to
outer to clean dust and impurity.
Return filter element clean, according to FIG. 9-6-7, dismantle filter cartridge, take out the
filter element, blow it from inner to outer to clean impurity.
Pilot filter element, according to FIG. 9-6-9, take out pilot filter element, blow it from inner to
outer to clean impurity.
171
9.6.5 Draining Water and Sediment in Hydraulic Oil Tank
FIG. 9-6-10
1) Unscrew drain valve cap.

2) Tighten the water pipe onto the drain valve till impurity and water flows from
the bottom of the oil tank.
3) After drain water and impurity from the bottom, clean hydraulic oil will flow
out from the water pipe;
4) After drainage, install water pipe and drain valve cap.
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9.7 MAINTENANCE FOR INITIAL 250 HOURS OF OPERATION
9.7.1 Changing Gear Oil for Main Winch Reduction Gearbox
Note！
■ Note is as the same as in the chapter 9.3.14.
FIG. 9-7-1 Main winch reduction gearbox

1) Remove connection hose at oil level sight glass and oil drain pipe, discharge gear oil from
reduction gearbox;
2) Disassemble the joint on the oil outlet, and clean iron scurf and impurity；
3）Reinstall oil drain pipe and remove exhaust valve, and then inject new gear oil;
4）Stop oil injection till gear oil flows out from the sightglass of oil level;
5）Reinstall the connection hose of sight glass and exhaust valve;
173
9.7.2 Change Gear Oil for Rotary Head Reduction Gearbox
FIG. 9-7-2 Main Winch Reduction Gearbox

1）Remove oil level plug or open sight glass;
2) Open drain pipe plug to drain gear oil, plug it after finishing;
3) Add gear oil from reduction gearbox oil filler or oil pot filler till gear oil flows out from
sight glass or oil level plug;
4) Install sight glass and oil level plug.
9.7.3 Changing Gear Oil for Swing Reduction Gearbox
FIG. 9-7-3
1）Remove oil filler plug;
2）Remove the plug of oil drain pipe to drain gear oil;
3）Lift up oil pipe to the height of oil filler;
4） Inject gear oil from oil filler till filling-up.
5）After plugging the oil pipe, lower and put it back to the original position.
174
9.7.4 Changing Gear Oil for Travel Reduction Gearbox
FIG. 9-7-4
1） Rotate the reduction gearbox to the position as above figure;
2） Remove the plug of observation hole;
3） Remove the drain plug to drain gear oil;
4） Rotate travel reduction gearbox to place the observation plug on the highest position and
drain plug on the level position;
5） Inject gear oil from the observation hole till gear oil flows out from the oil drain hole.
9.7.5 Changing Gear Oil for Auxiliary Winch Reduction Gearbox
FIG. 9-7-5-1
1） Turn roller;
2） Aim observation hole at oil drain hole and oil filler;
3） Remove the plug of oil filler and oil drain hole successively;
4）Drain out gear oil in the reduction gearbox and plug on the oil drain hole;
6）After proper capacity of gear oil injected, plug on the oil filler.
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图 9-7-5-1
1）Turn the roller to the position as shown in figure, and open the roller plug;
2）Open the oil outlet through the roller plug to discharge clean gear oil after rotating the
roller for 180°。
3) Open the oil level plug after the roller is turned to the position as shown in above figure;
4）Inject gear oil from the oil inlet port till it flows out from the position of oil level plug.
9.7.6 Changing Gear Oil for Rotary Head Gearbox
Warning：Pay attention to avoid personal injury caused by hot oil spraying when unscrewing
the plug.
Note：Change gear oil as possible as it cools down after work.
1. Prepare an oil container.

2. Connect oil drain hole with oil container (prepare an oil pipe with suitable length and
size in advance).
3. Raise the mast to incline rotary head to a certain angle.
4. Drain out the used oil.
5. When changing oil, the environment temperature is too low. Heat up some new oil (to
50℃) before adding, and wash the reduction gearbox inner casing with it.
Note！
 Risk of damaging reduction gearbox！

