KR160M

Hydraulic rotary drilling rig

Operation & maintenance manual

Warning

If this machine is used improperly, it may cause a serious accident. Before operating and maintaining this
machine, operators and maintainers must read and understand this manual fully. This manual should be
stowed with the machine so as to read timely. All relevant personnel should read this manual periodically.
Note
Jiangsu TYSIM Machinery Technology Co., Ltd has other language of this operation & maintenance
manual. If necessary, please contact with the local distributor.

Warning

If this machine is used improperly, it may cause a serious accident. Before operating and maintaining this machine,
operators and maintainers must read and understand this manual fully. This manual should be stowed with the machine so
as to read timely. All relevant personnel should read this manual periodically.
Note
Jiangsu TYSIM Machinery Technology Co., Ltd has other language of this operation & maintenance manual. If necessary,
please contact with the local distributor.
 KR160M OPERATION AND MAINTENANCE MANUAL

CONTENTS
CONTENTS..........................................................................................................................２
1 CONTACTS.......................................................................................................................５
2 PREFACE..........................................................................................................................１
2.1 Guide..............................................................................................................................１
2.2 Specially Point out..........................................................................................................２
3 SAFETY.............................................................................................................................３
3.1 Safety Precautions.........................................................................................................３
3.1.1 Operation forbidden warning........................................................................３
3.1.2 Machine height and stretch-out limit warning...............................................４
3.1.3 Warning for incorrect connection of cables and starters..............................４
3.1.4 Hydraulic tank pressure release warning.....................................................５
3.1.5 Warning for Possible Damage to Lifting Hole...............................................５
3.1.6 Warning on High-pressure Gas....................................................................５
3.1.7 Warning on the High-Pressure Oil Cylinder..................................................６
3.1.8 Not to Use Ether Warning.............................................................................６
3.1.9 Engine Speed Automatic Electronic Control (AEC) Warning.......................６
3.1.10 Battery Safety Warning...............................................................................６
3.1.11 Warning for Fan Blades..............................................................................７
3.1.12 Warning for Others.....................................................................................７
3.2 Major Safety Precautions...............................................................................................７
3.2.1 General Hazard Information.........................................................................８
3.2.2 Compressed air and pressure water............................................................９
3.2.3 Trapped pressure.........................................................................................９
3.2.4 Fluid penetration...........................................................................................９
3.2.5 Asbestos information.................................................................................１０
3.2.6 Beware of Equipment dropping down and Other Mechanical Injury........１０
3.2.7 Coolants....................................................................................................１０
3.2.8 Battery.......................................................................................................１０
3.2.9 Prevention of Fire and Explosion..............................................................１１
3.2.10 Tubes, Pipelines and Hoses...................................................................１１
3.2.11 Track information.....................................................................................１２
3.2.12 Thunder Injury Prevention.......................................................................１２
3.2.13 Mounting and Dismounting.....................................................................１２
3.2.14 Before Starting the Engine......................................................................１３
3.2.15 Starting the engine..................................................................................１３
3.2.16 Before Operating the Rig........................................................................１４
3.2.17 Operating the Rig....................................................................................１４
3.2.18 Parking the Machine...............................................................................１６
3.2.19 Stopping the Engine................................................................................１６
3.2.20 Operator's Workbench............................................................................１６
3.2.21 Guards (Operator Protection).................................................................１６
3.2.22 Rig Working Area....................................................................................１６
3.2.23 Mast inclination.......................................................................................１７
3.2.24 Winch Operations...................................................................................１７
3.2.25 Moving the rig.........................................................................................１８
3.2.26 Passing through Bridges and Tunnels....................................................１８
3.2.27 Moving the Rig with Mast Upright...........................................................１８
3.2.28 Prevention of Dropping Down.................................................................１８
3.2.29 Connecting of the Steel Ropes...............................................................１９
3.2.30 Safeguards for Operators.......................................................................１９
3.2.31 Emergency Stop.....................................................................................１９

