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Rotary Drilling Rig
SR200C
Safety, Operation & Maintenance Manual

SR200C (SY) Rotary Drilling Rig
SR200C (SY)
Rotary Drilling Rig
Safety, Operation & Maintenance Manual
WARNING
Read and follow the safety precautions and instruction in this manual and on the machine
decals. Failure to do can cause serious injury, death or property damage. Keep this manual
with the machine for reading and future reference.
SR200C (SY) Rotary Drilling Rig
Sany Group
Sany Heavy Machinery Co., Ltd,
Sany Industry Park,
liliu Road, Nankou,

Changping District, Beijing, China 102202
Email: crd@sany.com.cn
http://www.sanyhi.com
© 2013 by Sany Group. All rights reserved. No part of this publication may be repro-
duced, used, distributed or disclosed except during normal operation of the machine as
described herein. All information included within this publication was accurate at the
time of publication. Product improvements, revisions, etc., may result in differences be-
tween your machine and what is presented here. Sany Group assumes no liability. For
more information, contact Sany Group.
Important Safety Information
Most accidents that involve product operation, maintenance and repair are caused by failure to
observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially
hazardous situation before an accident occurs. A person must be alert to potential hazards. This
person should also have the necessary traning, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and could
result in injury or death.
Do not operate any lubrication, maintenance or repair on this product, until you have read and
understood the operation, lubrication, maintenance an d repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard
warnings are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the Safety Alert Symbol by a Signal Word such as DANGER,
WARNING, CAUTION OR NOTICE.
DANGER
Indicates an imminent hazard which, if not avoided, will result in serious injury or
death.
WARNING
Indicates a potentially hazardous situation which, if not avoided, could result in injury or pos-
sibly death.
CAUTION
Indicates a possible potential hazardous situation which, if not avoided, could result in minor
or major injury.
NOTICE
Indicates a situation which can cause damage to the machine, personal property and/or the
environment, or cause the equipment to operate improperly.
SANY cannot anticipate every possible circumstance that might involve a potential hazard. The warn-
ings in this manual and on the product are, therefore, not all inclusive.
Exemption Clauses
Specific Declaration
Rotary drilling rig is a foundation machine used for drilling piles. Any other use or any operation
beyond the specified working range is not authorized use. Sany expressly bears no liability for
any consequence due to any unauthorized use.
Information in this manual is used to guide qualified operators to operate and maintain rotary drill-
ing rigs correctly. Sany expressly bears no liability for any consequence caused by any operation
without observing the information in this manual.
It is forbidden to convert the rotary drilling rig without authorization. Sany expressly bears no li-
ability for any consequence. When crack or electrical malfunction on the rotary drilling rig occurs,
please contact the supplier, and don’t conduct welding or make changes without permission, or
else, for any consequence due to such contravention, Sany shall not bear any liability.
Use genuine spare parts from Sany. Sany expressly bears no liability for any machine damage or
accident due to the use of untested or unauthorized spare parts or tools.
Operate and maintain parts (such as engine, a/c) on the rotary drilling rig, and observe related
regulations on Users’ guide supplied from their manufacturer.
Sany expressly bears no liability for any machine failure or damage due to force majeure of natu-
ral disasters (earthquake, typhoon) and wars.
Sany cannot predict every circumstance that might involve a potential hazard in operation or
maintenance. Operators and owners should highly attach importance to safety. Local specific
safety rules of the countries may be stricter. If they differ from the regulations on this manual, ob-
serve the stricter one.
Obligations of Sany
• Offer qualified products along with correct information.
• Abide by after-sales service commitment and keep a record for all maintenance work and repair
work.
• Provide training for rig operators and service persons as required.
Obligations of Owners or Authorized Persons
• Only trained personnel who fully understand the Parts Book and Safety, Operation and Mainte-
nance Manual are allowed to operate and service the rotary drilling rig.
• Ensure the operation and maintenance personnel are qualified for the job and know their re-
sponsibilities.
• Periodically check related personnel’s safety awareness during working.
• Should any fault threatening safety occurs, shut down the rotary drilling rig immediately.
• Sany service personnel have the right to carry out safety inspection to the rotary drilling rig
when required.
• Besides check items regulated by Sany, observe local laws and regulations to check the rotary
drilling rig.
• Ensure timely maintenance and repair of the rotary drilling rig.
• Make a detailed plan for the proper use of the rotary drilling rig.
Obligations of all working personnel
• If there is any abnormal symptom which may cause abnormal working of the rotary drilling rig or
potential hazard, report to your leader. If possible, correct the abnormalities in time.
• All personnel working around the rotary drilling rig must observe all warning signals and take
care of their own and others’ safety.
• All personnel should know their working tasks and procedures.
• Be aware of potential danger, such as high voltage, unrelated personnel or soft ground. If there
is potential danger, report to the operators and signalmen immediately.
Obligations of managers
• The operator must have been trained and fully understand the provision of Safety, Operation
and Maintenance Manual. The operator must be healthy and licensed. Otherwise, he/she is not
allowed to operate the rotary drilling rig.
• Ensure the operators have good judgment ability, cooperation awareness and psychological
quality. Otherwise, he/she is not allowed to operate the rotary drilling rig.
• Ensure the signal person has good visibility and hearing ability, knows standard command sig-
nals. The signal person shall also have enough experience to recognize hazardous factors and
inform the operators to avoid the hazards in time.
• Ensure assistant workers can identify the model and working condition to choose a proper ro-
tary drilling rig.
• Each operating personnel of a project shall bear certain safety responsibilities and is required to
timely report unsafe factors to the supervisor.
SR200C(SY) Rotary Drilling Rig Table of Contents
Table of Contents
1 Introduction
1.1 Overview................................................................................................................... 1-3
1.2 Your Documentation Package................................................................................... 1-4
1.2.1 Recommendations on Using the Documentation........................................... 1-4
1.2.2 Documentation Storage................................................................................. 1-5
1.3 Organization of This Manual..................................................................................... 1-5
1.3.1 Table of Contents........................................................................................... 1-5
1.3.2 Introduction.................................................................................................... 1-6
1.3.3 Safety............................................................................................................. 1-6
1.3.4 System Functions.......................................................................................... 1-6
1.3.5 Operation....................................................................................................... 1-6
1.3.6 Maintenance.................................................................................................. 1-6
1.3.7 Troubleshooting............................................................................................. 1-6
1.3.8 Specifications................................................................................................. 1-7
1.3.9 Appendix........................................................................................................ 1-7
1.4 Your Sany Machine................................................................................................... 1-8
1.4.1 Special Tips.................................................................................................... 1-8
1.4.2 Application of Rotary Drilling Rig................................................................... 1-8
1.4.3 Machine Directions........................................................................................ 1-9
1.4.4 Machine Information...................................................................................... 1-9
1.4.5 Product Nameplate...................................................................................... 1-10
1.4.6 Chassis Nameplate.......................................................................................1-11
1.5 Contact Information..................................................................................................1-11
2 Safety
2.1 Foreword................................................................................................................... 2-3
2.2 Hazard Words........................................................................................................... 2-4
2.2.1 Hazard Word Levels....................................................................................... 2-4
2.2.2 Other Signal Words........................................................................................ 2-5
2.3 Safety Decals and Plates.......................................................................................... 2-6
2.3.1 Locations........................................................................................................ 2-6
2.3.2 Meaning......................................................................................................... 2-8
2.4 Safety Equipment.................................................................................................... 2-19
Safety, operation & maintenance manual - July, 2013 I

Table of Contents SR200C(SY) Rotary Drilling Rig
2.4.1 Hydraulic Lock Lever................................................................................... 2-19

2.4.2 Extinguisher................................................................................................. 2-19
2.4.3 Emergency Exit............................................................................................ 2-20
2.4.4 Seat Belt...................................................................................................... 2-20
2.4.5 Emergency Stop Switch .............................................................................. 2-21
2.5 Safety Precautions.................................................................................................. 2-22
2.5.1 Be Cautious of High Pressure Fluid............................................................. 2-22
2.5.2 Dust Hazard................................................................................................. 2-23
2.5.3 Mechanical Injury......................................................................................... 2-24
2.5.4 Battery Hazards........................................................................................... 2-26
2.5.5 Fire Prevention............................................................................................. 2-27
2.5.5.1 Away from Fire................................................................................... 2-27
2.5.5.2 Daily Checks...................................................................................... 2-28
2.5.5.3 Fire Treatment.................................................................................... 2-29
2.5.6 Scald Prevention.......................................................................................... 2-30
2.5.7 Safety Information of Hose.......................................................................... 2-31
2.5.8 Fluid Leakage.............................................................................................. 2-32
2.5.9 Crawler Safety Information.......................................................................... 2-33
2.5.10 Lightening and Strong Wind Precautions..................................................... 2-34
2.5.11 Falling Protection......................................................................................... 2-34
2.5.12 Noise Protection........................................................................................... 2-35
2.5.13 Vibration....................................................................................................... 2-35
2.5.14 Wire Rope Safety Information...................................................................... 2-35
2.5.15 Climbing on/off Drilling Rig........................................................................... 2-37
2.5.16 Kelly Bar and Drilling Tools.......................................................................... 2-38
2.5.17 Working at Areas with Underground Pipelines............................................. 2-39
2.5.18 Working at Areas with High Voltage Power Lines........................................ 2-40
2.5.19 Electrical Accident........................................................................................ 2-41
2.6 Safety during Operation.......................................................................................... 2-42
2.6.1 Staff.............................................................................................................. 2-42
2.6.2 Personal Protective Equipment . ................................................................. 2-44
2.6.3 Keeping the Drilling Rig in Good Service Condition..................................... 2-46
2.6.4 Safety on Construction Site......................................................................... 2-47
2.6.5 Signals to Control Operation........................................................................ 2-49
II Safety, operation & maintenance manual - July, 2013

2.6.6 Drilling Rig Danger Area.............................................................................. 2-55

2.6.7 Avoiding Tipping........................................................................................... 2-56
2.6.8 Before Entering the Cab.............................................................................. 2-58
2.6.9 Before Starting the Engine........................................................................... 2-59
2.6.10 Before Operating the Drilling Rig................................................................. 2-60
2.6.11 Drilling Rig Operation................................................................................... 2-61
2.6.12 Construction of Drilling Rig ......................................................................... 2-63
2.6.13 Drilling Rig Dismantling................................................................................ 2-65
2.6.14 Parking Safety.............................................................................................. 2-65
2.6.15 Transporting Drilling Rig............................................................................... 2-67
2.6.16 Drilling Rig Maintenance.............................................................................. 2-68
2.6.17 Winch Operation.......................................................................................... 2-69
2.7 Maintenance Safety .............................................................................................. 2-70
2.7.1 Maintenance Personnel............................................................................... 2-70
2.7.2 Risks in Maintenance................................................................................... 2-70
2.7.2.1 Preparing for Maintenance................................................................. 2-73
2.7.2.2 During Maintenance........................................................................... 2-75
2.8 Environment Protection........................................................................................... 2-78
2.8.1 Proper Waste Disposal................................................................................ 2-78
2.8.2 Mud Pollution............................................................................................... 2-79
2.8.3 Fuel Emissions............................................................................................. 2-79
3 System Function
3.1 General Structure of Rotary Drilling Rig.................................................................... 3-3
3.2 Function Description................................................................................................. 3-5
3.2.1 Undercarriage................................................................................................ 3-5
3.2.2 Upper Carriage.............................................................................................. 3-5
3.2.3 Hydraulic System........................................................................................... 3-6
3.2.5 Main Winch.................................................................................................... 3-8
3.2.6 Auxiliary Winch............................................................................................... 3-9
3.2.7 Mast............................................................................................................. 3-10
3.2.8 Rotary Drive .................................................................................................3-11
3.2.9 Kelly Bar....................................................................................................... 3-12
3.3 Components Explanations...................................................................................... 3-13
3.3.1 General View of the Operator Cab............................................................... 3-13
Safety, operation & maintenance manual - July, 2013 III

3.3.2 Chassis Monitor System.............................................................................. 3-15

3.3.2.1 Screen Introduction............................................................................ 3-15
3.3.2.2 Screen Display and Operation........................................................... 3-21
3.3.3 Hydraulic Lock Lever................................................................................... 3-23
3.3.4 Operation Control Assistant......................................................................... 3-24
3.3.5 Air Conditioning System . ............................................................................ 3-27
3.3.6 Radio............................................................................................................ 3-33
3.3.6.1 Control Panel .................................................................................... 3-33
3.3.7 Traveling Lever/pedal................................................................................... 3-39
3.3.8 Left and Right Operation Handle................................................................. 3-40
3.3.8.1 Left Operation Handle Button Function.............................................. 3-40
3.3.8.2 Right Operation Handle Button Function........................................... 3-40
3.3.8.3 Left Operation Handle Directional Function....................................... 3-41
3.3.8.4 Right Operation Handle Directional Function..................................... 3-42
3.3.9 Mast Adjusting Lever.................................................................................... 3-43
3.3.10 Display......................................................................................................... 3-45
3.3.10.1 Start-up and Language Select Interface............................................ 3-45
3.3.10.2 Drilling Operation Main Interface........................................................ 3-46
3.3.10.3 Alarm Interface................................................................................... 3-48
3.3.10.4 Operation Interface............................................................................ 3-48
3.3.10.5 Calibration Interface........................................................................... 3-50
3.3.10.6 Setting Interface................................................................................. 3-51
3.3.10.7 Oil Pressure Interface........................................................................ 3-51
3.3.10.8 Mast Vertical Adjusting Interface........................................................ 3-52
3.3.11 Anti-collision Function of the Operator Cab................................................. 3-54
3.3.12 Slack Rope Switch-off.................................................................................. 3-55
3.3.12.1 Display Protection.............................................................................. 3-56
3.3.13 Seat.............................................................................................................. 3-57
3.3.14 Limit Switch.................................................................................................. 3-60
3.3.15 Level............................................................................................................ 3-61
3.3.16 Alarm Lamp (optional).................................................................................. 3-61
4 Operation
4.1 Basic Operation......................................................................................................... 4-3
4.1.1 Job Preparations............................................................................................ 4-3
IV Safety, operation & maintenance manual - July, 2013

4.1.2 Visual Checks................................................................................................ 4-3

4.1.3 Job Set-up...................................................................................................... 4-5
4.1.4 Checks Before Starting the Engine................................................................ 4-7
4.1.4.1 Checking Coolant Level ...................................................................... 4-7
4.1.4.2 Checking Engine Oil Level................................................................... 4-7
4.1.4.3 Draining Water and Sediment in Fuel Tank.......................................... 4-7
4.1.4.4 Checking Fuel Amount and Refuel....................................................... 4-7
4.1.4.5 Checking Hydraulic Oil Level............................................................... 4-7
4.1.4.6 Checking Water Oil Separator.............................................................. 4-8
4.1.4.7 Checking the Electrical Circuit............................................................. 4-8
4.1.4.8 Checking Horn Function....................................................................... 4-9
4.1.5 Starting the Engine...................................................................................... 4-10
4.1.5.1 Normal Start-up.................................................................................. 4-10
4.1.5.2 Starting The Engine in Cold Weather................................................. 4-12
4.1.6 After Starting the Engine.............................................................................. 4-13
4.1.6.1 Breaking in a new Machine................................................................ 4-13
4.1.6.2 Warming-up Operation ...................................................................... 4-13
4.1.7 Shutting down the Engine............................................................................ 4-15
4.1.8 Checks after Each Workday......................................................................... 4-18
4.1.9 Traveling...................................................................................................... 4-19
4.1.9.1 Traveling Operation............................................................................ 4-20
4.1.9.2 Traveling up and down Slopes........................................................... 4-25
4.1.10 Upper Carriage Swing.................................................................................. 4-26
4.1.11 Adjusting Drilling Center Distance............................................................... 4-28
4.1.12 Crowd Control.............................................................................................. 4-30
4.1.13 Main Winch Operation................................................................................. 4-32
4.1.14 Auxiliary Winch Operation............................................................................ 4-36
4.1.15 Rotary Drive Control..................................................................................... 4-38
4.1.16 Depth Measuring Control............................................................................. 4-39
4.1.17 Calibration.................................................................................................... 4-40
4.1.17.1 Depth Measurement Calibrating........................................................ 4-40
4.1.17.2 Swing Angle Calibrating..................................................................... 4-41
4.1.17.3 Verticality Calibration.......................................................................... 4-42
4.1.18 Crawler Extending and Retracting............................................................... 4-43
4.1.19 Parking the Drilling Rig................................................................................ 4-44
Safety, operation & maintenance manual - July, 2013 V

4.1.19.1 Regular Parking................................................................................. 4-44

4.1.19.2 Checks During Parking...................................................................... 4-46
4.1.19.3 Machine Locking................................................................................ 4-46
4.1.19.4 Long-term Storage............................................................................. 4-47
4.1.20 Operation in Cold Weather........................................................................... 4-48
4.1.20.1 Checks in Cold Weather.................................................................... 4-48
4.1.20.2 Operation Tips in Cold Weather......................................................... 4-50
4.1.20.3 After Daily Operation.......................................................................... 4-53
4.1.20.4 After Cold Season.............................................................................. 4-53
4.2 Drilling Rig Construction.......................................................................................... 4-54
4.2.1 Construction Preparation............................................................................. 4-54
4.2.1.1 Drilling Rig Checks............................................................................. 4-54
4.2.1.2 Drilling Tool Selection......................................................................... 4-56
4.2.2 Drilling Rig in Place...................................................................................... 4-57
4.2.3 Drilling.......................................................................................................... 4-58
4.2.3.1 Drilling in Clay Layer.......................................................................... 4-58
4.2.3.2 Drilling in Sand Layer......................................................................... 4-58
4.2.3.3 Drilling in Pebble Layer...................................................................... 4-59
4.2.3.4 Drilling in Shale Layer........................................................................ 4-60
4.3 Rigging & Derigging................................................................................................ 4-62
4.3.1 Requirements for Rigging and Derigging..................................................... 4-62
4.3.1.1 Guidelines for Rigging and Derigging................................................ 4-62
4.3.1.2 Notes on Rigging and Derigging........................................................ 4-63
4.3.1.3 Preparation for Rigging and Derigging............................................... 4-64
4.3.2 Rigging Drilling Rig...................................................................................... 4-65
4.3.2.1 Removing Swing Locking Connecting Rod........................................ 4-65
4.3.2.2 Extending the Crawlers...................................................................... 4-66
4.3.2.3 Mounting Counterweight.................................................................... 4-66
4.3.2.4 Connecting Upper Mast and Middle Mast ......................................... 4-68
4.3.2.5 Connecting Pulley Yoke .................................................................... 4-70
4.3.2.6 Installing Main Winch and Lower Mast............................................... 4-72
4.3.2.7 Mounting Rotary Drive ...................................................................... 4-73
4.3.2.8 Connecting Hoses.............................................................................. 4-74
4.3.2.9 Connecting Electric Device................................................................ 4-77
4.3.2.10 Connecting Middle Mast and Lower Mast.......................................... 4-78
VI Safety, operation & maintenance manual - July, 2013

4.3.2.11 Installing Wire Ropes......................................................................... 4-80

4.3.2.12 Drilling Rig Test Run........................................................................... 4-84
4.3.3 Installing Drilling Tool................................................................................... 4-86
4.3.3.1 Connecting Rope Swivel to Kelly Bar................................................. 4-86
4.3.3.2 Connecting Kelly Guide to Kelly Bar.................................................. 4-87
4.3.3.3 Aligning Drilling Rig with Kelly Bar Upper End................................... 4-88
4.3.3.4 Connecting Wire Rope and Rope Swivel........................................... 4-89
4.3.3.5 Installing Kelly Bar.............................................................................. 4-89
4.3.3.6 Installing Drilling Bucket..................................................................... 4-93
4.3.4 Disassembling Drilling Tool.......................................................................... 4-94
4.3.4.1 Disassembling Drilling Bucket............................................................ 4-94
4.3.4.2 Removing Kelly Bar .......................................................................... 4-95
4.3.5 Disassembling Drilling Rig .......................................................................... 4-99
4.3.5.1 Disconnecting Pulley Yoke and Upper Mast...................................... 4-99
4.3.5.2 Disconnecting Upper and Middle Mast ........................................... 4-100
4.3.5.3 Removing Rotary Drive and Crowd Cylinder Connection................ 4-101
4.3.5.4 Disconnecting Middle Mast and Lower Mast.................................... 4-102
4.3.5.5 Removing Rotary Drive.................................................................... 4-103
4.3.5.6 Removing Main Winch and Lower Mast........................................... 4-104
4.3.5.7 Removing Counterweight................................................................. 4-105
4.4 Wire Rope............................................................................................................. 4-107
4.4.1 Installing Wire Rope .................................................................................. 4-107
4.4.2 Unloading and Storing Wire Rope .............................................................4-114
4.4.3 Discarding Wire Rope.................................................................................4-116
4.5 Drilling Rig Transport..............................................................................................4-118
4.5.1 Transport Requirements.............................................................................4-118
4.5.2 Safety Guidelines for Transport..................................................................4-118
4.5.3 Transport Parameters................................................................................ 4-120
4.5.3.1 Transport Status (A)......................................................................... 4-120
4.5.4 Loading and Unloading the Machine......................................................... 4-124
4.5.4.1 Requirement for Loading and Unloading the Machine . .................. 4-124
4.5.4.2 Loading the Machine........................................................................ 4-126
4.5.4.3 Fastening Method............................................................................ 4-127
4.5.4.4 Unloading the Machine.................................................................... 4-127
4.5.5 Requirements for Sea Transportation........................................................ 4-128
Safety, operation & maintenance manual - July, 2013 VII

4.5.5.1 Hoisting the Machine........................................................................ 4-129

4.6 Kelly Bar................................................................................................................ 4-131
4.6.1 Instructions................................................................................................. 4-131
4.6.2 Welding...................................................................................................... 4-133
4.6.3 Transport and Storage............................................................................... 4-138
4.7 Drilling Tool............................................................................................................ 4-140
4.7.1 Overview.................................................................................................... 4-140
4.7.2 Kelly Box.................................................................................................... 4-140
4.7.3 Drilling Tool Categories.............................................................................. 4-142
4.7.3.1 Drilling Bucket Single-edge.............................................................. 4-142
4.7.3.2 Drilling Bucket Double-edge............................................................. 4-144
4.7.3.3 Cone Auger...................................................................................... 4-146
4.7.3.4 Straight Auger.................................................................................. 4-148
4.7.3.5 Core Barrel....................................................................................... 4-150
4.7.3.6 Double-layer Core Barrel................................................................. 4-152
4.7.3.7 Core Barrel With Centralizer............................................................ 4-153
4.7.3.8 Underreamer Bit............................................................................... 4-154
4.7.3.9 Casing Drive Adapter....................................................................... 4-155
4.7.3.10 Easily Worn Parts of Drilling Rig...................................................... 4-156
4.7.4 Drilling Tool Operation............................................................................... 4-157
4.7.4.1 Drilling Bucket.................................................................................. 4-157
4.7.4.2 Auger................................................................................................ 4-157
4.7.4.3 Core Barrel....................................................................................... 4-158
4.7.4.4 Belling Tool....................................................................................... 4-159
5 Maintenance
5.1 Maintenance Precautions.......................................................................................... 5-3
5.2 Maintenance Information........................................................................................... 5-5
5.2.1 Lubricating the Lube Points........................................................................... 5-8
5.2.2 Drilling Rig Oil...............................................................................................5-11
5.3 Maintenance Schedule .......................................................................................... 5-14
5.4 Maintenance Procedures........................................................................................ 5-26
5.4.1 Every 10 Service Hours............................................................................... 5-26
5.4.1.1 Crawler Tension - Check and Adjust.................................................. 5-26
5.4.1.2 Hydraulic Cylinders- Check................................................................ 5-29
VIII Safety, operation & maintenance manual - July, 2013

5.4.1.3 Gearbox Gear Oil Level- Check......................................................... 5-32

5.4.1.4 Shock Absorbing Device for Rotary Drive - Check............................. 5-33
5.4.1.5 Crawler Track - Visual Inspection....................................................... 5-37
5.4.1.6 Wire Rope - Inspect........................................................................... 5-38
5.4.1.7 Wire Rope - Maintain......................................................................... 5-39
5.4.1.8 Rope Swivel Flexibility - Check.......................................................... 5-40
5.4.1.9 Rope Swivel - Lubricate..................................................................... 5-41
5.4.1.10 Engine Oil Level - Check.................................................................... 5-43
5.4.1.11 Water and Sediment in Fuel Tank- Drain .......................................... 5-45
5.4.1.12 Hydraulic Oil Level - Check................................................................ 5-46
5.4.1.13 Cooling System Coolant Level - Check.............................................. 5-48
5.4.1.14 Fuel Amount - check and Refuel........................................................ 5-51
5.4.2 Initial 50 Service Hours................................................................................ 5-53
5.4.2.1 Engine Oil and Filter - Change........................................................... 5-53
5.4.2.2 Fuel Filter - Replace........................................................................... 5-57
5.4.2.3 Filter of Water Oil Separator - Replace.............................................. 5-59
5.4.2.4 Fuel Tank Strainer - Clean................................................................. 5-60
5.4.3 Every 50 Service Hours............................................................................... 5-61
5.4.3.1 Winch Reducers Oil Level - Check.................................................... 5-61
5.4.3.2 Switches, Buttons and Operation Handles - Check........................... 5-62
5.4.3.3 Rope Hold-down Rollers - Check....................................................... 5-62
5.4.3.4 Rotary Drive Mounting Bolts - Check................................................. 5-63
5.4.3.5 Driver Strip - Check and Change....................................................... 5-64
5.4.3.6 Rotary Drive Sliding Strip - Check and Replace ............................... 5-65
5.4.3.7 Crawler Track Mounting Bolts - Check............................................... 5-66
5.4.3.8 Air Intake and Exhaust System - Visually Check............................... 5-67
5.4.3.9 Window Wiper - Check....................................................................... 5-67
5.4.3.10 Window Washer - Check.................................................................... 5-67
5.4.3.11 Kelly Guide Swing Bearing - Replace................................................ 5-68
5.4.3.12 Impact Ring - Check and Replace..................................................... 5-69
5.4.3.13 Spring of Kelly Bar- Check and Replace............................................ 5-69
5.4.3.14 Shock Absorbers - Check................................................................... 5-70
5.4.4 Initial 250 Service Hours.............................................................................. 5-71
5.4.4.1 Aux. Pump Filter Element - Change................................................... 5-71
5.4.4.2 Winch Reducer Oil- Change.............................................................. 5-72
Safety, operation & maintenance manual - July, 2013 IX

5.4.4.3 Gear Oil for Swing Reducer - Change............................................... 5-73

5.4.4.4 Travel Reducer Oil - Change.............................................................. 5-75
5.4.4.5 Pilot Filter Element - Replace............................................................. 5-77
5.4.4.6 Return Filter - Replace....................................................................... 5-79
5.4.4.7 Bolts Connecting Swing Bearing - Check.......................................... 5-88
5.4.4.8 Reducer Gear Oil - Change............................................................... 5-88
5.4.4.9 Oil Suction Filter - Clean.................................................................... 5-90
5.4.5 Every 250 Service Hours............................................................................. 5-91
5.4.5.1 Wire Rope Sheaves - Check.............................................................. 5-91
5.4.5.2 Rotary Drive Gear Oil - Check........................................................... 5-91
5.4.5.3 Hoses - Check and Replace ............................................................. 5-92
5.4.5.4 Kelly Guide Sliding Strip - Check and Replace.................................. 5-93
5.4.5.5 Engine Oil and Filter - Change........................................................... 5-93
5.4.6 Initial 500 Service Hours.............................................................................. 5-94
5.4.6.1 Gearbox Gear Oil - Change............................................................... 5-94
5.4.7 Every 500 Service Hours............................................................................. 5-94
5.4.7.1 Engine Crankcase Breather - Clean.................................................. 5-94
5.4.7.2 Kelly Bar Baffle - Check..................................................................... 5-95
5.4.7.3 Kelly Bar Drive Gibs - Check.............................................................. 5-95
5.4.7.4 Kelly Bar Tube - check....................................................................... 5-96
5.4.7.5 Kelly Bar Locking Recesses - Check................................................. 5-96
5.4.7.6 Bolts Connecting Swing Bearing - Check.......................................... 5-97
5.4.7.7 Fuel Filter - Replace........................................................................... 5-97
5.4.7.8 Filter for Water Oil Separator - Replace............................................. 5-97
5.4.7.9 Fuel Tank Strainer - Clean................................................................. 5-97
5.4.7.10 Gearbox Gear Oil - Change............................................................... 5-97
5.4.7.11 Winch Reducer Oil- Change.............................................................. 5-97
5.4.8 Initial 1000 Service Hours............................................................................ 5-98
5.4.8.1 Hydraulic Oil - Change....................................................................... 5-98
5.4.9 Every 1000 Service Hours......................................................................... 5-106
5.4.9.1 Hydraulic Hose - Check................................................................... 5-106
5.4.9.2 Hydraulic Hose - Change................................................................. 5-107
5.4.9.3 Battery - Clean and Recycle............................................................ 5-108
5.4.9.4 Air Conditioner/cab Heater Filter (recirculation) - Inspect and Replace
.......................................................................................................................5-110
X Safety, operation & maintenance manual - July, 2013

5.4.9.5 Travel Reducer Oil - Change.............................................................5-111

5.4.9.6 Gear Oil for Swing Reducer - Change..............................................5-111
5.4.9.7 Pilot Filter Element - Replace............................................................5-111
5.4.9.8 Return Filter Element - Change........................................................5-111
5.4.9.9 Aux. Pump Filter Element - Change..................................................5-111
5.4.9.10 Oil Suction Filter - Clean...................................................................5-111
5.4.10 Every 2000 Service Hours..........................................................................5-112
5.4.10.1 Gearbox Gear Oil - Change..............................................................5-112
5.4.10.2 Hydraulic Oil - Change......................................................................5-112
5.5 Storage of Drilling Rig............................................................................................5-113
5.5.1 Cleaning the Drilling Rig.............................................................................5-113
5.5.2 Machine Storage.........................................................................................5-113
5.5.2.1 Maintenance to the Drilling Rig during Storage.................................5-113
5.5.2.2 Maintenance to The Drilling Rig before Moving from the Ware-
house.............................................................................................................5-115
6 Troubleshooting
6.1 Motor System Common Faults and Troubleshooting................................................ 6-3
6.2 Electrical System Common Faults and Troubleshooting......................................... 6-20
6.3 Hydraulic System Common Faults and Troubleshooting........................................ 6-22
6.4 Troubleshooting of Work Unit.................................................................................. 6-28
6.5 Air Conditioning System Common Faults and Troubleshooting.............................. 6-40
6.6 SR150C/SR200C ( SY) Wear Parts List................................................................. 6-43
7 specifications
7.1 Dimension Giagram.................................................................................................. 7-3
7.2 Overall Dimensions................................................................................................... 7-4
Appendix
Common Misoperation.................................................................................................... 8-5
Safety, operation & maintenance manual - July, 2013 XI

XII Safety, operation & maintenance manual - July, 2013

SR200C(SY) Rotary Drilling Rig Introduction
Introduction
1 Introduction
1.1 Overview.................................................................................................................... 1-3
1.2 Your Documentation Package................................................................................... 1-4
1.3 Organization of This Manual...................................................................................... 1-5
1.4 Your Sany Machine.................................................................................................... 1-8
1.5 Contact Information..................................................................................................1-11
Safety, operation & maintenance manual - July, 2013

1-1
Introduction SR200C(SY) Rotary Drilling Rig
WARNING
Always read, understand and follow the
Safety section before and during operation
or maintenance of this equipment. Failure
to do this could result in machine damage,
personnel injury or even death.
1-2 Safety, operation & maintenance manual - July, 2013

1 INTRODUCTION
1.1 Overview
●● Sany-built rotary drilling rigs offer high-qual-

ity performance and excellent after-sales
service support.
●● Sany-built rotary drilling rigs are widely
used throughout the industry for various
types of applications.
●● Sany is a leading manufacturer of construc-
tion equipment worldwide.
Fig.1-1
This operator’s manual provides safety, opera-

tion, maintenance, troubleshooting and techni-
cal specifications. In order to properly use your
equipment, it is important to read this manual
carefully before beginning any operations.
Items addressed in this manual are designed
to help you:
●● Understand the structure and performance
of your drilling rig.
●● Reduce improper operation and point out
possible hazardous situations.
●● Increase equipment efficiency during op-
eration.
●● Prolong the service life of equipment.
Safety, operation & maintenance manual - July, 2013 1-3

●● Reduce maintenance costs.

Always keep this manual nearby for ease of
reference and have all personnel involved with
any work operations read it periodically. If a
copy of the manual is not with the machine at
the time of use, do not use the equipment until
you have obtained a replacement copy from
your Sany distributor.
If you sell the machine, be sure to give this

manual to the new owner.
Continuing improvements in the design of this

machine can lead to changes in detail which
may not be covered in this manual. Always
consult your Sany distributor for the latest Fig.1-2
available information on your machine or if you
have questions regarding information in this
manual.
1.2 Your Documentation Package
The documentation for this machine includes

the following items:
●● Safety, Operation & Maintenance Manual
(SOMM) — this manual is in the seat pock-
et of operator cab.
●● Parts book — this publication consists of
parts lists and matching drawings for order-
ing spare parts as-needed. If it was not al-
ready shipped with your machine, the parts
book for your machine is available directly
from Sany.
1.2.1 R ecommendations on using the

documentation
●● This documentation applies only to this

machine and should not be used with any
other machines.
●● To ensure that the documentation is always
complete and up to date.

●● Keep all pages inside its binder (if shipped

loose leaf).
●● Insert Sany replacement pages immedi-
ately into the appropriate book; destroy old
versions of those pages.
1.2.2 Documentation storage
●● Always keep the manual with the machine

in the operator cab.
●● The parts book is best left either shelved
in the workshop area or office. It should al-
ways be available to the maintenance and
service personnel as required.
1.3 Organization of This Manual
The SOMM is designed for use and mainte-

nance of this machine. Each section of this
manual provides information you should be
familiar with before operating or performing
maintenance on this machine. Keep a copy of
this manual inside the operator cab for your
reference at all times. Replace this manual im-
mediately if it is damaged or lost.
Note:
Due to improvement and updating of products,
some information in this manual may differ
from your machine. If you have any questions,
contact your Sany distributor before operating
or working on the machine.
1.3.1 Table of Contents
This section provides a listing of topics that

are contained in this manual along with the
page number each starts on. There are also
tables of contents at the start of each section
in this manual.

1.3.2 Introduction
This section provides an overview of what is

covered in the rest of this manual, including
machine label information and Sany contact
information.
1.3.3 Safety
This section covers basic safety information

relating to this equipment. It also describes
what the hazard alerts mean that are used
throughout the manual.
1.3.4 System functions
This section provides an overview of all the

controls and operating systems.
1.3.5 Operation
This section provides detailed operating pro-

cedures.
1.3.6 Maintenance
This section provides all general maintenance

and repair procedures.
1.3.7 Troubleshooting
This section includes common malfunctions

and fault diagnostics procedures for the op-
erating systems. Basic mechanical, hydraulic
and electrical systems troubleshooting are in-
cluded.

1.3.8 Specifications
This section provides general required ma-

chine information for this rotary drilling rig.
Some information may vary due to design
changes.
1.3.9 Appendix
This section provides bolt tightening torque

and common misoperation.

1.4 Your Sany Machine
1.4.1 Special tips
Read this manual carefully. For any conse-

quence caused by violation of the following
provisions, Beijing Sany Heavy Machinery
Co., Ltd will assume no responsibility:
●● Modify or repair rotary drilling rig without

the permission of the company.
●● Dismantle, weld, or add parts on rotary drill-
ing rig without the permission of the com-
pany.
●● Use drilling tools or other accessories
which are not provided or recognized by
the company without the permission of the
company.
●● Fail to install, operate, and park rotary drill-
ing rig according to requirements in the
manual. Fig.1-3
●● Use fuel, lubricating oil, and grease which
are not comply with requirements in the
manual, or the lubricating oil and grease
dosage is insufficient.
●● Failure to have prompt and effective main-
tenance and service according to require-
ments in the manual.
1.4.2 Application of rotary drilling rig

Sany rotary drilling rig is designed for the fol-
lowing operations:
●● Filling pile construction

●● Engaged pile construction
●● Diaphragm wall grab pile construction

1.4.3 Machine directions
All views are taken from the operator’s seat

and facing forward as indicated by the arrow
Front
in Fig.1-2. In this manual, the front, back, left
side, and right side indicates, when the cab Operator’s seat
faces the front and the traveling drive is be-
hind of the machine.
Left Right
Driving
wheel
Back
Fig.1-4 Machine Directions
1.4.4 Machine information
The serial numbers and model numbers on

the components are the only numbers that
your Sany distributor will need when order-
ing replacement parts or requiring assistance
for your equipment. The product nameplate
contains main properties, transportation, and
production code of the product. When inquir-
ing information about the machine, provide the
production code so that the agent or service
personnel could rapidly provide parts and in-
formation about the machine. Record this in-
formation in this manual for future use.

1.4.5 Product nameplate
Shown in figures 1-5 and 1-6 is the nameplate Sany Heavy Machinery Co., Ltd.
and its locations.
The product nameplate is on the left side of

the boom frame.
Fig.1-5
Nameplate
Fig.1-6 Product Nameplate

1.4.6 Chassis nameplate
Chassis nameplate is located on the left side

of chassis. As shown in the right figure.
Chassis nameplate
Fig.1-7 Chassis Nameplate
1.5 Contact Information
Thank you for choosing Sany. In case of any

problem, please contact by:
Address:
Sany Industry Park, Nankou, Changping Dis-

trict, Beijing
Postal code: 102202
Website: www.sanyhi.com

E
G
PA
K
AN
BL
1-12 Safety, operation & maintenance manual -July, 2013

SR200C(SY) Rotary Drilling Rig Safety
Safety
2 Safety
2.1 Foreword................................................................................................................... 2-3
2.2 Hazard Words........................................................................................................... 2-4
2.3 Safety Decals and Plates.......................................................................................... 2-6
2.4 Safety Equipment.................................................................................................... 2-19
2.5 Safety Precautions.................................................................................................. 2-22
2.6 Safety During Operation.......................................................................................... 2-42
2.7 Maintenance Safety .............................................................................................. 2-70
2.8 Environment Protection........................................................................................... 2-78
Safety, operation & maintenance manual - July, 2013

2-1
Safety SR200C(SY) Rotary Drilling Rig
WARNING

2 SAFETY
2.1 Foreword Machines covered by this manual are used

for various operations under normal condi-
This Safety, Operation and Maintenance tions. Never use the machine in flammable or
Manual is a guide for you to operate your ma- explosive environment, or in areas containing
chine properly. It contains technical and safety asbestos dust.
information necessary for operation of your
The information, specifications, and illustra-
machine. Read and understand each section
tions in this publication are on the basis of
of the manual.
information that was available at the time that
Only eligible and experienced operators with the publication was written. Sany reserves the
an official license (according to local laws) are right to change these information at any time
allowed to operate the machine. without prior notice. Consult Sany dealer to
obtain the latest information or if you have any
Always operate your machine according to question on the information provided in this
national, provincial, prefectural and municipal manual.
laws and regulations. The operation safety
information and description in this manual are
just suggestive and attentive.
Sany cannot anticipate every possible circum-

stance that might involve a potential hazard
during operation and maintenance. The safety
messages in this manual and on the product
are, therefore, not all inclusive. If a procedure,
work method or operating technique that is not
specifically recommended in this manual is
used, you must be sure that it is safe for you
and for others. You should also ensure that
the product will not be damaged or be made
unsafe by the operation, lubrication, mainte-
nance or repair procedures that you choose.
Modifying or abusing the machine according

to your own will might impair the machine’s
performance, or result in more serious poten-
tial hazard. For instance, the specific volume
of fuel oil exceeds set limit or the machine is
overloaded. Drive and operate the machine
carefully. Improper operation or application
may cause personal injury or damage. Sany
assumes no responsibility for such losses.

2.2 Hazard Words
2.2.1 Hazard word levels
The following hazard words are used to inform

you there may be potential dangers that lead
to personal injury or damage.
In this manual and the messages on machine,

the following signs are used to indicate the de-
gree of potential hazard.
DANGER
Indicates an imminent hazard which, if not
avoided, will result in serious injury or death.
WARNING
Indicates a potentially hazardous situation
which, if not avoided, could result in injury or
possibly death.
CAUTION
Indicates a possible potential hazardous situa-
tion which, if not avoided, could result in minor
or major injury.
NOTICE
Indicates a situation which can cause damage

to the machine, personal property and/or the
environment, or cause the equipment to oper-
ate improperly.
This hazard alert symbol appears with most

hazard alerts. It means attention, become
alert, your safety is involved! Please read and
abide by the message that follows the hazard
alert symbol.

2.2.2 Other signal words
Besides above-mentioned signal words, the

following words indicate additional information
to be followed to protect the machine, or pro-
vide you with very useful information.
Note:
It is followed by information on how to avoid

reduction of machine service life.
Remark:
It is followed by very useful information.

2.3 Safety Decals and Plates
2.3.1 Locations
This section describes locations of various safety

decals and their meaning for Sany rotary drilling
rig.
10
11
9
8
7
12
6
5
3 4 2 1
13
14
15 16 18
17
Fig.2-1 Decals Location Diagram I

10
23
1 2 19 20 21 22
24
25
17 18
Fig.2-2 Decals Location Diagram II

2.3.2 Meaning
1. Be cautious of slewing of the drilling rig, and

keep safety distance.
Fig.2-3
2. Perform safe operation according to the

manual during maintenance.
Fig.2-4
3. Carefully read the manual before operating

the machine.
Fig.2-5

4. Wear hard hat.
Fig.2-6
5. Keep clear of personnel and objects

underneath the boom.
Warning
During the drilling rig is
being amplituded, keep
clear of personnel and
objects underneath the
boom.
Fig.2-7

6. Lubrication decals, lubricating methods and

intervals for various lubricating points.
Fig.2-8 SR200C Rotary Drilling Rig Lube Points

7. Functional parameters of auxiliary winch.
CAUTION
Carry Capacity for Drum of
Auxiliary Winch
1. Maximum Pulling Force of 140kN
Aux. Winch Wire Rope
2. Diameter of Aux. Winch Wire Rope 28 mm
3. Pulling Speed of Aux. Winch 64 m/min
11831712
Fig.2-9
8. Anti-crush for winch.
Fig.2-10
9. When folding mast, avoid breaking or

crushing electric wire. CAUTION
When connecting the top mast with middle
mast,Please pay attention to the wire which
crosses the masts to avoid breaking and
squeezing the wire.
11831830
Fig.2-11

10. Make sure pins of rope swivel and Kelly

bar are reliably connected.
CAUTION
11831827
Fig.2-12
11. Bolt torque values of Kelly bar and Kelly
guide.
T
CAUTION
Make sure fasten the bolts by using torque spanner,
when assemble the Kelly with Kelly guide. Fasten
torque up to 274N·m-323N·m. Do check it after
working every 50 Hrs, Otherwise would cause
serious accident.
11831840
Fig.2-13
12. Stay clear of the running rotary drive, and

be careful not to be scaled.
Warning
Please keep away from
the rotary drive when
it is rotating and rising.
Please don’t touch to
prevent from being scald.
Fig.2-14

13. Functional parameters of main winch.
CAUTION
Carry Capacity for Drum of
Main Winch
1. Maximum Pulling Force of 200kN
Main Winch Wire Rope
2. Diameter of Main Winch Wire Rope 28mm
3. Pulling Speed of Main Winch 72 m/min

11870980
Fig.2-15
14. D o n o t o p e r a t e d r i l l i n g r i g w i t h o u t
permission.
CAUTION
Strictly prohibit the unauthorized
from operating the drill.
Labelling：
Date:
11831831
Fig.2-16

15. Safety decals in operator’s cab.
CAUTION
3 20
1. Uppercarriage Swing Left 25. Mast Incline Rightward
1 2 18 19 2. Uppercarriage Swing Right 26. Mast Incline Forward
3. Main(Auxiliary) Winch Down 27. Mast Incline Backward
4 21 4. Main(Auxiliary) Winch Up 28. Loudspeaker
22 5. Pushbutton Switch in Effect 29. Crowd/Derricking Switchover
23
14 16 26 6. Uppercarriage Swing Effective 30. High Torque At Normal Speed/Low
5 7. Depth Reset Speed Mode
24 25
8. Main/Auxiliary Winch Switchover 31. Floating
6
7 17
27 9. Spare Button 32. Spare Button
15
8 28
29 10.Pilot on/off 33. Keyhole
9 11.Radio Control Panel 34. Track Retract
30
10 31
12.Air-condition Panel 35. Track Extend
32 13.Level 36. Retract Tensioning Cylinder
14.Left Track Forward 37. Extend Tensioning Cylinder
15.Left Track Backward 38. Retraced Support Cylinder
33
11 16.Right Track Forward 39. Extend Support Cylinder
Radio Control Panel
Air-condition Panel
Seat 42 17.Right Track Backward 40. Lighting switch

12
43 18.Power Unit Rotate Clockwise 41. Spre button
13 44 19.Power Unit Rotate Counter Clockwise 42. Adjusting Speed Switch
45 43. Front Light
46 20.Crowd/Derricking Mechanism Down
47 21.Crowd/Derricking Mechanism Up 44. Cat Front Light
34 35 22. Air-condition Tuyere 45. Wiper
36 37 46. Washing Switch
23. Joystick Safety Button
39
38 24. Mast Incline Leftward 47. Side Light
40 41
The operation height of the drill is 18.5m, the minimum necessary construction yard is 9.5m
×9.5m, the ambient temperature for operating the drill ranges from ℃
-18to 43℃, and the altitude
of the ground supporting the drill should not exceed 4000m.Before construction,you should pay special attention to measure,clear and adjust the site.Otherwise,the drill would be unable to be
operated or resulting in serious accident Even cause death.Keep the drill and attachments a safety distance of more than 3m from high-voltage wire and the distance between the mast and the
high-voltage wire of 50000V should not be less than 3m. When the voltage exceeds 50000V,the distance from the mast to the high-voltage wire should increase 1m per additional 10000V . voltage
Do not operate or work on this drill unless you have read and understand the instructions and warnings in the operation and maintenance manuals. Failure to follow the instructions or heed the
warnings could result in injury or death. Proper care is your responsibility. If you want to replace the manual or have lost your manual, contact After-Sales Department. Pay attention to safety is your
first duty.
B
A: Pedestal of mast cylinder
C
B: Triangle hinged fulcrum
C: Mast pedestal
P1 P2 P3
The following notes are strongly recommended during lying or erecting the mast
1. In the process of lying or erecting the mast: please make Kelly guide near A position;make the power unit near B position, see P1.
2. In the process of lying mast: firstly ensure that the mast lies slowly around B point on the premise of unchanging of derricking
mechanism, see P2. Then lower the derricking mechanism to achieve mast lying. Especially when the mast is about to lie
at the pedestal, please control the handle to ensure its slow lying, see P3.
3. The process of mast erecting is contrary to lying.
4. Make sure the slow action of erecting or lying mast to avoid damage to the machine.
11867511
Fig.2-17

16. Warning decals in operator’s cab.

CAUTION
Rotary Drilling Rig

SR XX
Loadsupporting Capacity for Girders

1. Rated Load for Mast XXX kN
2. Design Load for Mast XXX kN
3. Rated Load for Connector XXX kN
4. Design Load for Connector XXX kN
5. Rated Load for Boom XXX kN
6. Design Load for Boom XXX kN
7. Rated Load for Support Bar XXX kN
8. Design Load for Support Bar XXX kN
70°
When you are unable to get out the driving cab,
please break down the glazing to escape from.
11831079
Fig.2-18
17. Transportation & lift point decal.
Fig.2-19

18. Transportation anchor point decal.
Fig.2-20
19. Safety warning decal for refueling.
Fig.2-21
20. Guard against falling when operating on

top of upcarriage body.
Fig.2-22

21. Keep safe distance when drilling rig is

rotating or dumping soil.
Fig.2-23
22. S t r i c t l y p r o h i b i t o p e r a t i n g w i t h o u t
authorization.
Fig.2-24
23. Drilling rig decal with its model and

specifications. BEIJING SANY HEANY
INDUSTRY CO., LTD
Fig.2-25

24. Lock up drilling rig against of injury caused

by mast sliding.
WARNING
11831659
Fig.2-26
25. Lubrication points and lubrication interval
of chassis swing support.
CAUTION
Lubricate once a week
11831484
Fig.2-27

2.4 Safety Equipment

2.4.1 Hydraulic lock lever
WARNING
Be sure the hydraulic lock lever is in

locked position before entering or leaving
the cab.
Always be aware of the hydraulic lock lever
position while in the operator cab. failure
to do so may result in accidental move-
ment of the controls and cause personal
injury or possibly death.
When it is in horizontal state (1), the hydraulic

system is unlocked. The hydraulic system of 1
the machine could function normally.
When it is in vertical state (2), the hydraulic

system is locked. The hydraulic system of the
machine cannot function except for the crawl-
er extending & retracting, traveling, and mast
vertical adjusting. 2
Fig.2-28 Hydraulic Lock Lever
1. Unlocked state
2. Locked state
2.4.2 Extinguisher
Operators must know how to use the fire extin-

guisher. Always check status of the extinguish-
er. Damages or inoperable fire extinguishers
should be replaced.
The fire extinguisher is usually placed at the

rear part of the operator’s cab.
Fig.2-29

2.4.3 Emergency exit
There are two emergency exits in operator’s

cab, the door and rear window. During an
emergency, if you fail to successfully escape
from the cab door, use the escape hammer
to smash the rear window, which could be Indicator on rear window
served as an alternate exit.
Escape hammer
Fig.2-30
2.4.4 Seat belt
If there is a rollover accident, operator may be

injured or thrown from the cab resulting in seri-
ous fatal accident.
●● Be sure to fasten seat belt when oper-

ating the machine.
●● Before operating the machine, be sure
to check condition of the seat belt,
buckle, and connecting pieces.
●● If any wear or cracks are discovered,
replace the seat belt, buckle, and con- Fig.2-31
necting pieces. The seat belt should be
replaced for every three years.

2.4.5 Emergency stop switch
The emergency stop switch (1) is located on

the left side of chassis, next to the chassis
nameplate.
In case of an emergency, push downward the

switch (1) and the engine of the drilling rig will 1
stop. When restarting the engine, reset the
emergency stop switch and unlock stop state
first, and the engine can be started.
Fig.2-32

2.5 Safety Precautions
2.5.1 Be cautious of high pressure

fluid
WARNING
Injury hazard or risk of possibly death!

Before removing any hydraulic parts, high
pressure fluid will result in injury or casu-
alty.
Never remove any hydraulic parts before
pressure is released.
●● Compressed air or high pressure fluid can

splash, which may result in personal injury.
●● The maximum pressure of air for cleaning
cannot be higher than 205 Kpa, and the
maximum pressure cleaning water cannot
be higher than 275 Kpa.
Fig.2-33
●● When checking for leakage, use thin slab

or carton board. High pressure fluid could
possibly penetrate human tissues.
●● Attention should be taken to protect hands
and body against high pressure fluid. Wear
mask or safety glasses to protect eyes.
Fig.2-34

●● If the fluid enters the skin, it must be re-

moved as soon as possible and go to a
doctor at once.
Fig.2-35
●● After the engine has stopped for a long

time, the pressure is still in hydraulic sys-
tem. When releasing the pressure, it may
cause sudden move for the machine or ac-
cessories.
●● Be cautious when disconnecting the hy-
draulic pipe or joints. High pressure oil will
make the hose whip. The released high
pressure oil may cause hydraulic elements
(such as pipe plug) to sprout rapidly.
●● When the fluid in tank is heated, the pres-
sure will go up. When opening the cap, the
fluid will sprout.
2.5.2 Dust hazard
●● If there is possibly asbestos in the air, be

sure to operate the machine at upwind lo-
cation. Personnel should use dust mask.
●● Inhaled unknown dust may cause damage
to respiratory system.
●● Make sure the construction site is well ven-
tilated. Adopt necessary measures, such as
spraying water.
Fig.2-36

2.5.3 Mechanical injury
WARNING
To avoid being caught by machine’s rotat-
ing components, operator cannot wear
long hair, loose fitting clothes, necklace,
bracelet, or ring. Failure to do so may re-
sult in injury or possibly death.
●● When working around rotating components,

be cautious of hands, feet, clothes, and
hair to avoid being caught in or crushed by
rotating components.
●● Avoid objects like tools or parts falling into Fig.2-37

rotating area of swing components.
●● Guard against dropping objects above the

cab.
NOTICE
Risk of damaging the drilling rig!

The drilling rig is not equipped with fops
protective devices. When used in areas
with falling object, it may pose hazard. Fig.2-38
Take extra protective measures.
●● Do not walk or stand in the space under-

neath hanged load.
●● Do not make any adjustment to the drilling
rig components when the drilling rig or en-
gine is running.