 Gasoline is not allowed to use, wash the reduction gearbox with diesel. Drain out the
detergent completely.
6. Unscrew air plug on the upper of reduction gearbox to inject lubricating oil to the
center line of sight glass.
7. Check oil level.
8. Tighten the air plug.
176
9.8.1 Checking and Changing Servo-frame Wear Plate
Check servo-frame wear plate for abrasion at 250 hours. After initial check, determine the
second inspection according the abrasion. Replace it if serious damage is found.
1）Uninstall Kelly from the machine.
2）Lower the servo-frame with a hoist device.
3）Check wear plate, replace it if serious damage is found. The replacement criteria are as
below:
Wear plate on the left and right, when abrasion of value a is less than 14mm, replace it;
Wear plate on the front and rear, when abrasion of value b is more than 80mm, replace it.
FIG. 9-8-1 Gap of Servo-frame Wear Plate
9.8.2 Rotary Head Gear Oil Sample and Inspection
 Check oil color whether it’s black.
If it’s black, indicates that working temperature over than 100℃（212°F）, which may result in
gear oil quick-wear and loss of lubrication, thus, oil replacement interval should be shortened
properly.
 Check oil for water and sediment.

 If any sediment or water is found, the seal ring should be checked and replaced if
necessary.
 Check oil for solid substance.（grinding scrap）.
The maximum content of solid substance in each reduction gearbox should not be over than
0.15% of the total capacity. The size of solid particle can’t excess 5μm (according to
DIN51592). No matter how much the quantity exceed, the rotary head should be removed to
check.
177
9.8.3 Checking and Changing Hoses
Open and lift up the engine hood.
1. Check hoses for leakage caused by crack or other defects, any soften or loosen near
the clamp.
2. Change hoses with cracks or soften one, and tighten loosened clamp.
3. Unscrew the pressure cap of cooling system slowly to release pressure, and then
remove the cap.
4. Drain coolant in the cooling system to let the liquid level lower than the hose
position.
5. Loosen hose clamp and disconnect the damaged hose.
6. Replace damaged hoses with new ones.
7. Replace and tighten the hose clamp.
8. Fill enough coolant into the cooling system.
9. Lock engine hood.
9.8.4 Replacing Engine Oil and Filter –see chapter 9.4.4
9.8.5 Cleaning Air Conditioner Condenser
After the air conditioner is used for a certain time, regularly check condenser fin for impurity,
such as mud, dust and leaves. If found, wash the fin with compressed air or water.
Note：1. When washing with compressed air and water, protective goggles, face shield and
safety shoes should be put on.
2. To protect cooling fin, keep it with the compressed air nozzle for a certain distance.
Because damaged cooling fin may result in leakage or overheating. On dusty working area, the
cooling fin should be checked every day instead of maintenance interval.
FIG. 9-8-2 Condenser Installation Position
178
9.9.1 Checking Wire Rope Sheave
Note：Risk of broken wire rope！

●Sluggish sliding of wire rope sheave may result in excessive abrasion.
●If the problem still exist after lubrication, the sheave frame and sheave should be repaired or
changed.
9.9.2 Changing Main Winch Reduction Gear Oil- see 9.7.1
9.9.3 Replacing Rotary Head Gearbox Gear Oil- see 9.7.2
9.9.4 Changing Engine Oil and Filter-see 9.4.1
9.9.5 Changing Fuel Filter-see 9.4.2
9.9.6 Changing Oil-Water Separator Filter –see 9.4.3
9.9.7 Maintenance of Engine Breather
FIG. 9-9-1 Ventilation Device of Crankcase
9.9.8 Checking and Changing Air Conditioner Inner and Outer Air Filter Element
1. Air conditioner inner and outer filter element is installed on the inner circulation air inlet
port and cab outer side respectively (near the door) to clean air; If clogged, air flow reduce or
no air flow.
2. Clean inner and outer filter element with compressed air, if filter attached by oil or it’s dirty,
179
wash it with a neutral lotion. Dry it after washing, and then use. If it’s still dirty after washing,
please replace it.
Note：Normal maintenance interval is 500 hours, if used in dusty area, the maintenance interval
should be shortened.
FIG. 9-9-2 Mounting position of air conditioner inner and outer filter element
180
9.10.1 Changing Air Filter, Return Filter Element, Pilot Filter Element see –chapter 9.6.4
9.10.2 Changing Swing Reduction Gearbox Oil see-chapter 9.7.3
8.10.3 Changing Travel Reduction Gearbox Oil see–chapter 9.7.4
9.10.4 Changing Auxiliary Winch Reduction Gearbox Oil see–chapter 9.7.5
9.10.5 Changing Rotary Head Reduction Gearbox Oil see –chapter 9.7.6
9.10.6 Hydraulic Hoses Inspection
Note！
 If hydraulic pump, pipes and joints are damaged because of mechanical effect, heat
effect or other effect, that should be changed.
 Keep pipes, tubes and hoses a long enough distance away from hot engine parts
(exhaust system), and make sure there’s no friction.
 Keep hydraulic hose stored in a dry place to avoid sunlight and ultraviolet rays.
Hydraulic tubes should be checked by after-sale engineer at least every year. Regularly check
hoses for leakage. During visual inspection, even if only found tiny damage, hoses should be
changed immediately.
Possible damage of hoses:
 Sliding joint in the hose.