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 KR160M OPERATION AND MAINTENANCE MANUAL
4 TECHNIQUE INSTRUCTION.....................................................................................２０
4.1 KR160M Drilling Rig overall dimensions.....................................................................２０
4.2 Major Technical Data of KR160M Drilling Rig...........................................................２１
4.3 Major Components......................................................................................................２２
4.3.1 Power system (Engine).............................................................................２３
4.3.2 Hydraulic system.......................................................................................２３
4.3.3 Electrical system.......................................................................................２４
4.3.4 Traveling Mechanism................................................................................２４
4.3.5 Working Equipment...................................................................................２４
4.4 Operation handle button.............................................................................................２８
4.4.1 Left operation handles..............................................................................２９
4.4.2 Right operation handles............................................................................２９
4.5 Operating procedure...................................................................................................２９
4.5.1 Left operation lever...................................................................................２９
4.5.2 Right operation lever.................................................................................３０
4.5.3 Switch over procedure..............................................................................３０
4.5.4 Floating.....................................................................................................３０
4.6 Travel operation levers (pedals)..................................................................................３０
4.7 Mast Adjusting Lever...................................................................................................３１
4.8 Hydraulic System Putting Through Switch.................................................................３１
4.9 Pressure gauges.........................................................................................................３２
4.10 Display System........................................................................................................３２
4.10.1 Boot screen.............................................................................................３２
4.10.2 Main action page.....................................................................................３３
4.10.3 AUX-Operation page..............................................................................３４
4.10.4 IO Check page.......................................................................................３６
4.10.5 Maintenance information inquiry.............................................................３７
4.10.6 Parameter determination.......................................................................３９
4.10.7 Mast adjusting handle.............................................................................４４
4.10.8 Instructions for Left and Right Control Handles.....................................４５
4.10.9 Wire Number Correspondence Table.....................................................４５
4.11 Engine Working Monitor Panel.................................................................................４６
4.11.1 Pre-start Monitoring Function..................................................................４８
4.11.2 Warning Categories.................................................................................４９
4.11.3 Gauges....................................................................................................５１
4.11.4 Main menu...............................................................................................５２
4.12 Service hour meter....................................................................................................５７
4.13 Supplementary control panel....................................................................................５７
5 USE AND OPERATION OF THE DRILLING RIG.................................................５９
5.1 Start-up the Rig...........................................................................................................５９
5.1.1 Before starting...........................................................................................５９
5.1.2 Start-up.....................................................................................................５９
5.2 The rig shutdown and the engine shutdown...............................................................６０
5.3 The Rig Entering Worksite..........................................................................................６１
5.4 Construction Operation of the Rig...............................................................................６５
5.4.1 Working equipment test running...............................................................６５
5.4.2 Preparation for Construction Work............................................................６６
5.4.3 Drilling Operations....................................................................................６６
5.5 The Rig Retreating from Worksite...............................................................................６９
5.5.1 Rig equipment disassembling...................................................................６９
5.5.2 Loading the Rig onto Truck.......................................................................７２
5.6 CFA operating condition.............................................................................................７２
5.6.1 Install the long spiral drill bit......................................................................７２
5.6.2 Install the long spiral drilling rig................................................................７３