●● Start the engine with the method of jumper

motor solenoid terminal, and it may cause
unexpected move for the machine.
Fig.2-39
●● If some component must be supported,

make sure of the reliability of the crane,
sling, jack, or other supporting objects. Do
not use slag brick, stand, or individual jack.
●● The dismantled protective device must be
installed after maintenance.
Fig.2-40
●● When driving the pins, the pin may fly off

and hurt personnel nearby and cause per-
sonal injury.
CAUTION
Risk of injury!
When removing or striking pins, wear pro-
tective glasses, and make sure there is no
person in the direction the pins may fly.
Failure to do so may cause injury.
Fig.2-41

2.5.4 Battery hazards
WARNING
Personal injury or possibly death hazard!

When battery gases contact open flame,
they may explode and cause death. Never
let battery gases contact open flame.
●● Avoid sparks, lighted match, cigarette, or

other open flames near battery top.
●● Do not place metal object across the termi-
nals. Use voltmeter or hydrometer. Fig.2-42
●● Do not charge a frozen battery. Heat the
battery first to 16°.
●● The electrolyte of the battery is poisonous.
If the battery explodes, the electrolyte will
splash into eyes and possibly cause blind-
ness.
●● When checking the electrolyte, wear pro-
tective glasses. After touching battery or
connectors, wash hands.
Fig.2-43
If sulphuric acid is splashed onto body, do as

follows:
●● Wash the skin with clean water first.

●● Use soda or lime water to neutralize acidity.
●● Flush with clean water again for 10 to 15
minutes, and go to a doctor at once.
Fig.2-44

2.5.5 Fire prevention
Fuel, lubricant, rags with oil are flammable

substances.
WARNING
Never let the flammable liquid contact fire

or leak it on hot surface or electrical sys-
tems. Failure to do so may result in injury
or possibly death.
22222222Away from fire
●● Do not smoke when refuelling or maintain-

ing the machine. Also do not smoke in the
area where there may be coolant.
●● Stop the engine when refueling. When die-
sel oil or hydraulic contacts a hot surface, it
may cause fire.
Fig.2-45
●● Do not operate or maintain the machine
close to a fire.
●● Do not weld or cut on the pipe or tank body

containing flammable liquid. Avoid heating
or welding beside the hydraulic pipeline.
●● Before welding or weld-cutting the pipe or

tank body, wash them with flame retardant
or flame retarding solution and solvent. Fig.2-46
●● When heated paint will produce poisonous
gas. Remove before welding or heating.

22222222 Daily checks
●● Clean up flammable substances from the

machine, such as fuel, lubricating oil, rags,
and scraps.
●● Damage or loss of thermal protection shield
may cause a fire. If any unusual situation is

discovered, repair it or equip with new ther-
mal protection shield before operating the
machine.
●● Check oil leakage, and check whether
the pipeline is damaged, or whether
the clamp and bolts are loose, etc.
●● Check all the cable and wiring daily for
loose, disconnected, or damaged.
●● Before starting electrical equipment, tighten
all the loose wire and repair damaged wires.
Clean and tighten all the electrical connec-
tors.
Fig.2-47

22222222 Fire treatment
●● Evacuate from the machine immediately.

●● If time allows, stop the engine. A running
engine will make the fire more severe.
●● If time allows, shift all the control devices
into neutral position.
●● If time allows, use the fire extinguisher be-
hind the seat in the cab.
Fig.2-48
First aid for accidental burns:
●● Immediately flush the burnt area with cold

water.
●● Wrap antibiotic bandage on the burnt area
and go for medical treatment.
Fig.2-49

2.5.6 Scald prevention
●● When operation is started, the cooling sys-

tem of the engine is hot and has pressure.
Hot water or steam from the engine, radia-
tor will cause serious burns.
●● During operation, engine oil, gear oil, and
hydraulic oil will become hot. The engine,
hose, pipes, and other parts will also be-
come hot. Maintenance work shall be start-
ed only after the oil and parts cool down.
●● Temperature of all the working components
of drilling rig such as rotary drive tank body
and pin axles will be higher because of fric-
tion. Direct skin contact may result in seri-
ous burns.
●● Antirust agent in cooling system contains
strong alkaline substances, may result in
personal injury. Avoid contact with skin,
eyes, and mouth.
Fig.2-50
●● Never open the radiator cap before the

engine cools down. When opening the cap,
slowly rotate the cap. When pressure is
completely released, remove the cap.
●● After drill rig operation, the hydraulic oil
tank is pressurized. Make sure to release
pressure before removing the cap.
Fig.2-51

2.5.7 Safety information of hose
Damage will cause hydraulic oil seepage and

a sudden move of working devices, which may
result in unexpected consequence.
●● Do not bend strike the pipes delivering

high pressure fluid. Do not install bent,
distorted, or damaged pipes.
●● Repair or replace, loose, or damaged

pipes. Leaking fuel and oil may cause
a fire.
● ● Because of aging, fatigue, and wear,
the hose containing flammable fluid

may crack under pressure.
● ● The aging hose should be periodically
replaced.
●● Make sure all the pipe clamps are cor-
rectly mounted to avoid vibration, and
possible hose damage during machine
operation.
●● When maintaining or dismantling hy-
draulic elements such as hose and
valve block, plug all connecting port to
avoid foreign matter entering hydraulic
oil and causing pollution.
For any of the following situation, replaced the
hose as soon as possible:
●● End connector is damaged or leaked.

●● Hose outer surface is scratched or cut.
●● Exterior protective layer is scratched or Fig.2-52
pierced by steel wire or electrical wire.
●● Exterior protective layer is partially expand-
ed.
●● The hose has crack and distortion marks.
●● Interior frame damages the exterior protec-
tive layer.

2.5.8 Fluid leakage
●● Periodically check the hydraulic pipeline.

Carefully check all the hoses, and do not
check leakage by hand. The leaked fluid
should be cleaned promptly.
●● Carefully check all the connecting and
parts of the hose whether they are loose.
Tighten all the joints and connecting pieces
with recommended torque.
●● When installing or dismantling hydraulic
components, or during oil changing and
maintenance, use a container with suffi-
cient capacity to hold the fluid. Never dis-
charge oil onto the ground.
NOTICE
Fig.2-53
●● Do not spill any oil on the ground.
●● Put your used oil in a clean plastic con-
tainer with a tight lid. Never store used
oil in a container that once held chemi-
cals, food, or beverages.
●● Do not mix the oil with anything else,
such as antifreeze, solvent, or paint.
●● Take used oil to a service station or other
location that collects used oil for recy-
cling.
For more information, go to http://www.epa.
gov/osw/conserve/materials/usedoil/

2.5.9 Crawler safety information
●● Apply high pressure lubricating grease to

crawler adjusting system to keep the crawl-
er tensioned.
●● Grease in crawler tension cylinder has high
pressure. If the high pressure grease is
spewed onto body, it may cause serious or
fatal injury.
●● Function of the buffer spring is to buffer
the impact force on the tension pulley. It
includes a high pressure spring, incorrect
dismantling may cause sudden fly off of the
spring and then result in personal injury.
WARNING
Failure to observe the following may pose
Fig.2-54
risk of getting burned, hit or being injured
by the falling objects!
●● Pins and bushings on track shoe is
very hot after working. To avoid getting
burned, never contact with these parts
for long period of time.
●● The drilling rig chassis can extend. to
avoid getting hit, keep clear from both
sides of the crawler during extending
process.
●● During the process of dismantling or in-
stalling the crawler, the crawler may sud-
denly slide. Keep clear from both sides
of the crawler.

2.5.10 Lightening and strong wind pre-

cautions
●● When there is lightening near the drilling rig,

do not climb up or down the drilling rig. Dur-
ing lightening strike, if the operator is in the
cab, he should stay inside. If the operator
stands on the ground, keep a distance from
the drilling rig.
Fig.2-55
●● If the wind force scale reaches force eight,

stop drilling operation and lay the mast in
horizontal position.
Remark:
Force eight wind power: wind speed 17.2 m/s
to 20.7 m/s, 62km to 74km per hour.
2.5.11 Falling protection
When performing maintenance, repair, or in-

stallation work, there is potential falling hazard.
Protection methods must be taken, for exam-
ple, wear safety belt or use special falling pro-
tection devices.
WARNING
Fig.2-56
Rotation of drilling rig and crawler may
cause injury or possibly death!
During traveling, construction and drilling,
standing on the crawler or upper carriage
is prohibited. Failure to do so may result in
Fig.2-57

2.5.12 Noise protection
●● Being around loud noise for a long period

of time will cause hearing impairment or
loss.
●● Wear proper hearing protector such as ear-
plug so as to avoid hazardous or uncom-
fortable loud noise.
Note:
Noise for operator in the cab of the machine is

≤80db (a).
Fig.2-58
2.5.13 V
ibration
When the equipment is in operation, vibration

is less than 0.5m/S ︿ 2.
2.5.14 Wire rope safety information
Wire rope is one of the crucial parts for rotary

drilling rig and also a quick-wear part. Correct
selection and reasonable utilization and main-
tenance could extend service life of the wire
rope and avoid accidents.
●● Connection between wire rope, hook, and

wire rope connector, and inspection, main-
tenance, and discarding of wire rope must
strictly comply with relevant laws and regu-
lations for crane industry in the country.
●● Newly replaced wire rope should usually
share the same model and specifications
with the former installed wire rope. If adopt-
ing a different model, the user should make
sure the new wire rope is not inferior to the
original wire rope.

●● Do not use wire rope with potential safety

hazard, such as kinking, broken wire, de-
formation, and so on.
●● Wear protective gloves when dealing with

wire ropes.
Replace as soon as possible, if any of the fol-

lowing situation happens:
●● Broken wire appears at the rope end or

nearby.
●● Strand cracks.
●● Resilience decreases, rope diameter is un-
dersized, and lay length extends.
●● Exterior and interior side of the wire rope is
severely corroded.
●● Wire rope wear.
●● Wire rope deformation.
●● Rope diameter undersized.

2.5.15 Climbing on/off drilling rig
●● Only climb on or off the machine from ar-

eas with steps and/or handrails. Check and
clean the steps and handrails before climb-
ing on the machine.
●● When climbing on or off the machine, face
the machine and maintain three-point con-
tact with handrails and steps. Three-point
contact could be both feet and one hand or
one foot and both hands.
Fig.2-59
Fig.2-60
Fig.2-61

●● Never attempt to bring tools or articles

when climbing on or off the drilling rig.
●● Never use any lever as handrail when en-
tering or leaving the cab.
●● Never walk or climb outside the area speci-
fied for the drilling rig.
●● Remove all mud, oil, and water from the
pedal, handrail, and shoes.
CAUTION
In order to avoid injury, never climb on or

leave the machine when the machine is
traveling or running. Never jump from the
machine. Failure to do so may cause injury.
2.5.16 Kelly bar and drilling tools Fig.2-62
WARNING
The toppling drilling tool and Kelly bar may

result in injury or possibly death. Take ef-
fective safety measures during transporta-
tion.
●● Stored drilling tools or Kelly bar may topple

over resulting in serious fatal accidents.
●● Choose proper location to store Kelly bar
and drilling tools.
Fig.2-63

2.5.17 W orking at areas with under-

ground pipelines
●● Before drilling, the contractor should con-

firm whether there is underground utilities
at the working area.
●● If there is underground utilities, develop a
reasonable construction scheme to guaran-
tee safety of utilities and working personnel.
●● Operator should be clear about specific po-
sition of the pipeline, and use proper meas-
ures, and proceed with caution.
●● If pipeline or its protection is damaged ac-
cidentally, the operator must stop operation
and report to responsible person.
Fig.2-64

2.5.18 Working at areas with high volt-

age power lines
WARNING
If you will be working in an area where

overhead power lines pose a hazard, it is
important to be aware of the dangers in-
volved with these systems. Always be cau-
tious when working near overhead power
lines. Failure to follow the information list-
ed below could result in injury or possibly
death.
●● Personnel working near high voltage power

lines must be familiar with safety rules
during operation. Personal protection and
accident precautions should comply with
relevant regulations of the power company
in charge.
●● To ensure the equipment does not exceed
the clearance range, operator should con-

sider factors such as mast position, ground
condition and wind force.
●● If construction around high voltage power
lines cannot be avoided, notify relevant
electric department, and ask professionals
to handle it.
●● If the ambient humidity is higher, electric
shock may also happen without touching
the power line.
Note:
When working near overhead power lines, any

parts of the machine, working tools, or hoisted
load should keep a safety clearance of three
meters. When the voltage is above 5000v, for
each 1000 volts, the corresponding distance
should increase one meter.
Fig.2-65

2.5.19 Electrical accident
WARNING
Risk of injury or possibly death!

If the drilling rig comes in contact with
electric lines, leaving the drilling rig or get-
ting close to or touching the drilling rig will
pose an electric shock hazard!
If the drilling rig comes in contact with
electric lines, ground surface around the
drilling rig is also electrified, this also pos-
es a hazard!
●● If the drilling rig comes in contact with

electrical lines, operator should discon-
nect the drilling rig from electrical lines,
warn workers nearby to keep clear of
the drilling rig, and ask technician to
cut off the power.
Fig.2-66
●● If an accident happens, cut off the power

immediately, call a doctor, and do first aid
under the guidance of doctor or rush the
injured to hospital.
●● A l loperators should know first aid

about electrical accidents.
Fig.2-67

If the drilling rig comes in contact with electric

lines, operator should follow the procedures
below:
●● Be sure the high voltage power line is cut
off.
●● The best manner is to jump down instead of
climbing off.
●● Jump away from the drilling rig with both
feet together.
●● Do not touch any parts of the drilling rig
with body after hitting the ground.
●● When hitting the ground, hop or jump with Fig.2-68
both feet together away from the drilling rig.
Do not stride.
2.6 Safety During Operation
2.6.1 Staff
WARNING
Operating the machine while distracted can
result in the loss of machine control. Use
extreme caution when using any device
while operating the machine. Operating the
machine while distracted can result in per-
sonal injury or death.
●● Before starting work, staff must read this

manual and relative safety information, and
fully understand the safety instructions.
Relevant personnel (such as assembly and
maintenance personnel) must also be fa-
miliar with the equipment and safety infor-
mation.
●● The operator must understand the rig’s
structure, performance, operation methods,
maintenance procedures, various com-
mand signals and basic drilling knowledge.
No one other than the operator is allowed
to operate drilling rigs.

●● An operator must pay attention to his op-

eration. Staff should understand how to use
safety equipment and the adequate meas-
ures to take if damages occur.
●● Be familiar with such dimensions as height,
width and swing scope in order to maintain
a safe distance between the equipment
and nearby obstacles.
●● Long hair, loose and sloppy clothes, neck-
laces, bracelets or rings could get caught
on the machine.
●● Operating under fatigue, or the influence of
alcohol or illness may lead to severe acci-
dents.
●● During operation, staff must wear safety
equipment, such as hard hat, protective
shoes, goggles, gloves, mask, work clothes
and other required items.
●● An operator should be responsible for op-

erations under his control. He has the right Fig.2-69
to refuse operations demanded by others,
which can lead to dangerous accidents or
infringe laws and regulations.
●● Only those who have experienced opera-
tion training can operate the equipment un-
der the direct supervision and guidance of
an experienced operator.
●● Only professionals who are familiar with hy-
draulic, electrical, welding and debugging
are allowed to carry out relevant mainte-
nance and service of the machine.
●● If the operator has any question about the
safety of the machine, he must stop it at
once and report to person in charge.
●● The owner or authorized person should
check the safety awareness of operation
and maintenance during their operation.

2.6.2 Personal protective equipment
Wear adequate protective equipment accord-

ing to the on-site situation.
●● Hard hat: wear hard hat to protect your

head.
Fig.2-70
●● Goggles: wear goggles to protect eyes.
Fig.2-71
●● Earplug: earplugs are needed if the sound

volume is expected to surpass 90db (a).
Fig.2-72

●● Gas mask: protect staff from hazardous

gas, steam, fog or dust near the operation
site.
Fig.2-73
●● Protective gloves: wear gloves to avoid

possible damages during operation.
Fig.2-74
●● Safety boots: wear safety boots to reduce
the possibility of foot injury.
Fig.2-75
●● Protective suit: wear protective suit to pre-

vent hazards of burning, corrosion, sprain
or scratch on the body.
Fig.2-76

2.6.3 Keeping the drilling rig in good

service condition
Making sure the rig is in a good operation sta-

tus can effectively reduce the occurrence of
accidents, and improve construction efficiency
and equipment service life.
●● The inside of cab should remain clean and

neat. The operator’s personal items should
be kept where they will not affect his op-
eration, tools, and other necessary items
should be placed into the tool case or the
storage areas.
●● All signs on the drilling rig are designed for
the purpose of safe and proper operation.
All relevant staff should get familiar with
the location and meaning of the signs, and
keep the signs intact and clear, preventing
them from being covered.
●● Keep the machine clean; remove all obsta-
cles such as broken stones, grease, tools
and other items that do not belong to the
machine.
●● All decals, tags and identification plates for
caution and danger should be installed and
kept clear. Replace at once if they are dam-
aged or lost.
●● Keep alarms and horns in good working
condition.
●● Without the written consent by the manu-
facturer, the user shall not perform any
modification or accessory addition which
affects the safety of the machine, including
installation and modification of safety de-
vices or pressure regulating valve.
●● Ensure that all the protective equipment for
the drilling rig, such as hood, cover plate
and protective cover, are installed correctly
on the required location of the machine.
●● Be careful of protecting control units when
washing or cleaning the drilling rig. Fig.2-77

2.6.4 Safety on construction site
WARNING
Use extra caution in construction site. Fail-
ure to follow the information listed below
could cause injury or possibly death.
●● The construction site must be equipped

with distinctive decals preventing non-rele-
vant staff from entering. The site should be
blocked from around.
●● The mud pit should enclosed, and warn-
ing decals of “caution, danger and warning”
must be erected.
●● Bore holes shall be covered with a cover
plate of enough load-bearing capacity.
Warning decals should be erected near the
cover plate to indicate the whole location
and the danger.
Fig.2-78
●● The connection and disconnection of all
power supplies and electric circuits on the
construction site shall conform to the cur-
rent industry standards.
●● The construction site shall be equipped with
good surrounding illumination.
●● Thoroughly inspect the area for any unu-
sual conditions that could be dangerous
before starting any operations.
●● Before starting any work operations, travel
or maintenance and repair procedures, be
sure all personnel are at a safe distance
away from any point on the machine. Never
allow anyone to stand near the machine
while it is in operation, under maintenance
or being repaired.
Fig.2-79
●● If they must approach, signal them to stop
where they are, lower all work equipment
to the ground, set the work equipment
hydraulic lock lever in the LOCKED
position and shut the engine down. When it
is safe for them to approach, signal them to
approach.

●● Make sure all controls are in neutral before

starting the rig.
●● Position the rig on level ground if possible.
Install blocking under each track to insure a
stable lifting platform in case the ground is
broken or soft.
●● Before moving the rig, make sure there is
nothing in the way of travel. Make sure the
Kelly bar is out of the ground and secured
before moving.
●● Before raising the mast, make sure it is
clear of tools or objects that could fall.
Check to see that no hydraulic hoses
become snagged during raising.
●● Keep work area clear of cuttings, tools and
other objects.
●● When leaving the job site, always lower
all work equipment to a safe position,
neutralize work equipment controls and
lock and secure your equipment properly to
avoid tampering by unauthorized personnel.
●● Never leave your equipment running and
unattended. Always park the equipment
in a stable, level area, lower any work
equipment to a safe position, lock the
controls and turn the engine off before
exiting the operator cab.
●● Use extra caution when working near
overhanging banks or on grades that could
cause the drilling rig to slide or roll over.
Fig.2-80

2.6.5 Signals to control operation
●● Only trained and qualified persons are al-

lowed to give signal.
●● Both operators and support personnel shall
make clear the meaning of signals being
used.
●● An operator shall stop his operation when
he is unclear about the meaning of any sig-
nal.
●● An operator shall receive indication signals
from a single person.
●● The flagman shall stand in a safe location,

where he can view all the operation sites.
Attention Fig.2-81
One arm stretches upwards with the palm

open
Fig.2-82

Stop in emergency
Both arms stretch out and keep waving
Fig.2-83
Begin moving
One arm stretches upwards and keep waving
Fig.2-84
Indicate more room for moving
Place both hands at level near the chest, in-

dicating there is still some horizontal distance
before stopping moving
Fig.2-85

Stop moving
Arms stretch outwards horizontally
Fig.2-86
Move forwards slowly
Keep arms at level with palms backwards and

wave slowly
Fig.2-87
Retreat slowly
Keep arms at level with palm centre forwards

and wave slowly
Fig.2-88

Indicate more room for moving
Place both hands at level near the chest, in-

dicating there is still some horizontal distance
before stopping moving
Fig.2-89
Move in the right direction
Keep the back of left hand upwards, with the

thumb indicating the direction for moving
Fig.2-90
Move in the left direction
Keep the back of right hand upwards, with the

thumb indicating the direction for moving
Fig.2-91

Rotate in the right direction
Right thumb indicates rotating direction with

left hand circling
Fig.2-92
Rotate in the left direction
Left thumb indicates rotating direction with

right hand circling
Fig.2-93
Lift the load
Right palm upwards, left hand moves up and

down before the chest
Fig.2-94

Lower the load
Right palm downwards, left hand moves up

and down before the chest
Fig.2-95
Crawler extends
Lift the arms, with fists clenched slightly and

both thumbs pointing outwards
Fig.2-96
Crawler retracts
Lift the arms, with fists clenched slightly and

both thumbs pointing inwards
Fig.2-97

2.6.6 Drilling rig danger area
●● The drilling rig’s swing and sudden tilt may

result in serious injury or death.
●● Put up warning decals if necessary, to en-
sure non-relevant staff do not approach
danger areas.
●● The operator shall warn others to keep
clear.
Danger area within which the drilling rig moves
Fig.2-98
Danger area within which the drilling rig

perform swing motion
Fig.2-99

2.6.7 Avoiding tipping
CAUTION
Operator shall fasten his seat belt. if ma-
chine tipping occurs, it is safe for the op-
erator to stay in the cab. Never attempt to
jump off the toppling machine. Failure to
do so may cause injury.
Tipping may occur in the following conditions:
●● The drilling rig is traveling on unstable or

sloping grounds, including backfill, slope,
Fig.2-100
suspended land, ravines, drainage, land-
slides, embankment.
●● The winch is overloaded.
●● Sudden acceleration or deceleration in Fig.2-101

moving, sudden upper carriage swing and
whole vehicle rotation.
When the drilling rig is at its normal traveling
position, the operator shall look towards the
uphill direction when traveling up a slope. He
shall look towards the downhill direction when
traveling down a slope. Such requirement is
aimed to keep the rig’s centre of gravity as far
back as possible to ensure that sudden move-
ment of centre of gravity does not lead to the
rig’s instability.
Before traveling up or down a slope, adjust

the mast’s inclination angle. Avoid change of
direction and motion on a slope. Do not stop
the vehicle or perform swing operation when Fig.2-102

traveling up or down a slope. Pay attention to

the mast’s inclination angle when traveling up
a slope. Over inclination may make the drilling
rig tilt backwards.
Before driving the drilling rig, put work unit,

Kelly bar, drilling tool to a lower location.
When the drilling rig is operating on a work

site with slopes extend the crawler to its ut-
most width (for rigs with this function). At this
moment, the maximum grade of slope on the
ground is 2°, only suitable for solid and rigid
ground.
Do not reduce the speed suddenly when

traveling down a slope. Before passing dan-
gerous ground, be sure to check the grade of
slope and whether the ground is solid enough.
Make judgment and selection on the routes
and ground in advance, try your best to avoid
dangerous ground.
Level sloping and sinkable ground in advance.

Ensure the drilling rig’s requirements for incli-
nation angle are met and the ground is rigid
enough to bear the drilling rig.
When working or traveling on the frozen

ground, pay attention to the effects of temper-
ature and pressure on the ground.

2.6.8 Before entering the cab
CAUTION
Keep the cab door in locked position. If
unlocked in operation, the door may move
automatically, leading to the operator’s
distraction from attention or even injury.
●● Before entering the cab, be sure to remove

mud and grease from the soles of your
shoes. In order to avoid falling.
●● Wipe the dust off the glass surface to en-
sure good vision, and put the cab door to
a locked position of being either opened or
closed.
●● The operator may adjust the seat back tilt.
Select the desired position in order to allow
full pedal travel and full lever travel.
Fig.2-103

2.6.9 Before starting the engine
●● Check whether gauges are in good condi-

tion, and whether levers are in neutral posi-
tion. Ensure that the illumination system on
the drilling rig works well.
●● Check the area near and under the ma-
chine for blockage, loosed bolts, oil/coolant
leakage, or damaged or worn parts.
●● If the engine’s start, switch or lever is at-
tached with tags of “no operation” of similar
decals, never start the engine or any lever.
●● Before starting the engine, shift the lever to
the neutral position, and shift the hydraulic
lock lever to the locked position (L).
F
Fig.2-104
●● The waste gas discharged from the engine
is harmful to human health. Be sure to run
the engine in the well-ventilated environ-
ment.
●● If the user has to run the engine in an en-
closed area, he shall vent engine waste
gas outside the area.
●● The engine shall be warmed in advance
in cold weather. If the electrolyte is frozen,
melt it before recharging and starting the
engine.

2.6.10 Before operating the drilling rig
●● Clear all obstacles.

●● Ensure that all persons not involved in drill-
ing operation keep clear off the dangerous
areas.
●● Be familiar with dangerous terrains near
the drilling rig, such as cable trench and
backfill.
●● Lock the door in a fixed position and make
sure it will not sway during operation.
●● Adjust the rear-view mirror to enhance the
visibility.
●● Ensure that horn and all alarms on the drill-
ing rig are in good working condition.
●● Before moving the drilling rig, examine the
relative positions of upper carriage.
●● Fasten the seat belt.
Note:
●● The right traveling direction: front idlers are
in the front under the cab, while traveling

drives are at the back.
Traveling drive Front idler

●● When the cab is in its normal traveling posi-
tion, move the drilling rig forwards by push-
ing the pedals forwards and move it back- Fig.2-105
wards by pushing the pedals backwards.
Push the left pedal, the left track moves
and the drilling rig rotates in the right direc-
tion. Push the right pedal, the right track
moves and the drilling rig rotates in the left
direction.
●● When the guide wheels are behind the cab,
all pedal motions and corresponding drilling
rig motions reverse the motions at the nor-
mal traveling position.

2.6.11 Drilling rig operation
WARNING
In order to avoid accident, personal injury

or possibly death, do as follows:
●● Ensure that there is no one standing
within the rig operation radius before op-
erating the drilling rig.
●● Never perform any operation before the
job site is clear.
●● Never drive the machine near objects,
cliff or digging area edges. Keep a safe
distance to areas with risks of landslide.
●● Never operate the machine in bad weath-
er. Rain or fog affect vision.
●● Never stand on the tracks to operate the
drilling rig.
●● Never move the mast while moving the
drilling rig.
●● Never rotate the equipment rapidly.
●● Never change the drilling rig’s motions
suddenly or repeatedly.
●● The operator must sit on the cab seat to op-

erate the drilling rig to avoid losing control.
●● When the drilling rig is traveling, especially
on uneven or rocky ground, the mast may
sway vertically or horizontally. Ensure that
the mast’s swaying range does not exceed
the specified value.
Remark:
The scope of mast inclination: forward inclina-

tion should be within 15°; backward inclination
should be within 30°; lateral inclination should
be within 10°.
●● Before rotating the swing system, check

whether there are obstacles within the

reach of drilling tool and mast, whether they

are high enough off the ground. Ensure that
ropes and mast do not hit other items.
●● When the drilling rig is traveling and before
rotating upper carriage rotary table, tilt the
mast backwards to a certain angle in order
to increase stability.
●● For the minimum distance to obstacles,
adhere to national and local construction
! !
safety laws and regulations.
IN
G
●● Pay extra attention when the drilling rig is BO
traveling on soft ground. Place wooden or
iron plates under the tracks if the ground is
soft or tends to sink.
●● Provide enough illumination if the drilling rig
has to be operated at night.
Fig.2-106

2.6.12 Construction of drilling rig

Before construction, choose the adequate
drilling rig, Kelly bars and drilling tools to meet
the geological and construction requirements.
●● Before construction, level the ground in ad-

vance.
●● Lock the traveling mechanism to prevent
unexpected moving of the drilling rig.
●● In case of soft ground, such as backfill and
silt, consolidate the ground in advance
before construction. When necessary, put
thick steel plates. Thickness of steel plate
should be no less than 20mm, their length
and width should be 1m longer than those
of the track.
●● Before lowering or erecting masts, make
sure the boom is higher than the cab to
avoid the cab being crushed.
●● When the drilling rig is in operation, its up-
per carriage and undercarriage must be
kept in parallel.
●● Never dump soil by lifting or lowering drill-
ing tools rapidly or knocking the tools upon
other objects.
●● Pay attention to the drill bucket and boom
height off the ground to avoid collision.
●● The drilling rig may tilt because of too large
crowd force generated by rotary drive or
during the drilling bucket is being lifted. If
this happens, stop operation immediately.
●● When the drilling rig is shut down for main-
tenance, raise the drilling bucket out the
hole to avoid being buried.
●● When the inclination angle of chassis does
not exceed 2°, construction on uneven
ground can be performed by adjusting mast
verticality.
●● Always check the wire ropes on the main
winch drum and rewind them if they get
twisted.

●● Always check Kelly bar working conditions.

If it cannot be retracted or extended, or
other abnormal conditions occur, report it at
once.
●● Always check the working conditions of
rope swivel. If wire ropes are twisted, check
the rope swivel, and replace it when neces-
sary.
●● When there is any sign of abnormalities,
stop the machine for trouble shooting and
resume work after it is repaired.
●● When the drilling rig is moving among dif-
ferent holes, keep a safe distance from
completed pile holes and blind holes, and
avoid the drilling rig’s overturn.
WARNING
●● traveling near a completed hole may lead
to the collapse and the rig’s overturn.
●● when Kelly bar or drilling tool is not
pulled out of the hole or is near the
ground, never attempt to tilt mast, per-
form swing or traveling operation. failure
to do so will cause serious damage to
the machine and personnel nearby.
Fig.2-107

2.6.13 Drilling rig dismantling
●● Use proper tools and allocate adequate

staff and support accessories. Crane and
sling shall have enough load-bearing ca-
pacity.
●● All the grounds should be even, solid and
open. There should not be obstacles like
high-voltage lines overhead.
●● Be sure to seal the hydraulic pipes well
and avoid oil leakage. Pay attention to the
oil pipe’s minimum bending radius. Do not
bend oil pipes.
●● The dismantled components should not be
placed on the ground. Put crosstie or plank
on the ground in the first place. Dismantled
small parts and pieces shall be placed in a
designated location.
CAUTION
Ensure that there is no one in the shaft
exiting direction and in the possible parts
moving direction. Failure to do so may
cause injury.
2.6.14 Parking safety
●● Always park the machine in a flat, stable

level location away from moving equipment,
pedestrians or traffic.
N
●● Place the left and right travel levers to neu-
tral position (N) before parking your ma-
chine.
N
Fig.2-108 Netural Position

●● Move the hydraulic lock lever to the

LOCKED position (L).
●● Stop the engine.
●● Turn the ignition key switch to the OFF po-

sition and remove the key.
Fig.2-110 Ignition Key Switch
●● Turn the battery disconnect switch to the

OFF position. Remove the disconnect
switch key if you do not operate the ma- OFF ON
chine for an extended period of time. This
will prevent drainage of the battery. A bat-
tery short circuit, any current draw from cer-
tain components, and vandalism can cause
the drainage of battery.
Fig.2-111 Battery Disconnet Switch

2.6.15 T
ransporting drilling rig
●● To transport the drilling rig, you must select

a vehicle with adequate load-bearing ca-
pacity, which must meet relevant transpor-
tation standards on special vehicles.
●● Be sure to dismantle the machine on solid
level ground.
●● The platform must be wide enough and its
inclination angle from the ground shall not
exceed 15°. The ramp shall be clean, free
of snow, oil or other item.
●● When loading the machine to the trailer or
unloading it from the trailer, a signalman
should provide support.
●● When loading the machine to the trailer or
Fig.2-112
unloading it from the trailer, pay attention to
the height of unit and the location of mast
to avoid collision. Ensure that the drilling rig
and trailer are in the same line, and tracks
on both sides have the largest contact area.
The front idlers shall be near the end of the
trailer, rotary drive at the sides of traveling
drives. Travel slowly onto the trailer at a
constant speed.
●● The drilling rig is specially equipped with
anti-rotation lock pins to avoid accidents
caused by the rotation of swing system
during transportation. Lock pins shall be in-
serted into the correct notch.
●● When passing through bridges and tunnels,
ensure the maximum load of bridge and
the size of tunnel meet the rig’s transport
requirements.
●● When transporting the drilling rig on a high-
way, fasten it tightly and follow the require-
ments of transportation laws and regula-
tions. Avoid sudden stop or sharp turn.
●● If the machine required to be shipped by
sea, anticorrosion treatment is necessary.

WARNING
●● when loading the machine on the trailer
or unloading it from the trailer, there is
rollover hazards when traveling on the
contract surface of trailer and spring-
board. travel slowly and steadily. FAS-
TEN THE SEAT BELT and HOLD THE
ARMREST firmly.
●● when loading the machine on the trailer
or unloading it from the trailer, make
sure the rig is traveling along the center
line of the trailer. never adjust the rig’s
direction or continue traveling after the
drilling rig strays from the center line.
●● strictly observe the transporting require-
ments in this manual. FAILURE TO do
so MAY CAUSE INJURY OR POSSIBLY
DEATH.
2.6.16 Drilling rig maintenance
●● Before performing any maintenance, serv-

ice or repair on the drilling rig, be sure to re-
DANGER
move the ignition key and hang warning de-
cals reading “DO NOT OPERATE” signs on
the drilling rig’s key switch, levers or control
panel, in order to avoid injury incurred by
wrong operation. DO NOT OPERATE
●● When performing maintenance and serv- When this is not being used,
ice, choose the adequate device to ensure keep it in the storage compartment.
good operation.
Fig.2-113

2.6.17 Winch operation
●● The winch is equipped on the drilling rig to

perform hole-drilling operation and shall not
be used other than such purpose.
●● Winching operation shall comply with rele-
vant laws and regulations where the drilling
rig operates.
●● The maximum lifting capacity of the winch
shall be made clear. Overloading must be
prohibited.
●● The lifted load shall be tied up firmly. Do not
lift items slantwise. Do not lift items that are
extruded together or buried in the soil or
has odd accessories.
●● When the load is about to depart from the
ground, make sure that the hoisting wire
rope and load are perpendicular to the
ground. It can avoid vibration when lifting
the load from the ground.
WARNING
When lifting the load, ensure that it is
placed ahead of the mast and the angle be-
tween wire rope and mast does not exceed
15°. Failure to do so may cause injury or
possibly death.

2.7 Maintenance Safety
2.7.1 Maintenance personnel
All maintenance to be performed on this

machine must be by trained and authorized
personnel. It is important to follow all mainte-
nance procedures and safety information.
Always be aware of the hazards when per-

forming maintenance on this machine.
2.7.2 Risks in maintenance
●● Comply with the operation requirements

listed in lubrication and maintenance parts.
●● For some potentially hazardous location,
use special caution when performing lubri-
cation and maintenance work.
●● On the machine decals, different signal
words are used to express the potential
level of hazard, including “notice, caution,
warning, or danger”. Its level goes up suc-
cessively, and caution should be enhanced.
Swing injury
Standing within the swing radius range may

result in injury or death.
Related parts: Counterweight, and upper car-

riage components.
Related maintenance: Add grease to the

swing gear ring of upper carriage.
Measures: Sound the horn to alert before

starting the machine. Never allow personnel to Fig.2-114
stand within the swing radius.

Hand injury and dragging hazard

DANGER
Be cautious of hand injury. All the rotating and
moving parts may cause hazards of hand in-
jury, body being caught, or dragging.
Related parts: Wire rope, all the pulleys,

winches, undercarriage, swing mechanism,
and boom mechanism.
Related maintenance: Replace wire rope;

add grease to crawler tensioning cylinder,
check and change for driving gear oil, etc. Fig.2-115
Measures: When replacing wire rope, adding
grease to crawler tensioning cylinder, check
and change for driving gear oil, arrange au-
thorized person.
Falling hazard
Climbing on and off the machine in incorrect

way easily poses falling hazard.
Related parts: All the climbing position, and

walking position.
Related maintenance: All the maintenance to

the upper carriage.
Measures:
Fig.2-116
●● Use the steps and handrails when climbing
on and off the machine. Check and clean
the steps and handrails before climbing on
the machine.
●● When getting on and off the machine, al-
ways face the machine and maintain a
three-point contact with the handrails and
steps.
●● When it requires to walk on the mast, be
sure to lower the mast in place and take ef-
fective measures to prevent slipping or fall-
ing.
Fig.2-117 Three-point Contact

Burn hazard
High temperature may cause burn to mainte-

nance personnel.
Relevant parts: Engine exhaust system, wa-

ter tank, engine, and working hydraulic system.
Relevant maintenance: Engine maintenance,

change of coolant, and hydraulic system main-
tenance.
Measures: After long time running for the en-

gine, do not immediately do maintenance to
hydraulic system, engine coolant, air intake,
air exhaust, and all that directly contacts the Fig.2-118
engine cylinder. Do this when the temperature
of the maintained position drops to the extent
that you can touch with hand.
High pressure fluid hazard
The spurting out fluids under pressure such as

diesel, hydraulic oil and grease can penetrate
skin or rip into eyes, and cause serious injury,
blindness, or death.
Related parts: Hydraulic pipeline components,

crawler tensioning cylinder.
Relevant maintenance: Maintenance of

hydraulic system, and maintenance of crawler
tensioning devices. Fig.2-119
Measures:
●● Tighten all the connections before pressu-

rizing.
●● Release pressure before disconnecting the
hydraulic pipeline.
●● Use a card to check for leakage and protect
your hands and body against high pressure
fluids. Wear mask or glasses in order to
protect your eyes.
Fig.2-120

Fire hazard
Leakage of fuel, hydraulic oil, and grease may

cause a fire.
Related maintenance: Hydraulic oil pipeline,

fuel system, and electrical system.
Measures:
●● After maintenance, clean up the fuel, hy- Fig.2-121

draulic oil, grease, debris, and other flam-
mable material. Check and clean the ma-
chine everyday in order to promptly remove
the accumulated flammable materials.
●● Clean and tighten all the circuit connection.
Check for looseness, twist, hardening, or
cracks of the cable and electrical wire.
●● Put fire extinguishers on site.
22222222 Preparing for maintenance
●● Notify the operator and assign a supervisor. Fig.2-122

●● Shut down the engine. If it is necessary to
run the engine during lubrication and main-
tenance work, run the engine.
●● Park the drilling rig on solid and level
ground, lower the work equipment to the
ground, then turn off the engine and re-
move the ignition key.
●● Neutralize the controls, then set the hy-
draulic lock lever to the locked position (L).
Fig.2-123

●● Before performing any maintenance or re-

pairs to the machine, OSHA law requires
all lock-out-tag-out procedures be used to
prevent any accidental operation of the ma-
chine during maintenance.
●● Make sure unauthorized person cannot
start the drilling rig (lock the cab door). In- DANGER
stall the proper alert tag to the work equip-
ment levers to warn others not to operate
the machine.
●● Before performing lubrication and mainte-
nance, lock the power switch and ignition Fig.2-124
switch of the electrical system.
●● Alert all personnel in your area that the
machine will be down for maintenance. If
necessary, tag the machine around specific
points to warn others that this machine is
down for maintenance. DANGER
If the machine is down for maintenance
DO NOT OPERATE
●●
for an extended period of time, be sure to

check and see if all lock-out-tag-out sys- When this is not being used,
tems are still in place. keep it in the storage compartment.
●● If you will be working under the machine, Fig.2-125

always use approved jack stands which will
support the weight of the machine.
●● If large heavy attachments from the ma-
chine should be removed, always be sure
to use the correct lifting equipment rated for
the capacity of the load you will be lifting.
●● After the attachment or part has been re-
moved, store it where it cannot fall or move.
Always be sure what you are storing is sit-
ting stable on a stable surface and clear of
all walkways or fire exits.
●● Before starting maintenance, clean the
drilling rig, and especially remove lubri-
cant, fuel, or any additives at the joints and
coupling. Do not use corrosive detergent.
Adopt non-fibre cleaning rag.

●● Before spraying with water or steam or

using any other detergent, cover all the
components that may be affected by water,
steam, or detergent.
●● After cleaning, remove the covering articles.
Check for residues within these areas.
●● After cleaning, check for leakage of all the
fuel pipeline, engine oil line, and hydrau-
lic oil line. Check the joints for looseness,
cracks, or damage.
●● Always use the proper tools for the job.
Fig.2-126
Using tools that are incorrect, defective or
damaged could cause serious injury. Keep
your tools clean, and when the job is com-
plete, take inventory of the tools you were
using to be sure no tools were left in the
machine.
●● During maintenance, oil fluids overflowing
may occur. Prepare suitable container.
22222222 During maintenance
●● Suitable space and auxiliary equipment are

needed for maintenance.
●● Carefully blockade the maintenance area.
●● When changing a single component or larg-
er combined component, park it. Make sure
there is no damage.
●● Only use auxiliary equipment with enough
bearing capacity.
●● Do not stand, walk, or work under hoisted
load.
●● Only assign experienced personnel to di-
rect within the view of the operator. Send
signals to the operator.
●● When performing maintenance work, con-
nect loose bolts.
●● If the safety equipment needs to be re-
moved during maintenance, it must be rein-
stalled afterwards.

●● Make sure all the tools and equipment

parts meet the requirements of environ-
ment protection and safety.
●● Be sure flammable materials are stored
away from places with fire hazard.
●● Regularly check the electrical equipment
of the drilling rig. Immediately repair or
change the loose joints and burnt cable.
●● Only qualified electrician or trained per-
sonnel under the supervision of qualified
electrician can perform maintenance to the
electrical system according to electrical
regulations.
●● Only use original fuse with specified electric
current intensity.
●● Before performing maintenance to the hy-
draulic system, release pressure.
●● Regularly check for leakage of all the hoses
and joints of the hydraulic system. Check
for damage to appearance. If any damage
is found, repair or replace immediately.
●● Only professional person with hydraulic
knowledge can perform lubrication or main-
tenance to hydraulic.
●● When handling lubricants, grease, or other
chemical substances, abide by safety regu-
lations for corresponding products.
●● Use caution when handling high tempera-
ture system (scald or burn hazard).
●● Avoid over lubrication.
―― over lubrication will cause grease or lu-
bricant to leak, and result in operation
fault.
―― lubricant or grease dropped on passage
way will cause people to slip.
―― over filling oil level will cause oil foam,
which could result in high oil tempera-
ture and result in the oil overflowing.
―― if too much grease is added, it will cause
the bearing sleeve push-out.

●● Be sure no tools are left in the machine af-

ter work.
●● Be cautious of the protection for pipe open-
ing, joint, and wire to avoid oil leakage.
●● During maintenance, use caution to guard
small parts, and take proper anti-pollution
measures.
●● Perform welding and grinding work only on
explicit permission.
●● Before welding and grinding, keep the drill-
ing rig clear of dust and flammable materi-
als.
●● Never handle wire rope with your bare
hands or cloth type gloves. When handling
wire rope, always wear thick leather gloves.
Broken or damaged wire strands could
easily penetrate your skin or cause serious
lacerations.
Fig.2-127

2.8 Environment Protection
NOTICE

cling.
For more information, go to http://www.epa.
gov/osw/conserve/materials/usedoil/
2.8.1 Proper waste disposal
●● Improper waste disposal will do harm to the

environment and the ecosystem.
●● Potentially hazardous substances in SANY
equipment include hydraulic oil, fuel, cool-
ant, brake fluid, filter, accumulator and so
on.
●● Environment protection laws and regula-
tions may vary from region to region. For
proper waste disposal process, refer to lo-
cal environment protection or recycling cen-
tre or your designated dealer.
Fig.2-128

2.8.2 Mud pollution
If mud protection is used, pay attention to the

following aspects:
1. Determine the volume of mud pit according

to the construction situation.
2. Lay out the mud discharging system rea-

sonably.
3. Recycle, store and reuse drilling fluid ad-

equately.
4. Clean the job site after construction is com-

pleted. Waste mud shall not be abandoned
at will.
Fig.2-129
2.8.3 Fuel emissions
●● Shut down the engine or lower its power at

work intervals in order to reduce the dis-
charge of waste gas or noise.
●● The use of poor fuel not only does harm to
the machine, but also emits large amount
of harmful gas and dust, causing pollution
to the environment.
Fig.2-130

E
G
PA
K
AN
BL

SR200C(SY) Rotary Drilling Rig System Function
System Function
3 System Function
3.1 General Structure of Rotary Drilling Rig.................................................................... 3-3
3.2 Function Description................................................................................................. 3-5
3.3 Components Explanations...................................................................................... 3-13

System Function SR200C(SY) Rotary Drilling Rig
WARNING

3 SYSTEM FUNCTION
3.1 General Structure of Rotary Drilling Rig
Fig.3-1 General Structure of Drilling Rig

Table 3-1 Function descriptions

Sn Name Function
Controlled by hydraulic system, could achieve forward traveling, back-

1 Travelling Mechanism ward traveling, left steering, right steering, and pivot steering function,
and accordingly drive the drilling rig to travel and move.
2 Counterweight Enhance the stability of the drilling rig.
3 Upper carriage House the engine, hydraulic system, control system, and the cab.
A moveable link between the triangle and the upper carriage. Adjust the
4 Boom
distance between the mast and the upper carriage.
5 Boom Cylinder Control rotation of the boom.
Rotate synchronously with the boom to keep the triangle parallel with the
6 Supporting Rod
upper carriage.
7 Auxiliary Winch Auxiliary lifting appliance used for load handling.
8 Triangle Used to place the auxiliary winch.
9 Mast Cylinder Adjust the angle of the mast.
10 Auxiliary Winch Wire Rope Auxiliary lifting appliance used for load handling.
11 Main Winch Wire Rope Used to lift and lower the Kelly bar.
12 Middle Mast Guide for Kelly bar and rotary drive.
13 Upper Mast Guide for Kelly bar.
14 Pulley Yoke Wire rope sheave, and support and guide wire ropes.
15 Swivel Connect main winch wire rope and Kelly bar to prevent rope twist.
16 Kelly Guide Used to guide Kelly bar and mount bearing.

It transmits torque and rotary movement from rotary drive to the drill buck-
17 Kelly Bar et. It is telescopic tubular shape drilling bar. The maximum hole depth
depends on the whole length of Kelly bar.
18 Crowd Cylinder Provide downward pushing and upward pulling force for the rotary drive.
19 Rotary Drive Provide rotary power and torque for Kelly bar and drill bucket.
20 Mast Rotary Table Rotary connection between mast and triangle.
21 Main Winch Used for lifting and lowering Kelly bar.
22 Drilling Bucket Drill and transport slag and soil.
23 Main Winch Frame Used to locate main winch and guide rotary drive.
24 Lower Mast Erode and convey soil.

3.2 Function Description
3.2.1 Undercarriage
Undercarriage carries the upper carriage and

moves it from one drilling spot to the next. The
traveling mechanism is mainly composed of
track roller bracket, hydraulic motor, reducer,
sprockets and tensioning device, tracks, track
wheel and idlers. Traveling mechanism is con-
trolled by hydraulic system. It can achieve for-
ward traveling, backward traveling, left steer-
ing, right steering, and pivot steering function.
Fig.3-2 Undercarriage
3.2.2 Upper carriage
Upper carriage is mainly composed of swing

unit, hydraulic pump assembly, operator’s cab,
engine, counterweight, hydraulic oil tank, and
fuel tank.
Fig.3-3 Upper carriage

3.2.3 Hydraulic system
The rotary drilling rig adopts whole hydraulic

control drive. Its working principle is illustrated
in the figure below:
Boom
Boom cylinder
Main winch
Auxiliary winch
Mast cylinder
Crowd winch
Travel motor
Rotary drive Swing motor
Travel handle
Main valve
Auxiliary valve
Left handle
Right handle
Logic valve Pilot main pipe

Crawler extend/
retract cylinder
Pump group
Oil filter
Oil tank
Fig.3-4 Hydraulic System

3.2.4 Electrical system
The electrical system is composed of sensor,

electrical control unit and actuating element.
The electrical system of the machine is illus-

trated in the figure below:
1. Other input device

2. Display
3. Executing device
4. Leveling handle
10 18
5. Signal detecting device
1 11 6. Display
7. Chassis controller
7
12 8. Electromagnetic valves
9. 2024 controller
15 19
2 10. EMC module
11. Start electromotor
12. Hydraulic pump
16 13. Other input device
3 8 14. Buzzer
18. Engine
15. Accumulator group
4 19. Generator
9 13 20 21 16. Fuse box
5 17
17. Other device
6 14 20. GPS
21. Air conditioner
Fig.3-5 Electrical System

3.2.5 Main winch
Through the winding/unwinding of the relevant

rope (a), the main winch (b) controls the up/
down movements of the Kelly bar (c) and the
drilling tool connected to the bar.
Fig.3-6 Main Winch

3.2.6 Auxiliary winch
Through the winding/unwinding of the relevant

rope (d), the auxiliary winch (e) is used to hoist
and handle objects.
Fig.3-7 Aux Winch

3.2.7 Mast
Main feature of the mast is to allow for the slid-

ing of the rotary drive and the Kelly guide.
The mast structure is made in such a way to

allow using the max working torque for the
whole sliding length of the rotary drive along
the guides.
Terminology:
1) Pulley yoke
2) Upper mast
3) Middle mast
4) Lower mast
1 2 3 4
Fig.3-8 Mast

3.2.8 Rotary drive
Rotary drive is a very important component of

drilling rig. It provides rotary movement and
torque for Kelly bar and drilling bucket. It is
composed of hydraulic motor, reducer, reducer 1
box, buffer unit, crowd sledge, connecting
plate, flange or casing driver. 2
Terminology:
1. Connecting plate
2. Reducer
3. Casing 3 4
4. Casing driver plate Fig.3-9 Rotary Drive

3.2.9 Kelly bar
It is possible to equip the machine with Kelly

bars of two different types:
1
●● Friction bars
●● Locking bars
The difference between the two types is that
the internal elements of the friction bars trans- 2
mit the thrust force each other by friction, while
those of the locking bars transmit this force
through special locking recesses.
3
Main elements:
1. Kelly eye
2. Shock absorbers
4
3. Drive gib
4. Locking recesses
5. Shock absorbing spring
6. Drive stub
5
Fig.3-10 Kelly Bar

3.3 Components Explanations
3.3.1 General view of the operator cab
1. Left Operation Handle
Fig.3-11 Internal Structure of the Operator Cab I

2. Left Travel Pedal
3. Left Travel Control Handle
4. Right Travel Control Handle
5. Right Travel Pedal
6. Display
7. Engine Monitor
8. Mast Adjusting Lever
9. Right Operation Handle

Fig.3-12 Internal Structure of the Operator Cab II
10. Auxiliary Control Panel

11. Seat
12. Radio Panel
13. Air Conditioner Panel
14. Operating Box
15. Hydraulic Lock Lever
16. Bubble Level

3.3.2 Chassis monitor system
33333333 Screen introduction
The instruction of the devices for operating

your machine is listed below.
To operate your machine safely and properly, it
is important to fully understand how to use the
device and what is indicated on the screen.
8
1
a b c d e a b c d e
2
Rotary drilling rig chassis
9
10
3
C H C H
11
E F E F
4 12
12345 12 12 12 12 12 12345 12 12 12 12 12
Lo Lo
5
F1 F2 F3 F4 F5 F1 F2 F3 F4 F5 13
6
ESC Enter ESC Enter
14
7
Fig.3-13 Monitor
1. Warning lamp 8. Working mode monitor

2. Signal indicators 9. Throttle gear monitor
3. Display screen 10. Engine coolant temperature
4. Guidance icons 11. Fuel level
5. Function keys (F1 – F5) 12. Clock
6. ENCODER knob 13. Fault code
7. Navigation keys 14. Service hour meter

WARNING LAMP (1):

When the controller detects a fault and trans-
mits the signal to the monitor, the alarm lamp
will light up and turn red. It remains unlit under
normal conditions.
SIGNAL INDICATORS (2):

These indicators can be illuminated, as re-
quired, to indicate special signals.
Swing to Left (a)
Light (b) 1
a b c d e a
Swing Braking (c) 2
Emergency Shutdown (d)
Swing to Right (e)
Fig.3-14 Signal Indicators
SCREEN DISPLAY (3): 3
C H
●● Items displayed on the screen include

coolant temperature gauge (above), and
E F
fuel level gauge (below). 4
12345 12 12 12 12 12 1234
●● Working modes H, S, L and B are displayed Lo
in the upper-left corner. B is breaker mode;

5
S is the default mode. Switch the working F1 F2 F3 F4 F5 F1
mode by pressing F1. 6

ESC Enter ESC
FUNCTION BUTTONS (5):
Functions of the five buttons (F1 - F5) are in- 7

dicated respectively by the icons displayed in
the area (4).
●● F1 – Working mode: Press F1 to select a

working mode in a H–S–L–B sequence.
S
H – Heavy load working mode
S – Standard working mode
L – Light load working mode
B – Breaker working mode
Fig.3-15

Remark:
Mode H and S is common for rotary drilling

rigs.
●● F2 – Auto-idle switch: Press F2 to switch

between auto idle mode and non-auto idle
mode.
Auto idle mode is indicated by a tortoise;
Non auto idle mode is indicated by a rabbit.
Fig.3-16
●● F3 – High/Low travel speed switch: Press

F3 to select high or low travel speed. Lo
indicates high travel speed; Hi indicates
high travel speed.
●● F4 – Alarm cancel switch: Press F4 to

display the alarm code and discontinue the
Fig.3-17
alarm.
●● F5 – Information menu: Press F5 to enter
the information menu and set system
information.
Description above is the functions of key F1
– F5 under normal operation condition. Their
functions may differ under different working
conditions.