 Outer layer damage, cut and abrasion (any exposure of enhancement layer)
 Hose harden, chap and burn.
 Crack, damage and serious corrosion on joints.
 Leakage of joints or hoses.
 Hoses twine, broken, flattening and twist.
 Hoses outer layer deformation and soft.
Other items for daily inspection:

Tighten, repair or change following as requirements.
 Oil leakage
 Clogging
 Pipe clamp, cover and protective objects.
181
 Over storage time and service life.
9.10.7 Hydraulic Hoses Replacement
Even if hoses are not damaged, it still need to be changed after worked for maximum 6 years,
of which including maximum 2 years storage.
Note for changing hydraulic hoses:
 On the basis of date of production marked on the hoses to calculate working hours
and storage time.
 When dismantling pipe joint, new sleeve and pipe joint should be replaced.
 Before installation, components in the hydraulic pipeline should be cleaned first.
 Pay attention to protect hose end to avoid impurity.
9.10.8 Cleanness Control for Hydraulic System
Note！
 If oil is dirty, the hydraulic components will be abraded quicker, resulting in the valve
spool stuck and clogged resistance hole.
 The cleanness of hydraulic oil should be under level NAS9.
Following points should be observed to keep the hydraulic system oil clean.
 Clean hydraulic oil tank before filling oil.

 Clean the surrounding of oil filler and fill oil with fine filter. Install the oil cap at time
and keep the oil tank is sealed.
 After initial 500 hours of operation, clean or change filter element and filter hydraulic
oil. After that clean or change filter element and hydraulic oil every 500 to 1000 hours
of operation. If the drilling machine has been stored for over than one year, the
hydraulic oil should be changed or filtered.
 If the drilling machine is stopped for a long time, air with water will enter into the oil
tank via air filter, and bring water into hydraulic oil, emulsifying oil and denaturing it,
thus, it will take a while to heat up oil eliminating water and then operate the
machine.
9.10.9 Temperature Control of Hydraulic Oil
Hydraulic oil should be not over than 80℃ normally, no more than 90℃ at most during
operation.
 If oil is too hot, the service life of hydraulic components will be shortened by more
abrasion, increasing inner leakage caused by less oil viscosity and worse lubrication.
182
Besides, the aging of seal parts will be accelerated and oil quality will be easier to go
bad.
 If oil is too low, oil viscosity will be increased, the loss of pressure will be more, and
oil will flow slowly affecting the flow of resistance hole and extending the time of
motion, thus, the machine will be sluggish, even will not able to work.
 When oil temperature is over then 80℃, stop operation to idle the machine cooling
down. When starting the machine at -20℃, power on and idle the rotary head for a
while, then operate it after the oil is heated up.
Note for Hydraulic System Maintenance：
 Pressure and flow parameter of hydraulic components have been set before machine
delivered from the factory, forbid to change that. If adjustment is necessary,
professional personnel are needed for that.
 After initial start-up or disassembly for repair, air will exist in the hydraulic pipeline,
power on the machine to idle and make cylinders to move within the maximum stroke
repeatedly to exhaust air, and loosen pipe joint if necessary.
 When the reduction gearbox is rotating, brake it with the balance valve instead of
itself. Failure to comply may result in the burn of reduction gearbox friction plate and
lead to the damage of reduction gearbox.
 Forbid to step on hoses and materials, failure to comply may result in hose joints
damage or looseness, hose crack and lead to oil leakage.
 When replacing hoses, figure out the type and load capacity of hoses. Don’t replace
low-pressure hoses with high-pressure hoses to prevent hose breakage. Don’t use
hoses with small diameter with the larger ones, failure to comply may increase
pressure loss for the pipeline, reducing the work efficiency of drilling machine.
 Hoses and joints on the rotary drilling rig are sealed by O-ring. Press plate, joints and
nuts should be fastened, as looseness will result in the damage of seal ring and oil
leakage. Check joints and fixed screw for looseness regularly.
9.10.10 Use of Battery
Warning！
 Vapor and explosion of battery may result in personal injury.