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 KR160M OPERATION AND MAINTENANCE MANUAL
5.6.3 Turn rotary method to CFA method...........................................................７６
5.6.4 Drill operation using a CFA operating method.........................................８０
5.6.5 Process flow under CFA operating condition...........................................８０
5.7 Daily Maintenance of Drilling Rig................................................................................８４
5.7.1 Inspect before operation of drilling rig.......................................................８４
5.7.2 Daily lubrication maintenance for the rig...................................................８４
5.8 Key parts periodic maintenance..................................................................................８６
5.8.1 Steel rope..................................................................................................８６
5.8.2 Engine.......................................................................................................９０
5.8.3 Electrical system...................................................................................１０２
5.8.4 Air Filter and Air Conditioner in the Cab................................................１０４
5.8.5 Hydraulic System..................................................................................１０６
5.8.6 Swing Gear............................................................................................１１５
5.8.7 Track driving..........................................................................................１１７
5.8.8 Rotary table...........................................................................................１１９
5.9 Common Trouble shooting and maintenance material recommendation...............１２１
5.9.1 Common Trouble shooting....................................................................１２１
5.9.2 Lubricating oil........................................................................................１２１
5.9.3 Solvents and Oil Dosage Table.............................................................１２２
5.9.4 Stage maintenance for fittings...............................................................１２３
5.10 Appendix 1 Table for Bolt Tightening Torque.........................................................１２３
6 KR160M ROTARY DRILLING RIG CORRECT OPERATION METHODS....１２４
6.1 Unload earth operating mode..................................................................................１２４
6.1.1 Scram unloading earth..........................................................................１２４
6.1.2 Up and down unloading earth...............................................................１２５
6.1.3 Unloading-earth ware / Scraping-earth ware........................................１２５
6.1.4 Gravitation unloading earth...................................................................１２５
6.1.5 Assistance unloading earth...................................................................１２５
6.1.6 Form open type unloading earth...........................................................１２５
6.2 Pressure operating mode........................................................................................１２６
6.3 Kelly bar unlocking..................................................................................................１２６
6.4 Drill bucket cutting teeth rake angle selection.........................................................１２７
6.5 Full-length/segmentation machine and tools drilling method..................................１２９
6.6 Lubrication gap (Breathing Space)..........................................................................１２９

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 KR160M OPERATION AND MAINTENANCE MANUAL

1 CONTACTS

Thanks for your purchasing the KR160M Hydraulic Rotary Drilling Rig of our

company, the followings are our contacts:

Our address: No.3 Building, 311 Yanxin Rd, Huishan Economic Development

Zone, Wuxi, Jiangsu, China.

Sale line: +86-510-83590747

Service line: +86-510-83590757

Post code: 214174

Web site: http://www.tysim.cn

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 KR160M OPERATION AND MAINTENANCE MANUAL

2 PREFACE

2.1 Guide

Honorific user:
Welcome to become a member of the owners of TYSIM hydraulic drilling rig.
What TYSIM supplies you the products of the professional piling equipment, and
the professional service.
KR160M Drilling Rig is designed by professional engineer team,and use the
best caterpillar chassis.It has absorbed the merits of leading brands domestic and
abroad, and has reached or surpassed the other brands products level in the world.
KR160M Drilling Rig has adopted popular luffer of parallelogram structure and is
more manoeuvrable and flexible with higher operating efficiency. All the key parts of
model KR160M rig are from leading brands worldwide, which ensure reliability of
the whole machine: Cab and chassis from the Caterpillar, complete set of hydraulic
elements from the Rexroth of Germany, high quality steel material, and precision
sealing bearing from Japan. The program is adopted in the electric system to
supervise the rig's operation; EMC electronic module is adopted for the engine
monitoring, and provides a number of malfunction alarms, as well as safety device
for the whole design and assembling.
Model KR160M drilling rig can be fit with various drilling tools such as auger,
bucket and so on, able to drill clay layers, sandy layers, pebble layers, medium air-
slaked and slight air-slaked mudstone layers. The rig structure is strong and
reliable with powerful resistance to shock; the rotary table provides high pulling
torque suitable for everlasting congealed ground layer and pebble layer where
conventional drilling rig is unable to drill in.
This manual introduces you the rig principle, structure, safety operations,
service, constructional works, as well as concrete related knowledge. Do not use
the machine nor carry out any lubrication, maintenance or repair work before
reading and understanding the information about how to use, lubricate, maintain or
repair the machine.
Dear customer, we thank you for your trust of our corporation and for your wise
choice of KR160M Drilling Rig. We sincerely wish you great success in your
foundation construction undertakings!

Following the principle to keep improving products, TYSIM may not

inform you of the modified parts in time. Please consult our corporation when
you wish to.

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 KR160M OPERATION AND MAINTENANCE MANUAL

2.2 Specially Point out

Honorific user:

Do not operate or service KR160M Drilling Rig before reading the

instructions of this manual carefully!