ENCODER KNOB (6):
This knob can be turned in both the left and

right directions to regulate the value. It can
also be pushed in for confirmation.
The knob can have different functions on dif-

ferent screens.
NAVIGATION KEYS (7):
The up , down , left and right

keys are used to set a pass code or scroll
through a list of options. Press ESC to exit
and press ENTER keys to confirm.
Enter
These keys are defined with different functions

on different screens.
WORKING MODE SELECTION (8):
H - Heavy Load Operating Mode
S - Standard Operating Mode Sany Heavy Machinery

Rotary Drilling Rigs
L - Light Load Operating Mode
S is the default mode after starting your ma-

chine. 8 9
ENGINE SPEED MONITOR (9) Fig.3-18 Working Mode Selection
It displays the current engine speed level. Turn

the fuel control dial to modify the engine speed
level reading, ranging from 0 to 11.

COOLING WATER TEMPERATURE (10):
There are in all 13 sectors (yellow) to indicate

temperature ranged from 0 to 120 Celsius de-
grees.
●● It is shown as figure (A) when the engine

（A）
has just been started.
●● It is shown as figure (B) when the
temperature stays between 0 and 110
Celsius degrees.
●● If the temperature exceeds 110 Celsius
degrees, the corresponding part of the half （B）
circle turns red, as shown in figure (C). At
the same time, the warning lamp (1) and
the icon above F4 will be illuminated in red.
●● When the temperature decreases below
110. Celsius degrees, the warning lamp
goes out automatically. （C）
Fig.3-19 Cooling Water Temperature
FUEL LEVEL (11):
●● The monitor measures fuel level ranging

from 0 to 100%, displayed by 13 yellow
ranges.
●● When fuel level is below 8%, all ranges （A）
disappear, as shown in Fig. A. At the same

time, alarm lamp (1) and icon above F4
light up and turn red.
●● When fuel level rises above 8% (as shown
in Fig B), the alarm lamp goes out. （B）
●● When the fuel tank is refilled, Fig C is

displayed.
（C）
Fig.3-20 Fuel Level

CLOCK (12)
The clock is located in the right side under fuel 14 13 12

level gauge. It shows the current local time.
12345 12 12 12 12 12
FAULT CODE (13)
Lo
●● Fault code is displayed right under the fuel
level gauge.
●● When a fault is detected, a red number will
Fig.3-21
appear, indicating the corresponding fault
code. The alarm lamp and the icon above
F4 light up and turn red, and the buzzer
sounds.
●● No number is displayed when no fault is
detected.
SERVICE HOUR METER (14)
●● Service hour meter is located at the left

side under the fuel level gauge, indicating
the current service hour of the machine. "h"
stands for hour, and "m" stands for minute.
●● Press F5 when the normal operating
display is on to switch to Information Menu
password entry interface.

33333333 Screen display and operation
1. Initialization Screen
When turning the key switch to ON position,
Sany logo will be displayed on the screen, as
Rotary Drilling Rig Chassis
shown in Fig.3-22
Password Entries
Passwords are needed before accessing the

following three screens: system information,
system setting and system clock setting.
Buttons Operation:
●● F1: Press this button to scroll through the
corresponding number from 0 to 9, or press
the up key or the down key to
change current number.
●● F2: Press this button to move the cursor
from left to right in a cycling manner, or Fig.3-22 Initialization Screen
press the left key or the right key to
locate the number to be changed.
●● F3: Press this button to confirm the
password you have entered. If you have
entered the correct password, you are
allowed to access the corresponding
screen; if you have entered the wrong
ENTER INFO SEARCH CODE:
password, you will be prompted to enter the
password again.
00000
●● F5: Press this button to go back to previous
screen.
●● ESC and Enter: They are featured with
similar functions to F5 and F3 respectively.
F1 F2 F3 F4 F5
ESC Enter
Fig.3-23 Information Query

2. Operations Access the next interface:
●● F1 - Select an option: Use F1 key to scroll

through the list of options; or use the
Encoder knob to select an option. When an
option is selected, the option is highlighted System Info
with white bold characters against blue

background, while the unselected options OPERATING INFORMATION
are displayed in white characters against MACHINE CONFIGURATION

FAULT RECORD
black background. FUEL THROTTLE INST.AUX
●● F2 - Confirm a selection: After selecting an LANGUAGE SELECTION
option, press this button to view.

●● F4 - System Function Setting: Press F4 Engine.pump and valve para
to enter system function setting screen

(system setting password entry).
F1 F2 F3 F4 F5
●● F5 - Return key: Press the key to go back
to the main menu. Its function is similar to ESC Enter
the key.
3. Operating Information
Fig.3-24 Information list
On this menu you can view the information of
the engine, fuel throttle, pilot pressure, main
pump and main valve.
1) Engine Information
Engine menu:
—— Coolant Temperature ℃ Engine Information
—— Fuel Level %
Fuel Capacity ℃： 123
—— Oil Pressure kPa
Coolant Temp ℃： 123
—— Hydraulic Oil Temperature ℃
Oil Pressure KPa： 123
Hydraulic Oil Temp ℃： 123
F1 F2 F3 F4 F5
ESC Enter
Fig.3-25 Engine Information

Throttle menu:
—— Throttle gear N
—— Engine Speed rpm
—— Gear Position V Fuel Throttle Information
―Throttle Position V
Throttle Gear N: 12
Engine Speed rpm: 1234
Gear Position V: 1.23
Throttle Position V: 1.23
F1 F2 F3 F4 F5
ESC Enter
Fig.3-26 Throttle Information
3.3.3 Hydraulic Lock Lever
WARNING
Be sure the hydraulic lock lever is in

locked position before entering or leaving
the cab.
Always be aware of the hydraulic lock
lever position while in the operator cab.
Failure to do so may result in accidental
movement of the controls.
When it is in horizontal state (F), the hydraulic

system is unlocked. The hydraulic system of F
the machine could function normally.
When it is in vertical state (L), the hydraulic

system is locked. The hydraulic system of the
machine cannot function except for the crawler L
extending & retracting, traveling, and mast
vertical adjusting.

3.3.4 Operation Control Assistant
1 2 3 4 5 6
START
X
MA
ON
OFF T
HEA
MIN
9 8 7
Fig.3-28 Operation Control Assistant
1. Engine ignition switch
OFF: insert or remove the engine ignition

switch only while the ignition switch is in the
OFF position. Turn the ignition key to the OFF
position to shut down the engine.
ON: turn the engine ignition key clockwise to

the ON position in order to activate all cab cir-
cuits.
START: turn the engine ignition key clockwise

to the START position in order to start the en-
gine. Release the ignition key after the engine
starts. The ignition key will return to ON posi- Fig.3-29 Engine Ignition Switch
tion.

2. Engine speed control dial
Turn the engine speed control dial to control

the engine speed. Select the desired position
from the 10 available positions. The selected
position is indicated on the electronic monitor
panel.
DECREASE: Turn the engine speed control

dial counterclockwise in order to decrease the
engine speed.
INCREASE: Turn the engine speed control

dial clockwise to increase the engine speed.
3. Light switch
This switch is used to control the working light

(one) on the right platform.
Fig.3-30 Light Switch

4. Window wiper switch
This switch is used to control the window wip-

er of the front window and clean the window.
Note: If the window wiper does not operate

with the switch in the ON position, turn the
switch off immediately. If the switch remains
on, wiper motor failure can cause.
Fig.3-31 Window Wiper

5. Detergent switch
Press the switch, detergent spurts out from

front window.
6. Overhead lamp switch
This switch is used to control the work lamps

(two) in operator’s cab.
7. Track extending and retracting switch
This switch is used to control track extending

and retracting.
8. Generator indicator
The indicator lamp will turn on when the key

switch is in the ON position; the indicator lamp
will turn off when the engine keeps running; if
the lamp does not turn off, check the genera-
tor and find abnormalities.
9. Preheat indicator

3.3.5 Air conditioning system
1 2 3 4 5
FULL AUTO AIR CONDITIONER

MODE AUTO
A/C
6 7 8
Fig.3-32 Control Panel
1. OFF switch
2. Fan speed control
3. Temperature control
4. MODE control
5. AUTO control
6. Fresh air/ recirculation
7. LCD display
8. A/C power
Remark:
When AUTO control (5), fresh air/recirculation control (6) and A/C power (8) are switched
on, the indicator light above respective switch is on.

(1) OFF switch
The switch(1) is used to switch off the fan and

air conditioner.
When the OFF switch (1) is pressed, the tem-

perature and air delivery shown on the LCD
OFF
display disappear, the indicator lights above
the AUTO control switch and A/C power switch
are off, and the air conditioner stops operation.
Fig.3-33
(2) Fan speed control
The switch (2) is used to regulate the amount

of air delivery.
Six air delivery levels are available for selec-

tion.
Air delivery level is shown on the LCD.
●Press to increase the air delivery.
●Press to decrease the air delivery.

Fig.3-34
●Air delivery level is selected automatically
under AUTO control.
LCD display and air delivery

A B
● A: LCD display
a
● B: Air delivery b
c
● a: Low flow
d
● b: Moderate flow -1 e
f
● c: Moderate flow - 2
Fig.3-35
● d: Moderate flow - 3
● e: Moderate flow - 4
● f: High flow

(3) Temperature control
This switch (3) is used to control the tempera-

ture inside the operator cab.
The temperature can be set between 18°C

(64.4°F) and 32°C (89.6°F).
●● Press to increase the air delivery.

●● Press to decrease the air delivery.
●● The temperature is generally set at 25°C
(77°F). Fig.3-36
LCD display and function
L C D d i s p l a y ( °C) Set temperature

18.0 Maximum cooling
18.5-31.5 Adjust temperature inside operator cab to the preset temperature
32.0 Maximum heating
(4) MODE control

LCD 4
Use the switch (4) to select air outlets.
●● When the switch (4) is pressed, the LCD

will display the mode selected. The air will
come out of the outlets displayed.
●● The blowing pattern changes automatically
under AUTO control.
Fig.3-37

LCD Dis- Air Outlet

Air Outlet Mode Remark
play A B C D
Front outlet for face ○ Disabled in auto mode

Front and back outlets
○ ○
for face
Front and back outlets
○ ○ ○
for face and feet
Air outlet for feet ○
air outlet for feet and
○ Disabled in auto mode
defroster
Air outlet for defroster ○ Disabled in auto mode
A air outlet for back
B air outlet for face
C air outlet for defrosting
D air outlet for feet
Remark:
Air comes out of the outlet identified with ○.
(5) AUTO control
This switch (5) can be used to set air delivery

level, outlets and fresh air or circulation auto-
matically according to the preset temperature.
AUTO
●● Pressing the AUTO control switch(5), the
indicator light above the switch comes on. Fig.3-38
●● Generally, pressing this switch and setting
with the temperature control switch (3) to a
suitable temperature, the air conditioner will
run automatically.
●● Changing from AUTO control to manual
control requires only resetting the air
delivery level, outlets and fresh air/
recirculation mode. The indicator light
above the switch goes out.

1 2
(6) Fresh air/recirculation FULL AUTO AIR CONDITIONER
This switch (6) is used to open or close the

fresh air inlet.
●● After the switch is pressed, the indicator

light above the switch is on, indicating a
6 7
state of taking in fresh air.
Fig.3-39
●● Fresh air and recirculation modes toggle
automatically under AUTO control.
The air inlet is closed. The air will

recirculate in the operator cab.
It is suitable for rapid cooling or
Recirculation
heating of the operator cab. It is
also used when the external air is
contaminated.
Fresh air is taken into the operator
cab.
Fresh air
It is used to take in fresh air and
defog.
(7) LCD display

c
LCD display (7) shows the preset temperature
(a), air delivery (b) and outlet position (c) dur- a

ing operation.
b
●● By pressing the OFF switch (1), the display
of preset temperature (a), air delivery (b) Fig.3-40
and outlet position (c) disappears, and the
operation stops.

(8) A/C power switch
The A/C power switch (8) is used to switch on/

off the air conditioner or its operation (cooling,
dehumidifying and heating).
A/C
●● When the fan is working (the LCD displays
(b)), press the A/C power switch (8) to
activate the air conditioner. The indicator
above the switch will be illuminated. Press Fig.3-41
this switch again to deactivate the air
conditioner. The indicator goes out.
●● The air conditioner is disabled when the fan
is switched off (outlet position disappears
from the LCD display).

3.3.6 Radio
33333333 Control panel
6 5 4 3 2 1
PRESET STATION
1 2 3 4 5 6 AS/PS AM/FM TIME SEL
TUNING TIME ADJ VOL

AM ST
FM
H M ADJ — +
7 8 9 10
Fig.3-42 Radio Control Panel
1. Power Switch
2. Sound Effect Switch
3. Time Display
4. FM/AM Band Selector
5. AS/PS Button
6. Preset Buttons (1, 2, 3, 4, 5, 6)
7. LCD Display
8. Tuning Buttons
9. Time Set Buttons
10. Volume Control

Power Switch
Push the power switch (1) in order to turn on
the radio. The frequency is shown on the LCD
display (7). Push the power switch again in or-
der to turn off the radio.
Sound Effects Conversion

●● Pressing the switch (2) each time, the
sound effects will be displayed in turn:
VOL→ BAS → TRE→ Balance.
●● The host machine will return to frequency
display in terms of no operation within 5
seconds.
●● The state of sound effects will be displayed

on the LCD display (7).
Time Display
●● Pressing the switch (3) will display
frequency in priority.
●● When the frequency is displayed, pressing
the switch (3) will display the present time
for 5 seconds. The display will resume
displaying frequency after 5 seconds.
●● Depress the button (4) for more than 5
seconds in order to display the region:
ASIA: EU.
FM/AM Band Selector
Press the switch (4) to select the desired
band. Pressing the button each time toggles
the band between FM and AM.
AS/PS Button
The button (5) is used to auto scan and preset

stations.
●● Auto Scan:
When tuning in the radio, pressing the but-
ton AS/PS (5) allows you to scan each
preset station, which will be played for 10
seconds, while the number of the preset
station scanned is blinking on the display. If

you want to tune in some station, press the

button (5) again.
●● Preset Stations:
When tuning in the radio, depressing the
button AS/PS (5) for more than 2 seconds
will activate the auto scanning of current
stations. Six radio stations that have the
strongest signal will be stored in turn to the
(6) buttons (1-6). Now you can play any of
the preset stations.
Tuning in Preset Stations (1, 2, 3, 4, 5 and 6)
●● If the buttons (6) have been preset with

some stations, you can press any of the
buttons to play the preset station.
LCD Display
The band, radio frequency, preset number and

time will be displayed on the display (7).
Tuning button
Press the button (8) to change frequency.

Time Set Button
Press the button (9) to reset the time.
H: Hour
M: Minute
ADJ: Set to 00 minute
Volume Control
●● Press the button "+" (10) in order to

increase the sound volume. The maximum
volume is 40.
●● Press the button "-" (10) in order to
decrease the sound volume. The minimum
volume is 0.
●● In case of no operation within 5 seconds,
the display returns to show the frequency.

Radio Operation
Presetting Radio Station
1. Press the power switch (1) in order to show

the frequency on display (7).
2. Press one of the tuning buttons (8) to locate

the desired frequency. There are two tuning
ways: manual and automatic.
3. When desired frequency is shown on the

display (7), depress one of the preset but-
tons for at least 1.5 seconds. The voice will
disappear. But the voice will come back
when the presetting operation (storing to the
memory) is completed. The preset button
number and the frequency will be displayed,
indicating the completion of presetting
operation. After presetting the stations,
press one of the preset buttons (6) for at
least 1.5 seconds in order to tune in the
preset station.
Remark:
The AS/PS button can be used to preset the

stations automatically.
Searching Radio Station
1. Press the power switch (1) in order to show

the frequency on display (7).
2. Press one of the tuning buttons (8) to locate

the desired frequency. There are two tuning
ways: manual and automatic.
●● Manual Tuning
Press one of the tuning buttons (8) till the fre-
quency appears on the display (7).
＜ key: Decrease the frequency.
＞ key: Increase the frequency.

When the frequency reaches its maximum or

minimum limit, it will cycle in the order of max-
min or min-max.
●● Automatic Tuning
Depress one of the tuning buttons (8) will ac-

tivate automatic scanning of radio stations.
When any station is found, the tuning stops.
To scan next station, depress one of the tuning
buttons (8) again.
＜ key: Decrease the frequency.
＞ key: Increase the frequency.
If this button is pressed during automatic tun-

ing, automatic tuning will be cancelled. The
setting returns to the previous frequency be-
fore the button is pressed.
Sound Effect Convertion Method:

●● VOL - Volume: Press "+" in order to
increase the volume, which can be
increased to 40. Press "-" in order to
decrease the volume, which c a n b e
decreased to 0.
●● BAS - Bass: Press the SEL key (2) in order
to access sound effect and select BAS.
Press VOL key (10) within 5 seconds in
order to change the bass level between +7
and -7.
●● TRE - Treble: Press the SEL key (2) in
order to access sound effect and select
TRE. Press VOL key (10) within 5 seconds
in order to change the treble level between
+7 and -7.
●● BAL - Balance: Press the SEL key (2) in
order to access sound effect and select
BAL. Press VOL key (10) within 5 seconds
in order to change the balance of the left
and right audio channels between L9 and
R9. BAL.0 means that both audio channels
are kept balanced.

Remark:
For any mode, the display will return to show
previous setting if no operation is done within
5 seconds.
Setting the Time Correctly

1. Press the button (3) to display the time. The
display will return to show radio frequency
after 5 seconds and the time cannot be re-
set. In this case, press the time display but-
ton (3) again.
2. Press one of the time adjustment keys (9) in

order to select hours or minutes.
H key: Hour adjustment
(Pressing this key once will increase 1 hour.)

M key: Minute adjustment
(Pressing this key once will increase 1 minute.)

By pressing the H key or the M key, the hours
or minutes will keep going till the key is re-
leased.
ADJ key: When pressing the ADJ key, the
time will be preset as following:
●● When it displays 00-05 minutes, the time

will return to 00 minute and 00 second. (The
hours remain unchanged.)
will advance to 00 minute and 00 second.
(The hours will be more.)
1
can not be preset. (Time remains the
same). A
Fig.3-43

Antenna
Before moving your machine into any build-
ing, it is necessary to put away the antenna
in order to prevent intervention. Put away the
antenna by the following steps:
1. Loosen the antenna’s mounting bolt (1) in

order to place the antenna in position (A).
2. Tighten the bolt (1) after storing the anten-

na.
Radio Operation Precautions

●● To be safe, the volume should be kept at a
level that you could hear the outside sound
during operation.
●● The penetration of water into the
loudspeaker or radio may lead to
unexpected trouble. In this case, be careful
of not getting the device wet.
●● Do not use benzol, diluent or other solvent
to clean the control panel or push buttons.
Soft dry cloth shall be used for cleaning. If
the device is too dirty, wipe it with alcohol.
●● When disconnecting or replacing the
battery, the preset stations and the clock
will be cleared. Therefore, the settings
should be readjusted.
3.3.7 Traveling lever/pedal
The travel lever and pedal is an integrated

device. Tramping the pedal and push or pull
the handle can both achieve the traveling and
steering operation for the drilling rig.
Fig.3-44 Traveling Lever/Pedal

3.3.8 Left and right operation handle
33333333 Left operation handle button func-

tion
A- PWM button: Pushing upward is to activate

slewing, while pushing downward is to reset
depth.
B- Button: Switch over between the main and B A
auxiliary winches. D
C
C- Button: Backup.
D- Button: To activate the buttons.
Fig.3-45 Left Handle Diagram

33333333 Right operation handle button func-
tion
E-PWM button: Pushing upward is free-fall,

while pushing downward is backup button.
F-Button: Switch over between crowding and

derricking.
F
G-Button: High torque with normal/low speed. E G H
H-Button: Horn.
Fig.3-46 Right Handle Diagram

33333333 Left operation handle directional

function
Lower Main Winch

B A
A
Lower Auxiliary Winch
C D Rotate Left of Rotate Right of
Upcarriage Upcarriage
Raise Auxiliary Winch
Raise Main Winch
Fig.3-47 Left Handle
●● When switched to main winch control: push

forward to lower the Kelly bar, and pull
backward to make main winch raise the
Kelly bar.
●● When switched to auxiliary winch control
and auxiliary unlocked: push forward to
lower the auxiliary winch rope, and pull
backward to raise it.
●● Push upward the button A and push the
handle left to make the upper carriage slew
left, and push upward the button A and
push the handle right to make the upper
carriage slew right.

33333333 Right operation handle directional

function
E F
G F Crowding
E G
H Lower Boom
H Rotary Drive Rotary Drive
Rotate Positively Rotate Reversely
Raise Boom
Hoisting
Fig.3-48 Right Handle
●● Push it left to make the rotary drive rotate

positively, and push it right to make the
rotary drive rotate reversely.
●● High torque with low speed: depress button
G and push the right handle left to make
the rotary drive rotate positively with low
speed and high torque; depress button G
and push the right handle right to make the
rotary drive rotate reversely with low speed
and high torque.
●● When switched to crowding: push it forward
to extend the crowd cylinder piston rod,
namely, to crowd the Kelly bar; pull it
backward to retract the crowd cylinder
piston rod, namely, to raise the rotary drive.
●● When switched to boom: Push it forward to
lower the boom mechanism, to make the
mast move forward; pull it back to raise the
boom mechanism to make the mast move
backward.

3.3.9 Mast adjusting lever
NOTICE
Never operate the handle too fast. It may

pose hazard to the moving mechanism.
Operating this lever (1), control the mast an-

gle.
1
Front
Front left Fro
press
Left the
button
Back left Bac

After the top button of the lever is depressed, Fig.3-49 Mast Adjusting Lever Back
the action of the adjusting lever could be acti-
vated.
●● P u s h forward the adjusting lever to

enable the mast forward movement;
●● P u l lbackward to enable the mast
backward movement;
● ● Push
1 left to enable
the adjusting lever
the mast leftward movement;
● ● Push the adjusting lever right to enable Front
the mast rightward movement.
Front left Front right
●● Push the adjusting lever front left to

enable the mast move forward and slightly press
Left the Right
leftward.
button
●● Push the adjusting lever back left to enable
the mast move backward and slightly
leftward.
Back left Back right
●● Push the adjusting lever front right to Back
enable the mast moves forward and slightly
rightward. Fig.3-50 Mast Adjusting Lever Function
Diagram

●● Push the adjusting lever back right to

enable the mast moves backward and
slightly rightward.
The movement range of the handle directly af-
fect the moving speed of the controlled mech-
anism, the smaller range of the handle, the
slower speed of the controlled mechanism; the
larger range of the handle, the faster speed of
the controlled mechanism. When the handle
range reaches the maximum, the speed of the
controlled mechanism is also the fastest.

3.3.10 Display
The display is human machine interface (hmi),

which could perform control operation for the
system, and provide alert for operation and
system assistance.
The display mainly indicates depth, speed,

slew angle, alert, switches operation functions,
and sets parameters.
The input voltage range for the display screen

is DC 20.4v-27.6v, and the ambient humidity is
20-85%RH.
333333333 Start-up and language select inter-

face
After the engine is started, the display shows F1 F5

the start-up interface, as illustrated on right fig- F2 F6
ure.
F3 F7
Display buttons layout:
F4 F8
From the top to bottom on the left side are: F1, F9

F2, F3, and F4; from the top to bottom on the
right side are: F5, F6, F7, and F8; the knob on
the bottom right is F9. Fig.3-51 Start-up Display Interface
It will access language select interface auto-

matically after three seconds.
Language select interface
Press F4 to select English, and press F8 to F1 F5

select Chinese. Then accesses the drilling op- Beijing Sany Heavy
eration main interface. F2 Machinery Co., Ltd. F6
F3 Sany Group F7
F4 ENGLISH CHINESE F8
Fig.3-52 Language Select Interface

333333333 Drilling operation main inter-

face
3 7
1 F1 F5
ALARM
4
2 F2 OPERATION STANDARD
GEAR
F6
SINGLE BUCKET DEPTH
REAL TIME DEPTH
5 8
MAIN WINCH PULL OIL PRESSURE
DRILL DEPTH
6
F3 CALIBRATION
MAIN WINCH SPEED
SWING ANGLE
F7
11 CROWDING
SET MAIN WINCH
F4 F8
MAST REPOSITION
TRAVEL LOCKED
10 9
Fig.3-53 Drilling Operation Main Interface
Interface info description:
1. The histogram indicates individual bucket

depth, namely, the drilling depth of each
bucket for the drilling rig.
2. The number indicates individual bucket

depth, synchronized with histogram 1.
3. The histogram indicates the drilling depth of

the current hole, the real time hole depth.
4. The number indicates the drilling depth of

the current hole, synchronized with histo-
gram 3.
5. Real time depth, namely the depth position

that the drilling bucket is located.
6. Main winch pull, namely the pulling force

that the main winch rope bears.
7. Cross histogram indicates the mast rake

values. With mast being perpendicular to
the ground as the origin, positive value on
X-axis represents rightward rake, negative
value on X-axis represents leftward rake,
positive value on Y-axis represents forward
rake, and negative value on Y-axis repre-
sents backward rake.
8. Swing angle, namely the swing angle of the

upper carriage. Swinging right is positive
value, while swinging left is negative value.
9. Indicating crowding or derricking mode;

travel unlocked or locked mode; main winch
or auxiliary winch activation mode.
10. when the red alert signal blinking ap-

pears, it indicates a failure or limit switch
activation. It’s accompanied with alert ring-
ing. When the blinking appears, it indicates
disconnection from the control unit.
11. Main winch speed indicates the lifting and

lowering speed of main rope.
Optional functions: display rotary drive torque,

crowding force, rotary drive rotate speed, main
winch speed.
Buttons description:
●● F1: Alarm. To access alarm interface
●● F 2 : O p e r a t i o n . To a c c e s s o p e r a t i o n
interface
●● F3: Calibration. To access calibration
interface
●● F4: Set. System parameters setting and
professional maintenance personnel enter
with password
●● F7: Oil pressure. To access digital oil gauge
indication picture
●● F8: Vertical adjusting. To access mast
vertical adjusting interface

333333333 Alarm interface
Press F1 button key in drilling operation inter-

face, and it will access alarm interface.
On this interface eight items of alarm indica- F1 ALARM F5

tions are available, including main winch limit, BACK
auxiliary winch limit, mast left limit, mast right

F2 MAIN WINCH LIMIT LUFFING REAR LIMIT
F6
limit, derricking rear limit, lubricant filter clog-
ging, auxiliary fuel tank filter clogging, and AUX.WINCH LIMIT LUBRICANT FILTER
CLOGGING
system fault. F3 AUX. FUEL TANK FILTER F7

MAST LEFT LIMIT CLOGGING
In case of an alarm, a red “√” will appear after F4

MAST RIGHT LIMIT SYSTEM FAULT
F8
the alarm item.
Press F5 button key in this interface and it will

return to drilling operation interface. Fig.3-54 Alarm Interface
333333333 Operation interface
Press F2 in drilling operation interface, and it

will access operation interface, which is mainly
operation switchover interface. In operation in-
terface, the “red solid circle” represents being OPERATION
selected, and “blank circle” represents being F1 BACK

F5
not selected.
F2 AUX.WINCH LOCKED/UNLOCKED TRAVEL LOCKED/UNLOCKED F6
Button description:
F3 LUFFING/CROWDING LIMIT SWITCH ACTIVATION/DEACTIVATION
F7
●● F2: Switch over between auxiliary winches
locked condition and unlocked condition.
F4 F8
●● F3: Switch over between derricking and
crowding (sharing the same function with F
button of right operation handle).
Fig.3-55 Operation Interface I
●● F6: Switch over between travel unlocked
and locked condition. In travel unlocked
condition, it drives the travel operation rod,
and the track travels normally; in travel
locked condition, the track can not travel.

●● F7:Switch over between limit switch

activation and deactivation condition. The
limit switch is activated, namely it alerts
when the actuating mechanism comes in
contact with the limit switch, and the action
stops immediately and will not continue; the
limit switch is deactivated, namely it alerts
when the actuating mechanism comes in
contact with the limit switch, and the action
does not stop and still continues.
●● F5: Return to drilling operation interface.
●● F8: Access the next interface of the
operation interface.
Button description:
●● F1: Switch over between main winch and

auxiliary winch.
●● F2: Main winch free-fall control (same as MAIN/AUX.WINCH
upward pushing function of the button E of F1 F5
the right operation handle).
●● F3: Eliminate the alarm sound. F2 FREE-FALL DEPTH RESET F6
●● F4: Switch over between slack rope switch-
off enabled and disenabled. F3 ALARM ELIMINATE SWING ANGLE
RESET
F7
●● F6: Reset the current depth, and re- SLACK ROPE SWITCH-OFF CAB COLLISION
F4
ENABLED/DISENABLED
F8
PROTECTION
ENABLED/DISENABLED
calculate the hole depth. (same as
downward pushing function of the button A
of the left operation handle).
●● F7: Swing angle reset key. The swing angle Fig.3-56 Operation Interface II
will be reset to “zero”, and the swing angle
indicator will also point to “zero” position.
●● F8: When the key is in activated state
and the mast rake is less than -20°, the
operator must raise the derricking to active
derricking rear limit. Switch first and then
the mast could be lowered and erected
normally.
●● F5: Return to the previous interface.

333333333 Calibration interface
Press F3 button key in drilling operation in-

terface, and it will access the first interface of F1 SAVE
CALIBRATION
BACK F5
calibration interface.
SWING ANGLE CALIBRATION
F2 F6
DEPTH MEASURING CALIBRATION
This interface is mainly to calibrate the slew

angle and depth measurement. DRILLING DEPTH M
F3 F7
SWING
Calibrating operation explanation:
CURRENT DEPTH M
Turn the knob F9 to select the data to be cali- F4 F8

brated. White invert means being selected,
such as . After selection, press
the button F9, and then the number begins to Fig.3-57 Calibration Interface I
blink, namely, it enters editing state. Turn the
knob F9 clockwise, the blinking number varies
in the sequence of “-, 0, 1, 2……9”. Select a
number and press button F9 to confirm. Suc-
cessively turn F9 in order to change other
numbers. After the changing, press the save
button, and the calibrated value can become
effective. Setting range of the calibrated val-
ues is -9000‰~9000‰.
Calibration formula:
Value after calibration=value before calibration
x (1+calibrating value)
Button description:
●● F1:Save. Save the set calibrated value to

the control unit. Only the save button is
depressed, the set calibrated value can be
effective. CALIBRATION
F1 SAVE BACK F5
●● F5: Return to drilling operation interface.
MAIN WINCH PULL COMPENSATION
●● F8:Access to next interface, the second F2 PULL RESET F6

interface of the calibration interface. This
GROUND PULL SET
interface is mainly to calibrate the main F3 F7
t
winch pull. MAIN WINCH PULL
t
Modification operation and formula is the same F4 F8
as the above.
Fig.3-58 Calibration Interface II

Button description:
●● F1:Save. Save the set calibrated value to

the control unit. Only the save button is
depressed, the set calibrated value can be
effective.
●● F6: Reset the main winch pull.
●● F8: Return to the previous calibration
interface.
●● F5: Return to the drilling operation interface.
333333333 Setting interface
Press the F4 button key in drilling operation

interface, and it accesses the setting interface.
This interface is for setting of system parame- F1 F5
ters. Only professional maintenance personnel PASSWORD INPUT
can enter with a password. F2 BACK F6
Press the button F5 to return to the drilling op-

F3 F7
eration interface.
F4 F8
Fig.3-59 Password Entry Interface
333333333 Oil pressure interface
Press the F7 button key in drilling operation

interface, and it enters digital oil gauge indica-
tion interface. This interface mainly indicates F1
MPa MPa MPa
F5
the pressure values of main pump 1, main 30 30
20 40 20 40 20
pump 2, and auxiliary pump, and the unit is 10 30
F2 10 50 10 50 F6
MPa.
0 60 0 60 0 40
If the frame following the sensors displays “√”, F3 MAIN PUMP 1 MAIN PUMP 2 AUX.PUMP F7
it indicates that the corresponding sensor has MAIN PUMP 1 SENSOR
fault. F4
MAIN PUMP 2 SENSOR BACK
F8
AUX.PUMP SENSOR
Press the button F8 to return to the drilling op-

eration interface. Fig.3-60 Oil Pressure Interface

333333333 Mast vertical adjusting inter-

face
Press the F8 button key in the drilling opera-

tion interface, it will enter mast vertical adjust-
ing interface. In this interface various operation Y+
BACK
and adjustment to the mast can be achieved.

F1 F5
MANUAL
F2 Y- F6
Button description:
●● F1: In inching mode, y positive direction X+

F3 F7
means the mast inclines forward.
●● F2: In inching mode, y negative direction X-
F4 X: Y: F8
means the mast inclines backward.
●● F3: In inching mode, x positive direction
means the mast inclines rightward.
●● F4: In inching mode, x negative direction Fig.3-61 Mast Vertical Adjusting Interface
means the mast inclines leftward.
●● F5: Return to the drilling operation mode.
Only in manual mode can it return to the
drilling operation interface.
●● F6: Switch over between manual, inching,
and auto operation mode.
Manual mode:
The display screen shows MANUAL. Only in

manual mode, can the mast adjusting lever be
activated. In other modes, the mast adjusting
lever is deactivated.
Inching mode:
The display screen shows INCHING. In inch-

ing mode, you can operate F1, F2, F3, and F4
buttons to adjust the mast in single direction.
Auto mode:
The display screen shows AUTO. In auto

mode, three types of automatic operation func-
tion are available including auto mast erecting,
auto mast lowering, and auto vertical adjust-
ing.

●● F7: Only when the F6 button is depressed

and it is switched to auto mode, can this
button function. Switch over between three
types of auto operation function including
auto mast erecting, auto mast lowering, and
auto vertical adjusting.
●● F8: Only when the F6 button is depressed
and it is switched to auto mode, can this
button function. Start or stop three types of
auto mast operation in button F7.

3.3.11 Anti-collision function of the op-

erator cab
CAUTION
Crushing hazard!
If the cab anti-collision function enabled/ -20° 0°
disenabled is in disenabled state, lowering

or raising the mast from +5° to -90° will
not be affected by boom back limiter. It
requires the operator to raise the boom
higher than the cab position before
lowering or raising the mast, so as to
prevent the mast crushing the cab and
causing injuries.
There is anti-collision function enabled/disena-

bled option on the second interface of opera- Fig.3-62 Crowding/Derricking Switchover Range
tion. Switch between enabled and disenabled
by pressing F8.
When the function is in enabled state and the

mast rake is between 0° to 20°, the switch be- F1
MAIN/AUX.WINCH
F5
tween crowding and derricking is available. If
the mast rake is between -20° to 90°, derrick-
F2 FREE-FALL DEPTH RESET F6
ing is allowed. If the cab anti-collision function
enabled/disenabled is in disenabled state,
lowering or raising the mast from +5° to 90° F3 ALARM ELIMINATE SWING ANGLE
RESET
F7
will not be affected by boom back limit switch. SLACK ROPE SWITCH-OFF CAB COLLISION
F4
ENABLED/DISENABLED
F8
PROTECTION
ENABLED/DISENABLED
Fig.3-63 Operation Interface

3.3.12 Slack rope switch-off
Press CALIBRATION in the main interface to

access the second interface of the calibration
interface.
CALIBRATION
F1 SAVE BACK F5
Pull reset key
MAIN WINCH PULL COMPENSATION
Press the pull reset key in order to return the F2 PULL RESET F6
pull force to zero when the Kelly bar touches GROUND PULL SET
the ground. F3 F7
t
MAIN WINCH PULL
Ground pull set key t
F4 F8
Set this value by the knob F9. Based on
the Kelly bar weight, the general computa-
tional formula is: Kelly bar weight *1/3 + rope
Fig.3-64 Calibration Interface
weight*3, and usually it is set to 4.5 tons.
Main winch pull compensation key
When the Kelly bar is away from the ground

and in static state (namely the Kelly bar does
not sway, and main winch pull indication is
stable), acquire the compensation value by
comparing the weight of Kelly bar (if equipped
with drilling bucket, add the bucket weight)
and actual indicated weight (main winch pull).
The formula is as follows:
Main winch pull compensation value = (actual

weight/main winch pull - 1) x 1000
MAIN/AUX.WINCH
Note: F1 F5
After the pull force is returned to zero, wait
for at least 100 seconds to shut down the
machine. In this way, the zero value could be
saved. F3 ALARM ELIMINATE SWING ANGLE
RESET
F7
On the second interface of the operation in-

SLACK ROPE SWITCH-OFF CAB COLLISION
F4
ENABLED/DISENABLED
F8
PROTECTION
ENABLED/DISENABLED
terface, there is slack rope switch-off enabled/

disenabled option, and it is in disenabled state
by default. It is illustrated in Fig.3-65.
Fig.3-65 Operation Interface II

When the key is in activated state and main

winch pull value is less than the set value,
operate the main winch, and it will not be low-
ered any more;
●● When the key is in deactivated state, even

if the pull value is less than the set value,
operate the main winch, and it can still be
lowered normally;
●● Slack rope switch-off function does not
function in free-fall condition.
333333333 Display protection
●● Do not strike or scratch the display screen

with hard objects.
●● Prevent water, chemical liquid, or metal
entering the display screen, because they
may cause display failure.
●● Avoid direct strong light and dust.
●● Make sure the display has enough radiation
space. Do not plug display louver.
●● Avoid sudden change of the ambient
temperature around the display.
●● Avoid violent swaying and vibration.
●● Avoid chemical gas in working environment.
●● Do not clean the display screen with
chemical substances.
●● After turning off the display power, turn on
the power again after a few seconds. If
the time interval is too short, it is possibly
unable to be started.

3.3.13 Seat
WARNING
Put the hydraulic lock lever in the LOCKED

position. Always do this procedure before
you adjust the seat and the console. This
will prevent any possibility of unexpected
movement of the machine.
NOTICE
Adjust the seat at the beginning of each

work period or when you change operators.
Select the desired position in order to allow
full pedal travel and full lever travel.
Always use the seat belt when you operate
the machine.
Adjust the seat height:
A multi-position, adjustable seat is provided for

operator comfort. Pull up the seat and release
until you hear a click, the height rises up a
gear; pull up the seat again and release until
you hear a click, the seat rises up a gear; pull
up the seat and release, then the seat returns
to the original position.
Fig.3-66 Adjusting the Height of Seat

Adjust the seat back tilt:
Pull up lever and move the seat back to the

desired position. Hold the seat in the desired
position and release the lever.
Lever
Fig.3-67 Adjusting the Back Tilt of Seat
Adjust the seat forward or backward:

Lever
座椅前后调节杆
Pull up lever and hold the lever. Move the seat
to the desired position. To lock the seat in the
selected position, release the lever.
承重调节器
Fig.3-68 Adjusting the Seat Forward or

Backward
Adjust the load bearing of the seat:
Adjust the load bearing dial according to the

operator’s weight.
Adjust the angle of armrest:
Operate the dial on the bottom of each arm-

rest. Place the armrest in the upright position
when you enter the machine or when you exit
the machine.

Seat belt:
Be sure the belt is not twisted and fits your

waist comfortably. Place the male end of the
belt into the latch until you hear a click indicat-
ing the belt is locked in place.
Fig.3-69 Adjusting the Seat Belt I
Adjust the seat belt around your waist snugly.
Fig.3-70 Adjusting the Seat Belt II
Depress the button on the latch to unfasten

the seat belt.
Note:
Occasionally inspect the belt for signs of

damage or wear. Never use a seat belt that
is damaged or worn. If the belt is found to be Fig.3-71 Adjusting the Seat Belt III
damaged or worn in any way, replace it imme-
diately.
Even if the belt appears undamaged, it is ad-

vised to replace it every three years. The date
of manufacture of the belt is shown on the
back of the belt.

3.3.14 Limit switch
The limit switch is used to limit the movement

range of the winch, mast, and boom. It is es-
sential guarantee for safe operation.
Table 3-2 Limit switches

SN Name Function
When it comes in
contact with load,
Auxiliary
1 it stops the lifting
Winch Limit
operation of the
auxiliary winch.
When it comes in
contact with Kelly
Main Winch guide sliding lug,
2
Limit it stops lifting op-
eration of the main
winch.
When the mast

inclines rightward
Limits mast to limit angle and
3
inclination to right comes in contact, it
stops action of the
mast cylinder.
When the mast

inclines leftward
Limits mast to limit angle and
4 comes in contact, it
inclination to left
stops action of the
mast cylinder.
When the boom is

lifted to limit angle
5 Boom back limit and comes in con-
tact, it stops action
of the mast cylinder. Fig.3-72 Limit Switches

3.3.15 Level
The level is located on the left front side of cab

bottom plate.
The position of the bubble in the level indi-

cates the inclining amplitude of the chassis.
When the air bubble is in the middle, the chas-
sis is in level position.
Fig.3-73 Level
Note:
During operation, the position of the bubble

should be within 2°. If not, level the ground be-
fore operation.
3.3.16 Alarm lamp (optional)
The alarm lamp is located on the counter-

weight of the equipment.
When the machine is slewing, the alarm lamp

will operate to alert personnel nearby to be
cautious and keep clear of the slewing range
of the drilling rig.
Fig.3-74 Alarm Lamp

E
G
PA
K
AN
BL

SR200C(SY) Rotary Drilling Rig Operation
Operation
4 Operation
4.1 Basic Operation......................................................................................................... 4-3
4.2 Drilling Rig Construction.......................................................................................... 4-54
4.3 Rigging & Derigging................................................................................................ 4-62
4.4 Wire Rope............................................................................................................. 4-107
4.5 Drilling Rig Transport..............................................................................................4-118
4.6 Kelly Bar................................................................................................................ 4-131
4.7 Drilling Tool............................................................................................................ 4-140

Operation SR200C(SY) Rotary Drilling Rig
WARNING

4 OPERATION
4.1 Basic Operation
4.1.1 Job preparations
When preparing to operate the drilling rig, it is

important to be aware of your working condi-
tions and hazards involved. Always study the
job site carefully before starting any opera-
tions. Be sure you and others involved under-
stand all of the rules. If you do not understand
the rules, do not begin operations. Operate
the machine within the operating parameters
specified in this manual. Use the work equip-
ment only for its intended purpose, otherwise
equipment damage, personal injury or even
death may result. Keep in mind you are re-
sponsible for the safe operation of your equip-
ment at all times.
4.1.2 Visual checks
WARNING
Never operate a machine that is unsafe,

damaged or in need of repair. Failure to do
so may cause accidents or possibly death.
Before starting your machine or preceding with

any work operations, it is important to be sure
your equipment is safe to operate. Below is
a list of basic items to check before any work
is to begin. If any problems are found during
your pre-operational checks, have them re-
paired immediately.
●● Inspect the entire equipment for loose con-

nections and missing pins or bolts.
●● Look for any obviously damaged items and Fig.4-1 Pre-operational Checks
immediately replace or repair them.

●● Check all components for wear.

●● Check all electric lines for damage.
●● Look for leaks and fluid spills.
●● Be sure all safety decals are in place and
are not damaged. Be sure they are clean
and visible to all personnel. See: Chapter
2 Safety, “safety decals and plates” on
page 2-6.
●● Remove the dirt and debris around the en-
gine, battery and radiator.
●● Check the hydraulic unit, hydraulic tank,
hoses and joints for any leaks of oil.
●● Check the undercarriage (track, front idlers,
traveling drives and guards) for damage,
wear, loose bolts or roller leakage.
●● Check the handrail and step for any prob-
lem like loose bolts. Be sure the steps,
walkways and other areas are clean and
not covered with mud, concrete or debris.
●● Check the gauges and monitor in operator
compartment. Change the parts or compo-
nents in case of any problem. Clean their
surfaces.
●● Clean and check the rear mirrors for any
damage. Repair it in case of any damage.
Clean the mirrors and adjust their positions
so that the area behind the machine could
be seen clearly from operator’s seat.
●● Check the safety belt and holds for damage
or wear. Replace it with a new one in case
of any damage.

4.1.3 Job set-up
Once you have arrived at the job site be aware

of all overhead dangers, working clearances
and underground hazards before you start
your work operations. These three basic items
are critical to safe operation when performing
drilling procedures. Take time and study the
area thoroughly to be sure it will accommodate
your equipment and work operations. Review
all safety rules with the crew before starting
any work operations.
Overhead
dangers Working
clearances
Underground
hazards
Fig.4-2 Job Set-up

Underground Hazards
Always check in with the contractor. Talk with
the superintendant or person in charge where
the underground systems are located in rela-
tion to where you will be doing your drilling op-
erations. If necessary, contact the utility com-
panies and have them mark the areas where
the underground utilities are. Always be aware
of hidden dangers like voids, exposed pipes,
electrical stations or any underground condi-
tions that you could hit or which could result in
injury.
Fig.4-3 Checks before Operation I
Working Clearances
It is essential to maintain a safe distance from
obstructions such as cranes, scaffolding,
buildings, walls or any objects that could be
damaged, cause loss of control or possible
injury or death. Before starting any operations,
always study the area thoroughly. Never allow
yourself to get into a situation where equip-
ment or property could be damaged or person-
nel could be injured. If necessary, secure your
work area with safety fencing, security mark-
ings or designated safety personnel.
Fig.4-4 Checks before Operation II
Overhead Dangers
Always assume that a power line is live no
matter how large or how small. Never take the
word of someone on the job site that it has
been de-energized. Only a qualified represent-
ative of the responsible power company can
verify that all electrical systems have been de-
energized.
Fig.4-5 Checks before Operation III

4.1.4 Checks before starting the en-

gine
Before starting the engine, perform the checks

for items listed below.
44444444 Checking coolant level
See: Chapter 5 Maintenance, “cooling sys-

tem coolant level - check” on page 5-48.
44444444 Checking engine oil level
See: Chapter 5 Maintenance, “engine oil

level - check” on page 5-43.
44444444 Draining water and sediment in

fuel tank
See: Chapter 5 Maintenance, “water and

sediment in fuel tank- drain” on page 5-45.
44444444 Checking fuel amount and refuel
See: Chapter 5 Maintenance, “fuel amount

- check and refuel” on page 5-51.
44444444 Checking hydraulic oil level
See: Chapter 5 Maintenance, “hydraulic oil

level - check” on page 5-46.

44444444 Checking water oil separator
When there is water and sediment in water

cup of the water oil separator, do as follows to
drain the water oil separator.
●● Loosen the bottom drain knob (a) of water

oil separator by hand to drain water.
●● After draining, tighten the drain knob by
hand, and make sure it doesn’t leak.
Water oil separator
Fig.4-6 Water Oil Separator
44444444 Checking the electrical circuit
Check whether the fuse has damage or wrong

capacity, check short circuit or open circuit,
and also check loose terminals and tighten
any loose parts.
Specially check the electrical circuit of battery,

starter motor, and alternator.
Check for flammable materials around the bat-

tery, and remove the flammable materials.

NOTICE
●● If the fuse is frequently burnt out or there
is short circuit in electrical circuit, im-
mediately find out the reason and have it
repaired, or contact Beijing SANY Heavy
Machinery Co., Ltd authorized agent for
repair.
●● Upper surface of the battery should be
kept clean. Check the vent hole on the
battery cover. If the vent hole is plugged
by dirt or dust, flush the battery cover
and clear up the vent hole.
44444444 Checking horn function
Horn switch is located on the back of the right

handle.
Horn
Fig.4-7 Horn Switch
Be sure the horn immediately rings when the

horn button is pressed.
If the horn fails to ring, ask SANY distributor to

repair.

4.1.5 Starting the engine
44444444 Normal start-up
WARNING
Failure to do the following alerts may
cause injury or possibly death.
●● Exhaust gas is toxic. When starting the
engine in confined space, pay special at-
tention and guarantee good ventilation.
●● Before you start the engine, check for the
presence of bystanders or maintenance
personnel. Ensure that all personnel are
clear of the machine. Briefly sound the
horn before you start the engine.
Check whether the hydraulic lock lever is in

LOCKED position (L). If the hydraulic lock le-
ver is in UNLOCKED position (F), the engine
cannot be started.
F

1. Turn the battery disconnect switch to the

ON position.
ON
Fig.4-9 Battery Disconnet Switch

2. Turn the ignition switch to the ON position,
and the monitoring system is started.
OFF
3. Sound the horn to alert personnel nearby.
ON
4. Turn the ignition switch to start the engine.
Release the key, the switch will return to the
ON position.
START
Note:
●● During extremely hot weather, it is normal
for engine idle speed to be higher. No main-
Fig.4-10 Ignition Switch
tenance is needed.
●● To avoid damage to starter, never operate
the starter motor for more than 10 seconds
at a time.
●● If the engine cannot be started, turn the
switch to OFF position, and try again after
30 seconds.
●● After start-up, turning key while the engine
is running will cause damage to the starter.
●● During the engine running, never turn the
battery disconnect switch to OFF position.
Otherwise, it will result in severe damage to
electrical system.
●● If the ignition switch is kept in ON posi-
tion for two seconds or even longer period
of time, the pre-start check for monitoring
system will be enabled. If any fluid level is

low, the information will be displayed on the

display and corresponding fluid should be
added to specified level. Add fluid before
starting the engine.
44444444 Starting the engine in cold weather
WARNING
Failure to do the following alerts may
●● To avoid explosion, injury or damage,
never use starting aids.
●● Before you start the engine, check for the
presence of bystanders or maintenance
personnel. Ensure that all personnel are
clear of the machine. Briefly sound the
horn before you start the engine.
If the engine coolant temperature is low, the

air inlet heater will be activated. The display
will show relevant information about activation
of air inlet heater. Start the engine after the
message disappears.
Fig.4-11 Indicator of Air Inlet Heater
●● If the temperature is below 0 OC, run the

engine at idle speed to preheat for at least
five minutes.
●● If the temperature is below -18 OC or hy- MIN

draulic system is malfunctioning, longer Low Idle Position
pre-heating time will be needed.
Fig.4-12 Engine Speed Dial

4.1.6 After starting the engine
44444444 Breaking in a new machine
Your machine has been thoroughly adjusted

and tested before shipment. However, operat-
ing the machine under severe conditions at
the beginning can adversely affect the per-
formance of the machine or shorten the serv-
ice life. Therefore, SANY recommends that
you perform a break-in period of 100 hours for
a new machine.
During the break-in period:
●● After starting the engine, run the machine

at idle speed for 5 minutes.
●● Avoid sudden start-up, shut-down and fast
steering.
●● Run the engine in an economic way and
limit the engine power within 80% of the
full-load.
Note:
Avoid engine running empty-loaded for a long

time.
44444444 Warming-up operation
CAUTION
Under low ambient temperature, to avoid

accidents, never operate the machine with-
out warm-up, or there may be no reaction
or sudden fast movements phenomenon
during operation. Failure to do so may re-
sult in injury.
Do not immediately start operation after the

engine is started. First conduct the following
operations and checks:

1. After starting the engine, adjust the engine

speed control dial and run the engine with-
out load at low speed (about 1,100 rpm) for
X
RT
MA
about five minutes. STA
N
O
2. Adjust the engine speed control dial and run
OFF
the engine at medium speed (1,400 rpm) for
AT
five minutes.
HE
IN
M
3. Adjust the engine speed control dial and run
the engine at high speed for five to ten min-
utes. Fig.4-13 Engine Speed Control Dial
Remark: There are 11 gears on control dial.
4. After pre-heating, check whether various
Min is 1. Max is 11.
displays of the instrument are normal.
5. Check whether there is abnormality for

exhaust color, noise, or vibration. If any
abnormality is found, immediately have it re-
paired.
Note:
●● Use antifreeze recommended by Beijing
SANY Heavy Machinery Co., Ltd. Do not
add tap water or coolant of other brand.
The most applicable hydraulic oil tempera-
ture for chassis is above 50oC.
●● In cold weather, the hydraulic oil tempera-
ture is very low, and there may be transient
pause phenomenon when it is started,
which is normal situation. After warming-up,
the oil temperature will go up, and the phe-
nomenon will disappear automatically.
●● When the hydraulic oil temperature is low,
never operate or suddenly move the lever.
Before warming-up operation is finished,
never suddenly accelerate the engine.
Never run the engine at low speed or high
speed continuously for over 20 minutes,
which will cause oil leakage at oil supply
pipeline of the turbocharger. If it is a must to
run the engine at idle speed, apply load fre-
quently or run the engine at medium speed.