 Battery may release flammable vapor which is easy to cause explosion.
 Electrolyte is a kind of acidoid, which may result in personal injury when it contacts
with skin or eyes.
 Avoid spark near to battery, as that will cause explosion.
 Don’t allow jumping cable end touching mutually or with engine, as for incorrect
cable connection may result in explosion.
183
 Protective goggles should be put on when working on the battery.

 Cleaning battery
Clean battery surface with a clean cotton and keep wire rod clean, apply Vaseline on it, then
install the cap.
 Battery recycle
Please ensure the battery is recycled. Normally, used battery should be returned to one
of following places:
—Battery manufacturer
—Authorized battery collecting field
—Recycling plant
 Tighten battery clamp

Tighten battery clamp to prevent battery moving when machine is running.
 Changing battery, battery cable or battery cut-off switch change
1） Turn engine starting switch to OFF position, as below:
FIG. 9-10-1
2） Turn battery cathode switch to OFF position (cut-off) and take out the key, as
below：
FIG. 9-10-2
3）Disconnect cathode cable on the battery.
4）Disconnect anode cable on the battery.
5）Disconnect battery cable on the battery cathode switch, repair or change battery if necessary.
6）Connect battery cable on the battery cathode switch.
7）Connect anode cable of battery.
184
8）Connect cathode cable of battery.

9）Insert the cathode switch key to turn battery cathode switch to ON (connect) position, as
below:
FIG. 9-10-3
9.10.11 Checking and Changing Air Filter
Note：
If air filter element is clogged by dust, that will reduce the air inlet quality and engine
performance, even worse scrap engine and shorten the service life. Thus, the maintenance for
filter element is very important, please don’t ignore that.
FIG. 9-10-4 Air filter

Air filter is installed on the top of cab, filtering air with main filter element and safety filter
element.
1. Unscrew the end buckle of filter, and then pull out main filter element slowly, don’t
pull out the safety filter element again.
2. Check main filter element for breakage, if it’s complete, normally, blow dust for the
new filter element for 3 to 5 times. (determine according to working condition and
environment). Blow the filter element with low-pressure compressed air from inner to
outer, or remove the dust in the filter element by shaking or slapping lightly to avoid
the damage.
3. After dust blowing times for the main filter element is enough, please change main
filter element and safety filter element.
4. Reinstall filter element to correct place.
185
9.11 Maintenance for Every 2000 Hours
9.11.1 Changing Hydraulic Oil
Hydraulic oil is the work media of hydraulic system. Hydraulic oil with good quality can
improve the reliability of hydraulic system and extend the service life of hydraulic
components.
Note！
■ Before changing hydraulic oil, release the pressure air in the tank through air filter
completely;
■ Before changing hydraulic oil, prepare a container with enough capacity to place used
hydraulic oil avoiding environment pollution;
■ It’s forbidden to mix hydraulic oil of different types and models.
■ When oil temperature of hydraulic system is above 60℃，VG68 hydraulic oil should
be adopted;
■ When oil temperature of hydraulic system is below 60℃, a lower type hydraulic oil
should be adopted; When the environment temperature is lower than -25°, hydraulic
oil should be preheated.
■ Before adding new hydraulic oil, check the cleanness of hydraulic tank, wash it if
necessary.
■ Hydraulic oil return filter element should be washed prior to adding new hydraulic oil.
■ Effective filtering measurements should be taken to avoid oil pollution prior to adding
new hydraulic oil.
■ After adding new hydraulic oil, release air for hydraulic pumps before start-up, details
see chapter 9.1.2.5.
9.12 Maintenance for Every Two Years or 3000 Hours
9.12.1 Changing Coolant
After engine is used for two years or 3000 hours, the efficiency of coolant (additive) may
lose completely, thus, coolant should be changed for the protection of engine service life. The
replacement is as below:
1. Start the engine to heat the coolant to 80℃ and stop it.
2. After the coolant temperature reduce to 50℃,（water temperature indicates on the monitor）,
and then open radiator pressure cover plate and pressure cap.
3. Place a container under the radiator, unscrew the water drain plug on the bottom of radiator
water tank and pull it out slowly to enable coolant flowing into the container.
Note! Avoid being sprayed by hot coolant.
186
FIG. 9-12-1 Radiator pressure cover plate, pressure cap and water drain plug
4. Tighten the plug after draining coolant.
5. Add coolant into radiator, please refer to “9.3.14 Checking Coolant Level”
6. After filling, please install pressure cap and cover plate.
9.13 Machine Storage
9.13.1 Cleaning Machine
After work or before storage, the machine should be cleaned completely and batteries should
be disassembled to prevent short circuit.
Flush the machine with clean water. If necessary, special detergent should be used to clean dirt,
but acid or alkaline solution is allowed to use to avoid corrosion on the machine surface.
When washing with high pressure water, pay attention to electrical and hydraulic parts to avoid
the components damage and looseness of cable joints.
When cleaning the drilling rig in the cold environment, dry it immediately to prevent surface
freeze.
9.13.2 Storing Machine
9.13.2.1 Maintenance before Storing Machine
Note：
If parked for a long time, the machine should be operated at least once every month.
1）Check machine, repair abraded or damaged parts. Replace with a new one if necessary.
2）Clean air filter element.
3）Retract hydraulic cylinders. Apply lubricating grease onto exposed piston rod.
4）Lubricate all lubricating points.
5）Park the machine on firm level ground, cushion the crawler with thick steel plate or wooden
plate.
6）Clean the drilling rig. When parking in winter, clean each part, especially the track chain.
7）Uninstall the battery and keep it in a safe dry place after battery. If that’s not removed,
187
disconnect the battery cathode cable from the terminal.

8）Use antifreeze in winter, or drain out coolant. The coolant used by the drilling machine is the
one with freezing point of -35℃. If the environment temperature is lower than -35℃, drain out
the coolant. After the cooling system
is drained out, set a warning sign with letters of “No water in radiator”on a notable place.
9）Loosen the belt for A.C.generator and cooling fan.
10）Apply paint on necessary places of the machine to avoid rust, such as, apply grease to
protect telescopic beam surface and mast track.
11）Keep the machine in a safe dry place. If it’s stored outdoor, water-proof cover should be
placed.
12）During storage, regularly clean gear ring and drive sprocket surface and check for rust,
grease it if necessary.
9.13.2.2 Maintenance after Storage
Note：
Start the machine in a ventilation space.
If the machine is stored for a long time, the oil layer on the sliding surface may be damaged.
It’s necessary to travel, swing, or operate the hydraulic system for two to three times to
lubricate the sliding surface.
1）Lubricating grease should be removed if the hydraulic cylinder piston rod is applied before
storage.
2）Adjust belt tension for A.C.generator and fan.
3）Check all hoses and the connection.
4）Install new fuel filter, change engine oil filter and inject oil into engine.
5）Fill up the fuel tank and exhaust air for the fuel system.
6）Check all liquid level and oil quality.
7）Start engine and run it at half speed for a few minutes before full loaded.
8）Operate all hydraulic function circularly for several times.
Explanation：Following procedures should be done after the machine is kept for a long time.
1）Check all hoses and the connection.
2）Preheat the engine.
3）Switch off the engine.
4）Install a new fuel filter. Change engine oil filter and inject oil into the engine.
9.13.3 Daily Maintenance
Check oil tank capacity and oil quality.

Check oil leakage.
Check wire ropes of main winch and auxiliary winch for damage, reliable connection and
enough strength of rope retainer.
Check swivel joint of wire rope for flexibility and inner lubricating grease for pollution.
Check steel structure for crack, rust, sealing-off and other damage.
188
Tighten loosened hoses and bolts.