4.1.7 Shutting down the engine
NOTICE
Risk of damaging the engine!
If the engine is stopped before cooling
down, it will shorten the engine life. Es-
pecially when the engine is over-heated,
never stop it suddenly. Run the engine at
medium speed to make it cool down gradu-
ally, and then shut down the engine.
1. If you will be shutting the machine down,

locate a safe and stable area where the
machine will be out of the way and secure.
Always lower the work equipment to the
ground as shown in Fig.4-14.
Fig.4-14
2. Turn the engine speed dial to low idle posi-

tion, and run the engine for five minutes to
cool the engine down.
MIN
Low Idle Position

SAFETY
FUNCTIONS
SYSTEM
3. Turn the key to OFF position, and remove
OPERATION
the key from the ignition switch. Set the hy-
draulic lock lever to LOCKED (L) position.
MAINTENANCE
TROUBLESHOOTING
SPECIFICATIONS

4. If the engine fails to stop running after the

key is turned to OFF position, adopt the fol-
lowing procedures:
●● Push down the switch (1), and it will make
the engine stop running.

●● Push the switch back to the original posi-
tion, and make sure the engine could be
restarted. 1
Fig.4-18 Emergency Stop Switch
●● If the engine still cannot stop, turn the fuel

shutoff valve (located under the fuel tank)
clockwise to cut off fuel supply. When the
residual fuel in the fuel pipe is used up, the
engine will stop running.
Remark:
The engine may keep running for a few more
minutes.

4.1.8 Checks after each workday
1. Check the working components, rotation de-

vices, machine exterior and undercarriage,
check for oil leakage or water leakage. If
any abnormality is found, have it repaired
immediately.
2. Check whether there is paper and scraps in

the engine compartment, and remove the
paper and scraps to avoid fire hazard.
3. After operation in water or mud, remove the

water on the undercarriage.
4. Park your machine on a hard and level

ground.
5. Park your machine on planks if possible.
6. If the ambient temperature is below -35°C,

make sure to drain the cooling water of ra-
diator and engine (SANY uses the type of
antifreeze liquid that freezes at -35°C).
7. Open the drain valve to discharge accumu-

lated water of the fuel system so as to pre-
vent it from freezing.
8. Refuel the tank to maximum level. In this

way when ambient temperature drops, the
condensate in the tank could be minimized.

4.1.9 Traveling
●● When traveling with machine, make sure it

is safe around the machine, and sound the
horn before moving.
●● Because the operator does not have an all-
round view from the cab, the operator must
be assisted by a person giving hand signals
during travel. See: Chapter 2 Safety, “sig-
nals to control operation” on page 2-49.
●● Adjust the upper carriage in line with the
undercarriage.
●● Lower the working attachments and mov-
able loads as close to the ground as possi-
ble.
●● Before traveling, confirm the bearing capac-
ity of the bridge and road. Choose route as
required.
●● Do not allow the machine to come in con-
tact with electric wire and bridge edge.
●● Choose level ground as far as possible, and
remove all the obstacles from the traveling
route. Drive the machine in a straight line
as far as possible, and change directions
slightly and gradually.
●● When traveling on uneven ground, reduce
the engine speed, and choose low traveling
speed. Low speed will reduce possibilities
to damage the machine.
●● When traveling in working state, allow the
mast to tilt backward 20° and then travel.
●● Avoid making abrupt movements during
traveling.

44444444 Traveling operation
Standard traveling position:

The front idlers are at the front part of the Front
machine, while the traveling drive (traveling
Operator’s seat
motor) is at the rear part. If the traveling drive
(traveling motor) is at the front part, control di-
rections of travel levers/pedals are contrary to
Left Right
machine traveling direction.
NOTICE
The machine’s installed crawlers are
Sprocket
designed for standard operations. This
equipment should not travel over longer Back
distance. Failure to do so will damage the
crawler components. Fig.4-19 Standard Traveling Position
●● During long distance travel, rest 5 minutes

for every 20 minutes’ travel to prevent dam-
age to the traveling motor.
●● For stable operation, the traveling control
lever/pedal is equipped with damper. Dur-
ing cold weather, operating force of control
lever/pedal will increase. At this time, when
the hydraulic lock lever is in LOCKED posi-
tion (L), operate the traveling lever for sev- F
eral times.

●● When the traveling lever/pedal is released

from any position, it will automatically return Traveling Lever
to the neutral position, and the machine will
be in braking mode automatically.
●● Do not suddenly shift the lever, because it
may cause sudden moves. Avoid suddenly Forward
shifting the lever from forward to reverse (or Neutral Position
from reverse to forward). Avoid suddenly
Reverse
shifting the lever, e.g. Sudden stop from
high speed (release the lever).
Traveling Pedal
Fig.4-21 Lever Sudden Shifting

Unlock traveling mode before traveling opera-
tion. Operate the screen button to switch be-
tween TRAVEL UNLOCKED/LOCKED state,
see Chapter 3 System Function, “drilling
operation main interface” on page 3-46. It dis-
plays TRAVEL UNLOCKED on the display
screen..
F1 F5
ALARM
F2 OPERATION
F6
SINGLE BUCKET DEPTH
REAL TIME DEPTH

DRILL DEPTH
F3 CALIBRATION
MAIN WINCH SPEED
SWING ANGLE
F7
CROWDING
SET MAIN WINCH
F4 F8
MAST REPOSITION
TRAVEL UNLOCKED
Fig.4-22 Travel Unlocked State

Traveling control description:

1. Forward travel
Method 1: Step downward the front side of two

pedals.
Method 2: Push forward the two traveling le-

vers.
Fig.4-23 Forward Travel
2. Reverse travel
Method 1: Step downward the rear side of two

pedals.
Method 2: Push backward the two traveling le-

vers.
Fig.4-24 Reverse Travel
3. Pivot left turn (forward)
Method: Push forward the right traveling lever,

or step downward the front side of right pedal.
Stop
Fig.4-25 Pivot Left Turn (forward)

4. Pivot left turn (reverse)
Method: Push backward the left traveling lever,

or step downward the rear side of left pedal.
Stop
Fig.4-26 Pivot Left Turn (reverse)
5. Counter rotate turn (left)
Method 1: Step downward the front side of

right pedal and the rear side of left pedal at the
meantime.
Method 2: Push forward right traveling lever

and push backward left traveling lever at the
meantime.
Fig.4-27 Counter Rotate Turn (left)
6. Pivot right turn (forward)
Method: Push forward left traveling lever or

step downward the front side of left pedal.
Stop
Fig.4-28 Pivot Right Turn (forward)

7. Pivot right turn (reverse)
Method: Push backward right traveling lever or

step downward the rear side of right pedal.
Stop
Fig.4-29 Pivot Right Turn (reverse)
8. Counterrotate turn (right)
Method 1: Step downward the front side of left

pedal and the rear side of right pedal at the
meantime.
Method 2: Push forward left traveling lever

and push backward right traveling lever at the
meantime.
Fig.4-30 Counterrotate Turn (right)

44444444 Traveling up and down slopes
CAUTION
Tipping hazard!
Traveling on uneven or sloped areas, the
machine could possibly tip and may cause
injury to people.
The methods listed in the following must be

observed to guarantee the stability of the drill-
ing rig.
When operating on uneven or sloped area:
●● Reduce engine speed.

●● Choose low speed traveling manner.
●● Properly adjust position of various working
components to make the center of grav-
ity greatly close to the swing center and
ground.
●● Slowly operate the machine, and notice the
movement of the engine.
●● Do not travel up or down a steep slope.
When the slope is larger than 15°, it is pro-
hibited to travel.
Fig.4-31 Traveling on Sloped Areas I

●● If you have to conduct operation on slope,
pile up a solid platform with soil on the
slope so as to keep balance of the machine
during operation.
Platform
Fig.4-32 Traveling on Sloped Areas II

4.1.10 Upper carriage swing
WARNING
Risk of getting crushed or hit!

Before swinging the upper carriage, check
whether the danger area is free. The rear-
view mirror must be clean at all times.
Failure to do so may result in injury or pos-
sibly death.
Upper carriage swing to left:
Push button A of left operation handle upward

to activate rotation, and simultaneously push
the handle in left direction to make the upper
carriage swing to left.
A
Operator’s Cab
Fig.4-33 Upper Carriage Swing to Left

Upper carriage swing to right:

Push button A of left operation handle upward
to activate rotation, and simultaneously push
the handle in right direction to make the upper
carriage swing to right.
AA
Operator’s Cab
Fig.4-34 Upper Carriage Swing to Right
Note:
●● Release button A, and the machine will be

in rotation braking state automatically.
●● Released at any position, the handle will
return to neutral position automatically, and
the machine stops rotation.
●● The speed changes with the amount of
handle movement. Avoid violent operation.
Avoid sudden shifting for the operation han-
dle direction.

4.1.11 A djusting drilling center dis-

tance
CAUTION
Risk of personal injury! F
Prohibit any derricking operation when the
drilling tool is in the borehole. Failure to do
so may result in injury.
Press button F of right operation handle to

switch between crowding and derricking, or
switch to derricking state by operating screen
button (see Chapter 3 System Function, Fig.4-35 Right Operation Handle
“drilling operation main interface” on page
3-46.) And it reads Derricking on the screen.
F1 F5
ALARM
F2 OPERATION
F6
SINGLE BUCKET DEPTH
REAL TIME DEPTH

DRILL DEPTH
F3 CALIBRATION
MAIN WINCH SPEED
SWING ANGLE
F7
DERRICKING
SET MAIN WINCH
F4 F8
MAST REPOSITION
TRAVEL LOCKED
Fig.4-36 Derricking State

Increasing the machine’s distance to the

bore:
Push forward the right operation handle.
Fig.4-37 Increasing the machine's distance to

the bore
Reducing the machine’s distance to the

bore:
Push backward the right operation handle.
Note: Fig.4-38 Reducing the machine's distance to the

bore
●● Be sure there is no obstruction within the
moving range of the boom mechanism be-
fore derricking operation.
●● Released at any position, the handle will
return to neutral position automatically, and
the derricking operation stops.
●● The speed changes with the amount of
handle movement. Avoid violent operation.

4.1.12 Crowd control

F
Press button F of right operation handle to
switch between crowding and derricking, or
switch to crowding state by touching crowding
on the display.
Fig.4-39 Crowding/Derricking Switchover
F1 F5
ALARM
F2 OPERATION
F6
SINGLE BUCKET DEPTH
REAL TIME DEPTH

DRILL DEPTH
F3 CALIBRATION
MAIN WINCH SPEED
SWING ANGLE
F7
CROWDING
SET MAIN WINCH
F4 F8
MAST REPOSITION
TRAVEL UNLOCKED
Fig.4-40 Crowding State

Moving the crowd sledge down:
●● Push forward the right operation handle.
Fig.4-41
Moving the crowd sledge up:
●● Pull backward the right operation handle.
Note:
The speed changes with the amount of handle
movement. Avoid violent operation. Released
at any position, the handle will return to neu-
tral position automatically, and the movement
stops. Fig.4-42

4.1.13 Main winch operation
WARNING
Danger of getting crushed, entangled,

drawn-in and chafted!
●● Never put a hand in the winch moving
area.
●● Never reach between winch and rope.
●● Never seize a rope in motion.
Push downward button B of left operation han-

dle to switch between main and auxiliary
winch, or operate screen button to switch be-
tween main and auxiliary winch state. And it
shows Main Winch at the bottom of the screen.
F1 F5
ALARM
B
F2 OPERATION
F6
SINGLE BUCKET DEPTH
REAL TIME DEPTH

DRILL DEPTH
F3 CALIBRATION
MAIN WINCH SPEED
SWING ANGLE
F7
CROWDING
SET MAIN WINCH
F4 F8
MAST REPOSITION
TRAVEL UNLOCKED
Fig.4-43 Main Winch/Auxiliary Winch Switchover

WARNING
Serious injury hazard!
When unwinding rope from winches, en-
sure that three wraps of rope remain on the
drums, for safety reasons.
Lowering:
Push forward the left operation handle to ex-

tend main winch rope and lower the Kelly bar:
Fig.4-44 Lowering Main Winch Rope

Lifting:
Pull backward the left operation handle to re-

tract main winch rope and lift the Kelly bar:
Fig.4-45 Lifting Main Winch Rope
Free-fall:
During drilling operation, push upward the

button E of right handle, and the main winch
will automatically extend wire rope with the in-
crease of drilling depth, namely free-fall. E
Fig.4-46 Main Winch Free-fall

Slack rope switch-off:

When slack rope switch-off function is activat-
ed, lower main winch. When the drilling tools
touches the ground or the borehole bottom,
main winch rope will be in slack condition. If
the rope pulling force is smaller than set value,
the main winch lowering stops so as to avoid
main winch rope twisting.
Remark:
Slack rope switch-off does not work in free-fall
state.

4.1.14 Auxiliary winch operation
WARNING
Danger of getting crushed, entangled,

drawn-in and chafted!
●● Never put a hand in the winch moving
area.
●● Never reach between winch and rope.
●● Never seize a rope in motion.
Push downward button B of left operation han-

dle to switch over between main and auxiliary
winch, or switch to auxiliary winch state by
touching Main winch on the display.
WARNING
Serious injury hazard!
When unwinding rope from winches, en-
sure that three wraps of rope remain on the
drums, for safety reasons.
Lowering:
Push forward the left operation handle to ex-

tend auxiliary winch wire rope and lower the
load.
Fig.4-47 Lowering Auxiliary Winch Rope

Lifting:
Pull back the left operation handle to retract

auxiliary winch wire rope and lift the load.
Fig.4-48 Lifting Auxiliary Winch Rope

4.1.15 Rotary drive control
Positive rotation:
Push the right operation handle left to make Rotary drive

rotary drive rotate in a positive direction
(viewed from the cab, the rotary drive rotates
clockwise):
Fig.4-49 Rotary Drive Positive Rotation
Reverse rotation:
Push the right operation handle right to make

rotary drive rotate in a reverse direction
(viewed from the cab, the rotary drive rotates
counterclockwise):
Low-speed high torque: Fig.4-50 Rotary Drive Reverse Rotation
Press button G on the right handle, and push

the right handle left so as to make rotary drive
rotate positively at low speed. Push the right
handle right so as to make rotary drive rotate
reversely at low speed.

4.1.16 Depth measuring control
The borehole depth and current depth are

both showed synchronously on the display.
Resetting depth:
Push downward button A of the left operation

handle, or press F6 for depth resetting as illus-
trated in see Chapter 3 System Function, A
“operation interface” on page 3-48..
Fig.4-51 Button A
Note:
In order to have more accurate hole depth

readings, prior to each drilling, reset the depth MAIN/AUX.WINCH
when the bottom tooth of drilling bucket hits F1 F5

the ground.
F3 ALARM ELIMINATE SWING ANGLE

RESET
F7
SLACK ROPE SWITCH-OFF CAB COLLISION
F4
ENABLED/DISENABLED
F8
PROTECTION
ENABLED/DISENABLED
Fig.4-52 Depth Measurement Resetting

4.1.17 Calibration
444444444Depth measurement calibrating
Press “Calibration” in main interface to access

to calibration interface.
F1 SAVE
CALIBRATION
BACK F5
The method for setting depth measuring
compensation value is listed below: F2
SWING ANGLE CALIBRATION
F6
Turn the knob to select the data to be calibrat-
DRILLING DEPTH M
ed. Input calibrating value. F3 F7
SWING
Calibration formula: CURRENT DEPTH M
Value after calibration=(value after calibration/ F4 F8

value before calibration -1)* 1000
Fig.4-53 Calibration Interface

Example:
The borehole depth on the display is 2.62 me-
ters, while the actual depth is 2.18 meters. So
the value should be calibrated to the actual
2.18 meters.
According to calibration formula, the value af-
ter calibration should be -168.
Value after calibration = (2.18/2.62-1)*1000=
-168.

444444444 Swing angle calibrating
Press “Calibration” in main interface to access

to calibration interface.
F1 SAVE
CALIBRATION
BACK F5
The method for setting swing angle com- SWING ANGLE CALIBRATION
F2 F6
pensation value is listed below:
M
Turn the knob to select the data to be calibrat- F3
DRILLING DEPTH
F7
ed. Input calibrating value. SWING
CURRENT DEPTH M
Calibration formula: F4 F8
Value after calibration=(value after calibration/

value before calibration -1)*1000 Fig.4-54 Calibration Interface
Example:
The swing angle on the display is 190 degree,

while the actual swing angle is 180 degree.
So the value should be calibrated to the actual
180 degree.
According to calibration formula, the value af-

ter calibration should be -53.
Value after calibration=(180/190-1)*1000=-53

444444444Verticality calibration
Press “Set” in main interface. Input password

12318 to access to verticality calibration inter-
face.
Calibrating operation process:
1) Adjust the knob on theodolite bracket to

ensure the bubble in the center of level.
2) Make the front side of rig face the

theodolite. Adjust the focusing ring of
theodolite to ensure mast brim could be
seen clearly from the sight glass.
3) Adjust the mast to make the mast brim

overlap with the verticality line of sight
glass. Then calibrate X axis. Modify
“zero value” and save. The value after
calibration should be 000.0, that is, the
verticality degree of mast is 0 by theodolite
calibration.
4) Rotate the upper carriage by 90 degree.

Calibrate Y axis in accordance with step 3).

4.1.18 Crawler extending and retracting
1 1
Fig.4-55 Crawler Retracted State Crawler Extended State
1. Ensure the four crawler set pins (1) are re-

moved before retracting the crawler.
2. Press the crawler extending and retracting

switch on operation control panel. If press
rightward, crawler could extend. If press left-
ward, crawler could retract.
3. When the extending and retracting action is

finished, install the four set pins.
CAUTION
Tipping hazard!
Crawler extending could stabilize the ma-
chine. Ensure the crawler is in extended
state before operation of construction,
mounting, and dismounting.

4.1.19 Parking the drilling rig
444444444Regular parking
CAUTION
Risk of personal injury and damaging the
machine!
●● In wet weather, close the window and
cab door to protect the electrical compo-
nents in the cab.
●● Avoid parking the machine on the sloped
area. It may cause the machine to tip and
result in personal injury and machine
damage.
●● If parking machine on the sloped area
cannot be avoided, chock the crawlers
on both sides.
Fig.4-56 Parking the Drilling Rig on Sloped Area
1. Drive the machine to solid and even ground.
2. After tilting the mast backward for 20°, lower

the main winch until the drilling tools hits the
ground.
3. Turn the engine speed dial in counterclock-

wise direction to extreme position (low
speed idle position). Run the engine for
about 5 minutes so as to cool it down.
MIN
Low Idle Position

4. Pull the hydraulic lock lever to the LOCKED

position (L).
5. Turn the ignition switch to OFF position, and

remove the key from the switch. OFF
O
N
6. Close the window and cab door.
START
KG678

444444444Checks during parking
Check the engine water temperature, oil pres-

sure, fuel level and refill fuel. See: Chapter 5
Maintenance, “fuel amount - check and re-
fuel” on page 4-45.
If the ambient temperature is lower than -35°C,

be sure to drain coolant from the radiator and
engine jacket (freezing point of the antifreeze
applied by SANY is -35°C).
Note:
If the coolant is drained, be sure to mark “NO
WATER IN RADIATOR” tag at obvious loca-
tion. CAUTION
NO WATER IN RADIATOR
Fig.4-60 No Water in Radiator
444444444Machine locking
Be sure to lock the following areas after park- 3

ing the machine:
●● Cab door (1)
The operator cab door is equipped with a door
lock to prevent unauthorized access. Always 4
lock the operator cab when the machine is not
in use. 1
Fig.4-61 Lockable Areas I
2
●● Fuel tank filler port (2) (The fuel tank filler
port and strainer is located on the right front
side of the machine. The cap has a lock)
●● Engine hood (3)
●● Left side door of the machine (4) 5
●● Right side door of the machine (5)

Fig.4-62 Lockable Areas II

444444444Long-term storage
WARNING
Risk of gas poisoning!
When the machine is stored indoor, if it is
a must to have antirust operation, open the
doors and windows to ventilate so as to
avoid gas poisoning. Failure to do so may
result in injury and possibly death.
Before storage:
●● Clean and flush all the parts, and then
place the machine indoor. If you have to

store the machine outdoor, choose level
ground and cover the machine.
●● Before storage, refill the fuel tank (see:
Chapter 5 Maintenance, “fuel amount -
check and refuel” on page 5-51.), Have lubri-
cation, and replace engine oil (see: Chap-
ter 5 Maintenance, “engine oil and filter -
Change” on page 5-53.)
●● Apply a coat of grease on the metal surface
of piston rod.
●● Disconnect the negative terminal (-), and
cover the battery, or disconnect the battery
from the machine and have it stored sepa-
rately. +
●● If the ambient temperature is expected to _
drop below 0°C (32°F), add antifreeze to
the coolant.
During storage:
●● Run the machine once a month to make
the surface of moving parts applied with a

layer of new oil film. Meanwhile, charge the
battery.
●● For machines equipped with air-conditioner, Fig.4-63 Disconnecting the Battery
run the air-conditioner.
●● Run the crawler.

4.1.20 Operation in cold weather
444444444Checks in cold weather
1. Equipment stopping construction in cold

area:
●● Keep clean of the machine.
●● Engine: Check for antifreeze level, oil qual-
ity, and fluid and oil leakage. Replace the
fuel, oil and gear oil with oils applicable for
local temperature.
●● Hydraulic system: Check for leakage of
the motor, oil cylinder, main pump, pipeline
and joints. Check for scratch and corrosion
to cylinder piston rod. Exposed part of the
piston rod shall be applied with grease for
protection.
●● Electrical system: Disconnect the battery,
and place it indoor after charging.
●● Conduct antirust running, and run air-con-
ditioning system once a month, keep com-
pressor lubricated and certain thickness of
oil slick at the O-rings of air-conditioning
system, and prevent refrigerant leaking.
Note:
The antifreeze proportion is 45% when deliv-

ered, which is applicable for lowest tempera-
ture of -40°C (carry out according to local tem-
perature and attached table).
Table 4-1 Table for oil fluid selection in low temperature condition
Tempera- Hydraulic Battery
Fuel Engine Oil Gear Oil Antifreeze
ture Oil Acid%
-5℃ -10# 15W-40 46# 90W-140 TEEC-L35 1.29
-15℃ -20# 15W-40 46# 90W-140 TEEC-L35 1.3
-20℃ -35# 15W-30 T46# 85W-140 TEEC-L35 1.31
-30℃ -35# 5W-30 T32# 85W-140 TEEC-L35 1.33
Remark: Engine oil must be above API CF-4 grade.

2. Regular checks:
Wash and clear the oxides from the battery

terminal with hot water, and apply a layer of
grease after wiping to protect the terminal. For
wet battery, check proportion of the battery
acid, and add distilled water or electrolyte if
necessary.
3. Starting checks
●● Before starting the engine, check oil levels

and fluids level for the equipment. Drain
water or contaminants from the fuel tank at
least once a week.
●● When the ambient temperature is lower
than 3°C, turn on the preheating switch be-
fore starting the engine so as to preheat the
intake air.
●● Start the engine and idle the engine for five
to ten minutes. Operate the cylinder with-
out load to make hydraulic oil temperature
reach 40°C, and then start construction.
●● For construction in frozen weather, rec-
ommend operator to clear the mud from
around the carrier rollers and idler with a
shovel to prevent freeze on the next day.
●● Drain water from water oil separator after
work every day.
A
Fig.4-64 Water Oil Separator (A)

444444444Operation tips in cold weather
WARNING
Risk of poison and fire!
●● The antifreeze is toxic. Be cautious. If it

splashes into eyes or onto the skin, flush
with much clean water and seek medical
attention immediately.
●● The antifreeze is flammable, so keep it
clear of any fire. Do not smoke when
handling antifreeze.
Failure to do so may result in injury and
possibly death.
In cold weather, the engine is difficult to start,

the fuel may be frozen, and viscosity of hy-
draulic oil increases.
Adopt fuel according to climate and tempera-

ture. Therefore, always do the following:
1. Fuel and lubrication oil
All the components shall use low-viscosity fuel

and lubrication oil.
2. Coolant of the cooling system
For areas where permanent antifreeze is

not available, use ethylene glycol antifreeze
without preservatives in cold season. In this
circumstance, the cooling system should be
cleaned twice a year (spring and autumn).
When adding to cooling system, add anti-
freeze in autumn instead of in spring.

NOTICE
When replacing the coolant containing
antifreeze, or handling the antifreeze for
radiator repair, contact authorized agent
of Beijing SANY Heavy Machinery co.,
ltd or inquire local antifreeze distributor.
Be cautious do not allow the fluid flow
to the sewer or splash to the ground.
Note:
Do not use methanol, ethanol, or propane an-
tifreeze.
Avoid using any leak preventives, no matter it
is used individually or mixed with antifreeze.
Do not mix the antifreeze of different brands
for application.
3. Battery
WARNING
Risk of poison, fire or explosion caused by
battery!
●● The battery produces flammable gas,
keep fire or sparks away from the bat-

tery.
●● If the battery acid gets on your skin or
in your eyes, flush the area immediately

with fresh water and seek medical atten-
tion.
●● The battery acid could dissolve paint. if
the battery acid splash on the machine,

flush with water immediately.
●● If the battery acid is frozen, never charge
the battery or start the engine with differ-

ent power, which may cause the battery
to explode.
When the ambient temperature drops, the bat-

tery capacity decreases. If the charge ratio
is lower, the battery acid will be frozen. Make
sure the battery charging is close to 100% as

much as possible. Make the battery insulated

from low temperature so as to start the ma-
chine easily on the next morning.
Table 4-2 Charging ratio conversion table
Temperature
Battery
Acid Proportion 20℃ 0℃ -10℃ -20℃
Charging Ratio
100 1.28 1.29 1.30 1.31
90 1.26 1.27 1.28 1.29
80 1.24 1.25 1.26 1.27
75 1.23 1.24 1.25 1.26
Remark:
Measure the specified proportion of the battery
acid, and acquire the charging ratio from the
charging ratio conversion table above.
Note:
●● The battery capacity obviously decreases
in cold temperature, so the battery shall be
wrapped or removed and located in warmer
place, and reinstalled to the machine on the
next morning.
●● If the battery acid level is low, add distilled
water before starting work in the morning.
Do not add water after daily operation to
prevent liquid in the battery freezing in the
evening.

444444444After daily operation
To avoid mud or water on the undercarriage

from being frozen which makes the machine
unable to move on the next morning, follow
the precautions below.
●● Thoroughly remove mud and water from

the machine to avoid mud and dirt enter-
ing the inner side of the sealing with water
drops to damage the seal.
●● Park the machine on solid and dry ground.
●● If possible, park the machine on plank,
which can prevent the crawler from being
frozen with the soil, so it can move on the
next morning.
●● After operation, refill the fuel tank so as to
prevent condensed water when the tem-
perature drops.
444444444 After cold season
When the season changes and weather gets

warmer, do the following steps:
●● Replace the fuel and oil of all the compo-

nents with specified viscosity oils.
●● If permanent antifreeze cannot be applied
because of some reason, use ethylene
glycol antifreeze (winter season, one sea-
son type) as substitute. Or if antifreeze is
not available, completely drain the cooling
system, and thoroughly wash the inside of
the cooling system, and then add fresh soft
water.

4.2 Drilling Rig Construction
4.2.1 Construction preparation

1
44444444 Drilling rig checks
2
●● Inject grease into different lubrication
points.
3
●● Check hydraulic oil level and quality. Check
gear oil level and quality of the winch, ro-
tary drive, swing reducer.
Fig.4-65 Checking Gear Oil of Main Winch

1. Filler Port
2. Inspection Port
3. Drain Port
Fig.4-66 Checking Gear Oil of Rotary Drive
dipstick
Fig.4-67 Checking Gear Oil of Swing Reducer

●● Check engine oil level and quality. Check

whether the filter needs changing. dipstick
Fig.4-68 Checking Engine Oil
Fuel Filter
Fig.4-69 Fuel Filter
●● Check whether the drilling tooth needs

changing, and whether the opening and
closing of drilling bucket is normal.
Fig.4-70 Checking Drilling Tooth

●● Check whether actions of the drilling rig is
normal.

44444444 Drilling tool selection
●● Verify the geological survey materials.

Determine the bit diameter according to
requirements of the construction drawing.
Usually the bit diameter is 1 cm to 2 cm
smaller than the specified borehole diam-
eter. Be sure there is no overlarge fullness
coefficient.
●● During construction, according to layer in
the geological report, select proper drilling
tools in order to improve construction effi-
ciency and reduce cost.
●● For the structure features of main drilling
tools and their applicable layer, see: Chap-
ter 4 Operation, “drilling tool” on page 4-140.

4.2.2 Drilling rig in place
1. Drive the drilling rig to the position around

the pile. Make sure the working surface of
the drilling rig is solid and level. The ma-
chine should keep level. If the ground sur-
face is too soft, lay steel plate under the
crawlers of the drilling rig to guarantee sta-
ble operation for the drilling rig.
2. Clearance between the drilling rig swing
center and borehole should be 5.2 to 5.6
meters. In allowable circumstance, the
boom cylinder lifts the boom and mast to
high position as far as possible. In this way,
it could mitigate the impact to the borehole
by drilling rig weight and alternate tension
during lifting and lowering.
3. Keep the drilling rig clear of obstacles within
the swing radius.
Fig.4-71 Swing Radius

4. Rotate the upper carriage, extend and re-
tract the boom cylinder, and adjust the mast
to vertical in order to make accurate align-
ment and make the tip of the drilling tool
align with pile marking position.
5. After accurate alignment, reset the swing;
lower the drilling tool tip to the same plane
as the casing. Reset the borehole depth.
For resetting operation, see: Chapter 4
Operation, “depth measuring control” on
page 4-39.

4.2.3 Drilling
After the drilling rig is in place, drilling opera-
tion can be performed.
For drilling operation, see: Chapter 4 Opera-

tion, “kelly bar” on page 4-131. The drilling meth-
ods for common layers are listed below.
44444444 Drilling in clay layer
●● Features of clay are large viscosity, imper-

meable, and small drilling resistance.
●● In drilling operation, the output torque of
rotary drive cannot be too large. Control
the operation handle, and appropriately
increase the rotary drive rotating speed,
which is usually between 8—20 r/min.
●● Keep crowding in order to make the drilling
teeth cut into the clay layer.
●● Drilling depth for each drilling is determined
by the diameter and height of the drilling
bucket. If the pile diameter is above 800
mm, the drilling depth is 50% to 70% of
the bucket capacity; if the pile diameter is
below 800 mm, the drilling depth cannot ex-
ceed 50% of the drilling bucket capacity.
44444444 Drilling in sand layer
CAUTION
In drilling rig construction, 80% of the drill-

ing tool burials happen in sand layer. Be
cautious when drilling in sand layer. Fail-
ure to do so may result in injury.
Features of sand are no cementing property,

strong water permeability, low compressibility,
and big drilling resistance.
During drilling operation, ensure that the ro-
tary drive outputs large torque and low rotat-
ing speed. And the crowding manner is point
crowding.

For drilling into large diameter bore hole,

bailing bucket with double bottom is optimal
choice. Single bucket drilling depth should not
be deep enough. The drilling bit shall be lifted
or lowered slowly and evenly. Avoid drilling
tool being buried to the most extent.
44444444 Drilling in pebble layer
●● Pebble is mechanically loose. Its features

are large pores, strong water permeabil-
ity, low compressibility, and strong shear
strength.
●● During drilling operation, cut into the peb-
ble holes by the rotation of drilling teeth, in
order to squeeze the rocks into the bucket.
●● When drilling, run at low speed with large
torque so as to avoid the mud washing out
the borehole wall at high speed.
●● Strictly control each bucket drilling depth.
●● Lift and lower the drilling bit as slowly and
evenly as possible.
●● For layers with larger content of gravel, use
double layer core barrel. For boulder layer,
use short auger to loosen the boulder, and
then convey the spoil with core barrel.
●● In dense pebble layer, drill with low rotat-
ing speed. Hoist the Kelly bar with main
winch rope, and stir the pebbles with teeth
clockwise and counterclockwise. When
running into large resistance, reversely ro-
tate promptly and then convert to positive
swing. Perform this circularly and repeat-
edly. When the pebble is loose, float and
lower the Kelly bar.
●● If it drills fast, keeps heavy-load drilling
state via point crowding. Avoid back pres-
sure and continuous crowding. If no drill-
ing is performed for long period, raise the
auger bit for a little bit to prevent bore hole
collapse. Lower again in order to create
free surface for further drilling.

●● During bucket opening or closing, the buck-

et bottom hook is apt to be stuck by pebble
and fails to work. There is also possibility
for hook falling at the bore hole bottom. It
is better to seal the hook position with steel
plate.
●● If it is not sealed, you will have to thor-
oughly close the bucket every time. Make
sure the hook is completely hitched so as
to avoid the bucket bottom opening in the
hole.
●● Check set pins for teeth and the Kelly bar
whenever dumping slag. Promptly replace
the worn and broken teeth.
44444444 Drilling in shale layer
●● Shale is a kind of sedimentary rock formed

by mud and clay. It’s mainly composed of
fine-grained sediments without stratifica-
tion and it appears blocky. It has strong
cohesive force, lower compressive strength
(usually between 0.17 Mpa and 10 Mpa),
and cementing properties. It is very absorb-
ent.
●● Usually use interlocking Kelly bar. Some-
times adopt friction Kelly bar because of the
limitation of the pile depth.
●● The drilling teeth are staggered with the an-
gle of about 53°.
●● When adopting friction Kelly bar, crowd
continuously. When the layer resistance
goes up, keep on drilling. Adjust the crowd-
ing amplitude based on the resistance in
order to force the drilling teeth into primitive
rock and maintain cutting state.
●● When using interlocking Kelly bar, control
crowding manner. When the fore part of
the crawler is nearly propped up, it means
sharp crowding or no drilling. Now stop
crowding and verify the cause.
●● If the layer changes little, the drilling time
and depth for each bucket should be within

a certain range. Drilling depth for each

bucket in shale layer should be 40 cm.
●● When there is still drilling load, reverse and
shut the bucket bottom. Now the bucket
has certain resistance, and can avoid the
bucket bottom reversing with the core bar-
rel. The reverse should be no more than
two turns. Too much reverse will flatten
bore hole steps, which increases difficulties
for the drilling teeth to cut the rock.

4.3 Rigging & Derigging
4.3.1 Requirements for rigging and

derigging
WARNING
●● The operator must be familiar with all the
control elements and their capabilities
before starting rigging operation. Failure
to do so will cause severe injury.
●● Minor movements by the mast cylinder
can create sudden and uncontrolled ma-
jor movements of attached components
during disassembly. The operator must
keep in view the person performing the
derigging throughout the whole proce-
dure.
For safety of yours and others, follow the re-

quirements in this section.
Installation of accessories or optional parts

that are not approved by SANY will impair the
machine’s service life, and lead to accidents.
When accessories are not listed in Parts Man-

ual, contact Beijing SANY authorized sales
representative immediately.
44444444 Guidelines for rigging and derig-

ging
●● Read Safety, Operation & Maintenance

Manual thoroughly, and do not perform any
installation or dismantling operation until
you’ve understand the manual.
●● If Safety, Operation & Maintenance Manual
gets lost, ask the manufacturer or acces-
sory sales company for a new copy.
●● Before operation, make clear the signals to
be used, see: Chapter 2 Safety, “signals
to control operation” on page 2-49. When

the drilling rig has been installed, its swing

scope and gravity center are different.
●● Before starting operation, establish a guard
line to shield irrelevant staff.
●● In order to avoid serious accidents incurred
by wrong operation, do not put your feet on
the pedals other than operating the pedals.
44444444 Notes on rigging and derigging
●● Provide solid and level area for rigging and

derigging. Fig.4-72 Guard Line
●● Before rigging, check all parts for possible
damage resulting from transport.
●● When more than 2 persons are operating
the machine, clear signals should be fol-
lowed. See: Chapter 2 Safety, “signals to
control operation” on page 2-49.
●● Use a crane when lifting or carrying heavy
objects (more than 25kg).
●● When using a crane to lift a load, pay extra
attention to its gravity center.
●● When removing heavy parts, support them
before dismounting in order to prevent them
from swaying or falling after being sepa-
rated from the machine.
●● When removing and installing parts, ensure
that they are in a stable area, with no risk of
falling down.
●● Do not walk under the load lifted by a
crane.
●● Personnel working on the mast or on the
upper carriage must wear the prescribed
fall protection equipment.
●● During rigging operations, the upper car-
riage must be in line with the crawler and
be interlocked with it. The crawler should
be extended and locked.

44444444 Preparation for rigging and derig-

ging
Ground: flat, solid, open, no barriers such as

high-voltage lines overhead.
Tools: tools attachment
Equipment: one crane weighing over 20 ton.

Fig.4-73 High-voltage
Staff: 1 crane operator, 1 drilling rig operator,
3-5 workers.

4.3.2 Rigging drilling rig
44444444 Removing swing locking connect-

ing rod
CAUTION
Risk of personal injury.

To avoid hand injury, be cautious when re-
moving the swing locking connecting rod.
Swing locking connecting rod (1):

2 1
It is located in front of chassis swing bearing.
During transportation, it is used to link the

upper carriage and H beam of the traveling
mechanism, to prev ent the upper carriage
from rotating.
Operation procedures:
Move the drilling rig to the designated loca-

tion; remove the pin (2) that links the swing
locking connecting rod (1) and upper carriage, Fig.4-74 Swing Locking Connecting Rod
enabling the connecting rod to rest on the H
beam of the traveling mechanism. Reinstall
the removed pin (2) to the original position in
the connecting rod.
Note
●● If the pin of swing locking connecting rod
1
cannot be pulled out, operate the left op-
eration handle repeatedly to make the up- Fig.4-75 Removing Swing Locking Connecting
per carriage rotate slightly in the left or right Rod
direction. Then the pin can be removed.
●● In order to avoid small parts loss, install
connecting parts, such as pin and lock pin,
to their original positions.

44444444 Extending the crawlers
For detailed operation procedures, see: Chap-

ter 4 Operation, “Crawler extending and
retracting” on page 4-43.
Note:
Extending crawlers can enhance stability of

the machine. Always extend the crawlers be-
fore operations such as constructing, rigging
and derigging.
44444444 Mounting counterweight
WARNING
Tipping hazard!
The machine must be fitted with the appro-
priate counterweight before rigging opera-
tions are begun.
WARNING
Failure to observe the following informa-
tion may pose injury or possibly death haz-
ard.
No person must stand on or under a coun-
terweight while it is being mounted.
Persons working on the upper carriage
must wear a fall protection belt secured to
the upper carriage.

NOTICE
Counterweights consisting of several parts

are to be transported in upright position.
Failure to do so will cause damage to the
components.
1. Raise the mast over the counterweight

mounting position.
2. Remove mast transport support (1).
Fig.4-76 Mast Transport Support

3. Connect sling and U ring to counterweight
lug (2). Use crane to lift counterweight (3),
move it from position A to position B, and
then fasten with bolts.
3
2
Fig.4-77 Mounting the Counterweight I
Note: 1
B
Assemble the mast transport support, bolts
and nuts. Store them properly and guard A
against parts loss.
The counterweight is about 5 ton. Connecting

elements for lifting such as U ring and slings
shall meet the hoisting requirement.
2
Tighten the bolts according to the required
Fig.4-78 Mounting the Counterweight II
tightening torque. (See: Appendix, “bolt
tightening torque” on page 8-3)

44444444 Connecting upper mast and middle

mast
WARNING
Crushing hazard!
To avoid being crushed, never stand under
mast when lifting.
During the assembly operations, the opera-
tor must keep the person working at the
mast in view at all times. Failure to do so 2 1
may cause injury or possibly death.
1. Lower mast and rest it on the mast support.
2. Pull out the pin (3) connecting the upper

mast (1) and the middle mast (2).
3
3. Pull upper mast to make it rotate around the
connecting pin between upper mast and
middle mast. Do not stop until the upper
mast and middle mast become a straight
line. At the moment, the two flange faces
are jointed together and then connect them
Fig.4-79 Connecting Upper Mast and Middle
firmly by bolts.
Mast I
1 2
Fig.4-80 Connecting Upper Mast and Middle Mast II

<1> Upper mast
<2> Middle mast

4. Bolts mounting method: Insert a bolt that

is sleeved with a flat washer into the mast Bolt
flange mounting hole. Be sure to insert it
in the direction from upper mast to mid-
Washer
dle mast. Then put a spacer onto the bolt,
Block
screw on a nut and fasten it, screw on the
locknut finally. Nut
Lock nut
Fig.4-81 Installing Bolt
Note:
●● Install dismantled pin back to its original po-

sition and guard against parts loss.
●● Do not press electric wires when rotating
upper mast.
●● When mounting bolts do not fasten a bolt at
first. Tighten them gradually, following the
sequence from middle to sides.
●● Tighten the bolts according to the required
●● The weight of SR150C rotary drilling rig
mast is about 0.58 ton. The weight of
SR200C rotary drilling rig mast is about 0.83
ton. Connecting elements for lifting such
as U ring, slings, shall meet the hoisting re-
quirement.

44444444 C onnecting pulley yoke
WARNING
No person should be allowed to be under
the pulley yoke during lifting. Failure to
observe it may cause injury or possibly
death.
1. Remove transport support (1) connecting 1

pulley yoke (2) and upper mast (3).
2. Connect one end of sling to the pulley on

the pulley yoke and connect the other end
to the crane.
3. Operate the crane slowly to lift the pulley Fig.4-82 Pulley Yoke Transport Support
yoke, rotate the pulley yoke around the
jointed shaft. When pulley yoke is jointed
with mast flange face, fasten it with bolts.
For installing bolt, see: Chapter 4 Opera-
tion, “connecting upper mast and middle
mast” on page 4-68.
2
3
Fig.4-83 Connecting Pulle Yoke and Upper Mast

Note:
●● Pulley yoke weighs about 1 ton. Use the

sling of required specification.
●● Store transport support properly and guard
against parts loss.
●● Do not damage electric wires when rotating
pulley yoke.
●● When mounting bolts, tighten them gradu-
ally, from middle to sides.

44444444 Installing main winch and lower

mast
CAUTION
Accident hazard!
To avoid accident, no person should be al-
lowed to be near the machine during lifting
and transporting.
1. Ensure that main winch and lower mast are

connected at first.
2. Connect sling and U ring to main winch and

lower mast. Ensure that main winch and
lower mast can remain vertical after being
lifted.
3. Use a crane to lift main winch and lower

mast from position 1 to position 2.
2 1
Fig.4-84 Installing Main Winch and Lower Mast
4. Lift them to a suitable location, install pin

shaft and fasten them firmly.
5. Install connecting rod (3) between lower
4
mast and triangle, and use pin (4) to fasten
firmly.
Fig.4-85 Installing Connecting Rod

Note:
●● The total weight of main winch and lower

mast is about 2 ton. Use sling and U ring of
required specification.
●● For the connection of main winch oil pipe
to electric wire, see: Chapter 4 Operation,
“connecting hoses” on page 4-74. And see:
Chapter 4 Operation, “connecting elec-
tric device” on page 4-77.
44444444 M ounting rotary drive
WARNING
No person should be allowed to be near
the machine during lifting and transporting.
Failure to observe this may cause injury or
possibly death.
1. Connect sling and U ring to rotary drive to

ensure that crowd sledge guide remains
vertical after being lifted.
2. Use a crane to lift rotary drive, make the

crowd sledge guide slide into the guide rail,
move it from position 1 to position 2. 11
Fig.4-86 Installing Rotary Drive

Note:
The weight of rotary drive assembly is about 5
ton. Use sling and U ring of required specifica-
tion.

44444444 Connecting hoses
WARNING
When removing pipe, release pressure

first to prevent injury. Failure to do so may
cause serious personal injury.
NOTICE

cling.
For more information, go to http://www.
epa.gov/osw/conserve/materials/usedoil/
Before removing hoses, prepare a container

for holding oil to prevent residue oil from leak-
ing. Screw out drain plugs on main winch and
rotary drive, and then screw out drain plugs on
hoses, finally connect and fasten them accord-
ing to figures below in this section.
Fig.4-87 Connecting Hoses of Main Winch and

Rotary Drive

Connecting main winch hoses:
A-A
G3 G4
G1 G2
Fig.4-88 Connecting Main Winch Hoses I
Main winch motor
B A
Fig.4-89 Connecting Main Winch Hoses II

Table 4-3 Connecting main winch hoses
Pipe Name Hose Number Motor Oil Port
Drain Hose G1 T
Feeding Hose G2 S
Work Hose G3 A
Work Hose G4 B

Connecting rotary drive hoses
B-B
G5 G6 G7 G8 G9
Fig.4-90 Connecting Rotary Drive Hoses I
Rotary Drive Confluence

Hydraulic Block
K1 K2 K3 K4 K5
Fig.4-91 Connecting Main Winch Hoses II

Table 4-4 Connecting rotary drive hoses
Confluence Hydraulic Block Oil
Hose Name Hose Number
Port
T Control Hose G5 K5
Motor Feeding Hose G6 K4
Motor Drain Hose G7 K3
Main Hose A G8 K2
Main Hose B G9 K1
Note:
Store removed plug properly and guard

against loss.

44444444 Connecting electric device
To connect electric wires in main winch to

those in middle mast, insert the plug.
Fig.4-92 Electric Plug
Fig.4-93 Connecting Position of Electric Plug

444444444Connecting middle mast and lower

mast
NOTICE
Risk of machine damage!
Slow your operation when middle mast
lower flange face is just about to joint with
main winch upper flange face. Stop your
operation once they joint with each other,
otherwise, it may cause damages to the
machine.
1. Lift the mast. Stop once lower flange of mid-

dle mast joints the upper flange face of main
winch, and then connect them.
2. Remove the connecting rod (1) between

lower mast and triangle. 1
Fig.4-94 Dismantling Connecting Rod

3. Connect rotary drive (2) to crowd cylinder

(3): Use control handle to extend or retract
the crowd cylinder, adjust its position to
align the pin hole on the end of crowd cyl-
inder piston rod rotary drive pin hole, then
insert pin and connect them.
Fig.4-95 Connecting Crowd Cylinder and Rotary

Drive
Note:
●● When there is trouble in removing con-

necting rod, adjust the mast angle by mast
adjusting lever to facilitate the removal of
mast connecting rod.
●● Store the dismounted connecting rod and
pins properly, and guard against parts loss.
●● When installing bolts, tighten them gradu-
ally, following the sequence from middle to
sides.

444444444 Installing wire ropes
WARNING
Serious injury hazards!

Three wraps of wire rope must installed on
the drum of the crowd winch for safety rea-
sons. Failure to do so may cause serious
personal injury.
Installing main winch wire rope

1. Operate display screen to select MAIN
WINCH mode. Use left control handle to ex-
tend wire rope. For detailed operation, see:
Chapter 4 Operation, “Main winch opera-
tion” on page 4-32.
2. Remove the rope guard pins on major pulley,

and reel wire rope through major pulley on
pulley yoke.
3. Continue extending wire rope until its end

reaches rotary drive in front of the rig.
Rope guard pin
Fig.4-96 Extending Wire Rope with Enough Length

4. Install rope guard pins and secure.
5. Use wire rope clip (1) and rope clamp (2) to

tighten wire rope end.
1 2
Fig.4-97 Tightening Wire Rope End
Note:
●● When extending wire rope, perform guiding
operation. Provide wire rope with a load
and avoid getting twisted.
●● When installing rope clamp, press the Correct
clamp holder onto the wire rope working
section, press U-bolt onto wire rope end,
rope clamp opens towards the working sec- Wrong
tion. Never lay out rope clamp reversely or
alternatively.
Wrong
Fig.4-98 Fastening Method of Wire Rope End

Installing auxiliary winch wire rope

1. Operate display screen to select AUXILIARY
WINCH mode. Use left control handle to ex-
tend wire rope. For detailed operation, see:
Chapter 4 Operation, “auxiliary winch
operation” on page 4-36.
2. Remove the rope guard pins on minor pul-

ley, and install auxiliary winch contractor
weights, then thread wire rope through mi-
nor pulley yoke and contractor weights.
Auxiliary winch limit switch
Wire rope
Lifting bolt
Anti-collision switch
Fig.4-99 Install Auxiliary Wire Rope
3. Continue extending wire rope until its end

reaches rotary drive in front of the machine.
4. Install rope guard pins and secure.
5. Use wire rope clip and rope clamp to tighten

wire rope end.

Installation precautions
1. Determination of rope clamp number
The number of rope clamp is related to wire

rope diameter. Choose rope clamps suitable
for wire ropes. The recommendation list of
minimum number of rope clamp for all types of
wire ropes is as follows:
Table 4-5 Recommendation list of minimum

number of rope clamp
Wire rope nominal diameter(mm) ≤ 18 ＞ 18~26 ＞ 26~38 ＞ 38~44 ＞ 44~60
Minimum rope clamp number 3 sets 4 sets 5 sets 6 sets 7sets
2. Determination of distance between rope

clamps
The distance between rope clamps shall be 5
to 6 times longer than the wire rope diameter.
3. Fastening method for rope clamp

When installing rope clamps, press clamp
bracket onto the wire rope working section.
Press U bolt onto wire rope tail end, namely,
rope clamp opens towards the working sec-
tion. Never lay out rope clamp alternatively.
When installed, rope clamp’s fastening

strength shall not be below 85% of wire rope
breaking force.
When fastening rope clamp, pay attention to

each clamp’s load-carrying capacity. The clamp
farthest from the thimble shall be fastened
alone at first while the clamp nearest from
the thimble (the first clamp) shall abut against
the thimble as close as possible. Ensure that
clamps are screwed tightly and do not break
out layer steel wires of wire rope.
In actual usage, rope clamp shall be checked

after carrying load once or twice. Nuts shall be
further screwed tightly in most cases.

444444444Drilling rig test run
CAUTION
To test run the drilling rig, operate it at a
very low speed. Pay careful attention in
test. Failure to do so will cause personal
injury.
After mounting the drilling rig, main mecha-

nism of drilling rig should be tested and oil
leakage should be checked.
1. Boom mechanism test run
Operate the handle to extend and retract

boom cylinder. Operate derricking mechanism
to check whether its motions are normal. See:
Chapter 4 Operation, “Adjusting drilling
center distance” on page 4-28.
2. Rotary drive test run
Operate the handle to make rotary drive rotate

positively, rotate reversely or dump soil. See:
Chapter 4 Operation, “Rotary drive control”
on page 4-38.
3. Mast mechanism test run
Operate mast adjusting lever to raise and

lower mast; when mast is vertical, operate the
lever to adjust mast tilting state. Its sideward
angle shall be ±5°and forward inclination shall
be 15°, backward inclination shall be 30°,
check if all these motions are normal.
4. Main winch test run
Operate the handle to make main winch lift or

lower the load; when the handle is released,
the load shall be stopped and locked at its
current position. See: Chapter 4 Operation,
“Main winch operation” on page 4-32.

5. Auxiliary winch test run
Operate the handle to make auxiliary winch lift

or lower the load; when the handle is released,
the load shall be stopped and locked at its
current position. See: Chapter 4 Operation,
“auxiliary winch operation” on page 4-36.
6. Test effectiveness of all limit switches
Push boom back limit switch, mast left and

right limit switches, main and auxiliary winch
limit switches to check whether the display
screen alarms. Test the effectiveness of all
limit switches, and alarms indicate normal
working condition.

4.3.3 Installing drilling tool
44444444 Connecting rope swivel to Kelly

bar
Use pins, bolts and washers to connect rope

swivel to Kelly bar firmly.
Bolt
Washer
Pin
Rope Swivel Kelly Bar
Fig.4-100 Connecting Rope Swivel to Kelly Bar
Note:
●● Pay attention to the direction of rope swivel

and never install in reverse direction.
Upper Connection
●● Rotate rope swivel. Upper connection body Body
and middle connection body are jointed
as a whole, to be connected to wire rope. Connecting
Main Winch
Lower connection body is a whole, to be Middle
Connection Body
connected to Kelly bar.
tightening torque. (See: Appendix, “bolt Lower Connection
Connecting
tightening torque” on page 8-3) Body
Kelly Bar
Fig.4-101 Rope Swivel

44444444 Connecting Kelly guide to Kelly

bar
1. Connect Kelly guide (3) to Kelly bar (4) by

bolt (1), washers (2, 5) and nut (6), as illus- 1 2 5 6
trated in the right figure.
4
Fig.4-102 Connecting Kelly Guide to Kelly Bar I
2. Remove the two pins near the crowd sledge

guides and rotate the two crowd sledge
guides outwards. Install pins to their original
position to prevent the crowd sledge guides
from rotating.
Pins
Crowd Sledge Guide
Fig.4-103 Connecting Kelly Guide to Kelly Bar II

Note:
●● When installing bolts. Tighten them gradu-
ally.