Check lubricating parts of moving mechanism, large rotary surface, such as slewing bearing of
upper-carriage, on which lubricating grease should be applied enough.
Check main and auxiliary wire rope for lubrication, on which every strand should be greased.
Check three surfaces of mast track for full lubricating grease.
Check circuit relay for ageing, wires for damage.
Check key bar of Kelly for open welding and crack.
Check servo-frame slewing bearing for lubricating grease.
Check cooling liquid level and engine oil level.
Check fuel oil-water separator for water and sediment, and drain out that.
Check intake pipe for abrasion, pipe damage and loosened clamp.
Check cooling fan for crack, bend and rivet looseness.
Check crankshaft breathing pipe for dust, scrap or ice (especially in cold days).
9.13.4 Maintenance for a Long-term Storage
When stored for a long time, following procedures for the machine maintenance should be
observed:
Drain out coolant in cold days.（Skip this step if antifreeze is filled.）
Clean off the surface of the machine, such as mud, dust and oil.
Do an inspection before storage.
Drain out oil in the tank to avoid oil deterioration.
Remove the battery by disconnecting cathode and anode successively.
Cover muffler, air filter and electrical parts with PCV film to prevent water or dust.
Store the machine in a ventilated place to avoid moisture.
Charge the battery once every month.
189
10 TRANSPORTATION
10.1 Transportation of the Whole Machine
SWDM240 rotary drilling rig is available for transporting in whole machine, which refers to a
suitable trailer loaded with this machine still meets the requirements of the related road
regulations. The total weight of this equipment is about 59 ton excluding kelly bar and drill
tools.
See Fig 9-1 for machine shipping dimension, the transport width is 3000mm. Pay attention to
disassemble drill tool, kelly bar, pressurized cylinder and fold mast upper and lower end.
Fig 9-1 MACHINE TRANSPORT STATUS A

Table 10-1 Transport Status A Parameter
Item Unit Data
Transport length mm 16310
Transport width mm 3000
Transport height mm 3330
Track length mm 5755
Width of track shoe mm 800
Transport weight t 66
10.1.1 Machine Loading and Unloading
 Choose a flat ground.
 Lock the trailer wheels before loading.
 Trailer ramp should be within 15 degree; and have enough length, width and strength.
 Machine should be parked at the position where can move to loading slope directly;
190
drive wheel should be at the back of machine and backward running to trailer.
 Keep drill rig balance when passing through the joint between the ramp and trailer; keep
rotary head above ground by pushing up boom cylinders;
 Machine should be parked on the center of the trailer as possible as it could be.
10.1.2 Tying Down the Machine
Push hydraulic control lever to “LOCK”: position;
Turn ignition key to “OFF” position and pull key out from engine;
Pin upper carriage with undercarriage;

Lock doors;
Put wedges under crawlers, tie drill rig with cables.
10.2 DISASSEMBLED TRANSPORTATION
Drilling rig can be broken down for small trailer transportation. Dismount kelly bar, drill
tool, rotary head, drill mast, counterweight etc. Drill mast can be broken down into three
sections.
191
10.2.1 Rotary Head Parameter
FIG.10-3 Transport status-rotary head

Table 10-2 Transport status-Rotary head
Item Unit Data
192
10.2.2 Counterweight Parameter
FIG. 10-4 Transport status-counterweight

Table 10-3 Transport status-counterweight parameter
Item Unit Data
10.2.3 Kelly Bar Parameter
FIG. 10-5 Transport status-Kelly bar

Table 10-4 Transport status- parameter of Kelly bar
Item Unit Data
Transport weight t 10.2
193
Precautions for lifting kelly bar（as figure 6-8）

During the hoisting process of the whole kelly bar, staff must cooperate with operators to
observe and command.
The allowed lifting capacity of the hoisting machine should be larger than the one of the
kelly bar.
The rated load of the rope, used for lifting, should be large than the weight of the kelly
bar.
Select two steel ropes, with different length, for lifting, fix it on two ends of the kelly
respectively. The fixed point should be close to two ends, but not close to the center of the
kelly bar. It’s suggested that the fixed point should be at the position between 1/4 and 3/4 of the
total length.
It’s forbidden to lift the kelly bar with one steel rope.
FIG.10-6 Lifting of Kelly Bar
194
11 TROUBLESHOOTING
11.1 COMMON FAILURES AND SOLUTIONS
Failure Cause Solution
Engine does not Battery failure or low battery Replace or Charge

Starter damaged
start or difficult to Replace
Poor Connection/short circuit
start Check and Repair
See engine manual for other malfunction
Joysticks Air mixed in hydraulic system Check air leakage and vent
loose/slow action it
Hyd. oil temperature too low, too sticky Pre-heating engine
Hydraulic oil ageing Replace oil
System low pressure Check hydraulic system
Cylinder no Pilot valve failure Repair
working or work Cylinder oil seal damaged Replace
slowly Overflow valve failure Repair
Abnormal sound in Lubricating oil dirty and ageing Filtering and Replace
rotary head Lubricating oil level too low Filling lubricant

Gear damage, worn out
meshing Replace
Bearing worn out
Replace
Gauges damaged
No signal from Repair or Replace
Fuse Burnt
gauges Replace
Poor connection/short circuit
Repair
195
Swing platform no Pilot valve failure Repair and contract with
swing or slow Changing valve and brake valve failure supplier
swing Hydraulic motor failure
Swing reducer failure
Swing bearing failure

Add Nitrogen
Engine stops, No pressure or low pressure in box-type
Check valve port
boom down no accumulator;
work or work Check valve oil leakage;
slowly
One side of Pilot valve failure Repair
crawlers not Changing valve and brake valve failure Contact with supplier
moving/ moving Oil seal for center joint damaged Replace oil seal
slowly Hydraulic motor failure Contact with supplier
Travel reductor failure
Temperature of Impurity in radiator surface 1.Clean
hydraulic oil rise Hyd. Components worn out, low 2.Contact with supplier
too quickly or too efficiency 3.Drill too fast in heavy
high Overflow valve on/off over frequent load, reduces drill speed
Abnormal sound, Daily check and treat it
vibration or smell
196
11.2 ACCIDENTS AND SOLUTIONS DURING OPERATION
Accident Cause Solution
Hole Drilling tools collide with sleeves Careful management and
collapse and protective walls. construction.
Wrong hole boring method. Choose an appropriate hole boring
method.
Sleeves are not embedded into Compact the soil around the
compact soil. sleeves
Slurry is not suit for soil condition. Adjust the slurry properties
according to stratum condition.
Hole The drilling rig is not leveled and Adjust level and vertical
inclined Kelly bar is not vertical.
Serious abrasion of driving sleeve. Repair
Tilting rock surface. Gentle press and slow drill
Drill bit is Drill tools lifting and falling speed’s On one hand, the geographical
being too fast and produce sucking condition should be known all –
buried in pressure and activation pressure. round to avoid accidents. On the
the hole The deposit is very thick, the speed other hand, after the accident
is too fast so that the tools are stunk. happens, applicable measures shall
Slurry is not suitable. be taken.
197
12 MANUFACTURER INFORMATION
Company: SUNWARD INTELLIGENT EQUIPMENT CO., LTD.
Trade mark：
Add: Sunward Industrial Park, No.1335 Liangtang Road (E),Xingsha, Changsha, Hunan, China
Sales hotline：400-887-6230; Service hotline：400-887-8230
Maintenance point: Our office in various provinces and cities of China
Distributor information：
Distributor information
Distributor :
Add:
Tel:
Fax:
Email:
Contact:
Remark:
198
Overseas subsidiary information
No. Subsidiary Name Email Address
[email protected] D-09-02 MENARA MITRALAND