44444444 Aligning drilling rig with Kelly bar

upper end Rope Swivel
Lower Connection
Operation procedures are listed below:
1. Rotate Kelly guide. Ensure that rope swivel
lower connection opening and Kelly guide
opening are in the same direction. It is con-
venient for main winch to hoist Kelly bar.
Opening
Kelly Guide
Fig.4-104 Aligning the Openings
2. Place Kelly guide opening downwards to

support the Kelly bar, and adjust drilling rig
to align rotary drive with upper end of Kelly
bar.
Rotary Drive
Upper End of Kelly Bar
Fig.4-105 Aligning Drilling Rig with Kelly Bar

44444444 Connecting wire rope and rope

swivel
Operate mast adjusting lever slowly, tilt the

mast forward by 3° to 5°. Connect wire rope
Main Rope
and rope swivel by pins and bolts.
Rope Swivel
44444444 Installing Kelly bar
WARNING
Fig.4-106 Connecting Wire Rope and Rope
Swivel
the Kelly bar. Failure to do so may result in
injury and possibly death.
CAUTION
Prior to raising Kelly bar, ensure that rope

swivel opening is in the same direction of
wire rope and Kelly bar. Otherwise, it may
cause damages to rope swivel and Kelly
bar.
When Kelly bar is about to leave the
ground, make Kelly bar perpendicular to
the ground. To prevent Kelly bar from con-
tacting the machine when it is leaving the
ground.
Motions of the processes below shall be
very slow; otherwise, swaying Kelly bar
Fig.4-107 Confirmation of Rope Swivel Opening
will damage the machine.

1. Operate main winch slowly to raise Kelly bar

and at the same time travel with the ma-
chine towards the Kelly bar. Keep angle as
small as possible between wire rope and
mast. Raise Kelly bar off the ground slowly.
Fig.4-108 Diagram I of Raising Kelly Bar
Fig.4-109 Diagram II of Raising Kelly Bar
Fig.4-110 Diagram III of Raising Kelly Bar

2. When Kelly bar lower unit passes rotary

drive, stop lifting and adjust Kelly bar to ver-
tical status. Be sure to make the sliding strip
of Kelly bar joint with the front face of mast.
Fig.4-111 Diagram I of Inserting Kelly Bar into

Rotary Drive I
3. Lower boom mechanism gradually to align

Kelly bar outer key with corresponding key
slot in rotary drive. Lower Kelly bar slowly
into the key sleeve in rotary drive.
Fig.4-112 Diagram II of Inserting Kelly Bar into

Rotary Drive II
Remark:
Rotary drive key sleeve is equipped with key

slots for two types of Kelly bars: all friction
Kelly bar and interlocking Kelly bar. When in-
stalling Kelly bars, insert them into the right
key slots.

4. Pull backward the right handle to raise ro-

tary drive to the position of mast pivot while
raising boom slowly. Push forward the left
control handle to lower Kelly bar. Do not let
Kelly bar touch the ground.
Fig.4-113 Diagram I of Installing Kelly Guide
5. Lower mast to horizontal position and install

pins (1) to hitch crowd sledge guide (2) to
mast guide rail.
1 2
Fig.4-114 Diagram II of Installing Kelly Guide
Note:
●● Lower mast at low speed, and prevent Kelly

guide crowd sledge guide from separating
mast front face.
●● Try to lower Kelly bar gravity center to en-
sure the mast can be raised after being
lowered.

44444444 Installing drilling bucket
1. Place drilling bucket on the ground, with the

Kelly box upwards.
2. Operate drilling rig to raise mast, adjust the

position of rotary drive, to align Kelly bar
square stub with Kelly box.
3. Lower Kelly bar slowly, rotate rotary drive

when necessary to align Kelly bar square
stub with Kelly box. Insert Kelly bar square
stub into Kelly box and fasten them with pin
and lock pin.
Drilling Tool
Fig.4-115 Diagram of Installing Drilling Bucket
Fig.4-116 Diagram of Installing Drilling Bucket

4.3.4 Disassembling drilling tool
Before operation, ensure that drilling rig is in

extension status. For operation method, see:
Chapter 4 Operation, “Crawler extending
and retracting” on page 4-43.
44444444 Disassembling drilling bucket
1. Set the mast upright.
2. Lay drilling bucket on ground.
3. Remove pin and lock pin, disassemble drill-

ing bucket, and raise Kelly bar slowly. When
Kelly bar is going to be removed from drill-
ing bucket, swing upper carriage slowly to
lay down drilling bit.
Note:
●● When the pin connecting Kelly bar and

drilling bucket cannot be removed, operate
main winch repeatedly and slowly to loosen
the connecting pin.
●● Store pin and lock pin properly and guard
against parts loss.

44444444 Removing Kelly bar
WARNING

the Kelly bar. Failure to do so may result in
injury and possibly death.
CAUTION
The motion of the processes below must
be very slow. Failure to do so, swayi ng
Kelly bar will damage machine parts.
1. Lower Kelly bar. Remove the two pins near

the crowd sledge guides and open the two
crowd sledge guides outwards. Return pins
to their original position, and keep the crowd
sledge guides opened.
1 2
Fig.4-117 Removing Kelly Guide

2. Set the mast to upright and move the rotary

drive to the lowest position. Raise Kelly bar
to separate from rotary drive.
3. Operate mast adjusting handle slowly, make

mast lean forwards by 3° to 5°. Make sliding
plate on Kelly guide leave mast front face.
Fig.4-118 Raising Kelly Bar

4. Lower Kelly bar until Kelly rests with square

stub on ground. Go on lowering the Kelly
bar and at the same time travel in reverse
with the machine. Do not stop until Kelly bar
is laid on the ground entirely.
Fig.4-119 Diagram I of Lowering Kelly bar
Fig.4-120 Diagram II of Lowering Kelly bar
Fig.4-121 Diagram III of Lowering Kelly bar

5. Remove the rope swivel from the main rope

by removing pin. Main rope
Rope swivel
Pin
Fig.4-122 Disconnecting Main Rope and Rope

Swivel
6. Retract main winch wire rope to the suitable

length and fasten the rope end. Retract aux-
iliary winch wire rope to the suitable length
for transportation and fasten the rope end.
Note:
Install the pin and bolts to their original posi-

tion, in case of parts loss.

4.3.5 Disassembling drilling rig
Before operation, ensure that drilling rig is in

extension status. For operation method, see:
Chapter 4 Operation, “Crawler extending
and retracting” on page 4-43.
44444444 Disconnecting pulley yoke and up-

per mast
1. Lower mast to horizontal status to rest mast

on mast bracket.
2. Connect one end of sling to the pulley on

the pulley yoke and connect the other end
to the crane.
3. Operate crane to raise pulley yoke to ten-

sion the sling.
4. Dismantle bolts and washers on pulley yoke

connecting with upper mast.
5. Operate crane slowly to lower pulley yoke

to make it rotate around hinged axle. When 1
pulley yoke support plate joints with upper
mast support plate, install transport bracket
(1) and fasten it.
Note:
●● Dismantled bolts and washers properly and
guard against part loss.

●● Pulley yoke weights about 1 ton. Use the
sling of required specification. Fig.4-123 Installing Transport Bracket
●● Do not press electric wires when rotating

pulley yoke.

44444444 Disconnecting upper and middle

mast
NOTICE
Keep proper slack for the wire rope. Failure

to do so will cause damage to wire rope
when folding the mast.
1. Remove the bolts and washers that connect

upper mast (1) and middle mast (2).
2. Move upper mast connecting pin between

upper mast and middle mast. Do not stop
until upper mast and middle mast are paral-
lel.
3. Install pin of connecting bracket between

upper mast and middle mast.
1 2
Fig.4-124 Removing Upper Mast and Middle Mast Connection
Note:
●● Store dismantled bolts and washers prop-
erly.
●● Do not damage electric wires when rotating
pulley yoke.

44444444 Removing rotary drive and crowd

cylinder connection
1. Raise mast slowly to vertical status.
2. Extend crowd cylinder piston rod and place

rotary drive to the lowest end of mast.
3. Remove pin between rotary drive and crowd

cylinder. Operate handle to extend and re-
tract crowd cylinder to facilitate the removal
of pin shaft.
4. Retract crowd cylinder piston rod.
Note:
Install dismantled pin shaft and baffle back to
their original positions and guard against part
loss.
Fig.4-125 Removing Crowd Cylinder and Rotary

Drive Connection

44444444 Disconnecting middle mast and

lower mast
1. Install connecting rod (1) between lower

mast (2) and triangle (3) and install pin.
2. Remove connecting bolt between middle

mast and main winch.
3. Lower mast and rest it horizontally on the

mast bracket.
3
1
2
Fig.4-126
Note:
●● Store dismantled bolts and washers prop-
erly.
●● Do not damage electric wires during opera-
tion.

44444444 Removing rotary drive
NOTICE
Disconnect the leak-oil line last. Failure
to do so will cause damage to the compo-
nents.
1. Remove all pipes and electric wires con-

necting to rotary drive.
2. Connect sling and U ring to rotary drive and

choose a proper hoisting point. Ensure that
rotary drive sliding holder remains vertical
after rotary drive is lifted.
3. Use crane to lift rotary drive and separate it 1

from lower mast guide rail. Move it from po-
sition 2 to position 1.
Fig.4-127 Removing the Rotary Drive

4. Place dismantled rotary drive into a packing
box or onto level and firm ground.
Note:
●● Use sling and U ring of required specifica-
tion.
●● Protect electric wire plug properly and block
the removed oil pipe with plug to prevent it
from polluting hydraulic system.
●● When rotary drive is about to separate from
guide rail, motions must be very slow to
prevent parts from swaying to collide.

44444444 Removing main winch and lower

mast
WARNING
To avoid being hit, be cautious when lift-
ing and transporting. Failure to do so will
1. Remove all pipes and electric wires con-

necting to main winch.
2. Connect sling and U ring to main winch and

lower mast and choose a proper hoisting
point. Ensure that they remain vertical after
being lifted.
3. Operate crane to raise main winch and low-

er mast to tension the sling.
4. Remove connecting rod between lower

mast and triangle, and remove connecting
pin shaft between main winch and middle
mast.
5. Use crane to lift main winch and lower mast,

and move them from position 2 to position 1.
6. Place main winch and lower mast into a

level solid ground, with their guide rail side
downwards. Fig.4-128 Removing Main Winch and Lower Mast
Note:
●● Use sling and U ring of required specifica-
tion.
●● Protect electric wire plug properly and block
the removed pipe with plug to prevent it
from polluting hydraulic system.
●● When lower mast is about to separate from
middle mast, motions must be very slow to
prevent parts from swaying.

44444444 Removing counterweight
WARNING
Failure to observe the following informa-
tion may pose crushing and falling hazard!
●● No person must stand on or under a
counterweight while it is being dismount-
ed.
●● Persons working on the upper carriage
must wear a fall protection belt secured
to the upper carriage. 1
2
1. Pull up boom, and raise mast. Stop when
mast passes over counterweight mounting
position. Ensure that there are no barriers
over counterweight; otherwise it will affect
crane hoisting operation.
Fig.4-129 Diagram of Removing Counterweight I
2. Connect sling and U ring (1) to counter-
weight lug. Use crane to lift counterweight
(2), and move it from position A to position B. A
Place counterweight onto level solid ground.

B
Fig.4-130 Diagram of Removing Counterweight II
3. Use crane to hoist mast transport bracket

and fasten it with bolts.
Fig.4-131 Installing Mast Transport Bracket

4. Lower mast and rest it horizontally on mast

transport bracket. .
Fig.4-132
Note:
●● Connecting elements for lifting such as U
ring, slings, shall meet the hoisting require-
ment.
●● Protect mast bracket on counterweight dur-
ing hoisting.

4.4 Wire Rope
4.4.1 Installing wire rope
1. Before installation:
●● Replaced wire rope should have the same

type and specifications with the original
wire rope. If adopting a different type of
wire rope, be sure the performance of the
new wire rope is not inferior to the original
one.
●● When a long wire rope is cut off, the both
sides of the point where the cut is made
should be seized.
●● Inspect the grooves on drum and pulley to
see if they meet requirements of replaced
rope, before the wire rope is installed on
the machine.
●● Before the wire rope is put into service,
make sure all the devices related with wire
rope operation are in readiness and runs
normally.
●● Before the wire rope is installed, lay of di-
rection should be known.
2. Unwinding wire rope:
●● Wire rope shipped in coils can be unwound

either with the aid of a rotary plate or by
rolling off the rope on the ground. If roll-
ing off the rope on the ground, the ground
should be clean to prevent sand sticking
to the rope’s lubricant. Sand and dirt may
cause damage to the rope during operation.
Fig.4-133 Unwinding Way

●● Never unwind a wire rope from a reel or coil

in a sideways direction to the winding of the
rope. Sideways unwinding of wire rope
causes the rope to twist and will eventually
form loops.
Note:
●● Be cautious of knotting of the wire rope

when extending the wire rope.
●● Wire rope with knot is caused by load and Fig.4-134 Wire Rope with Knot
unable to return to normal. It must be re-
placed.
3. Cutting and seizing wire rope:
NOTICE
Be careful when cutting the wire rope.
Failure to do so may pose damage to wire
rope.
●● Wire rope scissors can be used to cut wire

ropes up to 8 mm in diameter. For wire rope
of larger diameters mechanical or hydraulic
cutters are available.
●● It is highly recommended to use high-speed
disk cutter to cut wire rope. Electric welding
and air cutting is only used on the condition
that the wire rope is to be discarded.
●● It is imperative to seize wire rope ends with

iron wire to avoid strands slacken. Proce-
dures are listed bellows:
1) Mark the point of the cut. Span the seizing
wire horizontally along the rope at an
enough length.
2) Wind the seizing wire around the wire rope

from the point of the cut.
Fig.4-135 Winding Iron Wire 1

3) Tightly wind the seizing wire around the

wire rope until the seizing is 3 times the
length of the wire rope’s diameter.
4) Twist the two ends of seizing wire together

with pliers.
5) Cut the twisted seizing wire with pliers to

the length of the wire rope’s diameter.
Lightly stamp the end of the twisted
seizing wire into a valley between two
outer strands. Cut the wire rope with an
abrasive wheel.

4. Wire rope installation:
●● When installing wire rope, be careful to re-

move wire rope from reel or drum without
twisting force. Ensure that there is no dam-
age to outer surface.
●● Protect the abrasion part between wire rope
and the machine.

●● Old wire rope should be discarded before

installing new wire rope. If old wire rope
is used, do not weld the old and new wire
rope or bind them together directly. Use
hemp cord and iron wire.
5. Winding wire rope from reel onto winch:
●● Each wire rope is manufactured with a

bending line. Make sure that the correct Right
bending line is maintained when the wire
rope is wound directly from the shipping
reel onto winch.
●● If the wire rope is wound from the bottom
of winch, the wire rope should be released
from the bottom of winch, vice versa. That Wrong
is to say, the wire rope is always wound
from top to top, from bottom to bottom.
Fig.4-139 Winding Wire Rope from Reel onto

Winch
6. Winding wire rope under load:
●● In the case of multiple layers winding on the

rope drum it may be necessary to tension
the wire rope.
●● If the initial tension is not enough, the drum
may be too loose, which could damage wire
rope.
●● The initial tension should be approx. 1 to 2
% of the wire rope’s breaking load. Fig.4-140 Winding Wire Rope under Load
●● Initial tension is produced by braking or by
operating a brake sheave mounted to the
outside of the reel.

Note:
Never generate initial tension by clamping the

rope, e.g. By passing the rope between wood-
en clamps, for this may lead to irreparable de-
formations.
Fig.4-141 Wrong Tensioning Way

7. Connecting and securing wire rope :
In order to extend the wire rope service life

and guarantee safe and reliable application,
properly install the wire rope according to the
following requirements.
1) Fixing the rope ends
●● When fixing with rope clamp, abide by reg-

ulations in GB/T5976 wire rope clamps. In
correct mounting, its strength should be no
less than 85% of the rope breaking force.
●● When fixing with wedge and sleeve, abide Right Right Wrong
by regulations in GB/T5973 wire rope
wedge joints, its strength should be no less
than that of the rope breaking force.
Right Wrong
Fig.4-142 Wedge Joints

2) Rope clamp layout
Mounting of rope clamp is illustrated in the fig-

ure on right. Buckle the clamp holder onto the
rope working section. Buckle U helix onto the
tail section of the wire rope. Do not lay the a: right
rope clamps alternately on the wire rope in re-
verse direction.
b: wrong
c: wrong
Fig.4-143 Layout of Wire Rope Clamp

Installation precautions
1. Determination of rope clamp number
The number of rope clamp is related to wire

rope diameter. Choose rope clamps suitable
for wire ropes. The recommendation list of
minimum number of rope clamp for all types of
wire ropes is as follows:
Table 4-6 Recommendation list of minimum

number of rope clamp
Wire rope nominal diameter(mm) ≤ 18 ＞ 18~26 ＞ 26~38 ＞ 38~44 ＞ 44~60
Minimum rope clamp number 3 sets 4 sets 5 sets 6 sets 7sets
2. Determination of distance between rope

clamps
The distance between rope clamps shall be 5
to 6 times longer than the wire rope diameter.
3. Fastening method for rope clamp

When installing rope clamps, press clamp
bracket onto the wire rope working section.
Press U bolt onto wire rope tail end, namely,
rope clamp opens towards the working sec-
tion. Never lay out rope clamp alternatively.
When installed, rope clamp’s fastening

strength shall not be below 85% of wire rope
breaking force.

When fastening rope clamp, pay attention to

each clamp’s load-carrying capacity. The clamp
farthest from the thimble shall be fastened
alone at first while the clamp nearest from
the thimble (the first clamp) shall abut against
the thimble as close as possible. Ensure that
clamps are screwed tightly and do not break
out layer steel wires of wire rope.
In actual usage, rope clamp shall be checked

after carrying load once or twice. Nuts shall be
further screwed tightly in most cases.
4. Test run:
●● After the wire rope is mounted, formal test

runs should be performed with low load.
●● After the wire rope is installed according to
requirements, if the wire rope rubs against
some part of the machine, provide proper
clamp to the part that it may contact.
●● In order to stabilize and position the wire
rope, test run the moving parts of the ma-
chine with about 10% of the load for several
times.
●● Avoid wire ropes twisting, knotting, distort-
ing, bending and rubbing.

4.4.2 Unloading and storing wire rope
●● Unload wire rope with caution. Pushing

down directly from high position is prohibit-
ed.
Fig.4-144 Right Operation I
●● To prevent damage to the wire rope when

unloading it, the coiled rope should be lifted
with a web sling and the reel with a rod in-
serted through the shaft of the reel.
Fig.4-145 Right Operation II
●● When rolling wire rope, crowbar can only

be used on flange of reel. Crowbar is
not allowed to contact wire rope directly.
The ground should be level. No sharp or
firm objects are allowed to appear on the
ground.

●● When unloading wire rope with fork truck,

the fork cannot contact wire rope directly,
even the wire ropes have outer layer.
Fig.4-146 Wrong Operation I
Fig.4-147 Wrong Operation II

●● Wire ropes are to be stored in a clean and
dry place. Specifications of wire rope should
be provided for recording and checking.
●● During storage, wire ropes should not be
put evenly. They must be stored on pallets
and must be covered for protection against
rain.
●● During storage, frequent check should
be carried out. Sand and mud should be
cleared off and grease should be added.

4.4.3 Discarding wire rope
Discarding of wire rope is subject to broken

wire, wear, or corrosion condition. Immediately
replace for any of the following condition. Nev-
er use for continuous service.
●● Broken wire occurs at the rope end or near-
by.
●● The broken wire gathers within the range of
6d rope length.
●● If broken wire appears after a period and
increases gradually, timely discard accord-
ing to standard.
●● The whole strand ruptured. Fig.4-148 Wire Rope Broken Wire

●● Damage of rope core causes the rope di-
ameter to reduce.
●● For different situations of decreasing flex-
ibility, discard according to standard.
●● If outer wire wear reaches 40% of its diam-
eter, the wire rope diameter decreases 7%
or even more.
●● Various visible deformations appears on the
wire rope.
Fig.4-149 Wire Rope Deformation

●● Deep pits appears because of corrosion of

outer wire rope.
●● Rope diameter reduces.
Fig.4-150 Wire Rope Diameter Reduces

●● Broken wire, decrease of strand clearance,
and increase of rope diameter appear be-
cause of inner corrosion.
Note:
●● In some application, fatigue is the main
cause of wire rope damage. Even no de-
fects are visible from the outer appearance,
there is broken wire inside. Therefore, if the
wire rope is qualified but out of service life,
timely replace with new wire rope. Fig.4-151 Wire Rope Diameter Bending
●● When discarding wire rope, find out wheth-
er the wire rope damage is caused by
mechanism defects. Clear of these defects
before replacing with new wire rope.

4.5 Drilling Rig Transport
4.5.1 Transport requirements
When transporting drilling rig, follow all rel-

evant local laws and regulations.
1. When transporting with a trailer, check it

for length, width, height and weight before
loading drilling rig. The height of the rear of
trailer should be under 1300mm, the height
of the middle part of trailer should be under
900mm.
2. Examine the transport route situation in ad-

vance, and transport regulation.
3. Sometimes it is necessary to take apart

the drilling rig to meet the limits on size or
weight required by local authorities.
4.5.2 Safety guidelines for transport
WARNING
Risk of serious injury or possibly death!

Attach lifting slings only to the provided
lifting points. Failure to do so may result in
1. Only use hoisting equipment and lifting

slings that have sufficient bearing capacity.
2. Arrest and secure movable parts of the

equipment.
3. Put accessories to be stored safely away so

they will not be an obstacle to traffic on the
roads and will not be interfered with by ac-
cident.
4. Cover up sharp edges, projecting points and

cutting blades.

5. The driver of the transporting vehicle is re-

sponsible for checking all the equipment,
the machine and accessories each time be-
fore he starts to drive.
6. The hauler in charge is responsible for the

transport of the equipment, the machine and
accessories.
7. The hauler should be informed of the trans-

port dimensions, the weights and the route.
8. Be familiar with transport dimension and

weight which are regulated by local laws.
9. A road permit must be obtained.

4.5.3 Transport parameters
44444444 Transport status (A)
3250
5487 3775
14200
Fig.4-152 Transport Status A
Table 4-7 Transport status A parameters of base

machine
ITEM UNIT D ATA
Transport Length mm 14200
Transport Height mm 3250
Transport Width mm 3400
Crawler Length mm 5487
Track Width mm 700
Transport Weight t 50

Transport status (B)

Base machine:
3400
5487 1835
12390
Fig.4-153 Transport Status B
Table 4-8 Transport status B parameters of base

machine
ITEM UNIT D ATA

Crawler Length mm 5487
Track Width mm 700
Transport Weight t 38.5

Rotary drive
Table 4-9 Transport status B parameters of rotary

drive
ITEM UNIT D ATA
Transport Weight t 3
Fig.4-154 Rotary Drive
Main winch and lower mast

Table 4-10 Transport status B parameters of main
winch and lower mast
ITEM UNIT D ATA
Fig.4-155 Main Winch and Lower Mast

Counterweight
Table 4-11 Transport status B parameters of coun-

terweight
ITEM UNIT D ATA
Fig.4-156 Counterweight

4.5.4 Loading and unloading the ma-

chine
44444444 Requirement for loading and un-

loading the machine
WARNING
Set traveling speed switch to low gear and
do not operate the switch to avoid danger
caused by high-speed movement. Failure
to do so may result in injury or possibly
death.
Precautions are listed as follows:
●● Set traveling speed switch to low gear and

do not operate the switch to avoid danger
caused by high-speed movement.
●● Turn engine speed dial to low speed.
●● When loading or unloading the machine,
choose solid and level ground and keep a
safe distance from road edge.
●● Use a slope with sufficient width, length,
thickness and strength, its maximum slope
angle being 15°. When using a soil slope,
compact the soil. When using the trailer’s
ramp, its angle from the ground shall not
exceed 15°.

●● When using ramp or a platform, place spac-

er blocks under trail wheels to prevent trail-
er from moving.
Max.15°
Distance Spacer blocks
Fig.4-157 Trailer Preparation
●● It is extremely dangerous to change direc-

tion when driving up or down a ramp. Drive
back to ground or trailer plate to change
traveling direction.
●● Because tracks are flat and straight, drill-
ing rig may suddenly lean forwards or
backwards when passing the jointing point
between ramp top and trailer plate. Drive
through this point cautiously.
●● When loading or unloading the machine,
never swing the drilling rig to avoid possible
rollover.
●● When the machine is traveling on a slope,
never operate any control lever other than
traveling lever.
●● Before loading or unloading, clean ramp or
platform and trailer thoroughly.

44444444 Loading the machine
1. Start the engine. Align tracks with ramp or

slope, and drive drilling rig in reverse onto
the trailer.
Fig.4-158 Loading the Machine
2. Raise mast to prevent working tools hitting

the ground when the drilling rig is driving up
a slope.
3. With the help of a guide person, drive drill-

ing rig slowly onto ramp or slope. When
traveling to the jointing point between ramp
top and trailer plate, the drilling rig will sway
forwards or backwards. At this moment,
adjust the drilling rig slowly and cautiously.
Drive it onto trailer plate at its minimum
speed.
4. Stop drilling rig at a suitable position on the

trailer plate. Ensure that the tracks of both
sides have an equal clearance from trail
sides.

5. Stop the engine and remove the key. Oper-

ate control lever several times until pressure
in hydraulic cylinder is released completely.
6. Pull hydraulic lock lever to locked position.
7. Shut cab window, ventilator and door, and

cover air vent to shield wind or rain.
8. Install swing locking connecting rod.
44444444 F astening method
Fasten the machine by chains or wire rope to

prevent it from sliding during transportation.
Note:
Bind chains or wire ropes on the H beam, and

never let them rest on or across hydraulic lines
or hoses.
44444444 Unloading the machine
The process of unloading the machine re-

verses that of loading it. (see: Chapter 4 Op-
eration, “loading the machine” on page 4-126.).
When unloading the machine, pay extra atten-
tion.
Note:
Raise mast height to prevent working tools hit-
ting the ground.

4.5.5 Requirements for sea transpor-

tation
The focus of sea transport is seawater corro-

sion resistance of rotary drilling rig.
1. Protection of non-paint finishing work piece
(plated piece, phosphoresced piece)
Brush rust preventing oil 377-HF evenly twice.
Use polyethylene film (bags) or wrapping film

for packaging, use polyethylene tape for seal-
ing bandage.
2. Coating surface protection
To protect exposed painting surface, choose

air bubble film to wrap, then use dust pre-
venting wrapping film to seal. Ensure that
the wrapping overlap shall be not less than
150mm; relevant parts are wrapped tightly
and fixed after being wrapped 3 rounds. Cover
surface shall be sealed by TESA (50530) paint
protection film.
Cab interior surface, painting surface, seat,

floor, operating handle, control panel shall be
packed by TESA51136 inner protective film.
3. Protection of reducer, exposed pipe joint,

bolts and pins end
Brush rust preventing oil 377-hf evenly twice.

Use dust preventing wrapping film to seal after
wrapping 3 rounds (if part assembly is com-
pleted, use dust preventing wrapping film to
seal by wrapping the part assembly).
4. Glass window protection

Use TESA (51136) transparent glass protec-
tion film to perform sealing operation. Start ap-
plying protection film from one end of outside
glass surface while scrapping in the same di-
rection by rubber scrapper. Ensure that protec-
tion film and glass surface are jointed firmly,
leaving no breakage or obvious air bubble.

5. Protection of electrical appliance system

and hoses
To protect power distribution box, use silicon

protection coating 494-714 to spray on ex-
posed plug (socket) and contact point, then
use water proof plastic bag or wrapping film to
seal it. Place desiccant into power distribution
box and fasten it. Use wrapping film to seal
and fasten exposed hoses, electric appliance
line and plug-in.
For desiccant, choose silica gel or surface,

and pack with cotton cloth (bag), and it is easy
to place and fix.
44444444 Hoisting the machine
Operation procedure:
1. Pull guide control lever to lock position.
2. Shut down the engine. Remove key.
3. Use steel chain and support rod with

enough length and ensure that they will not
collide with the machine during hoisting.
4. Wrap some protection material around steel

chain and support rod to prevent them from
damaging the machine as required.
5. Drive crane to an adequate hoisting posi-

tion.
Supprot Rod
6. As illustrated in the right figure, put steel Steel Chain
chain through under track brackets of two

Steel Chain
sides, and use support rod to support firmly.
So the steel chains are installed onto the
crane.
Precautions are listed as follows:

●● Do not hoist the machine if there are per-
sons on it.
●● Prevent anyone from being near or under
the hoisting machine. Fig.4-159 Hoisting

●● Ensure that wire ropes for hoisting the ma-

chine are strong enough. Do not use dam-
aged or aged steel chain or hoisting tool.
●● If you have any question about hoisting
method, types of hoisting steel chain and
hoisting tool, contact approved sales repre-
sentatives or SANY.
●● Pull control lever to locked position to pre-
vent the machine from moving unexpect-
edly when being hoisted.
●● Do not hoist the machine at a high speed.
Otherwise, hoisting steel chain and hoisting
tool will be overloaded to break.
●● Do not hoist the machine when the up-
per carriage is turning to one side. Prior to
hoisting the machine, ensure that the upper
carriage is in line with tracks.
●● When raising the machine, keep it in hori-
zontal status.
●● Do not use single steel chain to hoist. Oth-
erwise, it may be rotated, loosened or slip
from its position during hoisting, which may
lead to dangerous accidents.

4.6 Kelly Bar
4.6.1 Instructions
During construction process, Kelly bar trans-

fers torque and pressure onto drilling tool.
Therefore the Kelly bar must be treated with
as much care as drilling tools in order that the
consistent drilling performance be ensured.
To avoid damages to Kelly bar and misopera-
tion, please observe the following:
●● Not all types of Kelly bars are designed for
the max. torque of rotary drive. Know the
max. permissible torque of Kelly bar and do
not exceed it with the rotary drive.
●● Kelly bars and drilling tools are allowed to
be only used for drilling holes, other appli-
cations such as earth moving, conveying
and levelling are nor permissible.
●● If a Kelly bar is inserted in a borehole, do
not make any readjustments with the base
machine or the mast.
Note:
If the mast is displaced from its initial position
by working forces, it must be readjusted.
●● Start the drilling operation only when the
Kelly bar has been fully inserted in the
borehole and the auger bit hits the bottom
of the borehole.
●● For drilling in hard formations, the Kelly bar
must be interlocked or it will cause exces-
sive wear or damage of the Kelly bar.
●● In extremely tough weather, ensure that
there is no additional force applied on Kelly
bar: adjust the drilling pressure to suitable
value.
●● In conditions where the borehole is ex-
tremely deep and the diameter extremely
large, special attention must be paid that

the Round chisels are in good working con-

ditions. If wear or damage appears, replace
them in time. Do not attempt to make up
for worn teeth by increasing crowd force on
Kelly bar.
●● When extending a Kelly bar, adjust torque
and pressure to adapt to the condition.
●● When retracting a Kelly bar from borehole,
pay special attention to the outermost sec-
tion: if the outermost section lifts from its
rest on the rotary drive, one of the inter sec-
tions is not properly unlocked, stop lifting
by main winch. To avoid locking mecha-
nism will open, or the section would slip
through and get damage, reinsert Kelly to
the bottom of the borehole, and then ro-
tate rotary drive counterclockwise and pull
by the main winch to completely unlock and
properly retract all sections.
Note:
●● Kelly bar and mast must be parallel at all
times during operation.
●● After one section is retracted, the winch
load is increased, it will cause the base ma-
chine to tilt forward slightly.

4.6.2 Welding
NOTICE
Cut off power supply before welding to
protect electric elements.
The repair welding work can be only carried

out by trained and qualified welding personnel.
After welding, retract each section completely
one by one, and check if it is normal.
Steps for repairing:
1. Grind faces to be jointed, remove burrs and

clean weld zone free of grease
If the break is ragged, it may be necessary to

replace the section with new tubing, but the A
dimension must be kept.
“A”
Joint
Fig.4-160
2. Determine what material the parts are made
from
NOTICE
The square stub and steel pipe with diam-
eter of ￠ 377mm or below are made from
alloy steel and require preheating.
●● Use a sheltered location with enough space

(workshop).
●● Preheat the weld zone (approx. 200mm
outwards on both sides of weld joint) to ap-
prox. 200C°~250C°.

●● Perform welding.
3. Precautions for welding several parts to-
gether
●● Keep A dimension of Kelly inner bar.
“A”
Fig.4-161
●● Keep senior alignment.

●● After welding, grind the welds.
1) Butt welding
●● Use a fix-up equipment to hold parts

Joint
Spotweld 3 steel rods onto the tubing for fixture
Fig.4-162
●● Weld
Detail of B-B and “A”
Fig.4-163

2) Weld key bars
Uniform wear on key bars and locking One-side wear on material requires
键条、加压台均匀磨损时的磨损
recesses must not exceed 10mm 不均匀磨损时要尽快修理，防止
repair, to prevent functional failure
量不能超过10mm 损坏钻杆正常使用
Fig.4-164
Weld key bars onto the Kelly bar:
●● Fit-up key bars and spotweld

●● Spotweld on both sides at the same time
●● Avoid pitting surfaces
●● Produce flush welds
Fig.4-165
Note:
In this status, do not preheat the key bars.
To weld key bars, weld from the middle of Kel-

ly bar.
Avoid irregular distribution of heat over the

bar, keep the differences in temperature at a
minimum to prevent distortion.

To keep the temperature in balance during

welding, interactive manner is recommended:
after welding key bar (300mm), rotate Kelly
bar for 120°, then weld another key bar and
repeat.
Do not weld at recesses in zones

between arrows marked “-------”
Fig.4-166
3) Replace Kelly bar square stub
If support board or guiding ring tips off slightly,

repair welding
Fig.4-167
If square stub or the connection part of square

stub and steel pipe breaks, sent back to facto-
ry and repair. If on-site repair is needed under
special circumstances, perform repairing un-
der the guidance of Kelly bar Institute of R&D.
Fig.4-168

Requirements for repairing technique

Welding
SN Types of weld seams Preheat (C°) Keep warming Current
rod
Do not need
preheat when
Butt seams of key bar and key J506/
1 ambient —— 160±20
bar J507 temperature ≥
10C°
Butt seams of small diameter Insulation

2 70 kg. 200C°~250C° 160±20
steel pipe (≤φ377) cotton
Do not need
preheat when
Butt seams of large diameter J506/
3 ambient —— 160±20
steel pipe( ＞ φ377) J507 temperature ≥
3C°
Do not need
preheat when
Seams of key bar and large J506/
4 ambient —— 200±20
diameter steel pipe( ＞ φ377) J507 temperature ≥
3C°
Do not need
preheat when
Seams of key bar and small
5 70 kg. ambient —— 200±20
diameter steel pipe (≤φ377) temperature ≥
10C°
Adjust the
Besides item 2, preheat the current
Remove rust, scale and water others to the temperature above according
Remark
before welding the minimum temperature to the
required welding
machine
List of repair equipment

SN Name Quantity Purpose
1 Level bar 1 Level
2 Arc welder YD-400SS(DC) 1
3 Cutting torch G01-100 2 Cut
4 Angle grinder GWS14-150 3 Grind
5 Welding clamp 5
6 Torque wrench 3 Secure locknut
7 Inner hexagon spanner M16 2 Remove guiding ring
8 Adjustable spanner 2

Lists of consumables
SN Name Quantity Purpose
1 J506/J507/A302(φ4) 100KG Weld
2 J706/J707 (φ4) 60KG Weld
10~12 safety goggles against

3 20 Pieces Cut
radiation
4 Protective glove 20
5 Cutting nozzle 10
Protective goggles against

6 5
flying chips of grinding wheel
7 Dry powder fire extinguisher 2
8 Alkyd paint diluent 2
4.6.3 Transport and storage
Transport
CAUTION
Lifting equipment for loading and unload-

ing must be safe and of sufficient capabil-
ity. Avoid jerky and quick movements when
lifting to prevent the load shifting and slid-
ing away.
Preparation of Kelly bar for transport:
“A” ≤ 13000mm, underpinned with 2 timbers

preferably
“A” ＞ 13000mm, underpinned with 3 timbers

preferably
Fig.4-169

Storage
Kelly bars must be underpinned when put into
storage:
“A” ≤ 13000mm, underpinned with 4 timbers

preferably
“A” ＞ 13000mm, underpinned with 5~6 tim-

bers preferably Fig.4-170
NOTICE
Risk of damaging components.

Before use a Kelly bar again after a longer
period of storage, visually inspect the Kelly
bar for straightness. If there is an evidence
of deformation, consult SANY after-sales
service department or Kelly bar Institute of
R&D to prevent potential damage.
Note:
Do not put Kelly bar on the ground directly.
Do not put Kelly bar on gravel heap directly to

avoid gravel falling into Kelly bar.

4.7 Drilling Tool

4.7.1 Overview
There are many categories of drilling tools.

They are double-bottom single-door bucket,
double-bottom double-door bucket, cone au-
ger, straight auger, core barrel, double-layer
core barrel, core barrel with centralizer, under-
reamer bit. And there are also several sub-
categories for each.
4.7.2 Kelly box
There are three types of Kelly box, namely,

Bauer Kelly box, SANY 250 Kelly box and
SANY 150 Kelly box.
203_+0.5
8 65
290
100
Fig.4-171 Bauer Kelly Box (mm)

253 +_ 0.5
Fig.4-172 SANY 250 Kelly Box (mm)
153 +_ 1.5
131_+ 1.5
2 53
Fig.4-173 SANY 150 Kelly Box (mm)

4.7.3 Drilling tool categories
44444444 Drilling bucket single-edge
h1
h2
Fig.4-174 Drilling Bucket Single Edge Drilling Bucket Single Edge Parameter
Table 4-12 Drilling Bucket Single Edge parameter

Tooth type and number (TSAD/TSBD/TSCD/TSZAd/TSZ-
Size
BD/TSZCD/YSAD/YSBD/YSCD/YSZAd/YSZBD/YSZCD)
TSH Flat teeth and round YS Round

D h1 h2 TS Flat teeth
chisels chisels
mm mm mm V20 /FZ80 V20 /FZ80 B47K B47K

600 1200 1615 2 2 3 5
800 1200 1615 3 3 4 8
1000 1200 1615 5 5 5 11
Remark:
H1, h2 and teeth number in the table above

are just for reference, the height of bucket
should be based on actual conditions. For
more related problems, please consult our en-
gineers.
Drilling bucket with single edge is mainly used

for drilling borehole of medium and small di-
ameter. It is suitable for excavating all types
of soil, gravel or completely decomposed rock
and highly decomposed rock.

Choose different teeth according to different

layers. Common teeth include: B47K (round
chisels and bullet teeth), V20 (bullet teeth),
Bauer teeth and 1500 teeth. Choose B47K
round chisels when drilling pebble layers and
rocks; choose flat teeth when drilling soil lay-
ers and soft sand layers; choose Bauer teeth
when drilling dense gravel and pebble layers.
Drilling bucket with single edge shall be

equipped with teeth according to different lay-
ers. There are three teeth arrangement meth-
ods:
Table 4-13
Teeth arrangement Illustration Structure characteristics and applying layers
Characteristics:
1. Cross type alignment knife
2. Equip with V20, FZ80 flat teeth
Flat teeth 3. Drain hole installed inside.
Applying layers:
1. All types of soil, such as miscellaneous fill and
mud soil.
2. Sand layer, medium-density sand and gravel
Characteristics:
1. Use B47K round chisels as central drill guide
teeth
2. Add skirting and weld B47K Round chisels on
Flat teeth and
skirting
round chisels
3. Drain hole installed inside
Applying layers:
1. High-density sand, gravel
2. Soft rock layer: such as highly weathered rock.
Characteristics:
1. Different from flat teeth and round chisels,
double-bottom single-door core barrel welds
B47K Round chisels on cutter
Round chisels
2. Cutter is made of wear resistant steel.
Applying layers:
Suitable for drilling medium hard rock

44444444 Drilling bucket double-edge
h1 h2
Fig.4-175 Drilling Bucket Double Edge

Table 4-14 Drilling bucket double edge parameter
Tooth type and number (TSA/TSB/TSC/TSZA/TSZB/TSZC/YSA/
Size
YSB/YSC/YSZA/YSZB/YSZC)
TSSH Flat teeth and round chis- YSS Round

D h1 h2 TSS Flat teeth
els chisels
mm mm mm V20 /FZ80 V20/FZ80 B47K B47K

600 1200 1615 2 2 3 5
800 1200 1615 3 3 4 8
1000 1200 1615 5 5 5 11
Remark:

gineers.
Drilling bucket with double edges is mainly

used for drilling borehole of large and medium
diameter, suitable for all types of soil, sand
and gravel with small particles.

Drilling bucket with double edges shall be

equipped with teeth according to different lay-
ers. There are three teeth arrangement meth-
ods:
Table 4-15
Teeth arrangement Illustration Structure characteristics and applying layers
Characteristics:
3. Drain hole installed inside.
Flat teeth Applying layers:
1. All types of soil, such as miscellaneous fill
and mud soil.
2. Sand layer, medium-density sand and
gravel
Characteristics:
3. Add skirting and weld B47K round chisels
Flat teeth and round on skirting
chisels 4. Drain hole installed inside
Applying layers:
1. All types of solid hard soil, sand
2. Soft rock
Characteristics:
2. Equip with V20, 25T, FZ flat teeth
3. Add skirting and weld B47K round chisels
Round chisels on skirting
4. Drain hole installed inside
Applying layers:
1. All types of solid hard soil, sand
2. Medium hard rock

44444444 Cone auger
L h
Fig.4-176 Cone Auger Cone Auger Parameter

Table 4-16 Cone auger parameter
Size Tooth type and number
D L h YLDD YLSD YLSS
mm mm mm B47K B47K B47K

600 600 1500 10 14 14
800 600 1500 14 20 20
900 600 1500 14 21 21
1000 600 1500 15 23 23
1200 600 1500 16 28 28
1300 600 1500 18 30 30
1400 600 1500 20 32 32
1500 600 1500 22 36 36
Remark:
Cone auger is generally 2.5 times the height
of pitch. Increasing auger flights can increase
slag carrying capacity and have good guid-
ance. Reducing auger flights can increase
rotation speed and reduce resistance. Number
of teeth in the table refers to 360 ° cone screw
teeth arrangement number.
L, H and teeth number in the table above are

just for reference, the length of flights and
base tube should be based on actual condi-

tions. For more related problems, please con-

sult our engineers.
Cone auger can be divided into three types of

single-start single-flight, double-start single-
flight and double-start double-flight in terms of
structure. Arrange teeth on cone spiral flights
to form spiral cone corner, suitable for drilling
decomposed rock and rock formations of up to
100 Mpa unconfined compressive strength.
Table 4-17
Structure characteristics and apply-
Teeth arrangement Illustration
ing layers
Characteristics:
1.Three Round chisels forms the
central guide teeth, with a good
positioning effect
2.Arrange teeth upwards along the
spiral flights of two sides
3.Small drilling resistance and easy to
YLDD dump slag
Applying layers:
1.Highly cemented gravel and
permafrost layer
2. Medium hard rock
Characteristics:
1.Three Round chisels forms the
central guide teeth, with a good
positioning effect
2.Arrange teeth upwards along the
spiral flights of two sides
YLSD 3.Good guidance, great drilling
YLSS resistance and high slag carrying
capacity
Applying layers:
1.Highly cemented gravel and
permafrost layer
2. Medium hard rock

44444444 Straight auger
Fig.4-177 Straight Auger
Table 4-18 Straight auger parameter
D L h TLDD TLSD TLSS
mm mm mm B47K B47K B47K

600 600 1500 10 14 14
800 600 1500 14 20 20
900 600 1500 14 21 21
1000 600 1500 15 23 23
1200 600 1500 16 28 28
1300 600 1500 18 30 30
1400 600 1500 20 32 32
1500 600 1500 22 36 36

Straight auger can be divided into three types

of single-start single-flight, double-start single-
flight and double-start double-flight. Teeth are
welded in a straight line; wear resistant alloy
Flat teeth can use alone, or used together with
Round chisels.
Straight auger is mainly used for drilling soil,

sand, and solid sand layer with small amount
clay and gravel with not-too-large particle di-
ameter above underground water level.
Table 4-19
Structure characteristics and applying lay-
ers
TLDD Characteristics:
1.Cross type alignment knife
2.Equip with V20, FZ80 Flat teeth
3.Weld Round chisels on skirting
Applying layers:
soil, sand, solid sand layer with small
amount clay and gravel with not-too-large
particle diameter
TLSD Characteristics:
TLSS 1.Cross type alignment knife
2.Equip with V20, FZ80 Flat teeth
3.Weld Round chisels on skirting
Applying layers:
loose soil, sand and soft-hard interceded
layer

44444444 Core barrel
Fig.4-178 Core Barrel Core Barrel Parameter
Table 4-20 Core barrel parameter

D h YTD YTDR
mm mm B47K Rollers
500 1500 6 3
600 1500 7 5
800 1500 9 6
900 1500 11 8
1000 1500 11 9
1100 1500 12 10
1200 1500 13 10
1300 1500 15 10
1400 1500 16 10
1500 1500 18 10
1600 1500 20 N/A
1800 1500 22 N/A.
2000 1500 25 N/A.
2500 1500 30 N/A.
Remark:
H and teeth number in the table above are just

for reference, the height of bucket should be
based on actual conditions. For more related
problems, please consult our engineers.

For hard bedrock, large boulder and hard

permafrost layer, it is very hard for rotary drill-
ing bucket to drill in. But core barrel has more
advantages in this case. Core barrel has wide
applications and various structures. Common
structures include annular Round chisels core
barrel, annular gear core barrel. Core barrel
can change different drilling teeth according to
stratum characteristics.
Table 4-21
Structure characteristics and ap-

plying layers
Applying layers:
1.Highly or medium weathered
YTD
hard rock
YTDR
2.Slightly weathered rock with
relatively low hardness
Applying layers:
1.Slightly weathered or unlettered
YTDS
rock with very great hardness
2.High-strength concrete
Applying layers:
YTDZ 1.Hard rock
2. Medium hard rock
Applying layers:
YTDAS 1.Ordinary hard rock
2.Low-strength concrete
Applying layers:
1.Slightly weathered or unlettered
YTDR bed rock with very great
hardness
2.High-strength concrete

44444444 Double-layer core barrel
h2
h1
D2
D1
Fig.4-179 Double-layer core barrel Double-layer core barrel parameter
Table 4-22 Double-layer core barrel parameter
D1 D2 h1 h2 B47K Rollers
mm mm mm mm
1000 N/A 1700 1500 11 9
1200 N/A 1700 1500 12 10
1250 N/A 1700 1500 13 10
1300 N/A 1700 1500 15 10
1500 N/A 1700 1500 16 N/A
1800 N/A 1700 1500 18 N/A
Remark:

gineers.

Double-layer core barrel is a special drilling

tool designed and produced by Beijing SANY
Heave Machinery Co., Ltd to drilling in gravel.
Compared to other types of rotary drilling
tools, double-layer core barrel has the advan-
tages of high efficiency in drilling in gravel,
strong spoil carrying capacity and low drilling
tooth.
44444444 Core barrel with centralizer
Fig.4-180 Core barrel with centralizer
Table 4-23 Core barrel with centralizer parameter

D1 D2 h YTD YTDH
mm mm mm B47K Rollers
500 N/A 1500 6 3
600 N/A 1500 7 5
800 N/A 1500 9 6
1000 N/A 1500 11 8
1200 N/A 1500 11 9
1500 N/A N/A N/A N/A
Remark:
H and teeth number in the table above are just

for reference, the height of bucket should be
based on actual conditions. For more related
problems, please consult our engineers.

Core barrel with centralizer is made of central-

izing device to original small core barrel, and
is designed to perform rotary drilling rig’s stage
drilling in hard soil.
44444444 Underreamer bit

D1
Table 4-24 Underreamer bit parameter
Size
D1 D2
mm mm
600 1200
800 1600
1000 2000
1200 2400
1500 3000
In the same layer, if pile diameter is keep con-

stant, enlarging pile tip base area can greatly
increase pile load-bearing capacity. In general,
underreamer bit accompanied with rotary drill-
ing rig includes soil underreamer bit, which is
suitable for drilling common soil and equipped
with Round chisels made of alloy block or al- D2
loy drill head, and rock underreamer bit, which
is suitable for drilling hard bed rock and hard
frost soil and equipped with cutting tool made Fig.4-181 Underreamer bit
of Round chisels.

44444444 Casing drive adapter
Casing drive adapter connects rotary drive

and casing. During operation, rotary drive
transfers torque to casing to make it rotate. At
the same time, rotary drilling rig crowding de-
vice presses rotary drive down and transfers
force through rotary drive to casing to push it
into ground.
Fig.4-182 Casing Driver
1800 D1
1300
170
100
D2
95
Fig.4-183 Casing Driver Parameter (mm)

444444444Easily worn parts of drilling rig
Bauer teeth B47K teeth V20 teeth
Bauer teethholder B47K teethholder V20 teethholder
1500 teeth and teethholder

4.7.4 Drilling tool operation
44444444 Drilling bucket

●● Before placing a new bucket into hole,
check whether drilling teeth are all com-
plete. Check whether unlocking mechanism
works well.
●● For single-edge bucket, raise it when spoil
reaches 5/6 of bucket load capacity. For
double-edge bucket, raise it when spoil
reaches 2/3 to 4/5 of bucket load capacity.
Before raising drilling bucket, rotate bucket
counterclockwise 1 to 2 rounds under
crowding. Raise bucket when bottom gate
is closed.
●● If bucket is jammed when being raised,
move bucket upwards and downwards
while rotating it at a low speed. Raise buck-
et when it is released from jamming. Never
raise it by force.
●● If spoil cannot be automatically dumped
or dumped entirely when bucket bottom
gate is opened, repeatedly rotate drilling
tool to dump soil thoroughly. Never use up
and down lifting or left and right swaying to
strike other fixed objects to dump soil.
●● Replace or repair drilling teeth if they are
seriously worn out or drop off.
●● Never run in hole if there are any foreign
matters in hole.
●● Never use drilling tools to deal with acci-
dent.
44444444 Auger
plete.
●● When using cone auger to drill hard rock,
never rotate at a high speed. When it is dif-
ficult to drill into boulders, lift auger for a
while and drill again. Repeat several times

until boulder is loosened, then take it out.

●● In general, raise auger slowly when drilling
to 2 to 3 times of pitch to prevent it from
colliding with hole wall, which leads to spoil
leakage or auger jamming. When raising
auger under mud, rotate slowly to prevent
interlocking rod from locking Kelly bar.
●● If bucket is jammed when being raised,
move bucket upwards and downwards
while rotating it at a low speed. Raise buck-
et when it is released from jamming. Never
raise it by force.
●● If spoil cannot be automatically dumped or
dumped entirely, repeatedly rotate drilling
tool to dump soil. Never use up and down
lifting or left and right swaying to strike oth- Fig.4-184 Auger
er fixed objects to dump soil.
●● Replace or repair drilling teeth if they are
seriously worn out or drop off.
matters in hole.
44444444 Core barrel

plete and connection is good.
●● Raise auger when barrel is full. Raise auger
at a low speed. Because auger is equipped
with inner knife, it can remove core or large
boulder. It can forms a cutting free surface,
and is able to break rocks, facilitating bail-
ing bucket or short auger to drill.
●● Replace drilling teeth of same specification
if they are worn out or damaged.
matters in hole. Never use drilling tools to
deal with accident.
Fig.4-185 Core Barrel

44444444 Belling tool
●● Before running in hole, check whether bit

can retract and extend freely. Lift bit and
lower reamer wing slowly to retract or ex-
tend. Repeat several times until bit can
move freely.
●● Determine bit’s stroke according maximum
reaming diameter required by construc-
tion. Lift bit to its retraction status, and then
lower it slowly to under reaming diameter.
Write down the position difference of upper
tube and lower tube in the two cases (for
pushdown belling tool, write down connect-
ing central pin position difference between
upper and lower positions against outer
tube in the two cases). The difference is un-
der reaming travel.
●● Belling tool is not equipped with spoil re-
moving mechanism. When under reaming
depth reaches 1/3 of total stroke, raise bit,
use bit lower tray to bring out rock dust, or
take out hole bottom drilling spoil by lower-
ing bucket or auger or through positive/re-
verse circulation. In general, under reaming Fig.4-186 Belling Tool
is completed after 3 to 4 returns of drilling.
●● If belling tool meet with resistance or re-
tracting mechanism cannot move freely
when the bit is being raised, do not raise bit
by force. Do not feed on hole bottom, rotate
bit several times to complete bit raising.
●● If retracting mechanism cannot retract be-
cause it is covered by clay, it is not recom-
mended to ream in the soil layer. If reaming
is required, add adequate amount of medi-
um. Idle run drilling tool for several rounds
at hole bottom to get rid of resistance be-
fore raising bit.
●● Whenever bit is pulled out, check to see
if switching mechanism works freely and
whether Round chisels are damaged. If
there are questions, repair them before
lowering bit into hole.

E
G
PA
K
AN
BL

SR200C(SY) Rotary Drilling Rig Maintenance
Maintenance
5 Maintenance
5.1 Maintenance Precautions........................................................................................ 5-3
5.2 Maintenance Information......................................................................................... 5-5
5.3 Maintenance Schedule ......................................................................................... 5-14
5.4 Maintenance Procedures....................................................................................... 5-26
5.5 Storage of Drilling Rig...........................................................................................5-113

Maintenance SR200C(SY) Rotary Drilling Rig
WARNING

5 MAINTENANCE
5.1 Maintenance Precautions

●● Perform checks and maintenance work as
required. Be sure to replace components
according to requirements.
●● Keep all the handles, pedals, walking plat-
form above the machine cover, and steps
clear of dust, snow, ice, and oil.
●● During lubrication and maintenance, never
allow unauthorized personnel near the drill-
ing rig.
●● Wear protective equipment required by
maintenance operation, such as safety
clothes, safety glasses, and mask.
●● When washing the machine, do not spray
water on electrical components.
●● Keep the machine clean to find oil leakage,
crack, loose connecting parts and other
abnormalities. Keep grease zerk, vent hole,
and dipstick in order to prevent dust enter-
ing.
●● Only use parts allowed by the manufactur-
er.
●● Do not make any modification, addition, or
revision to the drilling rig without the per-
mission of manufacturer.
●● For any problem during lubrication and
maintenance process, contact Beijing
SANY after sales service department.

WARNING
When performing maintenance to the drill-
ing rig, guard against injuries and acci-
dents.
Park the drilling rig at safe location. shut
down all the control system. shut down the
engine. Perform maintenance to the rotary
drilling rig when all the parts have stopped
working. Failure to do so may cause injury
or possibly death.
If the machine must be running during main-

tenance checks, it is important to follow some
basic safety rules.
●● Place the alert tag beside the cab to alert

the machine is down for maintenance and
not to start or shut down the engine.
●● Only when all the maintenance tags are re-
moved, the engine can be started.
Note:
●● Before performing maintenance to the ro-
tary drilling rig, carefully read Chapter 2.
Safety. All the maintenance must be per-
formed under safe surroundings.
●● When performing any maintenance and
repair work, follow all the listed safety pro-
cedures of lubrication, maintenance, and
checks work.
●● Pay attention to the warning message on
the machine components. Perform the
maintenance according to requirements.
●● Perform maintenance according to required
intervals.
●● Comply with the service provisions for the
third party parts’ manufacturer of the ma-
chine.

5.2 Maintenance Information
Do not perform any maintenance and/or re-

pairs not authorized in Safety, operation &
maintenance manual for these machines. Al-
ways observe and follow all safety precautions
and use the proper tools when performing any
maintenance procedures.
Hour Meter Reading
Always keep track of the hour meter reading

on a daily basis. Confirm meter readings with
the required maintenance schedule listed in
this manual.
Genuine SANY replacement parts
Always use genuine SANY replacement parts

listed in the parts manual.
Genuine SANY lubricants
Always use genuine SANY machine oil and

grease. Select machine oil and grease of suit-
able viscosity according to ambient tempera-
ture.
Window washer fluid
Use automotive windshield washer fluid only,

which shall not be contaminated by foreign
substances.
Oil and lubricants
Always use clean oils and greases. Keep the

oil reservoir and grease reservoir clean, which
shall be free from any impurities. Drained oil
and used filter element after changing the oil
and replacing the filter element. Check the
used oil and filter element for signs metal par-
ticles and foreign material. If large amount of
metal particles and/or impurities are found in
the used oil and filter element, report to the
personnel in charge and take proper mea-
sures.

Hydraulic hoses, lines or components

If any hydraulic components have been re-
placed or removed, always bleed the air from
the system before resuming operation. Be
sure there are no leaks and the hoses or lines
do not rub on any other components.
Welding on the machine
●● Turn off the ignition key switch and wait for

1 minute before disconnecting the negative
(-) terminal of the battery.
●● Connect the ground cable of the welder at
least 1 m (3.3 ft.) Away from the place be-
ing welded.
●● If the ground cable is connected to any
electrical components (instrument, connec-
tor, etc.), The instrument will be out of fun-
tion. If there are any seals or bearings be-
tween the welder and the grounding point,
choose another grounding point away from
these parts.
●● Never use a grounding point in the vicinity
of the work equipment pin or hydraulic cyl-
inder.
●● Never apply more than 200V continuously.
Dusty work site

Observe the following items before working in
a dusty place.
●● When inspecting your machine or chang-

ing the oil, park your machine in a dust-free
place in order to prevent dust from getting
into the oil.
●● Clean the air filter cartridge immediately if
the filter’s alarm indicates clogging.
●● Clean the fins and other heat exchanger
parts frequently to avoid them being
clogged.
●● Clean and replace the fuel filter frequently.
●● Clean the electrical components, especially

the start motor and the alternator, to pre-

vent dust from building up on them.
Lubricants of different brands
Never mix lubricants of different brands and/
or grades together. If you need to use the lu-
bricant of another brand or grade, drain the
old lubricant completely and replace it with the
new brand.
Inventory your tools and parts
After performing maintenance or repairs to the
machine, always take time to inventory your
tools, parts used and nuts and bolts to be sure
none of these items were left on or inside the
machine. Failure to do so could result in unex-
pected failure or damage to the machine.
Securing access cover
When servicing the machine with the access
covers open, use a locking lever to secure the
cover to certain position. Otherwise, the cover
can be swung close by wind and cause bodily
injury.
Checks after maintenance or repairs
Always do the following after performing any
maintenance or repairs to the machine.
With the engine OFF.
●● Be sure you have completed all the steps
in the maintenance or repair of the machine
you have worked on.
●● If necessary, have a co-worker inspect your
work for correct and proper completion.
●● Be sure to inventory your tools and parts
after completion.
With the machine running.
●● Check for any leakage or overheating in
the system you have completed repairs or
maintenance on.
●● Be sure there are no abnormal sounds
coming from the engine or hydraulic system
and nothing is loose.

5.2.1 Lubricating the lube points
Main lubrication points and the name of the

SR200C rotary drilling rig are illustrated in
Fig.5-1 rotary drilling rig lube points diagram.
For oil of different lube points, refer to Table 5-1
Lube points list.
LUBRICATING CHART
LUBRICANTING TABLE
NO. LUBRICATING PARTS NUMBER USING OIL
3 2 1 10h １ MASTHEAD ROPE SHEAVES 4

２ ROPE SWIVEL 1
5 4 ５０ｈ３ ROTARY BEARING 2
（ INTERVALS ） 4 MASTHEAD PIN 2
５ UPPER MAST PIVOT PIN 2
６ SWING BEARING 3
BOOM PINS 4
７ BOOM CYLINDER JOINTS 4
SUPPORT ROD PINS 4
（INTERVALS） MAIN WINCH BEARING 1 LITHIUM BASE GREASE
8
AUXILIARY WINCH BEARING 1
2000h MAST PIVOT 12
9
MAST PIVOT PIN 2
1000h 15 18
GUIDE RAIL 2
500h 16 17 19 １０ CROWD CYLINDER JOINT 1
BACKSTAY CYLINDER JOINTS 4
250h 14 15 15 16 16 17 17 18 18 19 19 11 LOWER MAST PINS 2
１２ INNER GEAR RING 1
50h 14 14 １３ EXTENDING CYLINDER 8
１４ ENGINE OIL PAN 1 ENGINE OIL 33 L/per
10h （INTERVALS）１５ TRAVEL REDUCERS 2 13.8L/per
10 9 8 7 6 10h １６ SWING REDUCER 1 8 L/per
１７ MAIN WINCH REDUCER 1 8.5 L/per
11 12 13 50h GEAR OIL
AUXILIARY WINCH REDUCER 1 3 L/per
１８
ROTARY DRIVEGEARBOX 1 68 L/per
250h
１９ ROTARY DRIVE REDUCERS 2 6.3 L/per
1. Upper and bottom line indicate the intervals of the maintenance and replacement.
2. maintenance ； replacement ； The initial maintenance and replacement of the new machine.
3. The Lubricant used as per the "Maintenance Manual".
12896106
Fig.5-1 SR200C Rotary Drilling Rig Lube Points Diagram

Table 5-1 Lube points list
SN Lubrication Points No.of Points Frequency
1 Masthead rope sheaves 4 every 10 hours
2 Rope swivel 1 every 10 hours
3 Rotary bearing 2 every 10 hours
4 Masthead pin 2 every 50 hours
5 Upper mast pivot pin 2 every 50 hours
6 Swing bearing 3 every 10 hours
Boom pins 4 every 10 hours
7 Boom cylinder joints 4 every 10 hours
Support rod pins 4 every 10 hours
Main winch bearing 1 every 10 hours

8
Auxiliary winch bearing 1 every 10 hours
Mast pivot 12 every 10 hours

9
Mast pivot pin 2 every 10 hours
Crowd cylinder joint 1 every 10 hours
10 Guide rail 2 every 10 hours
Backstay cylinder joints 4 every 10 hours
11 Lower mast pivot pins 2 every 50 hours
12 Swing bearing gear ring 1 every 50 hours
13 Extending cylinder 8 every 50 hours
14 Engine oil pan 1 every 50 hours
15 Travel reducers 2 every 250 hours
16 Swing reducer 1 every 250 hours
17 Main winch reducer 1 every 250 hours
Auxiliary winch reducer 1 every 250 hours

18
Rotary drive gear box 1 every 250 hours
19 Rotary drive reducers 2 every 250 hours

Remark:
1.G rease for all the lube points should be

used between 20°C and 110°C. The grease
type is kp2k, and the product name is Shell
Albania ep2. Brush-on lubrication could be
applied below -30°C.
2.As for Russian area, if customer agrees,
use Shell Albia slc 460, which could be ap-
plied in -40°C working condition .

5.2.2 Drilling rig oil
The filler inlet of SR200C Rotary Drilling Rig are shown in Fig.5-2. For oil details, refer to Table 5-2.
Fig.5-2 SR200C Filler Inlet

Table 5-2 Recommended oil for SR200C rotary

drilling rig
Refueling
SN Lube point Requirements Oil type Product name Remark
volume(litre)
Summer 0# or 10# diesel oil
1 F u e l ta n k 540
Winter 10# diesel oil
Adjust the
Shell full effective
propor tion
Cooling ASTM antifreezing
2 24.5 for lower
s y s te m Above-37 ° C D3306/4985/6210 fluid (HD N
tempetature
engine coolant Antifreeze/Coolant
(about
Pre-diluted 50/50)
-50° C)
Shell full effective
Coolant ASTM
3 1.5 antifreezing fluid (HD
wa te r ta n k Above-37 ° C D3306/4985/6210
N Antifreeze/Coolant
engine coolant
Pre-diluted 50/50)
Please
consult She l l
Low temperature
API CF-4 Shell (Rimula) R2 technical
region (above-25
B o tto m of SAE10W/30 Multi 10W/30 per sonnel,
4 diesel oil
24.5 ° C)
if used in
Russia
API CF-4/ACE A E2 Shell (Rimula) R2
Above-20 ° C
SAE15W/40 Extra 15W/40
Extremely cold
API GL-5/MT-1 SAE Shell (Spirax) ASX
Tr a ve l i n g region (Above-40 For Russia
5 2×5 75W/90 75W-90
re d u c e r ° C)
Above-26 ° C Total Car ter EP 220 Industrial oil 220
Extremely cold
Main winch region (Above-40 For Russia
6 7.5 75W/90 75W-90
re d u c e r ° C)
Extremely cold
Auxiliar y API GL-5/MT-1 SAE Shell (Spirax) ASX
region (Above-40 For Russia
7 wi n c h 1.5 75W/90 75W-90
° C)
re d u c e r
Extremely cold Low-freezing
region (Above-35 synthetic antiwear Shell (Tellus) Arctic 32 For Russia
° C) hydraulic oil VG32
Please
consult She l l
Low temperature ISO 11158 HV low-
technical
Main oil region(Above-20 freezing antiwear Shell (Tellus) T 32
8 tank
239 per sonnel,
° C) hydraulic oil VG32
if used in
Russia
All seasons ISO HMantiwear
Shell (Tellus) 46
(Above-5 ° C) coolant VG46
All seasons ISO HM antiwear For
Shell (Tellus) B 46
(Above-5 ° C) coolant VG46 mainland
Extremely cold
Ro t a r y API GL-5/MT-1 SAE Shell (Spirax) ASX
region (Above-40 For Russia
9 d r i ve 2×5
° C)
75W/90 75W-90
re d u c e r
Extremely cold
Ro t a r y region (Above-40 For Russia
75W/90 75W-90
10 d r i ve 30 ° C)
casing API GL-4 SAE Shell (Spirax) G 80W-
Above-26 ° C
80W/90 90
Extremely cold
Slewing region (Above-40 For Russia
11 3.4 75W/90 75W-90
re d u c e r ° C)

Remark:
The refueling volumes listed in the chart are

only for reference, please take filler inlet as
standard.
Note:
●● If there is any change to the above number
of oil adding locations or adding times, con-

sult SANY after sales service department.
●● When operating the drilling rig with the am-
bient temperature lower than 00C, perform

the following warm-up operation in order to
guarantee the safety of the hydraulic sys-
tem.
●● After running the engine at idle speed for 7
to 10 minutes, increase the speed to 1000

- 1200 r/min. Perform no action to the drill-
ing rig. Run the machine without load for 30
- 40 minutes or even longer time in order
to increase hydraulic oil temperature and
make the hydraulic oil temperature reach
200C.
●● After the above operation, conduct normal
operation. Meanwhile, properly adjust the

warm-up time according to ambient tem-
perature.
●● When starting normal construction, operate
slowly and pay close attention to the run-
ning situation of the system.

5.3 Maintenance Schedule

Purpose:
●● Prepare for running
●● Keep good performance level
●● Shorten downtime
●● Keep operational performance for the rotary
drilling rig
●●Reduce repair cost
Precautions:
●● When checking or maintaining the hydraulic
system, choose clean location.
●● It is dangerous to perform inspection and
maintenance with load. Shut down the en-
gine and perform without load. Install a tag
reading “under inspection” or “under main-
tenance” at the cab door. UNDER MAINTENANCE
●● Do not disassemble or adjust the com-
ponents of the hydraulic system, such as
DO NOT OPERATE
pump, valve, and motor.
●● Only use genuine SANY spare parts.
●● Strictly comply with maintenance safety,
See: Chapter 2 Safety, “Maintenance
safety” on page 2-70. Fig.5-3

NOTICE
Carry out maintenance at the prescribed

intervals.
Note:
The specified intervals are based on the oper-

ating hours meter of the base machine.
Normally the intervals are cumulative, mean-

ing that when the 1,000 hours maintenance is
due, the 10, 50, 250 and 500 hours services
will also have to be carried out again.
If the equipment is used under extremely wet

and dusty conditions, shorten the time inter-
vals.
NOTICE
Maintenance carried out on the equipment

must be entered into the maintenance and
repair log supplied.
In case of a warranty claim, SANY shall
have the right to consult the log.
Symbol explanation for the following tables:
● Every (...hours)
■ First maintenance job (after...hours)

Entire Equipment
Components Maintenance interval
10 h 50 h 250 h 500 h 1000 h 2000 h 3000 h

Operation
daily weekly monthly 3 months yearly yearly 2 years
Entire Equipment
Visual inspection:
-Missing or damaged
●
parts
-Load-bearing steel
components should
undergo visual inspec-
●
tion prior to mounting to
check for fissures and
other damage
-Missing or loose bolts/
●
bolted connections
-Missing or damaged
safety devices, such as
●
fire extinguisher, first-
aid kits, warning signs
-Leaks ●
-Intake and exhaust air
●
system
-Window wiper ●
-Window washer ●
Check for proper
function of :
-Controls and indica-
●
tors
-Safety devices such
as Emergency STOP,
●
hydraulic lock lever,
limit switches
Wok platforms:
-Missing or loose pin/
●
screw connections
-Check the locks can
move easily and are ●
working properly
-Check and replace
●
hoses
Overhaul ●

Components
10 h 50 h 250 h 500 h 1000 h 2000 h 3000 h

Operation Note
Pulley yoke
-Check that the
connecting bolts
and screws for the
■
mast, if provided,
are firmly screwed
in; tighten screws
-Replace connecting Every

bolts for the mast, if 10000
provided h
Kelly guide
-Swing bearing ●
-Check and replace
●
sliding strip
Mast
Mast
-Lubricate mast rails ●
-Check that the con-
necting bolts and
screws between
■
the mast sections, if
provided, are firmly
screwed in
-Replace connect-
Every
ing bolts between
5000
the mast sections, if
h
provided
Mast prop(if pro-
vided)
-Ensure that bolt
safety mecha-
●
nism and bolts are
screwed in tightly
-Lubricate piston rod ●
Mast ladder (if
equipped)
-Check that the
mounting bolts are ●
firm

10 h 50 h 250 h 500 h 1000 h 2000 h 3000 h

Operation Note
-Check transition
between the parts of ●
the mast ladder
-Check fall protec-
tion equipment for ●
function
Mast pivot
-Lubricate mast
●
pivot
-Lubricate mounting
●
bolts
-Check flange bolts
are firmly screwed ●
in
Every
-Replace flange
10000
bolts
h
Winch
-Check oil level
Main winch ●
Aux. winch ●
Crowd winch ●
-Change oil
Main winch ■ ●
Aux. winch ■ ●
Crowd winch ■ ●
-Lubricate counter
bearings
Main winch ●
Aux. winch ●
Crowd winch ●
-Check that the
mounting bolts for ■
the winch are tight
Every
-Replace mounting
10000
bolts of the winch
h
Reducer

10 h 50 h 250 h 500 h 1000 h 2000 h 3000 h

Operation Note
Change travel re-
■ ●
ducer oil
Change swing re-
■ ●
ducer oil
10 h 50 h 250 h 500 h 1000 h 2000 h 3000 h

Operation Note
Cylinders
-Clean piston rods ●
-Check tightness of
●
cylinder
-Lubricate joints ●
Bearing and bearing pins
-Lubricate all bearings
and bearing pins that
●
are equipped with lube
nipples
Wire rope and accessories
Ropes,rope fasteners,
thimbles and sleeves
-Inspect for wear and
●
damage
-Rope tensioning de-
vices, connecting plates ●
and terminations
-Discard wire ropes ●
-Maintain wire ropes ●
Rope swivel
-Lubricate ●
-Check if bolts are se-
●
cure
-Check rotation function ●
Rope hold-down roll-
ers
-Check parallel position
●
to cable drum
-Inspect for wear and
●
damage
Rope sheaves

10 h 50 h 250 h 500 h 1000 h 2000 h 3000 h

Operation Note
-Inspect for wear, dam-
age, and if bearing gap ●
is exceeded
-Check sheaves are
●
free to rotate
-Check if bolts are se-
●
cure
-Check groove radii
for deviation and edge ●
formation
-Put grease in lube
● ●
nipples
Rope roller brackets
-Ensure that mounting
bolts are firm, tighten ■
bolts
Every
-Replace mounting
10000
bolts
h

Work Equipment
10 h 50 h 250 h 500 h 1000 h 2000 h 3000 h

Operation Note
Rotary drive
Rotary drive
-Clean ●
-Inspect for wear
●
and damage
-Check for leakage ●
-Check magnetic
bars for adhesion
●
of metal parts (if
equipped)
-Check shock ab-
●
sorbers
-Check and replace
●
sliding strip
-Check and replace
●
driver strips
-Check oil level
Reduction gearbox
●
gear
Oil can ●
-Change oil
Reduction gearbox
■ ●
gear
Reducer ■ ●
-Take oil sample
●
and check it
-Check if mounting
bolts of casing are ■ ●
securely fastened
-Check filter pres-
sure gauge (if ●
equipped)
-Change filter ■ ●
-Lubricate oil seal ●
Kelly driver/ guide flange/ shock absorber
-Check springs,
shock absorbers
●
and buffer rings for
damage

10 h 50 h 250 h 500 h 1000 h 2000 h 3000 h

Operation Note
-Check that the
mounting bolts are ●
firm
Cardan joint (if equipped)
-Check rubber buf-
●
fers for damage
-Check if bolts are
●
secure
Crowd sledge
-Check sliding strips
●
for wear
Kelly bar
-Check impact ring ●
-Check spring ●
-Check shock ab-
●
sorber
-Check tube ●
-Check locking re-
●
cesses
-Check baffle ●
-Check drive gibs ●
Drilling tool
-Clean and check
for wear and dam- ●
age

Uppercarriage
10 h 50 h 250 h 500 h 1000 h 2000 h 3000 h

Operation Note
Engine Observe separate manual for the engine!
Check engine oil level ●
Change engine oil ■ ●
Clean crankcase
●
breather
Drain out oil tank wa-
●
ter and sediments
Cooling system Observe separate manual for the engine!
Hydraulic system
Hydraulic tank
-Check oil level ●
-Change oil ■ ●
-Take oil sample and
●
check it
Hose assemblies
-Have them checked
for damage by a ●
skilled person
Filter replacement
-Pilot filter element ■ ●
-Return filter element ■ ●
-Leak-oil filter element ■ ●
-Aux. pump filter ele-
■ ●
ment
-Water separator filter
●
element
Accumulators
-Charge nitrogen ●
Hydraulic oil radia-
tor
-Clean ●
Check coolant ●
Ev-
-Add coolant extender ery 3
years

10 h 50 h 250 h 500 h 1000 h 2000 h 3000 h

Operation Note
Ev-
-Replace coolant ex-
ery 6
tender
years
-Check for damage ●
Swing mechanisms
-Grease external gear
●
teeth on swing ring
-Grease swing bear-
●
ing
-Check mounting
■ ●
bolts
Counterweight
-Check they are prop-
erly in place and firm
●
and all the fixating
elements are applied
Electric system
Batteries
-Check electrolyte
●
level
-Check cable connec-
●
tions
Check switches,
buttons and control ●
levers
Fuses
-Check the fuses ●
Filter
-Clean oil suction filter ■ ●
-Replace engine filter ■ ●
-Replace fuel filter ■ ●
-Replace water sepa-
■ ●
rator filter
-Replace return filter ●
-Check and replace
●
air circulation filter
Fuel tank
-Check fuel level and
●
add fuel
-Clean fuel strainer ■ ●

Undercarriage
10 h 50 h 250 h 500 h 1000 h 2000 h 3000 h

Operation
Crawler track assemblies
Visual inspection
-Missing or damaged parts ●
-Carry out a visual inspection
of load-bearing steel compo-
●
nents to check for fissures
and other damage
-Perform a visual check of the
crawler drive wheels, tread
rollers and travel gear to en- ●
sure they are firmly attached;
tighten if necessary
Travel gear
-Check oil level ●
-Change oil ■ ●
Crawler tracks
-Check the track tension ●
-Check that the mounting
bolts for the crawler track ●
shoes are firm
Telescopic guide
-Clean and grease ●
Optional Equipment
10 h 50 h 250 h 500 h 1000 h 2000 h 3000 h

Operation
Air conditioner
-Put air conditioner into op-
●
eration
-Clean air filter (optional)
-Clean condenser ●
Check compressor belt ●

5.4 Maintenance Procedures

5.4.1 Every 10 service hours
55555555 Crawler tension - check and ad-

just
WARNING
Risk of personal injury or possibly death
from grease under pressure!
Grease coming out of the relief valve under
pressure can penetrate the body causing
Do not watch the relief valve to see if
grease is escaping. Watch the crawler or
crawler adjustment cylinder to see if the
crawler is being loosened.
Loosen the relief valve one turn only. If
crawler does not loosen, contact your Fig.5-4 Crawler Adjuster Position
SANY after sales service department.
1. Operate the machine in the direction of the

idlers. Stop with one crawler pin (A) directly
over the front carrier roller (2). Park the ma-
chine and turn off the engine.
Fig.5-5 Crawler Position

2. Place a straight edge (3) on top of the crawl-

er. The straight edge should be long enough 3 2
to reach from the idler (1) to the carrier roller
a
(2).
Fig.5-6 Measuring Sag Amount of the Crawler

1. Idler
2. Carrier Roller
3. Straight Edge
a. Sag Amount of the Crawler
3. Measure the maximum amount of sag in

the crawler. The sag is measured from the
highest point of the crawler grouser to the
bottom of the straight edge. A crawler that is
properly adjusted will have sag of 40.0 mm
to 55.0 mm (1.57 inch to 2.17 inch).
If the crawler is too tight or too loose, adjust

the crawler tension according to the proce-
dures below:
Tightening the track
1. Wipe grease fitting (b) before you add

grease.
2. Add grease through grease fitting (b) until

the correct tension is reached.
3. Operate the machine back and forth in order

to equalize the pressure.
4. Check the amount of sag. Adjust the crawl-

er, as needed. 1 2
Fig.5-7 Crawler Adjuster
b. Grease Fitting
c. Relief Valve

Loosening the track
1. Loosen relief valve (c) carefully until the

crawler begins to loosen. One turn should
be the maximum.
2. Tighten the relief valve (c) to 34±5N·m (25±4

lb ft) when the desired crawler tension is
reached.
3. Operate the machine back and force in or-

der to equalize the pressure.
4. Check the amount of sag. Adjust the crawl-

er, as needed.

55555555 H ydraulic cylinders- check
Every 10 operating hours or daily, and every

time before starting up again after longer pe-
riod of rest, clean all cylinders and check them
for tightness.
Table 5-3 Table for cylinder inspection

Cylinder Name Qty. Function Inspection Method
Located in When the crawler exten-

the H beam sion/retraction button
of undercar- depressed, the four
Crawler
riage; used cylinders should run
extending 4
for extending slowly and simultane-
cylinder
and retracting ously. The two cylinders
crawler on both on one side must be
sides. synchronous.
Used to sup-
port the paral- When the boom lower-
lelogram in the ing/raising button is
boom devices; depressed, the two
achieve raising boom cylinders should
Boom cylinder 2
and lowering slowly retract/extend
of the boom by simultaneously. The
extension and two cylinders must be
retraction of synchronous.
boom cylinder.
When the mast forward/

backward inclination
button is depressed,
Used to sup- the two mast cylinders Crowd
port the mast should extend/retract Mast cylinder cylinder
devices; adjust slowly and simultane-
forward or ously. When the mast
Mast cylinder 2 backward incli- leveling button is
nation of mast; depressed, the mast
adjust left or shall perform forward,
right inclination backward, left, or right Boom
of the mast. action. During forward cylinder
and backward inclina-
tion, the two cylinders
must be synchronous.
When the rotary drive Cylinder for
raising/ lowering but- folding mast
Used to raise or ton is depressed, the
lower the rotary cylinder retract/extend
Cylinder for drive; pressur- correspondingly and the Crawler extending
1
folding mast ize the rotary rotary drive rises/lowers. cylinder
drive during When the crowd button
drilling is depressed, the rotary
drive should be lowered
slowly.
When operating the
Crowd cylin- Used to tension tensioning cylinder,
1
der the wire rope retraction and extension
could perform well.

Daily maintenance for hydraulic cylinder
1. Check the lubrication on joint bearings on

both ends of hydraulic cylinder daily. Add
grease every week (or every 110 hours).
There are two lubrication points.
Fig.5-8 Lubrication Point
2. Visually check for cracks of various struc-

tural elements for hydraulic cylinder. Imme-
diately repair or replace when necessary.
NOTICE
Risk of corrosion damage in corrosion-
supporting environments! The tasks speci-
fied below must be carried out without fail.
3. Apply hydraulic oil to the piston rod or re-

tract/extend the piston rod several times
once or twice a week.
4. Before a longer standstill, preserve piston

rods with an acid-free grease.
NOTICE
Risk of causing damage to the piston rods!
Do not clean the piston rod with high pres-
sure water gun, sharp tools, caustic lye, or
abrasive.
Checking hydraulic cylinder for tightness
1. Check for looseness of hydraulic joints con-

necting the cylinder before and after each
working shift. If loose, tighten immediately.

2. Check for oil leakage of hydraulic cylinder

before and after each shift. Replace dam-
aged elements when necessary.
3. If barrel is damaged, replace hydraulic cyl-

inder when necessary (if the hydraulic cylin-
ders are used in pair, the matched cylinder
should be replaced at the same time).
Precautions for cylinder maintenance
1. Check the hydraulic cylinder during con-

struction. If the hydraulic cylinder acts slow-
ly, or no action, immediately shut down the
engine for inspection.
2. The cylinder on the rotary drilling rig bears

load. Use caution during repair or replace-
ment.
3. When repairing or replacing the balance

valve on the cylinder, retract the cylinder
piston rod to minimal extent, then dismantle
and replace it.
4. If you have any questions, contact SANY af-

ter sales service department.

55555555 Gearbox gear oil level- check
NOTICE
Risk of damaging the rotary drive!

●● Make sure the oil level is correct at all
times.
●● If the oil is cloudy, water has got in and
the oil must be changed immediately.
Drain out the used oil and flush the re-
duction gearbox with new oil repeatedly.
1. Set the rotary drive to the upright position.
2. Check oil level at gear standstill.
3. The oil must reach 1/2-2/3 of the sight glass.
Fig.5-9 Sight Glass

55555555 Shock absorbing device for rotary

drive - check
Check the shock absorbing device and key bar

for rotary drive on daily basis. Find out wear-
ing condition of the machine. Replace relevant
components. 1 2
NOTICE
Immediately replace damaged components
with new ones.
Replacing shock absorbing spring
1. Turn the nut (1) counterclockwise with open- Fig.5-10 Replacing Shock Absorbing Spring
ended wrench in order to loosen it for about Diagram I
one turn. 1. Nut
2. Washer
2. Remove all the nuts and washers. Store
them properly.
3. Remove welded buffer plate (3).

33
图 1 - 1 更换减震弹簧图二
Fig.5-11 Replacing Shock Absorbing Spring
Diagram II
3. Welded Buffer Plate

4. Check the removed shock absorbing springs

4
(4) successively. Replace them if crack or
deformation is found.
5. Install the removed buffer plate (3).
6. Install washers (2) and nuts (1), and tighten

with torque wrench.
Fig.5-12 Replacing Shock Absorbing Spring

Diagram III
4. Shock Absorbing Spring

Replacing rubber ball
1. Turn hexagon thin nut (1) and nut (2) coun-

terclockwise with open-ended wrench in or-
der to loosen it for about one turn.
1. 2.
2. Loosen hexagon thin nut (1) and nut (2)
under all the rubber balls counterclockwise.
Remove them and place together.
Fig.5-13 Replacing Rubber Ball I

1. Hexagon thin nut
2. Nut
3. Now fixing rod (3) could move up and down.

Push the fixing rod to the highest point.
3
Fig.5-14 Replacing Rubber Ball II

3. Fixing rod

4. Take seat (4), rubber ball (5), seat ring (6)

3 4
and fixing rod (3) out of the barrel. Pull out
fixing rod (3).
5. Replace rubber ball (5).
6. String seat (4), rubber ball (5), and seat ring

(6) together with fixing rod (3). Locate them
at corresponding position of the shock ab-
sorbing barrel.
5 6
Fig.5-15 Replacing Rubber Ball III

3. Fixing rod
4. Seat
5. Rubber ball
6. Seat ring
7. Screw on nut (2) successively in clockwise

1. 2.
direction. Tighten with torque wrench.
8. Screw on hexagon thin nut (1) successively

in clockwise direction. Tighten with torque
wrench.
Fig.5-16 Replacing Rubber Ball IV

1. Hexagon thin nut
2. Nut

55555555 Crawler track - visual inspection
WARNING
Crushing hazard, shearing hazard and

drawing-in hazard!
The machine must be stationary during
work on the undercarriage. A reliable com-
munication between the person working at
the undercarriage and the operator in the
cab must be provided at all times.
●● With the upper carriage positioned cross-

wise, thoroughly clean crawlers until they
are free of mud and dirt.
●● Walk around and inspect for wear, damage
and loss of oil, especially on following com-

ponents:
1 2 3 4
8 7 6 5
Fig.5-17 Crawler Track Assemblies
Track shoes (1)

Track links (2)
Carrier rollers (3)
Front idlers (4)
Track guide (5)
Tread rollers (6)
Crawler drive wheels (7)
Travel gear (8)
●● On machine with crawler extended, the

crawler telescoping surfaces should be kept
corrosion protected with grease.

55555555 Wire rope - inspect
●● For regular inspection intervals, consider

the following items:
―― laws and regulations of the country.
―― equipment variety and working environ-
ment.
―― working grade of the machine.
―― previous inspection results and defective
conditions
―― serviced time of the wire rope.
Fig.5-18 Inspecting Wire Rope
●● Pay special attention to the following parts:
―― moving parts and fixed end of the wire
rope.
―― the rope section wound over the pulley
―― rope section may be worn because of
external factor.
●● Observe any visible section for the rope full
length every day, in order to discover wear
and deformation. When broken wire, wear,
corrosion, or deformation is found, judge for
discard according to the regulations in code
of practice for examination and discard of
GB/T5972 crane wire rope.
●● Inspect the wire rope section extracted
from the fixing end. Check deformation
or wear for the fixing device. Inspect the
broken wire and corrosion condition in the
fixing device and the rope end. Guarantee
the tightness of wedge connector and rope
guard (detachable devices: wedge connec-
tor, rope guard, and holding plate, etc.).
●● Check the rope end device whether it com-
plies with requirements of corresponding
standard. The remaining section of the
wedge connector should be checked visu-
ally for broken wire. If broken wire occurs
near the rope end device or inside the rope
end device, cut the rope short and reinstall
it onto the fixing device for service. But the

rope length must meet the requirements of

minimum loops on the drum. Usually safe
loops are 1.5 to 2 turns. Normally we take 3
loops.
55555555 Wire rope - maintain
●● Promptly remove the dirt off the wire rope

after work so as to avoid corrosion.
●● The wire rope must be regularly lubricated
during application. Specially lubricate the
bending part of the wire rope.
●● When using wire rope in highly corrosive
environment, shorten the lubrication interval
for wire rope.
●● The applied rope grease variety should ac-
cord with the grease recommended by wire
rope manufacturer.
●● The lubricants used must be accord with
the lubricant recommended by wire rope
manufacturer.
●● If ends of broken wires, which may damage
adjacent wires, are detected during inspec-
tion, remove them.
●● Bend the wire end repeatedly to and from
with your fingers or a tool until the wire
breaks at the point where it is bonded in the
structure of the rope.
Fig.5-19 Broken Wire Rope

55555555 Rope swivel flexibility - check

Check the flexibility of rope swivel before and
after work every day. Rotate it by hand.
Upper connection body
1. Rotate the main winch in order to loosen the
wire rope connecting the rope swivel. Keep
proper slack for the wire rope during rotat-
ing process so as to avoid rope disorder for
main winch.
2. Fix one end, and rotate the other end. If it
rotates freely, it means the rope swivel is in Middle connection body
good condition. If the rope swivel still cannot
rotate after being greased, repair or replace
immediately.
Note:
Lower connection body
During drilling operation, when the rope swivel
is pulled out from the drilled hole, the rope
swivel will always rotate at high speed. Keep
Fig.5-20 Rope Swivel
observing now. If the rope swivel fails to ro-
tate, shut down the engine and inspect.

55555555 Rope swivel - lubricate
NOTICE
Risk of damaging the components!
When adding oil to grease nipple on one
end of the rope swivel, open the grease
nipple on the other end. The old grease
can be squeezed out. Failure to do so may
crush the oil seal in the rope swivel.
Check oil leakage for rope swivel on regular

basis. If there is leakage, immediately find out
the cause and replace related sealing compo-
nents.
Lubrication requirements:
1. Add grease once a week. The grease is 3#

lithium base grease.
2. When adding grease, check the lock

screws. If the lock screws (2) have exces- １
sive play, tighten promptly. There are two
locations.
3. When adding grease, check the upper

and lower pin shafts that connect the rope
swivel. If the lock bolts (4) are torn or have ２
excessive play, tighten immediately.
4. When the grease has been added, check

3
slew function by manually turning without a
load suspended. If it fails to rotate normally 4
or appears blocked, repair or replace imme-
diately. Fig.5-21
1. Filling bolt (filling port)
5. For construction with the ambient tempera- 2. Lock screw
ture under zero, promptly clean the rope 3. Dynamic and static contact face
swivel, wipe with cotton cloth, and apply 4. Lock bolt
grease on dynamic and static contacting
face (3) for antifreeze after each working
shift, in order to prevent rotation contact sur-
face being frozen. Before next working shift,
manually rotate the upper end of the rope

swivel, and check whether the dynamic and

static contact surface is frozen by ice. If it
is frozen, unfreeze it with hot water and dry
it, and check the rotating flexibility. Then it
could be put into service.
Note:
Dirt with fine sand and mud may easily enter. １
It will wear the bearing and reduce the flexibil-
ity, performance, and reliability.
Lubricating the rope swivel:
1. Level the mast.

２
2. Rotate the main winch in order to loosen
the wire ropes which connect with the rope
swivel until the rope swivel could be freely
rotated. Keep proper slackness for the wire 3
rope during rotation so as to avoid twisting 4
rope.
3. Screw off the filling bolt (1) on the upper

connector. Screw off the grease nipple (5)
on the lower connector at the same time.
Apply grease to the filling port (1) until 4
grease exits from the grease nipple (5).
2
Fig.5-22 Lubricating the Rope Swivel

1. Filling bolt (filling port)
2. Lock screw
3. Dynamic and static contact face
4. Lock bolt
5. Grease nipple

555555555 Engine oil level - check
CAUTION
Risk of scald!
Hot oil and components may cause per-
sonal injury. Never take out the dipstick or
filler plug when the engine oil is hot. Fail-
ure to do so may cause injury.
When the engine is stopped, check engine oil

level. Do not check oil level while the engine is
running.
1. Open the engine hood.
2. Take out the dipstick. Wipe off oil from the

dipstick, and re-insert the dipstick.
Fig.5-23 Opening Engine Hood
3. Take out and examine the dipstick. The oil

level should be between FULL and ADD
marks.
Fig.5-24 Engine Oil Dipstick

4. If necessary, remove the filler plug in order

to add lubricant.
5. Clean and install the filler plug.
6. Close the engine hood.
Note:
When checking oil level, park the drilling rig on

level ground. Oil level could be checked accu-
rately after the machine has been shut down
for about three hours.
Fig.5-25 Filler Plug

555555555 Water and sediment in fuel tank-

drain
1. Open the drain valve (a) by turning counter- a

clockwise. Allow the water and the sediment
to drain into a suitable container (the fuel
tank drain valve is located underneath the
fuel tank).
2. Securely tighten the drain valve (a) by turn-

ing the valve clockwise.
NOTICE
●● Never spill any oil on the ground. Fig.5-26 Drain Valve
●●Take used oil to a service station or other
cling.

555555555 Hydraulic oil level - check
CAUTION
Risk of scald!
Hot oil and hot components can cause
personal injury. Never allow hot oil or hot
components to contact skin. Failure to do
so may cause injury.
Note:
Do not remove the fill plug/vent plug if the hy-

draulic oil is hot. Otherwise, air may enter the Fig.5-27 Hydraulic Tank Located on the Right
hydraulic system and cause damage to the oil Side of the Upcarriage
pump.
1. Park the machine on level ground. Unlock

the hydraulic lock lever (F). Operate the
handle and adjust the mast, boom, crowd
cylinder in order to retract all the cylinder
piston rods. Then shut down the engine.
F
Fig.5-28 Unlocking the Hydraulic Lock Lever

2. Open the access door on the right side of

the machine.
Fig.5-29 Access Door on Right Side

3. Hydraulic oil is in low level (b) when the ma-
chine is in cooling state. Hydraulic oil is in
high level (a) when the machine is in work-
ing state.
Fig.5-30 Hydraulic Oil Level

a. High level
4. Close the access door. b. Low level

If the oil level is low, perform the following pro-

cedures:
●● Loosen the fill plug/vent plug slowly in order

to release all the pressure. Add hydraulic
oil.
●● Check the O-rings of fill plug/vent plug. If
the O-ring is damaged, replace with new O-
rings.
●● Clean and install fill plug/vent plug.
Fig.5-31 Fill Plug/Vent Plug

555555555 Cooling system coolant level -

check
WARNING
Personal injury can result from hot coolant,
steam and alkali.
Engine coolant is hot and under pressure
during operation. The radiator and all lines
of heaters and engine contain hot coolant
or steam. Any contact can cause severe
burns.
Remove cooling system pressure cap
slowly to release pressure only when en-
gine is stopped and cooling system pres-
sure cap is cool enough to touch with your
bare hand.
Cooling system coolant additive contains
alkali. Avoid contact with skin and eyes.
1. Open the rear access door on the left side.
Fig.5-32 Left Rear Access Door

2. Check the coolant level of the coolant tank.

Maintain the coolant level between FULL
mark and LOW mark. If the coolant tank is
empty, carry out the following procedures:
1) Unlatch and raise the engine hood. 1
Fig.5-33 Coolant Tank

1. FULL Level
2. LOW Level
2) Slowly loosen the pressure cap of cooling

system in order to relieve all the pressure.
Remove the pressure cap.
Fig.5-34 Pressure Cap
3) Add appropriate coolant to the cooling

system. See Table 5-2 recommended oil
for SR200C rotary drilling rig.
4) Start the engine. Operate the engine with-

out the pressure cap until the coolant level
stabilizes.
5) Maintain the coolant level within 13 mm

(0.5 inch) of the bottom of the filler pipe.

6) Inspect the gasket on the pressure cap. If

the gasket is damaged, replace the pres-
sure cap.
7) Install the pressure cap of cooling system.
8) Shut down the engine.
9) Close and latch the engine hood.
3. If additional coolant is necessary, remove

the reservoir and add appropriate coolant
solution.
4. Install the reservoir cap.
Fig.5-35 Reservoir
5. Close the rear access door on the left side.
Fig.5-36 Left Rear Access Door

555555555 Fuel amount - check and refuel
WARNING
Failure to be aware of the following alerts
could result in an unexpected fire or explo-
sion causing injury or possibly death.
●● Shut down the engine before refueling.
●● Avoid any dirt, dust, water, or other for- Fuel tank
eign matters entering the fuel system.
●● Never smoke when refueling.
●● Avoid any potential factors which may
cause a fire when refueling.
Fig.5-37 Location of Fuel Tank

1. Before adding fuel into the fuel tank cap, let
the fuel settle (no less than 48 hours).
2. Fill the fuel after daily work in order to

reduce sediments. For fuel type and vol-
ume, see Table 5-2 recommended oil for
SR200C rotary drilling rig.
Fig.5-38 Fuel Tank Cap

3. Observe fuel level from the message dis-

play. Add fuel before the indicator goes into
red area.
4. Be prepared for maintenance. See: Chap-

ter 2 Safety, “Preparing for maintenance”
on page 2-73.
Fig.5-39 Fuel Level
5. Open the fuel tank cap.
6. Be cautious not to splash fuel onto the ma-

chine when refuelling.
7. When the warning mark of the float at fuel

tank filler port is higher than the filler port,
stop adding fuel. Fuel in the fuel tank cannot
be over filled.
8. Reinstall fuel tank cap onto the filler port. Be

sure to lock the cap with key so as to avoid
loss or damage.

5.4.2 Initial 50 service hours
55555555 Engine oil and filter - Change
CAUTION
Hot oil and components may cause per-

sonal injury. Never allow hot hydraulic oil
or components to come in contact with
skin. Failure to do so may cause scald.
Note:
●● If the sulphur content in the fuel is greater
than 1.5% by weight, use an oil that has a
TBN of 30 and reduce the oil change inter-
val by one-half.
●● If lubricant is deteriorated or badly contami-
nated, change lubricant no matter how long
the service interval is.
●● Drain the crankcase while the oil is warm.
This allows waste particles that are sus-
pended in the engine oil to drain.
1. Park the machine on level ground. Start the

engine and heat it to 80°C.
2. The drain valve for engine crankcase oil is

located underneath the rear part of the up-
per carriage.
Fig.5-41 Location of Crankcase Drain Valve

3. Open the crankcase drain valve. Allow the

oil to drain into a suitable container.
NOTICE
●● Never spill any oil on the ground.
●● Take used oil to a service station or other Fig.5-42 Crankcase Drain Valve
cling.
4. Tighten the crankcase drain valve.

the machine.
6. Remove the oil filter (1) with a strap type

wrench.
7. Clean the filter housing base (2). All of the

seal material must be removed.
2
Fig.5-43 Removing Oil Filter

8. Apply a thin coat of engine lubricating oil to

the new filter seal.
Fig.5-44 Applying Lubricating Oil
9. Install the new oil filter by hand. When the

gasket comes in contact with filter base, turn
the filter for another 3/4 of a rotation in order
to tighten the filter.
Remark:
ngine oil filter index marks, and clearance

E
between marks is 1/4 of a rotation. Application
of index mark could help you tighten the filter.
10. Close the access door.
11. Unlatch and raise the engine hood.
12. Remove the oil filler plug, and add new oil
to the crankcase (refer to sump of d i e s e l
e n g i n e o i l ) . See Table 5-1 recommend-
ed fluids for SR260R rotary drilling rig
Fig.5-45 Oil Filler Plug

13. Start the engine to heat the lubricating oil.

Check the engine for leaks. Shut down the
engine.
14. Wait for 30 minutes to allow the oil to drain

back into the crankcase. Check the oil lev-
el with the dipstick. Keep oil level between
Ｄ
FULL and ADD mark on the dipstick. ＰＰＥ
ＳＴＯ
ＩＮＥ
ＥＮＧ
Ｌ
ＦＵＬ
ＡＤＤ
Fig.5-46 Dipstick
15. Close and latch the engine hood.

55555555 Fuel filter - replace
WARNING
Failure to be aware of these alerts could

result in an unexpected fire or explosion
causing injury or possibly death.
●● Remove all spilled fuel. Never smoke
when operating the fuel system.
●● When replacing the fuel filter, turn the
circuit breaker off or disconnect the bat-
tery.
NOTICE
Do not fill fuel filters before installing them.
Contaminated fuel will cause accelerated
wear to fuel system parts.
1. Open the access door on the left side of the

machine.
2. Place a suitable container for the used fluid

underneath drain hose (3).
3. Open drain valve (2). Allow the fuel in the

filter to drain into the container.
4. Securely tighten the valve. １
5. Remove the fuel filter (1).

２
6. Open the fuel filter opening. Check for ab-
normalities in the fuel filter.
３
7. Clean the mounting base of the fuel filter.
Be sure all the old seals are removed from
the mounting base.
Fig.5-47 Fuel Filter

1. Fuel Filter
2. Drain Valve
3. Drain Hose

8. Apply a thin coat of clean diesel fuel onto

the sealing surface of the new fuel filter.
9. Place the new fuel filter onto the base. Ro-

tate the fuel filter until the filter seal contacts
the base. Note the position of the index
marks on the filter relative to a fixed point on
the filter base. Index marks on the fuel filter
are separated by 90 degrees or 1/4 of a ro-
tation.
10. In order to properly tighten the filter, rotate

the filter by 270 degrees or 3/4 of a rotation. Fig.5-48 Apply Clean Diesel Fuel
11. Add fuel to the fuel tank. see: Chapter 5

Maintenance, “fuel amount - check and
refuel” on page 5-51.
12. Close the access door on the left side of

the machine.
NOTICE

●● Never mix the oil with anything else,
cling.

55555555 Filter of water oil separator - re-

place
. ●yL
● NOTICE
Failure to observe the following alerts may
pose risk of damaging the components!
●● Never fill the filter before mounting wa-
ter oil separator. Contaminated fuel will
cause accelerated wear to fuel system
parts.
●● Never start the engine before all the fuel
system maintenance is finished.
1. Open the access door on the left side of the

machine.
2. Open the drain valve (1) by turning counter-

clockwise. The drain valve is located at the 3
bottom of the water oil separator.
3. Drain water and sediments to a suitable

4
container.
4. Securely tighten the drain valve (1).
5. Remove filter (4) from the filter base (3). 2

Loosen the filter with filter wrench. 1
6. Remove the filter (4) from the bowl (2).
7. Clean the internal surface of the filter base

(3) and bowl (2). Fig.5-49 Water Oil Separator
1.Drain Valve
8. Remove the cap from the bottom of new fil- 2.Bowl
ter (4). Remove seals from the cap. 3.Filter base
4.Filter
9. Install the seal into groove of the bowl (2).
10. Install the bowl (2) onto new filter (4) and
lock it.
11. Install filter (4) onto the filter base (3), and
lock it.
12. Close the access door.

Note:
This kind of filter is cartridge type paper filter

and cannot be used repeatedly.
55555555 Fuel tank strainer - clean
1. Remove the fuel tank cap.

fuel tank cap

2. Inspect seal for damage. Replace the seal,
if necessary.
3. Remove screws, filter assembly, drain valve,

and gaskets.
4. Remove the strainer that is located in the

filler port.
5. Wash the strainer and the fuel tank cap in a

clean, nonflammable solvent.
Strainer
6. Install a new cap filter kit. Install the gaskets,
drain valve, filter assembly, and screws. Fuel tank
cap
7. Install the strainer into the filler port.
8. Install the fuel tank cap.
Fig.5-51 Removing the Strainer and Fuel Cap

55555555 Winch reducers oil level - check
Apart from oil level inspection on service inter-

val, check the reducer oil level for the following
situations and add lubricating oil if necessary:
●● Before starting the machine for the first

time.
●● Storage period for the drilling rig is over
three months.
Checking procedures:
1. Park the machine on level and flat ground.

Adjust the mast section to upright position.
2. Rotate main winch drum slowly to align the

oil inspection and filler port on inner flange
a
with the notch for inspecting oil on outer
flange. Remove oil level screw plug (a).
3. If oil comes out, the oil amount is sufficient.

Otherwise, the oil amount is insufficient.
Fig.5-52 Winch Reducer
Fig.5-53 Checking Winch Reducer Oil Level

55555555 Switches, buttons and operation

handles - check
1. Start the engine. Place hydraulic lock lever

to unlocked (F) position. F
2. Operate the switches, buttons and handles

in the operator’s cab. Check whether the
functions of them are normal. If it is not,
then maintain and service them. L
Fig.5-54
55555555 Rope hold-down rollers - check
1. Check rope hold-down rollers for wear and

proper function.
2. Check the roller is parallel to the drum of the

winch.
3. Check the roller mounting bolts are properly

in place and firm.
4. Adjust the tension screws until all springs

are equal. Do not tension worn-out springs
too much but replace them with new ones.
Fig.5-55 Rope Hold-down Roller
5. Re-align protecting bars that are bent, or re-
place them with new ones.
6. If there is excessive play, replace the roller

center pin, bushings and spacers respec-
tively with new ones.
7. If groove have been created in a roller,

reface the roller, or replace it with a new
one. Mind that a refaced roller will have a
diminished diameter so that the respective
tension will have to be pre-tensioned corre-
spondingly.

55555555 Rotary drive mounting bolts -

check
Check the bolts of buffer device and bush;

check the bolts of reducer shell and box.
Check them at the initial 10 hours, then check
them every 50 hours.
NOTICE
Do not tighten these bolts unless neces-
sary. Or the rupture of sealant will lead to
the looseness of the bolts.
1. Visually check if mounting bolts (a) are firm.
2. Unscrew mounting bolts found to be loose,

clean them and apply Loctite to threads,
reinstall and tension the bolts with the speci-
fied torque. See: Appendix, “bolt tighten-
ing torque” on page 8-3.
3. When changing oil, check the bolts in cas-

ing for damage.
Service requirements for bolts on crowd Fig.5-56 Mounting Bolts

sledge:
1. Tighten the bolts on crowd sledge guide

according to the table below:
Specification Performance Rating Specified torque Interval Remark

M20 12.9 720±30 every month SR150/200
M24 10.9 1030±50 every month Other models

2. Check the screws on the four crowd sledge

guide. If loose, tighten them with the Bolt
specific torque.
Screw
Fig.5-57 Bolts
55555555 Driver strip - check and change
If the wear is above 8 mm, reinstall Kelly driver

strips (4) by turning 180° or replace complete- 1 2 3 4
ly. Replace socket head bolts and washers
with new ones as well.
1. Unscrew socket head bolts (2).
2. Take out the driver strips need to be re-

placed.
3. Take out all the washers (3) in the hole.