SUNWARD INTELLIGENT NO.13A,JALAN PJU 5/1.KOTA
1
(M) SDN. BHD. DAMANSARA,PJU 5,47810,PETALING
JAYA SELANGOR.
[email protected] lo 33, biet thu 1, ban dao linh dam,
Công ty TNHH SUNWARD
2 phuong hoanh liet, quan hoang mai,
Việt Nam
hanoi, vietnam
SUNWARD EUROPE [email protected] Nijverheidspark 3, 3580 Beringen,
3
HEAVY INDUSTRY NV Belgium
PT.SUNWARD INDONESIA [email protected] JLN. PROF.LATIMENTEN NO 28,
4
MACHINERY GROGOL, JAKARTA BARAT -14440
[email protected]
5 SUNWARD USA CORP 2710 geesling rd,denton tx,76208
SUNWARD [email protected] No.18 ,St 110B,Ideal Garden Home
6 INTELLIGENT(CAMBODIA) City,Sangkat Teuk Thla,Khan Sen
CO.,LTD Sok,Phnom Penh,Cambodia
[email protected]
123001, г. Москва, ул.Большая садовая,
ООО "САНВАРД РУС" д.5, оф. 219А/
7
/SUNWARD RUS LLC / 123001, Moscow, Bolshaya Sadovaya
Street, No. 5, office 219A/
[email protected] 경기도 용인시 기흥구 구갈로 64,
603 실 Zip: 16972
SUNWARD KOREA CO.,
8 Add: Rm603, No.64 Gugal-ro,
LTD.
Giheung-gu, Yongin-si 16972,
Gyeonggi-do, South Korea
SUNWARD LAOS TRADE laos@sunward,cc Donnoune, xaythany District, vientiane
9
CO., LTD. Laos
SUNWARD [email protected]
Arwan Building,6th Floor,1339 Pracharat
10 EQUIPMENT(THAILAND)
1 Road,Wongsawang,Bangsue,Bangkok.
CO.,LTD
SUNWARD PHILIPPINES [email protected] 218 D. AQUINO ST. BRGY. 62 WEST
11
INC. GRACE PARK CALOOCAN CITY
PT. SUNWARD INDONESIA [email protected]
12
EQUIPMENT
SUNWARD SOURTH [email protected]
13
AFRICA
199

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ROTARY DRILLING RIG

SUNWARD INTELLIGENT EQUIPMENT CO., LTD.

Sunward Intelligent Equipment Co., Ltd.

1 SAFETY RULES ............................................................................................... 1

4.4 LUFFING MECHANISM AND DRILL MAST ......................................................... 22

8.1 KELLY ....................................................................................................................... 112

1.1 SAFETY PRECAUTION

Danger---indicates an imminently hazardous situation which, if not avoided, will result in

Warning---indicates a potentially hazardous situation which, if not avoided, could result in

Attention---indicates a potentially hazardous situation which, if not avoided, may result in

1.2 PREPARATION FOR EMERGENCY

1.3 WEARING SAFETY EQUIPMENT

◆Only get up/down the machine by pedal or armrest;

◆Never enter or leave the machine in its working or moving；

1.5 ADJUSTMENT OF OPERATOR’S SEAT

1.6 CORRECT START-UP OF ENGINE

1.7 BEFORE OPERATING MACHINE

Clean all obstacles in machine running way;

Check controller and safety devices are in good condition;

Make sure to follow all safety rules.

Operator must sit in cab seat to control machine;

Please do not drive machine near cliff, collapsing range;

It is better move along longitudinal slope and prevent horizontal direction;

After hole forming, fill it or cover and mark it in time.

Enough light should be provided in moving machine.

1.12 ALLOWABLE TRAVELING GRADE OF SLOPE

1.13 ALLOWABLE WORK GRADE OF SLOPE

1.14 PARKING MACHINE SAFELY

WARNING!! Never load in machine when it is in park mode.

1.15 WINCH WORK

1.16 SAFE MAINTENANCE

Before maintenance, cut off power supply and release

Technical staff can hear and reply operator clearly;

In maintenance, enough light must be provided in site.

Wear protective gloves in maintenance.

1.17 KEEPING MACHINE CLEAN

1.19 PREVENTING INHALATION OF ASBESTOS DUST

1.20 BEWARE HIGH PRESSURE LIQUID

1.22 AVOIDING HEATING FLAMMABLE LIQUID PIPES

1.23 PAINT REMOVING BEFORE WELDING OR HEATING

1.26 FIRE PREVENTION

Prevent fire caused by leakages of fuel, hydraulic oil and lubricant.

Do not twist or punch any high-pressured pipe.

Do not use any twisted or damaged pipe or hose.

Check connectors before every shift or after 8 hours operation.

Clean out flammable materials

1.27 SAFETY FACILITIES

1.28 PROTECTION AGAINST NOISE

2.1 MODEL DEFINITION

2.2 APPLICABLE RANGE

3.1 MACHINE STRUCTURE

3.2 MAIN TECHNICAL DATA

Item Unit Parameter

Friction Kelly m 69（5 sections）

Crowd cylinder Max. lifting force KN 240

Max. stroke mm 5000

Max. line pull KN 220

Track shoe width mm 800

4 MAIN STRUCTURAL FEATURES

8）Working environment: -25℃～65℃ 20％～90％（Relative humidity）