Fig.5-58 Driver Strip
4. Replace with a new driver strip (4).
5. Fit the new driver strip to sleeve with wash-

ers and socket head bolts in sequence.

55555555 Rotary drive sliding strip - check

and replace
Replacing short sliding strip (a)
1. Loosen and remove socket head screw (5).
2. Remove sliding strip holder (6) from the a

crowd sledge. c
b
3. Replace with new crowd sledge (1).
4. Press the crowd sledge with sliding strip

holder (6), and tighten with socket head
screw (5).
Fig.5-59 Sliding Strip I
Replacing long sliding strip ( b; c )
1. Remove the socket head screws (5) and put

together. 4 3 2
2. Replace with new long sliding strip (4).
5
3. Fix the new long sliding strip on holder (3)
1
with socket head screws (5). 6
Fig.5-60 Sliding Strip II

1. Crowd Sledge
2. Short Sliding Strip
3. Holder
4. Long Sliding Strip
5. Socket Head Screw
6. Sliding Strip Holder

55555555 Crawler track mounting bolts -

check
●● Visually check if the mounting bolts are

firmly in place.
●● Retighten loose bolts.
1 2 3 4 5
7 6
Fig.5-61 Crawler Track Mounting Bolts
Table 5-4
Bolted connection Torque value (Nm) Interval in operating hours

Track shoe (1) 1410±7 50
Carrier rollers (4) 410 250
Track guide (7) 580 250
Tread rollers (6) 780 250
Crossbeam (3) —— 250
Crawler drive wheels (5) 1100 250
Travel gear 1100 250
Telescopic cylinder 210 (M16) 250
After the first 50 and then
Slewing ring (2) 755 (M24)
every 2000

55555555 Air intake and exhaust system -

visually check
1. Open the two access doors on the left side

of chassis.
2. Check for black smoke or any abnormality.

If occurs, maintain and service air intake
and exhaust system.
Fig.5-62 Two Access Doors

55555555 Window wiper - check
1. Check whether the window wiper works

properly every week.
2. Check the condition of the wiper blades.

Immediately replace the wiper blades if the
wiper blades are worn or damaged.
Fig.5-63 Window Wiper
555555555 Window washer - check
1. Check the fluid volume in the washer tank.

If the level is low, open the cap and add
washer fluid.
2. In winter season, use all-season antifreeze

windshield washer fluid.

555555555 Kelly guide swing bearing - re-

place
1. Remove the Kelly bar from the drilling rig.

5
6 1 2 3 4
2. Dismount the Kelly guide from the Kelly bar.
Locate the Kelly guide with crane at the po-
●
sition illustrated in “Fig.5-64 Kelly Guide”. ●
3. Turn thin nut (1) and nut (2) counterclock- ●
wise with open-ended wrench and pneumat-

ic wrench. Loosen them for about one turn.
1
4. Remove thin nut (1), nut (2), washer (3),

and bolt (4). Properly keep them together.
5. Successively remove the remaining fasten-

ers.
Fig.5-64 Kelly Guide
6. Remove the swing bearing (5). Use caution
1.Thin nut
to fix the Kelly guide body.
2.Nut
7. Erect the Kelly guide without swing bearing 3.Washer
4.Bolt
and fix it.
5.Swing Bearing
6.Kelly guide body
8. Align the new swing bearing horizontally
with Kelly guide body (6) in accordance with
mounting position.
9. Use thin nut (1), nut (2), washer (3), and bolt
(4) to fix swing bearing (5) and kelly guide
body (6) at three locations with 120° clear-
ance.
10. Install thin nut (1), nut (2), washer (3), and
bolt (4) on the remaining installation holes.
11. Manually turn the swing bearing for two

turns. Check for abnormality. If it is not
smooth, add grease from the swing bear-
ing fill port.
12. Place the replaced Kelly guide at specified

location, or mount to the machine for use.

555555555 Impact ring - check and replace
Check impact ring every week. If the wear is

above 20 mm, replace it according to the fol- 1 2
lowing procedures:
1. Unscrew the nut (1).
2. Remove the pallet (2).
3. Pull out inner kelly bar from drive stub by

using auxiliary equipment, such as excava-
tor.
4. Replace impact ring.
5. Install inner kelly bar into outer kelly bar. Fig.5-65 Check and Replace Impact Ring
6. Install pallet (2). Tighten the nut (1) with

torque wrench. Tightening torque is 500N.m.
555555555 Spring of Kelly bar- check and re-

place
Check Kelly bar spring for damage every day.

Replace it immediately if damage occurs. The
replacement procedures are as followings:
1. Unscrew the nut (1).
2. Remove the pallet (2).
3. Pull out inner kelly bar from drive stub by

using auxiliary equipment, such as excava-
tor.
4. Remove impact ring.
5. Replace spring. Fig.5-66 Spring of Kelly Bar
6. Install inner kelly bar into outer kelly bar.
7. Install pallet (2). Tighten the nut (1) with

torque wrench. Tightening torque is 500N.m.

555555555 Shock absorbers - check
Check shock absorbers (a) every week. If

there are deformations and function not well, a
replace them.
Fig.5-67 Shock Absorbers

55555555 Aux. pump filter element - change
Change the filter element for the first time after

250 operating hours. Then change oil after ev-
ery 1000 operating hours or once a year.
CAUTION
Risk of injury!
Release the pressure in hydraulic system
before you change filter element. Or per-
sonal injury may occur.
●● Place a suitable container underneath the

filter housing and unscrew the bottom (3).
●● Remove filter element (2) from top (1) of
housing, and dispose of with hazardous
waste.
1
●● Clean the top and bottom of the housing.
●● Install a new filter element in the top of the
housing. 2
●● Install the bottom of the housing.
Fig.5-68 Filter Element

55555555 W inch reducer oil- change
CAUTION
Failure to follow the alerts may pose per-
sonal injury hazard!
●● Hot lubricating oil and components may
cause personal injury. Never allow hot oil

or components to contact skin.
●● When changing oil, drain it out when the
oil is hot. Namely, change oil after the

machine has operated for a period.
●● Gear oil may spurt out and pose hazard.
change gear oil when the winch stops
working.
1. Remove the oil level screw plug (2) on the

reducer.
2. Place a container to hold the oil.
3. Remove the oil level screw plug (2).
4. Remove the oil drain screw plug (3).
5. Drain the used oil into the container.
6. Install the oil drain screw plug (3).
7. Add new oil from the filler port (1). Open

another oil level screw plug (2) until new
oil comes out of the level inspection port.
When the outdoor temperature is lower, use
heated gear oil to flush the gearbox. See Fig.5-69 Winch Reducer
Table 5-2 recommended oil for SR200C 1. Filler Port (filler screw plug)
rotary drilling rig. 2. Oil Level Screw Plug
3. Oil Drain Screw Plug
8. Install the filler screw plug.
9. Install the oil level screw plug.

55555555 Gear oil for swing reducer -

change
CAUTION
Risk of scald!
When changing oil, drain it out when the
oil is hot. Change oil after the machine has
operated.
Hot oil and components can cause person-
al injury. Never allow hot oil or components
to contact skin.
Failure to do so may pose hazard of per-
sonal injury.
1. Remove the access cover located below the

swing drives.
2. Remove drain hose (2) from holder (1) on

the upper beam. Face the end of the hose
toward the container.
3. Use a universal joint with a socket exten-

sion to loosen the drain valve (3) in the hole.
Drain the oil into a suitable container.
Fig.5-70 Changing Oil for Swing Drive
4. Tighten the drain valve (3). Hook the drain
1.Holder
hose (2) to the holder (1). Make sure the
2.Drain Hose
end of the hose faces upward. 3.Drain Valve
5. Remove dipstick, and add the specified

quantity of oil through the dipstick tube. See
Table 5-2 recommended oil for SR200C
rotary drilling rig.
Filler
Dipstick
Fig.5-71 Dipstick

6. Maintain the oil level between the FULL

mark and the ADD mark.
7. Check the oil that has been drained for met-

al chips or metal particles. Consult SANY
after sales service department if any metal
chips or metal particles are found.
8. Dispose of the drained fluids according to

local regulations.
Fig.5-72 FULL Mark and ADD Mark

NOTICE
cling.

55555555 Travel reducer oil - change
CAUTION
Hot oil and components can cause person-
al injury. Never allow hot oil or components
to contact skin. Failure to do so may cause
injury.
When adding oil, use special tools. When

changing oil, drain it out when the oil is hot. oil level
Namely, change oil after the machine has op- screw plug
erated for a period.
1. Turn the oil drain screw plug of the travel re-

ducer on one side to the bottom position.
drain screw
plug
Fig.5-73 Travel Reducer

2. Remove the oil drain screw plug and oil
level screw plug. Allow the oil to drain into a
suitable container.
3. Clean the plug, and check O-ring. If there is
wear or damage, immediately replace the oil
drain screw plug, oil level screw plug, and
O-ring.
4. Install the oil drain screw plug. Add oil to the
travel reducer in order to make the oil level
reach the bottom of the oil level screw plug.
For details, see Table 5-2 recommended
oil for SR200C rotary drilling rig. Install
the oil level screw plug.
5. Perform the above procedures for the travel
reducer on the other side. Use another con-
tainer in order to separate the oil sample of
two travel reducers.
6. Completely remove the oil splashed onto
the surface.

7. Start the engine and run the travel reducer

for a few turns.
8. Shut down the engine and check the oil
level.
9. Check the drained oil for metal chips or
metal particles.
10. Correctly dispose of the drained material.
NOTICE
cling.

55555555 Pilot filter element - replace
CAUTION
personal injury. NEVER allow hot oil or hot
1. Park the machine on level ground.
2. Move the hydraulic lock lever to UN-

LOCKED position (F).
3. Turn the engine ignition switch to the ON

position. F
4. Move the handles and travel levers/pedals

to the full stroke positions in order to relieve
the pressure in the pilot lines.
L
5. Turn the engine ignition switch to OFF posi-
tion and return the hydraulic lock lever to
LOCKED position (L).

6. Slowly loosen the fill plug/vent plug on top
of the hydraulic tank in order to relieve the
internal pressure of the hydraulic tank.
7. After the pressure is relieved, tighten the fill

plug/vent plug.


the machine.
Fig.5-76 Right Side Access Door
9. Clean the area in order to keep dirt out of

the filter base.
10. Remove the used pilot filter element from

the filter base.
Note:
Used filters should always be disposed of ac-

cording to local regulations.
11. Clean the filter base.

Fig.5-77 Pilot filter
12. Coat the seal of a new pilot filter with clean

hydraulic oil.
13. Install the new pilot filter on the filter base.

Tighten the pilot filter by hand.
Fig.5-78 Applying Hydraulic Oil

55555555 Return filter - replace
CAUTION
personal injury. Never allow hot oil or hot
Note:
●● If the message display shows that the hy-
draulic return filter is plugged, turn off the
machine, inspect and repair.
●● The return filter is a cartridge type filter. The
amount of foreign material that enters the
hydraulic system is reduced when the filter
element is replaced.
1. Loosen the fill plug/vent plug in order to re-

lease all the pressure. Tighten the fill plug/
vent plug after the hydraulic tank pressure is
relieved.
Remark:
The return filter cartridge is located on the

side of the hydraulic tank.

2. Remove filter cartridge. Procedures are as

follows:
1) Remove bolts (1), washers (2) and cover

(3).
2) Remove screw plug (4) in order to release

the pressure in filter cartridge (5).
Remark:
hen plug is removed, the oil level in the re-

W
turn filter drops to the level of the hydraulic
tank.
Fig.5-80 Removing the Return Filter Cartridge I

1.Bolts
2.Washers
3.Cover
4.Screw Plug
5.Filter Cartridge
3) Pull up the handle at the top of filter car-

tridge (5) until the filter cartridge contacts
guide (A) on filter case (6).
５
Fig.5-81 Removing the Return Filter Cartridge II

5.Filter Cartridge
6.Filter Case
A .Guide

4) Turn the filter cartridge counterclockwise

by 180 degrees in order to align the pro-
jection of the filter cartridge with the notch
of the filter case. Pull out the filter car-
tridge.
Fig.5-82 Removing the Return Filter Cartridge III
5) Inspect the cover and O-ring (7). If either

part is damaged, replace the part.
Fig.5-83 Removing the Return Filter Cartridge IV

7.O-ring
6) Inspect the filter cartridge for debris and

for damage. If necessary, replace the filter
cartridge.

3. Remove the filter element. Perform the fol-

lowing procedures in order to remove the
filter element.
1) Remove plug (4). Make sure that all of O-

ring (18) is removed from plate (8).
４１８
Fig.5-84 Removing the Filter Element I

4.Plug
8.Plate
18.O-Ring
2) Remove spiral retaining ring (9).
Fig.5-85 Removing the Filter Element II

8.Plate
9.Spiral Retaining Ring

3) Hold the filter cartridge with one hand.

Grasp the grip of plate (8) with your other
hand. Lift plate (8) in order to separate
plate (8) from the filter cartridge. 8
11
4) Remove O-ring (11) from plate (8).
5) Lift filter element (12) from shell (10). 12

10
6) Pour the remaining oil into a suitable con-
tainer.
NOTICE
●● Put your used oil in a clean plastic con- Fig.5-86 Removing the Filter Element III
tainer with a tight lid. Never store used 8.Plate 10.Shell
oil in a container that once held chemi- 11.O-Ring 12.Filter Element

cling.

4. Clean the shell of the filter cartridge. Per-

form the following procedures in order to clean
the shell of the filter cartridge.
1) Turn shell (10) upside-down.
2) Remove screws (15).
3) Remove pad (14) from slide strip (13).
4) Wash the following parts in a clean non-

flammable solvent: Plug, plate (8), spiral
retaining ring, shell (10), and pad (14). Dry
the parts.
Fig.5-87 Cleaning Filter Shell
13.Slide Strip 14.Pad
15.Screws 19.Port
5. Install the filter elements. Perform the fol-

lowing steps in order to install the filter ele-
ments.
1) Apply spray type oil to the inside of shell
(10) in order to prevent rust.
2) Apply grease to a new O-ring (11).
3) Plate (8) will contact the inside of shell (10).
Apply grease to this point.
4) Apply grease to O-rings inside ports at the
bottom of shell (10).
5) Install new pad (14). Tighten the screws to
a torque of 0.4 N·m (3.5 lb in). Fig.5-88 Installing Filter Element I
8.Plate 10.Shell 11.O-ring
6) Apply spray type oil into the clearance be-
16.Boss 17.Notch
tween shell (10) and slide strip (13).
7) Turn over shell (10). Apply grease to the
two O-rings on new filter element. Install
filter element into shell (10).
8) Move boss (16) in alignment with notch
(17). Install plate (8) into shell (10).

9) Install spiral retaining ring (9) into the

groove in shell.
Fig.5-89 Installing Filter Element II

8.Plate
9.Spiral Retaining Ring
10) Apply grease to new O-ring (18). Install O-

ring on plug (4).
11) Install plug (4) into plate (8).
４１８
Fig.5-90 Installing Filter Element III

4.Plug
8.Plate
18.O-Ring

6. Install the filter cartridge. Perform the follow-

ing procedures in order to install the filter
cartridge.
B
C
Fig.5-91 Installing Filter Cartridge I

B.Port
C.Slide Strip
1) Check whether port (B) at the bottom of
the filter case is closed.
Remark:
If the port is open, rotate the slide strip (C)
counterclockwise to the stopper in order to ful-
ly close the port. When the port is fully closed,
any remaining oil in the filter case should be
completely removed.
2) Check whether port (D) of the filter car-

tridge is fully closed.
Remark:
The filter cartridge cannot be installed un- E
less the port is fully closed. If the port is open,
rotate slide strip (E) counterclockwise to the
stopper in order to fully close the port.
D
Fig.5-92 Installing Filter Cartridge II

D.Port
E.Slide Strip

3) Check whether O-ring (F) have been in-

stalled and whether oil has been applied
to O-ring (F).
F
4) Install the filter cartridge into the filter

case. Turn the filter cartridge clockwise Fig.5-93 Installing Filter Cartridge III
by 180 degrees and push down the filter F.O-rings
cartridge when the filter cartridge contacts
guide.
5) Install plug, cover, washers, and bolts.

Tighten bolts to a torque of 29 ± 5N·m
(22±4 lb ft).
Fig.5-94 Installing Filter Cartridge IV

1.Bolts

55555555 Bolts connecting swing bearing -

check
1. Check bolts visually.
Fig.5-95 Bolts Connecting Swing Bearing
2. Replace loose, cracked, or defective bolts.
3. When replacing with new bolts, apply thread

glue on the thread under the bolt head.
55555555 Reducer gear oil - change
CAUTION
Scalding hazard!
Hot gear oil can cause severe injury!
Change the oil when it is at operating tem-
perature.
To change the oil:
1. Have a collecting container ready.
2. Prepare a plastic tube or hose of suitable

size and length connecting drain plug and
collecting container.
3. Remove the drain plug. Fit the plastic tube

or hose.
4. Tilt the rotary drive by raising the mast.
5. Drain out used oil.

Fig.5-96 Drain Plug

6. If the outside temperature is low at the time

of the oil change, warm up (to approx. 50
°C) a part of the new oil and rinse the gear
housing with this oil before refilling.
Note:
Benzol or flushing oils may also be used here

for rinsing.
NOTICE
Risk of damage!
Do not use petrol or diesel oil for rinsing
here. Allow the rinsing fluid to drain off
completely.
7. Unscrew the plug on top of oil can. Fill the

oil until it reaches the middle of sight glass
(M).
8. Check the oil level.

M
9. Screw in the plug and tighten.
Fig.5-97 Middle of Sight Glass

55555555 Oil suction filter - clean
1. Park the drilling rig on level ground and shut a d

down the engine. b e
2. After hydraulic oil cools down, loosen the
c
air-bleed plug, and screw it after bleeding
the air.
3. Loosen fastening bolts (a), and remove cov-

er (c). When removing the cover, press it by
hand, so as to avoid being hurt by the cap.
4. Plug out the end of the rod, and remove

spring (d) and strainer (e).
Fig.5-98 Removing Spring and Strainer
5. Clear the dust off the strainer. Flush with a. Bolts b. Washers c. Cover
clean diesel oil. If the strainer is damaged, d. Spring e. Strainer
replace it.
6. Reinstall the strainer, and install gasket seal

(g) into the protuberant part of oil tank.
7. Install cover and fasten bolt. Make sure

the protuberant part could be inserted with
spring. Fasten bolt.
8. Clean the worksite after replacing it. Keep

the machine clean. Keep oil tank port and
cover clean during changing filter element.
f g
Fig.5-99 O-ring seal

f. O-ring seal
g. Gasket seal

55555555 Wire rope sheaves - check
1. Sluggish or seized rope sheaves subject the

rope to excessive wear and abrasion and
make the load distribute unevenly on the
rope structure.
2. Repair of replace as necessary sluggish or

seized rope sheaves, if greasing will not do.
Fig.5-100 Wire Rope Sheaves
55555555 Rotary drive gear oil - check
1. Inspect the oil for dark or black colouring.

If the colour of the sampled oil is dark or
black, the operating temperature of the oil
has been above 100°C. This result in an ac-
celerated ageing of the oil, and in reduced
lubricity. The oil change must be carried out
at shorter intervals.
2. Inspect the oil for water and dirt. If the oil is

found to be contaminated or water has got
in, the seal rings must be checked and re-
placed as necessary.
3. Inspect the oil for solid particles (abrasives).
The maximum permissible amount of foreign

particles in the total oil fill of one gearbox must
not exceed 0.15%. Lots of foreign matter may
only consist of small abrasion (up to max. 5
μm) (examination of foreign matters according
to DIN 51592). With coarse-grained abrasion
(above 5 μm) the gear must be dismounted,
regardless of the quantity of the abrasion.

55555555 Hoses - check and replace
1. Unlatch and raise the engine hood.
2. Check for leakage of all the hoses. Check

clamp.
3. Replace cracked or softened hoses. Tighten

the loose clamps.
4. Loosen the cooling system pressure cap

slowly in order to relieve all the pressure.
Remove the pressure cap.
Fig.5-101 Cooling System Pressure Cap
5. Drain the coolant from the cooling system

and replaced the hose.
6. Loosen the hose clamp and disconnect the

damaged hose.
7. Replace the damaged hose with a new one.
8. Replace and tighten the hose clamp.
9. Add appropriate amount of coolant to the

cooling system. See Table 5-2 recom-
mended oil for SR200C rotary drilling rig.
10. Latch the engine hood.

55555555 K elly guide sliding strip - check

and replace
Check wear condition of Kelly guide nylon

plate. After the first inspection, perform the
second inspection based on the working con-
dition. If it is excessively worn, replace it.
1. Remove the Kelly bar from the drilling rig.
2. Place the Kelly guide horizontally by using

crane. 12 34
6
3. Check for the sliding strip. If it is excessively
worn, replace.
5
Fig.5-102 Kelly Guide
55555555 E ngine oil and filter - change
For details, see: Chapter 5 Maintenance,

“engine oil and filter - Change” on page 5-53.

55555555 Gearbox gear oil - change
1. Place the rotary drive static.
2. Have a collecting container ready.
3. Remove the drain plug (2) and drain the oil.

1
4. Remove filler plug (1). Fill new oil until it
reaches 1/2 - 2/3 of the sight glass.
2
5.4.7 Every 500 service hours Fig.5-103 Changing Geabox Gear Oil
55555555 Engine crankcase breather - clean
Note: 2 3
●● Cleaning engine crankcase breather when
the engine cools down.
●● A plugged breather will cause excessive
crankcase pressure that may cause crank-
shaft seal leakage. Perform the mainte- 1
nance on regular basis.
4
1. Loosen hose clamp (3) and remove hose (4)
from breather assembly (1).
2. Remove bolt (2) and the washer. Remove

the breather assembly (1) and the seal.
3. Wash the breather element in solvent that is

clean and nonflammable.
4. Allow the breather element to dry before in-

Fig.5-104 Crankcase Breather
stallation.
1. Breather Assembly
5. Install a breather element that is clean and 2. Bolt
3. Hose Clamp
dry. Install breather assembly (1) and the
4. Hose
seal.

6. Install bolt and washer.
7. Install hose (4) on breather assembly (1).

Tighten hose clamp (3).
55555555 Kelly bar baffle - check
Check the Kelly bar baffle (b) every week. If

the baffle deforms badly and cannot function b
well, replace it.
55555555 Kelly bar drive gibs - check Fig.5-105 Kelly Bar Baffle
Drive gibs (c) are located on the top of each

section of bar and are used frequently. If open
welding occurs, repair it immediately. c
Procedures for checking inner Kelly bar drive

gibs :
1. Remove the baffle.
2. Pull out inner Kelly bar from drive stub.
3. Pull out other sections.
4. Check inner Kelly bar drive gibs.

Fig.5-106 Drive Gibs
5. Install Kelly bar in reverse way.
Note:
Check outer Kelly bar every 250 hours or ev-

ery month. Check inner Kelly bar every 500
hours.

55555555 Kelly bar tube - check
Tube (d) is on the lower part of each section of

bar and are used frequently.
Procedures for checking inner Kelly bar drive d

gibs :
3. Pull out other sections from top of Kelly bar.
4. Check inner Kelly bar tube.
5. Install Kelly bar in reverse way. Fig.5-107 Tube
Note:

hours.
55555555 Kelly bar locking recesses - check
Locking recesses (e) transfers pressure. If the

wear is less than 10 mm, repair welding in
construction site. If the wear is above 10 mm,
contact SANY after sales staff.
e
Procedures for checking locking recesses:
3. Check inner Kelly bar locking recesses.

Fig.5-108 Locking Recesses
4. Install Kelly bar in reverse way.
Note:

hours.

55555555 Bolts connecting swing bearing -

check

“bolts connecting swing bearing - check”
on page 5-88.
55555555 Fuel filter - replace

“fuel filter - replace” on page 5-57.
55555555 Filter for water oil separator - re-

place

“filter of water oil separator - replace” on
page 5-59.
55555555 Fuel tank strainer - clean

“fuel tank strainer - clean” on page 5-60.

“gearbox gear oil - change” on page 5-94.
555555555 Winch reducer oil- change

“winch reducer oil- change” on page 5-72.

55555555 Hydraulic oil - change
Precautions for hydraulic oil selection
NOTICE
Risk of damaging the components!

Make no attempt to start the engine
until the pump has been filled with hy-
draulic oil. Otherwise, it may lead to
damage to hydraulic components.
Know the operating temperature of relevant

circuits (closed circuit) in order to correctly se-
lect oil.
Select hydraulic oil like this: The operating

viscosity in working temperature range is in
the optimum range (V opt ) (see red area of
the selection diagram). We recommend high-
viscosity grade oils.
viscosity
E.g. Under the ambient temperature of X°C,

the circuit working temperature is 60°C, and
the corresponding viscosity grade is VG46 to
VG68 in operating viscosity range (Vopt red
area). VG68 should be selected. Temperature range of hydraulic oil
Fig.5-109 Hydraulic Oil Selection

1. Park the machine on level ground.
2. Open the access cover.

1
3. Remove bolts (1), washers (2), and cover (3)
from the top of the hydraulic tank. 2
3
Fig.5-110 Access Cover

1.Bolts
2.Washers
3.Cover
4. Clean the area thoroughly in order to keep

dirt out of the strainer cover and the fill plug/
vent plug.
5. Release the internal pressure from the hy-

draulic tank by loosening the fill plug/vent
plug. After the pressure is released, remove
the fill plug/vent plug.
6. Remove the hydraulic tank access cover

that is located under the upper carriage.
Check the drain valve. Drain valve is located
under the hydraulic tank.
Fig.5-112 Drain Valve

7. Remove screw plug (4).
Fig.5-113 Drain Valve I
8. Replace screw plug (4) with pipe nipple (5)

and hose (6).
Fig.5-114 Drain Valve II

5.Pipe Nipple
6.Hose
7.Drain Screw Plug

9. Loosen drain screw plug (7) in order to drain

the oil into a suitable container.
10. After the oil has been drained, tighten drain 6

screw plug (7) to a torque of 110±15N·m
(81±11 lb ft).
5
11. Remove pipe nipple (5) and hose (6).
12. Clean screw plug (4) and install it. Tighten

the plug to a torque of 75±5N·m (55±48 lb
ft).
7
the machine.
14. Clean the pump, the hydraulic lines, and

the hydraulic tank.
Fig.5-115 Drain Valve III
5.Pipe Nipple
6.Hose
7.Drain Screw Plug
15. Remove the screw plug from the tube. Al-

low the oil to drain into a container.
16. Inspect the O-ring. Replace with new O-ring

if wear or damage of the O-ring is evident.
17. Install the screw plug and O-ring into the

drain port.
Fig.5-116 Screw Plug of Tube

18. Remove bolts(8), washers(9), cover(10),

spring(11), and strainer(12).
Note:
8 11
Do not allow spring (11) to fall back into the 9
tank.
10
12
Fig.5-117 Removing Spring and Strainer

8.Bolts 9.Washers 10.Cover
11.Spring 12.Strainer
19. Wash the strainer in clean and nonflam-

mable solvent. Allow the strainer to dry.
Inspect the strainer. Replace the strainer, if
the strainer is damaged.
20. Remove O-ring seal (13) from the strainer.
13 14

13.O-ring seal
14.O-ring seal

21. Inspect O-ring seal (13) and (14). Replace

the O-ring seals if wear or damage is evi-
dent.
8 11
22. Install O-ring seal (13) on strainer (12). 9
23. Install strainer (12), spring (11), cover (10), 10
washers (9), and bolts (8).
12
Remark:
Make sure that the O-ring seals and the spring

are properly positioned during installation.
24. Fill the hydraulic system tank according to

required capacity. see Table 5-2 recom-
mended oil for SR200C rotary drilling
rig. Fig.5-119 Removing Spring and Strainer
8.Bolts 9.Washers 10.Cover
25. Inspect the O-ring seal on the filler plug for 11.Spring 12.Strainer
damage. Replace the O-ring, if necessary.
Clean the filler plug. Install the filler plug.
13 14

13.O-ring seal
14.O-ring seal

26. When the hydraulic oil has been replaced,

the air must be removed from the hydraulic
oil system. To remove the air from the hy-
draulic system, perform the following proce-
dures.
1) While the engine is stopped, remove drain

hose (15), connector (16), and oil seal (17)
from the top of the pump. Fill hydraulic oil
from the opening.
Fig.5-121 Bleeding Air from Hydraulic System I

15.Drain Hose 16.Connector
17.Oil Seal 18.Counter Flow Control Hose
2) Check for condition of oil seal (17). If the
oil seal is damaged, replace immediately.
3) After the pump is filled with oil, install drain

hose (15), connector (16), and oil seal (17)
onto the original location.
4) Start the engine, and run at idle speed.
5) Slowly loosen counter flow control hose

(18) until air is completely removed from
the pump.
6) Tighten the counter flow control hose (18).

7) Shut down the engine. Slowly loosen joint

(19) until hydraulic oil begins to flow out of
the opening. It indicates the air has been
removed from the pump.
Fig.5-122 Bleeding Air from Hydraulic System II

19.Joint
8) Tighten the joint (19).
27. Start the engine. Operate the engine at

idle speed for five minutes. Operate the
operation handle in order to circulate the hy-
draulic oil.
28. Shut down the engine. The oil should

reach 1/2-2/3 of the sight glass.
Fig.5-123 Sight Glass

29. Close the access door. Close and latch
the engine hood.

55555555 Hydraulic hose - check
Hose assemblies must be inspected at least

once a year by after sales staff. Check leak-
age for all the hoses on regular basis. In visual
inspection, even if slightest damage is found,
immediately replace all the defective hoses.
The potential defects of hoses are:
●● The joint slides in the hose.

●● The outer rubber layer is damaged, cut, or
worn (any explosion of reinforcing layer).
●● Hardening, crack, and burn of the hose.
●● Crack, damage, and severe corrosion of
the joint.
●● Leakage of joint or hose.
●● Winding, crush, flattening, and distortion of
hose.
●● Blistering, softening of hose outer layer.
Other items for daily inspection:
For the following items, tighten, repair, or re-
place if necessary.
●● Oil leakage.
●● Dirt plugging.
●● Pipe clamp, sleeve, and guard material.
●● Beyond storage and service life.
Note:
●● If the pipeline and joints of hydraulic pump
in engine compartment are damaged be-
cause of mechanical effect/thermal effect,
immediately replace.
●● Make sure the entire pipeline and hoses
maintain enough distance from the hot
engine components (such as exhaust sys-
tem). Make sure they will not rub against

each other.
●● Hoses and hose assemblies are to be
stored in a cool and dry place free of dust.
Avoid exposure to direct sunlight or UV ra-
diation.
55555555 Hydraulic hose - change
Even there is no damage, replace the hydrau-

lic hoses at least 6 years later, including 2
years storage time.
Precautions for changing hydraulic hoses:
1. Calculate working time and storage time ac-

cording to the production date on hydraulic
hoses.
2. Before installing each components in hy-

draulic lines, clean them.
3. Protect the hose port from entering dust.

55555555 Battery - clean and recycle
WARNING
Personal injury or possibly death can re-

sult from battery fumes or explosion.
Electrolyte is an acid and IT can cause per-
sonal injury if it contacts the skin or eyes.
Prevent sparks near the batteries. Sparks
could cause vapors to explode.
Never allow jumper cable ends to contact
each other or the engine. Improper jumper
cable connections can cause an explosion.
Always wear protective glasses when
working with batteries.
Battery-clean
Clean the battery surface with a clean cloth.

Keep the terminals clean and keep the ter-
minals coated with petroleum jelly. Install the
post cover after you coat the terminal post with
petroleum jelly.
Battery-recycle
Always recycle a battery. Always return the

used batteries to one of the following loca-
tions:
―― a battery supplier
―― an authorized battery collection facility
―― recycling facility
Battery hold-down-tighten
Tighten the hold-downs for the battery in order

to prevent the batteries from moving during
machine operation.

Battery, battery cable, or battery disconnect

switch-replace OFF ON
1. Turn the engine ignition switch key to the

OFF position. Turn all the switches to the
OFF position.
2. Turn the battery disconnect switch to the

OFF position. Remove the key.
Fig.5-124 Battery Disconnect Switch
3. Disconnect the negative battery cable at the

battery.
4. Disconnect the positive battery cable at the

battery.
5. Disconnect the battery cables at the battery

disconnect switch. Make necessary repairs
or replace the battery.
6. Connect the battery cable at the battery dis-

connect switch.
7. Connect the positive battery cable of the

battery.
Fig.5-125 Disconnecting the battery
8. Connect the negative battery cable of the
battery.
9. Insert the disconnect switch key and turn

the battery disconnect switch to the ON po-
sition.

55555555 Air conditioner/cab heater filter

(recirculation) - inspect and re-
place
The air conditioner filter is located on the lower

left side of the cab behind the seat.
1. Slide the operator seat forward.
2. Slide the filter element upward in order to

remove the filter element.
3. Do not use compressed air to clean the filter

element. Tap the air filter in order to remove
the dirt from the filter element. Avoid dam-
age to the filter element. Air Conditioner Filter
4. After you clean the filter element, inspect Fig.5-126 Air Conditioner Filter
the filter element. If the filter element is
damaged or badly contaminated, use a new
filter element.
5. Install the filter element.

Note:
An air recirculation filter element clogged with
dust will result in decreased performance and
short service life to the air conditioner or cab
heater. To prevent decreased performance,
clean the filter element, as required.

55555555 Travel reducer oil - change
For details,see: Chapter 5 Maintenance,

“travel reducer oil - change” on page 5-75.
55555555 Gear oil for swing reducer -

change

“gear oil for swing reducer - change” on
page 5-73.
55555555 Pilot filter element - replace

“pilot filter element - replace” on page 5-77.
55555555 Return filter element - change

“return filter - replace” on page 5-79.
55555555 Aux. pump filter element - change

“aux. Pump filter element - change” on
page 5-71.
555555555 Oil suction filter - clean
For details, see: Chapter 5 Maintenance, “oil

suction filter - clean” on page 5-90.


“gearbox gear oil - change” on page 5-94.
555555555 Hydraulic oil - change

“hydraulic oil - change” on page 5-98.

5.5 Storage of Drilling Rig
5.5.1 Cleaning the drilling rig
1. Thoroughly wash the machine after work or

before storage for the drilling rig. Discon-
nect all the batteries before washing so as
to avoid short circuit.
2. Flush with clean water. Use special deter-

gent to remove dirt, if necessary. Do not
wash with acid or alkaline solution so as to
avoid corrosion to the machine surface.
3. When washing with high pressure water,

use caution to protect electrical and hydrau-
lic elements in order to prevent damage to
elements or looseness of cable interface.
4. When washing in cold weather, immediately

dry the drilling rig so as to avoid freezing.
5.5.2 Machine storage
55555555 Maintenance to the drilling rig

during storage
1. Check the machine. Repair the worn or

damaged parts. Replace with new parts, if
necessary.
2. Clean the air cleaner filter element.
3. Retract the retractable hydraulic cylinder.

Exposed hydraulic cylinder piston rod shall
be applied with grease.
4. Lubricate all the lubrication points.
5. Park the drilling rig on solid and level

ground. If necessary, chock the tracks with
steel plate or wood plate.

6. Wash the drilling rig. Especially when stored

in winter season, different parts of the
drilling rig especially the crawler shall be
washed up.
7. After the battery is charged with enough

power, disconnect the battery and store it in
dry and safe place. If you do not disconnect
the battery, separate the battery negative
cable from the negative terminal.
8. In winter season, use antifreeze or drain out

coolant completely. SANY adopts coolant
with the freezing point of -35°c. If the ambi-
ent temperature is lower than -35°c, drain
the coolant. If the cooling system is drained,
attach a warning tag “radiator without cool-
ant” in conspicuous place.
9. Loosen the alternator belt and cooling fan

belt.
10. Apply grease on telescopic beam surface

and mast rail to prevent rust.
11. Park the machine in dry and safe place. If

stored outdoor, it should be covered with
waterproof guard.
12. If storing the machine for a long period

of time, run the machine at least once a
month.
13. During storage period, usually remove dust

from the gear ring and driving wheel sur-
face. Check for rust. If necessary, clear of
the rust and apply grease for lubrication.

55555555 Maintenance to the drilling rig be-

fore moving from the warehouse
If the machine has been stored for a long pe-

riod of time, the oil layer on the sliding surface
may be damaged. It is necessary to repeatedly
travel, swing and operate the hydraulic system
for twice or three times in order to lubricate the
sliding surface.
1. Apply grease to the hydraulic cylinder piston

rod before storage.
2. Adjust tension of alternator belt and fan belt.
3. Check all the hoses and the connections.
4. Install the new fuel filter. Replace the engine

oil filter and fill oil to the engine.
5. Pad the fuel tank in order to bleed gas from

the fuel system.
6. Check all the fluid levels.
7. Start the engine. Before full load operation,

run the engine at half speed for a few min-
utes.

E
G
PA
K
AN
BL

SR200C(SY) Rotary Drilling Rig Troubleshooting
Troubleshooting
6 Troubleshooting...................................................................................... 6-3
6.1 Motor System Common Faults and Troubleshooting............................................... 6-3
6.2 Electrical System Common Faults and Troubleshooting....................................... 6-20
6.3 Hydraulic System Common Faults and Troubleshooting....................................... 6-22
6.4 Troubleshooting of Work Unit................................................................................. 6-28
6.5 Air Conditioning System Common Faults and Troubleshooting............................. 6-40
6.6 SR150C/SR200C ( SY) Wear Parts List................................................................ 6-43

Troubleshooting SR200C(SY) Rotary Drilling Rig


6 TROUBLESHOOTING
6.1 Motor System Common Faults and Troubleshooting
Table 6-1
Fault Analysis Troubleshooting
Starter motor rotates, but fails to drive
Motor teeth damaged or spring broken
engine
Circuits loose or corrosion Clean and tighten
Engine cannot Battery short of electricity Charge

start up or starts
up too slow Starter motor solenoid has no voltage Check solenoid voltage
Crankshaft fails to rotate Check engine
Solenoid or starter motor fails Replace starter motor
No fuel in fuel tank Add diesel
Electric or manual fuel cut-off valve is Check whether conductor is loosened and whether
not open solenoid valve is normal
Engine can run,
but fails to start Improper start-up procedures Check whether start-up procedures are ok
up and there is no
smoke in exhaust Fuel filters plugged by water or other
Drain water separator or replace water filter
pollutant
Fuel injection pump does not receive Check fuel amount in fuel system/exhaust fuel sys-
fuel or there is air in fuel tem

Maximum intake resistance of fuel delivery pump

Check fuel intake resistance
shall not exceed 100mm Hg[4in.Hg]
Visual check. Unplug. Check exhaust system for

Intake or exhaust system is clogged .
choking..
Ensure that fuel return circuit is connected to fuel
Fuel return.
tank bottom.
Fuel return relief valve fails(refer to in-

Check/replace fuel pump return relief valve
line fuel pump only)
Visual check the fuel delivery situation of a fuel in-

Fuel injection pump wears or fails jector that connects engine and fuel injection pump
outlet. Remove fuel injection pump for calibration.
Engine can run, Fuel injection pump timing incorrect Verify/adjust fuel injection pump timing
but fails to start
up and there is no Camshaft timing incorrect Check/calibrate gear train timing alignment
smoke in exhaust
Confirm that transmission parts are not engaged
Check battery and starter. Check wire connector

Startup speed too low(minimum startup
for loosening or corrosion
speed=150rpm)
Start engine, check inside for choking (if the condi-
tion permits)
Cold startup auxiliary device does not Confirm that cold startup auxiliary device is work-
function ing
Check and replace filter, check air supply tube for
Insufficient air intake
choking
Air in fuel system or insufficient fuel Check fuel flow through filter and exhaust fuel
supply system
Fuel contaminated or No. 1 diesel is Confirm by using clean No. 2 diesel stored in pro-
used above 0°C[32ºF]. visional fuel tank to run the engine.


Ensure that fuel return circuit is connected to fuel
Fuel return
tank bottom.
Fuel return relief valve fails Check/replace fuel pump return relief valve
Maximum intake resistance of fuel delivery pump

Check fuel intake resistance
shall not exceed 100mm Hg[4in.Hg]
Check top dead center (TDC). Check/adjust fuel

Engine is diffi- injection pump timing If the condition permits, use
cult to or fails to Fuel injection pump timing incorrect
relief hole to check/adjust fuel injection pump tim-
start up, there is ing.
smoke in exhaust
Valve adjustment incorrect Adjust valve
One or more fuel injectors wearing or

Check/replace fuel injector
failure
Insufficient engine compression pres-
Check pressure and confirm failure
sure
Fuel injection pump/fuel delivery valve
Remove fuel injection pump for calibration
failure
Fuel level too low Check/fill fuel tank
Engine starts with load Driven mechanism separates
Too low idle speed to drive accessories Adjust idle rotation speed
Visual check exhaust for clogging, check intake for

Intake or exhaust system is clogged
clogging
Air in fuel system or insufficient fuel Check fuel amount in fuel system/exhaust fuel sys-
Engine starts, but supply tem, find and treat air supply
cannot keep run-
ning Confirm by check fuel filters, clean fuel system and
Fuel frozen to wax due to cold weather
use fuel and fuel oil heater suitable for weather
Verify by using a provisional fuel tank containing

Fuel contaminated high-quality fuel to run the run engine. Drain and
flush fuel feeding tank.
Fuel filter clogged Check/replace fuel filter
Fuel return manifold or return pipe (refer

Check/remove resistance
to CAV pump only)

Fuel level too low Check/fill fuel tank
If idle speed occurs, it is because idle

Adjust idle speed
speed for accessories is set too low
Check/repair high pressure fuel pipe, connector,

Engine speed High pressure fuel leakage
fuel injector sealing washer or fuel delivery valve
fluctuation
Exhaust air in fuel system and treat leakage
Air in fuel
source
One or more injectors damage or fail-
Check/replace fuel injector
ure
Fuel injection pump/fuel delivery valve
failure
If engine does not reach working temperature,

Engine temperature low
heat it to working temperature
Too low idle speed for accessories Check/adjust low idle bolt
Engine assembly too tight, damaged or

Confirm assembly conditions.
loosened
Check/repair high pressure fuel pipe, connector,

High pressure fuel leakage
fuel injector sealing washer or fuel delivery valve
Air in fuel system Exhaust fuel system and treat air source
Engine idle
rough(irregular Fuel return relief valve fails Check/replace fuel return relief valve
ignition or engine
vibration) Fuel delivery pump fails Check/replace fuel delivery pump
Clean prefilters and strainers. Check fuel

Fuel supply clogged
pipe for clogging, replace fuel filter.
Fuel injector needle valve jammed Check/replace fuel injector
Fuel injection pump or fuel delivery

Remove fuel injection pump for calibration.
valve failure
Valve seam not tightly Adjust valve
One more cylinders pressure low Check pressure and repair if necessary

If engine does not reach working tempera-

Engine temperature low
ture, heat it to working temperature
Check/repair high pressure fuel pipe, con-

Fuel injection tube leakage nector, fuel injector sealing washer or fuel
delivery valve
Air in fuel system or insufficient fuel Check fuel flow through filter and exhaust
supply cooling system Find and treat air source
Fuel return relief valve fails Check/replace fuel pump return relief valve
Fuel delivery pump fails Check/replace fuel delivery pump.
Clean prefilters and strainers. Check fuel pipe for

Fuel supply clogged
clogging, replace fuel filter.
Engine running
rough or lack of Verify by using a provisional fuel tank con-
Fuel contaminated.
ignition miss taining high-quality fuel to run the run engine
Valve adjustment wrong Check push rod for bending and adjust valve
Check top dead center (TDC). If equipment

Fuel injection pump timing adjustment
condition permits, use relief hole to check
incorrect
fuel injection pump or adjust its timing
One or more cylinders compression
Check compression and repair if necessary
pressure low
Fuel injector fails Check/replace fuel injector
Fuel injection pump (fuel delivery

valve) fails
Camshaft timing incorrect Check/replace gear train timing alignment
Camshaft or followers damaged Check camshaft and followers

Check by hand-held or digital tachometer,

Tachometer fails
calibrate if necessary
Check high idle speed under unloaded condi-

Engine overload tion, ensure that operation adapts right gear
position
Throttle pull rod damaged or adjust- Adjust fuel lever and confirm it has double-end
ment incorrect limit travel
Mechanical shutdown lever is partially
Check/adjust shutdown rod
geared
Fuel quality too poor or No,1 diesel is Confirm by using clean No. 2 diesel stored in pro-
used above visional fuel tank to run the engine
Engine cannot
reach nominal Check fuel flow through filter and find resis-
Fuel supply insufficient
rotating speed tance source
Fuel return relief valve fails Check/replace fuel return relief valve
Fuel delivery pump fails Check/replace fuel delivery pump
Check for leakage and repair. Check/clean

AFR controller leak or clog
clogged AFC tube and connector
If it is intermittent, fuel return manifold

Check/remove resistance
is blocked
Booster exhaust gas valve actuator

Repair booster
diaphragm break
Fuel injection pump fails Remove fuel injection pump for calibration


Check accessories for damage. Check drive
Engine overload mechanism, towing braker and vehicle load
for added load
Throttle lever adjustment incorrect Check/adjust lever double-end limit travel
Machine-shutdown rod jointed par- Check/replace shutdown rod at running posi-
tially tion
Fuel quality too poor or No.1 diesel Confirm by using No.2 diesel in provisional
is used above 0°C[32°F] fuel tank to run the engine
Check whether throttle slow re-

sponse is caused by the following
Engine output factors: AFR controller leak. Ex- Fasten connector, or repair pipe system or
power low haust gas valve pressure reduction exhaust gas valve pressure reduction film
film break, waste gate pipe system
damage
Check AFC pipe and connector between
AFC pipe system clogged
manifold and fuel injection pump
Check/repair high pressure fuel pipe, connec-
High pressure fuel leakage tor, fuel injector sealing washer or fuel deliv-
ery valve sealing ring
Check fuel flow through filter. Find clogging
Fuel supply insufficient
position.
Discharge air in fuel system, check fuel suc-
Air in fuel pipe.
tion pipe for leakage

Fuel delivery pump fails Check/replace fuel delivery pump
Fuel return relief valve fails Check/replace fuel return relief valve
Engine oil level incorrect Check/adjust engine level
Check/clean air filter core Check for other

clogging
If vehicle is equipped air intake valve or
switch connecting hood and outside, config-
ure valve to current climate
Air intake insufficient or overheat
Coolant passage clogged in intercooler
Check air-air intercooler for clogging, replace
clogged cooler
Check/clear scraps in front of air-air intercool-
er
Check air jumper tube on repair manifold
Air leakage between booster and
cover, air-air intercooler connector, hose or
air intake manifold
through hole for leakage
Check/repair exhaust system Check catalyst
Exhaust clogged
Engine output chamber for clogging
power low Fuel temperature too high-higher Confirm fuel oil heater has been closed.
than 71°C[160°F] Check fuel return pipe for clogging
Check repair manifold or booster sealing gas-

Exhaust leak between manifold
ket for leakage. Check exhaust manifold for
and booster
breakage
Redundant fuel injector sealing
Remove redundant fuel injector sealing gas-
gaskets are installed under fuel
kets
injector
Fuel Injector wears or fails Check fuel injector
Check whether pressure boosting meets
standard
Booster fails
Check/replace booster
Valve gap incorrect Check/adjust valve
Fuel injection pump timing incorrect Check/adjust fuel injection pump timing
Fuel injection pump fails Remove fuel injection pump for calibration
Engine compression pressure too Check compression. Check whether there is
low failure and repair as required


Engine stalls due to overload Use low gear
Check/replace air filter Check for other clog-
Intake clogged
ging
Exhaust clogged Check exhaust resistance
Check air jumper tube on manifold cover, air-
Air leakage between booster and
air intercooler connector, hose or through
air intake manifold
hole for leakage and repair
Check air-air intercooler for clogging. Check
Air-air intercooler fails inside charging resistance. Check air-air
intercooler for leakage
Check repair manifold or booster sealing
Exhaust leakage between booster
gasket for leakage. Check exhaust manifold
and air exhaust manifold
for breakage
Too much black
smoke in ex- Booster exhaust gas valve fails Check/replace exhaust gas valve
haust
Turbocharger fails Check/replace turbocharger
More than one sealing gasket is
Remove redundant gaskets
installed under fuel injector
7mm fuel injector is installed with Remove fuel injector and install adequate
9mm sealing gasket sealing gaskets
Fuel injector fails Replace fuel injector

Fuel injection pump failure or ex-
cessive fuel supply
Piston ring not sealed (blue smoke) Test pressure, calibrate if necessary
Fuel injection pump timing incorrect Check and adjust fuel injection pump timing
Check whether start-up procedures are cor-
Incorrect start-up procedures
rect
Air intake temperature too low
Check by using a provisional fuel tank con-
taining high-quality fuel to run the engine.
Poor fuel quality
Clean and flush fuel supply tank, using diesel
with cetane number in 42-50
Too much white
Check top dead center (TDC). Check/adjust
smoke in ex-
Fuel injection pump timing adjust- fuel injection pump timing Use relief hole tim-
haust
ment incorrect ing to check fuel injection pump or adjust its
timing
Fuel injector fails Check/replace fuel injector
Cooling fluid leaks into flaming air Check cooling fluid loss
Fuel injection pump/fuel delivery

valve failure


Check/fill cooling fluid
Cooling fluid level too low
Confirm leaking position and treat leakage source
Radiator inflatable fin clogged

Blow off scraps on fins
(restricted for cars only)
Insufficient of limited air flow through Check and repair fan wind scooper, shutters, fan
radiator sensor and fan clutch as required
Water pump or fan drive belt loose Check/calibrate belt tension
Radiator hose flat, clogged or leaks Check/replace hose
Engine oil level too high Check/discharge engine oil to correct oil level
Cooling fan wind scooper damaged or Check wind scooper, repair/replace or install wind
lost scooper
Replace radiator pressure cap with correct nominal
Radiator pressure cap fails or incorrect
pressure value
Discharge part of cooling fluid from cooling sys-
Freezing inhibitor density too high
tem, replace with water
Temperature sensor or thermometer
Confirm that thermometer and sensor are accurate
out of control
Thermostat fails, wrong or lost Check/replace thermostat
Cooling fluid tem-
Confirm injection speed does not exceed required
perature higher
range Exhaust installed thermostat properly
than normal tem- Air or fuel gas in cooling system
perature, gradu- If air bubbles continuously occur, check cylinder
ally overheated seal for leakage
Water pump fails Check/replace water pump
Radiator, cylinder cover, cylinder cover

sealing gasket or cylinder cooling cir- Flush cooling system and refill new coolant
cuit clogged
Contact vehicle manufacturer. Confirm fans, radia-
Vehicle cooling system design tor and other cooling system parts meet the stan-
dard
Fuel injection pump timing incorrect Confirm fuel injection pump timing is aligned
Fuel injection pump supply excessive Remove fuel injection pump for calibration
Cooling fluid level too low Refill cooling fluid
Temperature sensor or thermometer Confirm that thermometer and sensor are accu-
out of control rate, repair or replace if necessary
Fan drive belt loose Check belt tension
Radiator hose flat, clogged or leaks Check hose
Radiator cap fails or incorrect. Pres-

Check radiator pressure cap
sure cap nominal pressure too low

Thermostat incorrect or damaged Check thermostat
Radiator shutters are not opened en-

Check shutters, repair or replace if necessary
tirely or pressure cap is closed in cold
Open radiator pressure cap, check shutter thermo-
weather Shutter thermostat configured
stat configuration
incorrectly
Cooling fluid tem-
perature higher Air or fuel gas in cooling system Check cooling system for air or fuel gas
than normal tem-
perature, gradu- Engine and/or radiator non-windpipe
Check lines and exhaust system
ally overheated clogged or line incorrect
Water pump fails Check water pump operation. Replace water pump
Leakage between top tank and auxil- Check whether there is leakage between top tank
iary tank of radiator and auxiliary tank of radiator
Check/repair shutters, fan clutch and silicon oil

Excessive air flow through radiator
fan as required
Thermostat broken, damaged, contami-
Check/replace thermostat
Cooling fluid nated or poorly sealed
temperature
Temperature sensor or thermometer Confirm that temperature sensor or thermometer
lower than normal
fails is accurate
temperature
Coolant does not flow through tempera-

Check/clean cooling fluid passage
ture sensor

Visual check radiator, heater, hose and connecter,

and confirm leaking position
Radiator of driver’s cab radiator leaks
If there is engine oil in coolant, check gear box or
engine oil cooler for leakage
Visual check sealing gaskets of engine, gasket or

Oil leakage outside engine
drain plug
Overheat or compressed air leakage

will cause coolant to overflow through Check whether there is overheat or low power
radiator to drain
Check whether cooling fluid and gear box fluid are
Gear box cooler leaks (if installed)
Coolant loss mixed
Water-cooled compressor, compressor Check engine oil for coolant Check/replace com-
cap or cap gasket leaks pressor cap gasket
If engine is coolant intercooling, inter- Check/replace intercooler Check air intake mani-
cooler leaks fold or engine oil for coolant
Check/replace engine oil cooler Check engine oil

Engine oil cooler leaks
for coolant
Cylinder head gasket leaks Check/replace cylinder head gasket
Cylinder cracks or cavity Check/replace cylinder head
Cylinder coolant water jacket leaks Check/replace cylinder

Check/refill engine oil

Engine oil level low
Check whether there is serious outside engine oil
leakage that cause pressure reduction
Engine oil viscosity low Diluted or fails Confirm adequate engine oil is used. Check
to meet technical specification whether engine oil is diluted.
Pressure switch or manometer fails Confirm that pressure switch works normally
Engine oil pressure adjusting valve is

Check/replace valve
placed to OPEN position
Replace engine oil filter Review replacement inter-
Engine oil filter clogged
val
Engine oil cooler clogged Replace engine oil cooler
If engine oil cooler is replaced, tube

plug installed on cooler during transport Check/remove transport tube plug
is not removed
Engine oil pres-
Tube plug of cylinder or cylinder head
sure low Check/replace expansion plug
loose or lost
Fuel suction loosened or leakage of
Check/replace gasket.
broken gasket
Engine oil pump wears Check/replace engine oil pump
Main bearing cap loose Check/install new bearing, tighten bearing cap
Check/replace bearing, check replace piston cool-

Bearing wears
ing nozzle
Pressure switch or manometer fails Check whether pressure switch works normally
Engine oil too thick Ensure engine oil used is qualified

Pressure adjusting valve is placed to
Check/replace pressure adjusting valve
CLOSE position.
When replacing engine oil pump, six-
cylinder engine oil pump is installed Confirm that engine oil pump is installed correctly
onto four-cylinder engine
Outside leakage Visual check for oil leakage
Crankcase filled with excessive oil (level

Check whether level gauge calibration is correct
gauge calibrated incorrectly)
Confirm suitable engine oil is used.
Check whether viscosity is reduced due to fuel oil

Engine oil con-
dilution Engine oil dilution by fuel oil is due to fuel
sumption too high Engine oil disqualified
injection pump or delivery pump drive shaft sealing
ring
Check/reduce oil change
Engine oil is blown out of respiratory Check respiratory tube area for engine oil loss,
tube due to great downward gas leak- measure downward gas leakage and repair as
age required

Engine oil cooler leaks Check coolant for engine oil
Air compressor (if installed) engine oil

Check/replace air compressor
leak
Engine oil con- Turbocharger leaks oil into air intake or
Check air jumper tube for signs of oil leakage
sumption too high exhaust manifold
Valve sealing element wears Check/replace valve sealing element
Piston ring is not sealed-engine oil is

Check compression and repair as required.
burnt by engine
Drain and flush cooling system, fill correctly blend-

Coolant is not antirust, freezing inhibi- ed freezing inhibitor and water
tor and water blended incorrectly
Review freezing inhibitor replacement interval
Gear box engine oil cooler leaks (if

Check/replace engine oil cooler
equipped)
Review engine oil and filter replacement interval

Excessive oil sludge
Cooling fluid con- Confirm adequate engine oil is used
taminated
Check whether engine is running at lower-than-
There is fuel in engine oil, engine run-
normal temperature because of running at idle
ning temperature too low
speed too long
Fuel delivery pump seal leaks Check or replace Fuel delivery pump
Fuel injection pump seal leaks Remove fuel injection pump for repair
Fuel injection pump inner pile plug seal

Remove fuel injection pump for repair
leaks (in-line)
Fuel injector needle valve sealed poorly Find and replace the fuel injection pump that fails
Running for a long time under light load

Review vehicle usage situation with driver
or unloaded
Check whether idling is too long

Intake clogged
Check/replace fuel filter core
Fuel injector needle valve at OPEN

Exhaust mani- Find and replace the fuel injection pump that fails
position
fold leaks fuel or
Turbocharger engine oil return pipe
engine oil Check/clean oil pipe
clogged
Turbocharger sealing ring leaks engine
Check/replace turbocharger
oil
Check whether downward gas leakage is too
Too much downward gas leakage
much
Fuel injection pump timing incorrect Check/adjust fuel injection pump timing

Ethyl ether starting aids (if equipped)

Repair or replace ethyl ether starting aids
fail
Air in fuel system Discharge air in fuel system
Verify by using a provisional fuel tank containing

Compression Poor fuel quality high-quality fuel to run the engine. Clean and flush
knocks fuel feeding tank.
Engine overload Verify that engine nominal load is not exceeded
Fuel injection pump timing incorrect Check fuel injection pump timing
Fuel injector fails Replace fuel injector
Additional load caused by auxiliary

Check/repair auxiliary devices and vehicle parts
device failure
Check whether gear shift, deceleration and idling

Driver technique
operation are correct
Check whether there is outer leakage or engine oil
is diluted by fuel
Fuel leakage
Check fuel delivery pump and fuel injection pump
for inner leakage
Poor fuel quality or No.1 fuel is used Confirm No.2 fuel is used
Fuel oil consump-
tion too high Fuel Injector wears or fails Check/replace fuel injector
Injection pump timing incorrect Check/adjust fuel injection pump timing
Check adjustment sealing element on fuel injection

pump for damage If any sealing element is dam-
Fuel injection pump set incorrectly
aged, dismantle fuel injection pump and calibrate it
again.
Valve not in place Check/adjust valve
Power plant fails Check/repair power plant


Shut down engine by mechanical lever on fuel
Fuel cut-off valve does not function pump. Check whether magnetic valve works nor-
mally
Fuel injection pump fails Remove fuel injection pump for check/repair
Smoke inhaled into intake tube when Check air intake tube and determine gas
engine is running source position
Engine low idling too low Adjust engine idling rotation speed
Fan damages or auxiliary device fails Check/replace vibration parts
Fan hub fails Check/replace fan hub

Engine cannot
Charger bear wears or damaged Check/replace charger
slow down
Shock absorber fails (refer to six-cylin-
Check/replace shock absorber
der engine)
Engine counterweight timing incorrect
Align counterweight timing
(refer to four-cylinder engine)
Flywheel cover not aligned Check/calibrate flywheel timing
Check whether there is imbalance caused by dam-

Power parts loose or damages
age of crankshaft and connection rod
Engine seat loose or damages Check/replace engine seat
Check/repair according to requirements of the

Power train part wears or unbalanced
manufacturer
Check tension device and drive belt for damage
Ensure that water pump, tension, fan hub and
charger can rotate freely
Drive belt shrieks, tension insufficient
and abnormal high load Check belt for paint/engine oil or other material
Check accessory drive belt tension

Engine noise too Adjust valve, ensure that push rod is not bent, and
loud Valve gap too large
rocker arm is not seriously worn
Check whether turbocharger blade and turbine
Turbocharger noise
wheel touch the cover
Visual check and measure gear gap, replace gears
Gear train noise
as required
Power parts knock Check/replace connection rod and main bearing


Battery connection loose or corrosion Remove/fasten battery connection
Test battery load If battery is undercharged, test

Battery condition its load after charging. If it does not pass the load
test, replace battery
Charger is un-
charged or under- Charger belt slips Check/replace tension wheel
charged
Charger cam belt loose Repair/fasten belt
Charger conductor wears or damaged Repair conductor
Charger fails Replace charger

6.2 Electrical System Common Faults and Troubleshooting
Table 6-2
F10 open circuit Replace F10

Instrument
does not Corresponding sensor damages Replace corresponding sensor
function
Corresponding circuit open Check and repair circuit
Corresponding lamp damages Replace corresponding lamp

Lamp dam-
Corresponding switch damages Replace corresponding switch
ages
Corresponding circuit open Check and repair circuit
F1 open circuit Replace F1

System
has no Starting switch No.15 terminal wire connected
Connect corresponding terminal
response poorly
when start- Power relay coil connected poorly Connect wires well
ing switch
shifted to Power relay damages Replace power relay
position 1
Starting switch damages Replace starting switch
Starting switch No.17 lead wire connected
Connect corresponding terminal
poorly
Starting switch damages Replace starting switch
Hydraulic lever opened Close hydraulic lever
Motor does EPS control has output, K3 damages Replace K3

not func-
tion after EPS control damages Replace EPS control
starting
Starting motor damages Replace starting motor
Power relay damages Replace power relay
Battery short of electricity Replace battery
Power circuit loose Fasten wire terminal

Generator does not generate electricity Check generator and its circuit
Hydraulic lever does not touch travel switch Adjust travel switch position
Circuit connected poorly Check circuit

Engine
Pressure relay is not adjusted well or dam-
can-
aged (fails to raise speed automatically,
not raise Adjust or replace pressure relay
speed raising resumes normal after automatic
speed
idling is cancelled)
Alarming due to too high level of engine cool-
Check engine
ant
Middle-speed starting switch is placed at
Disconnect middle speed starting switch
closed position
Whether engine middle-speed movement If this switch is closed, adjust throttle

switch is closed button to ensure it does not raise speed
Engine Circuit connected poorly Check circuit

cannot
reduce Check adjustment throttle
Whether throttle mechanism movement is
speed Button stepping
normal
Electrical motor motion
Pressure relay not adjusted well or damaged Adjust or replace pressure relay

6.3 Hydraulic System Common Faults and Troubleshooting
Table 6-3
Hydraulic tank oil insufficient, main pump

Refill sufficient hydraulic oil
empty
Suction filter blocked Replace filters and clean system
Engine couplers damage (such as rubber disc,

Replace
spring disc)
Main pump damages Replace or repair main pump

Rotary drilling rig
undercarriage has Adjust to normal pressure, if it
no action fails to apply pressure to servo
Servo system pressure too low or no pressure relief valve, open and clean. If
spring fatigue occurs, add wash-
er or replace
Adjust to normal pressure, if it

Safety valve nominal pressure too low or fails to apply pressure, open and
jammed clean. If spring fatigue occurs,
add washer or replace
Main pump suction pipe breaks or drops off Replace new pipes
Main pump feeding oil to unilateral track dam-

Replace
ages
Track rail broken Connect
Travel pilot valve damages, travel servo pres-

Replace
sure too low
Unilateral track on
Main valve rod jammed, spring broken Repair or replace
one side does not
travel Travel motor damages Replace
Travel reducer damages Replace
Slewing connecter upper and lower cavities Replace oil seal or clean assem-
connected bly
Travel oil pipe breaks Replace

Hydraulic oil tank oil level insufficient Refill sufficient hydraulic oil
Engine speed low Adjust engine speed
Service system pressure too low Adjust to required pressure
System safety valve pressure too low Adjust to required pressure
Main pump oil supply insufficient, volume Adjust main pump variation point
changes in advance control bolt
Main pump inner leakage serious, ball sur-

Replace main pump or clean
face between oil distribution disc and cylinder
and replace filter core regularly
wears seriously, pressing force insufficient,
as required by maintenance
there is wearing between plunger and cylinder,
routine
leading to inner leakage
Travel motor, swing motor and oil cylinder
Rotary drilling rig have some degree of wearing, leading to inner Replace or repair wear parts
undercarriage leakage
motion lack of
strength
Rotary drilling rig operation lacks strength Replace hydraulic oil, replace
under carriage s temperature rises, because whole vehicle sealing elements,
sealing elements is aging, hydraulic parts readjust gap and pressure be-
wears gradually and hydraulic oil deteriorates tween hydraulic parts
Engine filters blocked, loading speed is re-

Replace filter core
duced highly, switch off when serious
Hydraulic oil filter clogging increase pump,

Replace filter core regularly as
motor and valve wearing, leads to inner leak-
required by maintenance routine
age
Gap between main valve rod and valve hole
wears seriously, leading to serious inner leak- Repair valve rod
age

Replace oil seal, replace dam-

Central swing connecter damage
aged parts if groove is damaged
Travel control valve high pressure cavity and

Replace
low pressure cavity linked by striking
No action when
Travel control valve serious inner leakage
traveling leftwards Replace
,leading to travel servo pressure too low
or rightwards
(normal in other In main valve, travel valve overload pressure
Adjust and grind
aspects) too low, or valve rod jammed
Leftward/rightward travel reducer fails Repair
Leftward/rightward travel motor fails Repair
Oil pipe breaks Replace

Too large difference between flows of two
Adjust
pumps
Error in main pump variation point adjustment
Adjust or repair
or one pump inner leakage too large
In main pump, one travel valve core inner or
Replace
outer spring damaged or stuck
Off-track when Travel motor wears and produces inner leak-
Repair or replace
traveling (normal age
in other aspects) Central swing connecter sealing elements
Replace seal elements
damage
Difference of tension on left and right tracks Adjust
Vehicle jamming occurs to travel braker Adjust
Pilot valve inner leakage or damages Replace

Pilot valve handle pressure plate crush too
Adjust
much
Movement of
Pilot valve core jamming Replace
travel mechanism
when not in op- Main valve rod jamming or valve rod spring
eration Repair
broken
Travel brake is not locked when drilling Adjust


Grade hydraulic oil required for rotary drilling
Replace hydraulic oil
rig is not used properly
Too much oil stains and mud on hydraulic oil
Clean
cooler surface, vent blocked
Adjustment belt tension or re-
Engine fan belt slips or breaks
place
Hydraulic oil tank oil level too low Refill sufficient hydraulic oil
Hydraulic oil tem- Hydraulic oil contamination make hydraulic

perature too high components such as motor, main valve and
cylinder wearing accelerate to cause inner
leakage. Oil temperature rises, travel, swing Replace all types of valve cores
and work device lack of strength. High oil tem- in time
perature will lead to hydraulic oil deterioration,
poorly sealed safety valve sealing and relief
loss.
Radiator protection oil line one-way valve Replace with spring or add
overflow pressure low spacer
Hydraulic oil pipe breaks Replace

Servo valve inner leakage, valve rod jammed
Repair or replace
or damaged
Main valve swing valve rod jammed Repair
No swing motion
(normal in other Swing motor damages Repair or replace
motions)
Swing brake not opened Adjust
Repair and replace damaged

Swing reducer inner damages
gears
Swing bearing damages Replace

Servo valve inner leakage too much Replace

Multiport valve swing overload pressure un-
Uneven speeds Adjust
even
of left and right
swing Multiport valve swing rod jammed slightly Grind
Swing hand-type brake Adjust

Replace pipes and seal ele-
Hydraulic oil pipe outward leakage serious
ments
Servo inner leakage large, pressure lower
Replace
than nominal value
Multiport valve swing overload pressure low Adjust
Swing lack of
strength (normal Swing brake jammed Adjust
in other motions)
Swing motor inner leakage serious Repair or replace
Multiport valve high pressure cavity and low
pressure cavity linked by striking. Valve has
casting cracks, leading to linkage of motions Replace
of unilateral direction or linkage of several mo-
tions
Pilot valve handle pressure plate crush too
Swing operation Adjust
much
of swing mecha-
nism when it is Pilot valve core jamming Repair
not in operation
Main valve rod spring broken Replace

Hydraulic oil tank oil insufficient Refill oil
Too much water or air in oil fluid Replace

Main pump plunger breaks, causing vibration
Replace
and noise
Safety valve of Multiport valve gives out
Adjust
sounds
Couplers damages Replace
Abnormal sounds
or vibration when Reducer gear damages Replace
rotary drilling rig
Cooler fan blade collides with wind scooper Adjust
undercarriage is
working Hard tube clamp vibration after being loos-
Adjust
ened
Filter clogged Replace
There is air in suction pipe Exhaust
Engine speed uneven Adjust
Work device bearing not lubricated or dam- Add lubricant or replace shaft or
aged casing
Seal damages Replace seal elements
Cylinder lack of Oil leaks because piston rod is pulled out of

Brush plate, spray, repair or
strength, oil leak- groove or piston rod chromium coating drops
replace
age off locally
Cylinder generates vibration and noise be-
Exhaust
cause there is air inside the cylinder
Engine speed too low Adjust to normal speed
Replace
Main pump fails
Oil pump system Replace Refill oil

fails to feed oil or
insufficient oil Oil tank oil insufficient Refill oil
Pilot valve insufficient pressure Adjust

Oil pipe broken, oil pipe connector loose, O
Replace
ring damage

6.4 Troubleshooting of Work Unit
Table 6-4
Fault Analysis Troubleshooting Deciding method
Too large gap between Slip automatically after shut-
Replace
friction plates down
Insufficient oil feeding Check feeding
Kelly bar lowers Measure through manometer
pipe pressure
down after shut-
down Float magnetic valve fails Pull out electrical appliance
Clean or replace
to return to middle posi- plug, and operate float magnetic
valve core
tion due to jamming valve manually
Measure main
Main winch pressure Measure by meter and record
winch pressure
value variation accurate number
value
Retain hydrau-
lic radiator to Watch instrument temperature
Outer temperature too let temperature at first. Using a thermometer to
low, hydraulic oil too thick remain three measure hydraulic oil tempera-
markers. Reduce ture is also allowed
viscosity
Use filter with
Sudden dropdown high accuracy to
during normal low- Hydraulic oil cleanness filter hydraulic oil Test by Rexroth cleanness de-
ering too low or replace new tecting instrument
hydraulic oil, and
replace filter core
Oil feeding pipe
is ideally in-
Oil feeding pipe position
stalled motor S Eye survey
improper
port rather than
BVD brake
Pull out electrical appliance
Clean or replace
Magnetic valve jammed plug, and operate float magnetic
valve core
valve manually
Braking cylinder oil seal Open reducer gear oil plug.

Sometimes Kelly Replace
damage Gear oil too thin
bar slips when it is
dumping soil Main winch oil feeding Connect oil feed-
insufficient ing pipe


Remove and
Motor relief valve jammed,
clean motor relief It is B port relief valve if constant
valve core cannot return
valve, then reas- displacement motor is lifted
to its original position
semble it
Friction plate in main
Replace friction
Dropdown when winch reducer wears seri- Check gear oil for metal scrap
plate
main winch is ously
lowering Kelly bar Magnetic valve fails to Clean or replace
return middle position magnetic valve
Main winch motor balanc- Replace bal-
ing valve core wears seri- ancing valve or
ously, leading to sudden motor if worn
stalling and dropdown seriously
Remove and
Motor relief valve jammed,
clean motor relief It is A port relief valve if constant
valve core cannot return
valve, then reas- displacement motor is lowered
to its original position
Main winch is only semble it
able to lower Kelly Measure main
bar winch lifting
Motor relief valve pres-
pressure, read-
sure adjusted too low
just if it does not
meet standard
Reducer friction plate fails Replace
Open reducer
Reducer gear bearing
box to replace
fails
damaged parts
Replace or repair
Main winch can Motor fails
motor
neither lift nor
lower Kelly bar Check spring
BVD braker fails and valve core in
relief valve
Check whether
Braking pressure low, fric- pressure is nor-
tion plate fails to open mal when main
winch fails to lift
Floating magnetic valve Pull out plug. Operate magnetic
Clean or replace
jammed valve manually
Circuit fails reconnect Measure through multimeter
Main winch no
floating Main winch no action, relief
Friction plate sintering Replace
valve overflows
Clean handle
Handle button fails Measure through multimeter
button


Reducer friction plate Replace friction Remove motor, visual check
sintering plate friction plate
Open reducer box to replace

Reducer gear damages Replace
damaged parts
Main winch main
oil pipe pressure Braking cylinder oil seal
Replace
normal, but can- damage
not move
Remove, check Measure brake pipe pressures
BVD braker fails
and clean when lifting and lowering
Main winch motor dam-

Replace motor Open for check.
ages
Measure mast verticality by the-

Level sensor damages Replace
odolite
Mast hydraulic lock dam-

Replace
Mast not vertical ages
Mast hydraulic cylinder Replace cylinder
damages or inner leakage seal elements
Inclination sensor plat-
Adjust platform
form error
Replace hinge
Oil cylinder big cavity
bolts with tech-
hinge bolt damper holes
nologic holes of
are of different sizes
Mast lifting out of same size
phase
Balancing valve fails Replace
Replace cylinder
Oil cylinder inner leakage Refer to (1-1)
seal elements


It has not been used
for a long time without Remove for
check Replace
anti-trust treatment. Now damaged parts
rusted.
Because sealing is dam-
Remove for
aged, mud enters swing
check Replace
swivel and damages
damaged parts
bearing
Insulate with wa-
Due to construction in ter and heat to
winter, grease is frozen 60 to squeeze
out grease
Remove for
Nut fastening bolt in
check Replace
Swing swivel fails swing swivel drops
damaged parts
to rotate or rotate
freely Remove for
Swing swivel installed
check Replace
firmly
damaged parts
Inner oil seal wears, shaft Remove for
at oil seal takes on sink check Replace
mark, bearing wears damaged parts
Improper method of feed-
ing grease into swing Remove for
swivel, squeezing grease check Replace
into it, leads to oil seal damaged parts
damaged
Swing swivel shaft sleeve
Remove for
wears too seriously, caus-
check Replace
ing sand and mud in to
damaged parts
damage bearing


Engine gives
out abnormal
Insufficient engine power sounds, black Check instrument
smoke and loses
speed control
Check sequence
Hydraulic oil line fails valve oil line,
main oil pipe
Readjust se-
Sequence valve fails Rotary drive lacks strength
quence valve
when drilling, no sharp speedup
Check reducer when throwing soil at a high
Fold-shape spring fails fold-shape speed
spring
Insufficient rotary Relief valve on oil feeding Readjust relief

drive torque valve releases pressure valve pressure
Main oil pipe pressure
insufficient when it does Readjust pres-
not flow through oil feed- sure
ing valve relief valve
Check reducer
Fold-shape spring fails fold-shape
spring
Relief valve on oil feeding Readjust relief

valve releases pressure valve pressure
Main oil pipe pressure

insufficient when it does Readjust pres-
not flow through oil feed- sure
ing valve relief valve
Repair end cap,
Cavitations damages end
Motor end cap oil replace O ring
cap, leading to damages
leakage and add oil feed-
of O-ring
ing device
Round-sky-square-earth
framework oil seal dam- Replace
Round-sky- ages
square-earth point Kelly bar straps, knocks
oil leakage on rotary drive
Replace bolts and install cushion
Loose caused by vibra-
tion in operation


Reducer friction plate
Replace
wears
Rotary drive shaft or Replace dam-
Rotary drive fails to rotate
Rotary drive re- bearing damage aged parts
ducer gives out Check lubricant
sounds Reducer overheat level and reducer
lower oil seal
Gear oil insufficient Install gear oil
Magnetic valve circuit
Reconnect
broken
Rotary drive high-
speed reverse Shaft seal damages Replace
rotation no action
Reducer friction plate Open and re-
sintering place
Oil tank oil flush Motor oil seal damage Replace
Open power
It can be seen Large gear ring and cas- control box to re-
from oil window ing bolt sheared place damaged
that large gear bolts
ring rotates but Open power
Kelly bar fails to Bolts connecting cas-
control box to re-
rotate ing and swing bearing
place damaged
sheared
bolts
Fill grease and
Wearing after long time of
tension oil cylin- Target track shoe
operation
der
Track too loose
Open tension
Track tension oil cylinder
oil cylinder and
seal damage
replace oil seal
Friction plate burnt Replace
Reducer gear damages Replace
Track fails to Braking cylinder X type

Replace
travel seal damage
Main valve jammed Clean or replace
Motor balancing valve
Clean or replace
jammed
Swing swivel fails to ro- Check/repair
Wire strand loose
tate freely swing swivel
Wire rope wears seriously Replace Wire strand broken
Wire rope broken
Check/repair
Rope guide roller wheel
or replace rope Eye survey
does not rotate
guide roller

Wire loose Check
Handle button fails Check or replace

Electrical appliance mod-
Replace
ule fails
Check Pilot oil
Pilot oil pipe and pilot
pipe and pilot
magnetic valve
Swing fails magnetic valve
Check whether
Reducer braking circuit
braking circuit is
fails
normal
Reducer friction plate sin- Replace friction

tering, swing motor fails plate
Fill new lubri-

Lubricating grease filled cating grease Abnormal sound. Sound of dry
Swing bearing
spoils to squeeze out friction
gives out abnor-
spoiled grease
mal sound
Bearing damages Replace Periodical abnormal sound
Balancing valve damages Replace, clean
Feeding no action, or valve core jammed valve core
has pressure
M4 valve core jammed Clean


Oil cylinder piston rod Replace piston
Oil feeding cylin- seal damage rod seal
der falls automati-
cally Balancing valve damages Replace balanc-
and cannot be locked ing valve
Check pilot
Pilot pump damages
pump
Connecting disc between

engine and pump fails Open for check
Check whether
Check diesel filter core three filters are
and water separator maintained in
time
Engine output power Check engine
Whole vehicle lack insufficient and there filters
strength Check main/
Main pump pressure auxiliary pumps
insufficient for damage or
leakage
Hydraulic filter core Replace filter
clogged core
Replace hydrau-
Hydraulic oil deteriorated
lic oil
Replace or ad-
Adjustment valve or relief
just relief valve
valve damage
pressure
Check engine air filter
Check engine
Check main valve pres- Test main valve

sure pressure
Check whether
Monitor blank main pump is
screen Check main pump running
Hydraulic oil tank oil level Check hydraulic

insufficient oil level
Monitor fails Replace monitor


Check control
Control unit circuit fails
circuit
Check power
Power supply circuit fails
supply circuit
Button or potentiometer Replace potenti-

on top of handle damages ometer
Replace limit
Oil cylinder no Mast limit switch and sen-
switch and sen-
action when oper- sor damage
sor
ating mast adjust-
ment handle Circuit loose or connected Connect circuit
poorly properly
Control unit parameter Oil cylinder balancing valve
Reset parameter
configured incorrectly jammed
Replace mag-
Magnetic valve damage Clean or replace
netic valve
Check limit
Limit switch alarms
switch for return
Handle calibration is ab- Check handle

M4 valve jammed
normal calibration data
Drilling rig mast Mast lifting effectiveness
has no action Check switch or Oil cylinder balancing valve
switch or mast lifting
handle jammed
handle fails
Circuit or control unit fails Check circuit
Check proportion
Proportion Valve fails
valve
Check relief
Relief valve overflows
valve
Engine power insufficient Check engine
Rotary drive feed- Check manometer reading and
or auxiliary pump pres- and auxiliary
ing lacks strength, engine speed
sure low pump
slow, and has no
action Whether pilot pressure is Check pilot oil
normal pressure
M4 valve jammed or not

opened entirely
Oil cylinder inner leakage Replace cylinder

or damages or seal


Right handle and pilot Check handle
control oil pipe fail and pilot oil pipe
Auxiliary valve core
jammed, cannot be Check valve core
opened entirely
Oil feeding cylinder bal- Adjust overflow
ancing valve overflow pressure to a
pressure low higher level
Check oil cyl-
Oil cylinder inner leakage inder, replace
sealed package
Rotary drive oil feeding
valve pressure too low, Check pressure
pilot pressure insufficient
Open filter core
Main valve rotary drive
check whether
Rotary drive idling control valve relief valve
there is any
has actions and pressure too low or
object jamming
load carrying has jammed
valve
no action
Dismantle motor
Idling pressure, it is normal if
Rotary drive motor inner to check whether
pressure can be increased to
leakage or damages output shafts are
above 20Mpa
rotating
Dismantle re-
ducer. Open it to
check for dam-
ages. Check
Rotary drive reducer fails whether three
grades of reduc-
tion gears are
worn and dam-
aged
Dismantle rotary
Rotary drive large gear
drive reduction
box drive bearing fasten-
gear box for
ing bolt broken
check


Check magnetic valve Open and clean
core valve core
BVD braker, check relief Check spring in
valve relief valve
Check friction
Remove motor, visual
plate wearing
Main winch has check friction plate
condition
no action
Remove motor, check Check whether
rotation and pressure motor has action
Check feeding valve pres- Adjust feeding
sure pressure
Whether motor reducer is
Replace
damaged
Dismantle depth
sounding con-
Check depth sounding necting shaft,
encoder drive device or bearing, small
access switch contact wheel, belt, catch
point plate. Check
whether they are
normal
Remove en-
coder, rotate
Check whether encoder
it manually to
or access switch works
check whether
normally
depth sounding
Depth sounding is is displayed
not displayed or
Check whether circuit is
displayed inaccu-
connected properly, check Check circuit
rately
for scratch marks
Check depth
Check power supply sounding 24V
circuit, input and output red power supply
signal wire wire is with elec-
tricity, two wires
Check monitor
depth sound-
Check monitor parameter ing calibration,
configuration nominal check whether
value compensation is
normal. If abnor-
mal reset it
Rope guide roller is not
Main winch rope Maintain in time
maintained in time
guide roller fails to
rotate Rope guide roller lacks
Refill lubricant
lubricant

Check elbow for cracks Replace elbow
Main valve oil pipe Check main valve for

Replace valve
flange leaks oil cracking
Replace flange to check
Replace O ring
O ring
Replace a pair
of batteries with
Battery short of electricity
full charge and
Drilling rig motor restart
fails to start up Do not start up
Start up with load
with load
Motor main circuit con-
Check circuit
tacted poorly
O ring damage Replace O ring
Replace electro-
Electro-hydraulic propor-
M4 valve leaks oil hydraulic propor-
tion valve damage
tion valve
Oil pipe breaks Replace oil pipes
Pilot switch not open or Check pilot
damaged switch
Main pump damaged or Check main
Engine runs nor- does not function pump pressure
mally, but whole
vehicle has no Check coupler
Engine torque does not
action that connects en-
transfer to pump
gine and pump
Replace control
Control unit damages
unit

6.5 Air Conditioning System Common Faults and Troubleshooting
Table 6-5
Electrical or plug-in contacted poorly
Fan switch, relay or temperature detect

Fan does not rotate Repair or replace
switch damaged
Fuse broken or battery voltage too low
There are obstacles air intake side
Fans run normally, but air Fins of evaporator or condenser clogged,

Clean
volume is small heat transfer not ideal
One of blowers jammed or damaged
Compressor clutch no attracting due to

circuit disconnection or poor contact
Repair
Compressor belt tension insufficient, belt
too loose
Compressor does not run
or have trouble running
Compressor clutch coil broken and fails
Replace clutch coil
to function
Reservoir high and low pressure switches Cool medium too low or too
function high
Refrigerant leaks Remedy leakage point

Refrigerant insufficient
Refrigerant refilled too few Refill adequate refrigerant
Readings of high and low

When ambient temperature is 30 ～ 500c, high pressure gauge reads as 1.47
pressure gauge under
to 1.67MPa while low pressure gauge reads as 0.13 to 0.20MPa
normal working condition
Expansion opened too widely Replace expansion valve

Pressure under low pres-
sure is relatively high and Replace expansion valve thermo-bulb
Install thermo-bulb properly
low pressure tube sur- contacted poorly
face has frost
Remove part of it to meet
Refrigerant volume in system too high
required volume


High and
low pres-
sure gauges Refill refrigerant to required
Refrigerant insufficient
are smaller volume
than normal
value
Low pres-
sure gauge
Low pressure rubber tube clogged, ex- Repair system, if clogged by
some reads
pansion valve clogged by ice or dirt ice, replace reservoir
as negative
pressure
Low Evaporator
Thermostat fails Replace thermostat
pressure frozen
too small
Expansion
valve inlet Clean or replace thermostat
Expansion valve clogged
side is cold valve
with frost
Expansion
valve outlet
side is not
cold, low Expansion valve sensitive heating pipe or
Replace expansion valve
pressure thermo-bulb has air leakage
sometimes
is negative
pressure
Pressure in Exhaust to vacuum, refill re-
Air mixed into circulation system
high pres- frigerant
sure gauge
is relatively
high and
High pressure in Discharge adequate refriger-
low pres- Refrigerant refilled too much
pressure ant
gauge sure gauge
pressure is relatively
too large high
Condenser
clogged by Clean condenser, remove
dust, con- Poor condensing effect of condenser clogging. Check and replace
denser fan condenser fan
damaged

Clean and refill refrigerant as

Pressures Refrigerant insufficient
required
High under high
pressure and low
Remove or replace failed
gauge pressure are Low pressure pipe clogged or damaged
parts
pressure relatively
too low low, com-
Compressor inner failure, compressor
pressor fails Replace compressor
and high pressure pipe overheated
Heater
Cold air is
valve not
offset by
closed,
warm air,
heater Replace heater magnetic
produc- Close heater magnetic valve
valve is valve
ing a poor
damaged
refrigerating
and fails
effect
to close

6.6 SR150C/SR200C ( SY) Wear Parts List
Table 6-6 2000 hour wear parts list

SN Code Backup name Code name Unit qty Remarks
CATERPILLAR MAIN ENGINE PORTION
Under carriage grease

1 10195293 B.SR150.01A Piece 1 User shall buy from SANY
nozzle connector
2 23000465 Rough air filter 142-1339 Piece 1 Bought locally by user
3 23000466 Fine air filter 142-1404 Piece 1 Bought locally by user
4 Diesel filer core IR0762 Piece 1 Bought locally by user
5 23000478 Water separator IR0770 Piece 1 Bought locally by user
6 23000476 Engine oil filer core IR0716 Piece 1 Bought locally by user
Main oil tank return filter

7 23000468 173-3511 piece 1 Bought locally by user
core
Main oil tank suction

8 23000467 158-9107 piece 1 Bought locally by user
filter core
9 23990650 Rough pilot filter 126-1813 piece 1 Bought locally by user
10 23000464 Fine pilot filter 126-2075 piece 1 Bought locally by user
STRUCTURE PORTION
11 10004554 Rotary drive long slider SR150.5.3.1-1 Piece 8

12 in total(for drilling hole)
12 10004558 Rotary drive short slider SR150.5.3.1-9 Piece 4
13 10004525 Kelly guide slider SR150.5.2-01 set 1 6 in toil(for drilling hole)
Rotary drive bumper

14 10004590 SR150.5.3.2-2 Piece 5
spring
connect rotary drive and

15 10004675 oil cylinder pin shaft SR150.5.3-04 Piece 1
feeding cylinder
16 23000472 oil seal 70×90×7/5.5 piece 1 for rotary drive motor
17 23000471 oil seal 60×85×10 piece 1 For Braving reducer
18 23002290 Inner hexagon screw M8×25 GB70.1 piece 50
for round-sky-square-
19 A210204000035 Inner hexagon screw M14×45 GB70.1 piece 12
earth
HYDRAULIC PORTION
Auxiliary hydraulic tank

20 23000474 FAX-400×10 piece 1
oil return filter core

Lubricating tank suction

21 23003517 WFC-8B×100 piece 1
filter core
22 21011012 O sealing ring 71×3.55 piece 2
23 A210609000171 O sealing ring 47.5×3.55 piece 2
26 A210608000060 O sealing ring 32×3.1 piece 2
33 23000469 O sealing ring 3.5×1.5 piece 3
34 A210434000013 Combined gasket 27 JB/T982 piece 2
ELECTRICAL PORTION
Over-wind protection
37 23000306 GJ-1 piece 1 Substitute FD676
switch
38 23000479 Switch power SD-350B-24 Piece 1
KELLY BAR PORTION
39 10005462 Kelly bar spring ZG20J414A-3A Piece 1
40 10005468 Spring seat（ T y p e Ⅱ ） ZG22J413.6C Piece 1 for DZG22J413 Kelly bar
41 10064144 Spring seat DZG22J313.6 Piece 1 for DZG22J313 Kelly bar
connect Kelly bar and

42 10005558 Pin shaft ZG22M513.7 Piece 1
drilling tool

Table 6-7 4000 hour wear parts list

CATERPILLAR MAIN ENGINE PORTION
Bought locally by
1 23000465 Rough air filter 142-1339 Piece 1
user
Bought locally by
2 23000466 Fine air filter 142-1404 Piece 1
user
Bought locally by
3 Diesel filer core IR0762 Piece 1
user
Bought locally by
4 23000478 Water separator IR0770 Piece 1
user
Bought locally by
5 23000476 Engine oil filer core IR0716 Piece 1
user
Main oil tank return filter Bought locally by

6 23000468 173-3511 piece 1
core user
Main oil tank suction filter Bought locally by
7 23000467 158-9107 piece 1
core user
Bought locally by
8 23990650 Rough pilot filter 126-1813 piece 1
user
Bought locally by
9 23000464 Fine pilot filter 126-2075 piece 1
user
STRUCTURE PART
for Pin
10 10004503 swing swivel assembly SR150.5.1 set 2 shaft, heavy
thimble
11 10004554 Rotary drive long slider SR150.5.3.1-1 Piece 8

12in total( for
drilling hole)
12 10004558 Rotary drive short slider SR150.5.3.1-9 Piece 4
6 in total(for drill-
13 10004525 Kelly guide slider SR150.5.2-01 set 1
ing hole)
for
2piece(bearing
14 10003963 Big pulley HL28G Piece 4
6319Z, bushing)/
Piece
Rotary drive bumper

15 10004590 SR150.5.3.2-2 Piece 10
spring
connect rotary
16 10004675 oil cylinder pin shaft SR150.5.3-04 Piece 2 drive and feed-
ing cylinder
for rotary drive

17 23000472 oil seal 70×90×7/5.5 piece 2
motor


For Braving
18 23000471 oil seal 60×85×10 piece 4
reducer
for round-sky-
19 A880380010344 Fish paper 0.3-0.5mm 1
square-earth
HYDRAULIC PORTION
for rotary drive

20 Braving reducer input shaft B.SR150.05 Piece 2
reducer
for feeding cylin-

21 23000002 Balancing valve 0835626572350006A piece 2
der
derricking/mast
22 23003501 Balancing valve 08441103033500A piece 2
cylinder
23 23000018 Magnetic valve 4WE6D6X/EG24N9K4 piece 2
Auxiliary hydraulic tank oil

24 23000474 FAX-400×10 piece 2
return filter core
Lubricating tank suction

25 23003517 WFC-8B×100 piece 2
filter core
37 23000469 O sealing ring 3.5×1.5 piece 5

41 B210780000174 connector GE08LMEDOMDA3C piece 2
42 B210780000176 connector GE08LREDOMDA3C piece 2
43 B210780001168 connector GE08SMEDOMDA3C piece 2
44 23000264 connector GE08L9/16UNFOMDA3C piece 2
45 B210780000184 connector GE18LR3/4EDOMDA3C piece 1
46 B210780000421 connector GE22LREDOMDA3C piece 1
ELECTRICAL APPLIANCE PORTION
Substitute
47 23000196 Limit switch HL-5030 piece 3
2145M12
Over-wind protection
48 23000306 GJ-1 piece 1 Substitute FD676
switch
49 23000479 Switch power SD-350B-24 Piece 1
KELLY BAR PORTION
50 10005462 Kelly bar spring ZG20J414A-3A Piece 2
for DZG22
51 10005468 Spring seat（ T y p e Ⅱ ） ZG22J413.6C Piece 2
J413Kelly bar
52 10064144 Spring seat DZG22J313.6 Piece 2
connect Kelly bar

53 10005558 Pin shaft ZG22M513.7 Piece 2
and drilling tool

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SR200C(SY) Rotary Drilling Rig Specifications
Specifications
7 Specifications
7.1 Dimension Diagram................................................................................................... 7-3
7.2 Overall Dimensions................................................................................................... 7-4

Specifications SR200C(SY) Rotary Drilling Rig
WARNING

7 SPECIFICATIONS
7.1 Dimension Giagram
Fig.7-30 SR200C(SY) Overall Dimension Diagram(mm)

7.2 Overall Dimensions
Performance parameters
1. Drilling unit
Table 7-1 Performance parameters of drilling unit
ITEM DATA
Max. Output Torque 200 KN•m
Max. Drilling Diameter 1800 mm
Max. Drilling Depth 58 m
Drilling Center Distance
(Distance from slewing 3727 - 5507 mm
center)
Max. Pull 160 kN
Max. Push 150 kN
Operating Weight (with

60 ton
standard Kelly bar)
2. Chassis
Table 7-2 Performance parameters of chassis
ITEM DATA
Chassis Model SY310RC
Engine Model AA-6HK1XQP
Engine Power 193.5 kW
Traction Power 360 kN
Max. Pressure of Hy-
34.3 MPa
draulic System
Hydraulic Pilot System
4 MPa
Pressure
Track Length 5487 mm
Track Width 3000 ～ 4000 mm
Track Shoe Width 700 mm

3. Rotary drive
Table 7-3 Performance parameters of rotary drive
ITEM DATA
Max. Output Torque 200 kN·m
Drilling Rev. 7 ～ 26 rpm
4. Main winch
Table 7-4 Performance parameters of main winch
ITEM DATA
Pulling Force (first
200 kN
layer)
Wire Rope Diameter 28 mm
Wire Rope Length 90 m
Pulling Speed 72 m/min
5. Auxiliary winch
Table 7-5 Performance parameters of auxiliary winch
ITEM DATA
Pulling Force (first
76 kN
layer)
Wire Rope Diameter 20 mm
Wire Rope Length 65 m
Pulling Speed 79 m/min
6. Crowd cylinder
Table 7-6 Performance parameters of crowd cylinder
ITEM DATA
Crowding Force 150 kN
Stroke of Crowd Sys-
4300 mm
tem

7. Mast rake 2. Auxiliary winch wire rope

Table 7-7 Performance parameters of mast rake Table 7-9 Auxiliary winch wire rope
ITEM DATA ITEM DATA

Left Rake 4° / 5° Standard
65 m
Right Rake 4° / 5° Length
Forward Rake 5° Nominal Diam-
20 mm
eter
Diameter Allow-
+0% ~ +5%
able Error
Wire rope specifications
Nominal Tensile
1770 MPa
1. Main winch wire rope Strength
Min. Breaking
Table 7-8 Main winch wire rope 252 kN
Force
ITEM DATA Surface Condi-
Ungalvanized
tion
Standard Length 90 m
Structure Clas- Non rotation resistant--
Nominal Diam- sification 6×29Fi
28 mm
eter
Rope Core Steel wire rope core--IWR
Diameter Allow-
+2% ~ +4% Lay Direction Right hand lay--ZS
able Error
Nominal Tensile Weight 1.67 kg/m
1770 MPa
Strength Operative Norm GB8918
Min. Breaking
569 kN
Force
Surface Condi- NOTICE
Ungalvanized
tion
Structure Clas- Non rotation resistant-- ●● The main rope length is only suitable for
sification 6×K36WS the Kelly bar of standard configuration.
Rope Core Steel wire rope core--IWR ●● When you have to change the main rope,
Lay Direction Right hand lay--ZS auxiliary rope or the crowd rope, ensure
Weight 3.74 kg/m that the rope model must be the Sany
Operative Norm GB8918 designated one. Failure to do so, Sany
will bear no liability for any consequence
caused by rope accident.

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SR150C&SR200C(SY) R otary Dril ling Rig Appe n d i x
Appendix
Appendix
Bolt Tightening Torque..................................................................................................... 8-3
Common Misoperation.................................................................................................... 8-5

Appendix SR150C&SR200C(SY) R otary Drilling Rig
WARNING
Always read, u n d e r s t a n d a n d f o l-
low the Safety s e c t i o n b e f o r e a n d
during operat i o n o r m a i n t e n a n c e o f
this equipmen t . F a i l u r e t o d o t h i s
could result i n m a c h i n e d a m a g e ,
personnel inju r y o r e v e n d e a t h .

SR150C&SR200C(SY) R otary Drilling Rig Appe n d i x
APPENDIX
bolt tight ening torque
Thread connection tightening torque(JG/T 5011.11-92) Unit: N·m
Performance Rating 4.6 4.8 5.8 6.8 8.8 10.8 12.9
Proof Stress MPa 230 310 380 440 600 830 970
M6 4-5 5-6 7-8 8-9 10-12 14-17 17-20
M8 10-11 13-15 16-18 18-22 25-30 34-41 41-48

M8×1 10-12 14-17 17-20 20-23 27-32 37-43 43-52
M10 19-23 26-31 31-36 36-43 49-59 68-81 81-96
M10×1 21-25 28-34 35-41 41-48 55-66 76-90 90-106
M12 33-39 45-53 55-64 64-76 86-103 119-141 141-167
M12×1.5 35-41 47-56 57-67 67-79 90-108 124-147 147-174
M14 53-63 71-85 87-103 103-120 137-164 189-224 224-265

Speci-
M14×1.5 57-68 77-92 94-110 110-131 149-179 206-243 243-289
fica-
tion of M16 82-98 111-132 136-160 160-188 214-256 295-350 350-414
Thread M16×1.5 87-104 118-141 144-170 170-200 228-273 314-372 372-441
M18 113-135 152-182 186-219 219-259 294-353 406-481 481-570
M18×1.5 127-152 171-205 210-247 247-291 331-397 457-541 541-641
M20 160-192 216-258 264-312 312-366 417-500 576-683 683-808
M20×1.5 178-213 239-287 294-345 345-407 463-555 640-758 758-897
M22 218-261 293-351 360-431 416-499 568-680 786-941 918-1099
1009-
M22×1.5 239-286 322-386 395-473 458-548 624-747 863-1034
1208
1167-
M24 277-331 373-446 457-547 529-634 722-864 998-1195
1397
1086- 1269-
M24×2 301-360 406-486 497-595 576-589 785-940
1300 1520
1056- 1461- 1707-
M27 405-485 546-653 669-801 774-801
1264 1749 2044
Performance Rating 4.6 4.8 5.8 6.8 8.8 10.8 12.9

Proof Stress MPa 230 310 380 440 600 830 970
Speci- 837- 1141- 1578- 1845-

fica- M27×2 437-524 589-706 723-865
1002 1366 1890 2208
tion of
Thread 908- 1052- 1434- 1984- 2318-
M30 550-658 741-887
1087 1259 1717 2375 2775
1005- 1164- 1587- 2196- 2566-
M30×2 608-728 820-982
1203 1393 1900 2629 3072
961- 1295- 1587- 1838- 2506- 3466- 4051-
M36
1150 1550 1900 2200 3000 4150 4850
1017- 1371- 1680- 1946- 2653- 3670- 4289-
M36×3
1218 1641 2011 2329 3176 4394 5135
1536- 2071- 2538- 2939- 4008- 5544- 6479-
M42
1839 2479 3039 3519 4798 6637 7757
1653- 2228- 2731- 3162- 4312- 5965- 6921-
M42×3
1979 2667 3269 3786 5162 7141 8345
2308- 3110- 3813- 4415- 6020- 8327- 9732-
M48
2763 3723 4564 5285 7207 9969 11651
2513- 3387- 4152- 4807- 6556- 9069- 10598-
M48×3
3008 4055 4970 5755 7848 10857 12688

Common Misoperation
Category Failure analysis
During travelling, the rig does not extend its crawlers.
The rig travels on unstable or inclined ground, such as backfill, sloping fields, gully
and slide etc.
During travelling, the rig does not incline backward or the inclination angle is to
little.
Common Sudden acceleration and deceleration; sudden rotation of upper carriage and the
misoperation whole machine.
causing roll-
During travelling up and down the slope, the rig is operated so brutal that its grav-
over
ity center suddenly changes and the rig becomes unstable.
The rig changes its direction, moves transversely or stops on the slope. The rig
swings during travelling up and down the slope.
If the mast inclines backward too much when travelling up the slope, the Kelly bar
will slip down and the rig will incline backward due to loss of gravity center.
If crawler does not extend when erecting the mast, rollover will happen when
swinging the machine.
The borehole is not vertical because the rig starts drilling borehole without adjust-
ing mast verticality. If you adjust it halfway, the drilling head will probably get stuck.
The mast cannot be raised because the mast extends too little when lowering the
mast. The weight of Kelly bar is easily to deform the mast or even break the mast.
When lifting the Kelly bar, limit switch is not noticed. Wire rope clip damages large
pulley too much.
If travel is unlocked when drilling, the Kelly bar will deform and crack due to misop-
eration of travelling handle.
Other common
The drilling head levels the ground and it causes square head cracking.
misoperation
When connecting upper mast and masthead, the harness in mast is broken.
When removing connection rod, the rod bends if adjust verticality directly by auto
mast erecting due to uneven ground.
The boom is lowered without completely lowering the mast. If the mast is adjusted
then, the cab will be crashed.
Use square head to drag drilling head (The weldment of square head easily
cracks).

Category Failure analysis
If the boom is not raised enough when the rig is driving down the trailer, rotary
drive flange will touche the ground, which may deform the flange, when the rig is
driving down the ladder.
Kelly bar kinks or cracks due to pulling heavy load.
When installing Kelly bar, main winch lifting and rig travelling coordinates not so
well that Kelly guide collides with crowd cylinder and cylinder damages.
The boom is so high and backward when drilling that the drilling bucket touches
crawler when swinging and dumping soil.
Travel reducer is too heated and damaged because of traveling too long one time.
Rotary drive rotation speed is too fast when drilling the floating rock. The sudden
resistance when hitting the floating rock results in square head cracking.
When operating with lockout rod, the rod is locked and the rod may smash rotary
drive reducer and rotary drive oil seal (or even smash the cylinder connecting ro-
tary drive or wire rope, causing fall of rotary drive).
The operator uses auxiliary laterally, which causes wire rope slipping from pulley.
Other common
misoperation Releasing rope so fast that the rope breaks or damages.
Releasing auxiliary rope so loose when lowering mast that cab roof steel frame is
scraped when raising the boom, or even the screws are torn.
The mast presses the wire rope into the mast holder when lowering the mast. The
wire rope damages.
After dumping soil, the Kelly bar is lowered directly without swing returning to zero,
which will cause larger borehole , more concrete and slip of casing.
When the engine output power is large, shut down the engine, and it may shorten
the life of turbocharger and engine.
The engine output power is large without heating the engine (especially when the
temperature is too low).
Welding the drilling tool without removing it. The electricity of the rig is not switched
off and harness or controller is damaged.
When removing the Kelly bar, swing to lower the Kelly bar. The wire rope and mast
is not parallel.
When operating the rig, answering telephone and chatting with people will cause
misoperation.
Note: the tables above are only for reference. If you have any questions, please feel free to
contact SANY after sales department.

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www.sanygroup.com
SANY HEAVY MACHINERY CO.,LTD
Sany Industry Park, Nankou, Changping District, Beijing, China 102202

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Quality Changes the World

Rotary Drilling Rig

Safety, Operation & Maintenance Manual

Sany Heavy Machinery Co., Ltd,

Sany Industry Park,

liliu Road, Nankou,

• Offer qualified products along with correct information.

• Provide training for rig operators and service persons as required.

Obligations of Owners or Authorized Persons

• Periodically check related personnel’s safety awareness during working.

• Ensure timely maintenance and repair of the rotary drilling rig.

Obligations of all working personnel

• All personnel should know their working tasks and procedures.

Safety, operation & maintenance manual - July, 2013 I

2.4.1 Hydraulic Lock Lever................................................................................... 2-19

II Safety, operation & maintenance manual - July, 2013

2.6.6 Drilling Rig Danger Area.............................................................................. 2-55

Safety, operation & maintenance manual - July, 2013 III

3.3.2 Chassis Monitor System.............................................................................. 3-15

IV Safety, operation & maintenance manual - July, 2013

4.1.2 Visual Checks................................................................................................ 4-3

Safety, operation & maintenance manual - July, 2013 V

4.1.19.1 Regular Parking................................................................................. 4-44

VI Safety, operation & maintenance manual - July, 2013

4.3.2.11 Installing Wire Ropes......................................................................... 4-80

Safety, operation & maintenance manual - July, 2013 VII

4.5.5.1 Hoisting the Machine........................................................................ 4-129

VIII Safety, operation & maintenance manual - July, 2013

5.4.1.3 Gearbox Gear Oil Level- Check......................................................... 5-32

Safety, operation & maintenance manual - July, 2013 IX

5.4.4.3 Gear Oil for Swing Reducer - Change............................................... 5-73

X Safety, operation & maintenance manual - July, 2013

5.4.9.5 Travel Reducer Oil - Change.............................................................5-111

Safety, operation & maintenance manual - July, 2013 XI

XII Safety, operation & maintenance manual - July, 2013

Safety, operation & maintenance manual - July, 2013

1-2 Safety, operation & maintenance manual - July, 2013

●● Sany-built rotary drilling rigs offer high-qual-

This operator’s manual provides safety, opera-

Safety, operation & maintenance manual - July, 2013 1-3

●● Reduce maintenance costs.

If you sell the machine, be sure to give this

Continuing improvements in the design of this

1.2 Your Documentation Package

The documentation for this machine includes

1.2.1 R ecommendations on using the

●● This documentation applies only to this

1-4 Safety, operation & maintenance manual - July, 2013

●● Keep all pages inside its binder (if shipped

1.2.2 Documentation storage

●● Always keep the manual with the machine

1.3 Organization of This Manual

The SOMM is designed for use and mainte-

1.3.1 Table of Contents

This section provides a listing of topics that

Safety, operation & maintenance manual - July, 2013 1-5

This section provides an overview of what is

This section covers basic safety information

1.3.4 System functions

This section provides an overview of all the

This section provides detailed operating pro-

This section provides all general maintenance

This section includes common malfunctions