Users should maintain carefully and operate properly KR160M Drilling Rig.
TYSIM will not be liable for any maloperations as the following:
1. User or users refit or repair the rig without permission of our corporation;
2. User or users dismount, weld or add parts to this rig without permission of
our corporation;
3. User or users use drilling tools or other attachments other than those
recognized by TYSIM on the drilling rig, without written permission.
4. User or users operate, install or store this rig in a way different from
provisions of this manual.
5. User or users choose fuel or lubricants different from those required in this
manual.
6. User or users do not perform service or maintenance according to the
requirements stipulated in this manual.
We provide 12 months or 2000 hours warranty period, which is governed by
the earlier; some parts’ maintenance period is governed by the Clause 5.9 of the
manual.

User or users must make daily log recording the rig operations, including those
not yet have influenced the operations, so that our corporation is able to provide
you with excellent service timely and accurately.
Technical parameter specified in the Beijing TYSIM technical data is the max
work capacity data.KR160M drilling Rig delivery standard configuration is not
configured for the max work capacity, we make comprehensive Considerations as
follow: the best service performance, highly work efficiency, the most common
construction technique, the lowest use-cost, the longest and the most dependable
service lifetime. Standard configuration covers about 80% construction
requirements of drilling and grouted pile foundation work. If you need special pore-
forming, we suggest you firstly establish detailed job specifications by detailed
geological data, so that you fix your machine configuration to satisfy your
construction requirements and prolong the service lifetime of your machine.

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 KR160M OPERATION AND MAINTENANCE MANUAL

3 SAFETY

3.1 Safety Precautions

Most of the accidents during operation, service and maintenance are resulted
from failure to follow the basic safety codes or precautionary measures. Our
corporation would like heartily to remind our users that safety is the primary
responsibility of the operators and service workers.
Before using or servicing the machine, you have to read and familiarize the
following precautions.
For your safety operation on this machine, TYSIM has fixed some safety
precaution marks on the rig. Please pay attention to such marks as you prompt. We
are going to make explanations of the safety marks one by one.
Hereby we would like to remind users, the purpose to fix the safety marks is for
your safety, so please pay attention to maintain the safety marks.

Any TYSIM service center can provide with new safety marks.

3.1.1 Operation forbidden warning

Warning
Any one shall not operate the machine or work on the machine before
reading the precautions and warnings in this manual, nor can any one move
the rig. Failure to follow the operation specifications or the warnings may
result in serious accidents, or even life injury. Hereby we remind you that
you will bear all the responsibility in case of such accident. In case you will
change for a new manual or if your manual is lost, you may contact with
TYSIM service center for a new one. Note that safety is your primary
responsibility.

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 KR160M OPERATION AND MAINTENANCE MANUAL
3.1.2 Machine height and stretch-out limit warning

Warning!
You should know the top height and the stretch-out limit. In case there is
not safe space between the machine and any part of the machine to a
power cable, electric shock may occur and serious injury may happen.
Failure to follow the operation specifications or the warning may result in
serious accidents, even life injury. Hereby we remind you that you will bear
all the responsibility in case of such accident, Keep 3 meters space. At
least 3 meters space between the rig mast and 50000V high voltage cable
shall be kept. 1 meter should be added to the space for ever 1000V
increase.

3.1.3 Warning for incorrect connection of cables and starters

Warning!
Incorrect connection of cables with starter may result in explosion with life
injury. Failure to follow the operation specifications or the warning may
result in serious accidents, even life injury. Hereby we remind you that you
will bear all the responsibility in case of such accident. Battery may be
located in separated compartments. When using jumper cable connection,
connect the cable polarity (+) with the (+) connecting pole of the battery
that is connected with the starter; and connect the negative (-) of the cable
from outside power line to the negative (-) connecting pole of the starter (In
case there is no negative connecting pole on the starter, connect it to
engine cylinder body).

Wrong connection of the battery may result in explosion and/or serious life
injury.

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 KR160M OPERATION AND MAINTENANCE MANUAL

3.1.4 Hydraulic tank pressure release warning

Warning!
Hydraulic tank
When the engine stops, slowly remove the tank cover to release the
hydraulic tank pressure without burning by the hot oil.

Check daily the oil level in the hydraulic tank.

Failure to follow the operation specifications or the warning may result in
serious accidents, or even life injury.
Hereby we remind you that you will bear all the responsibility in case of such
accident.
Please do not directly contact the hydraulic oil, especially not to inhale or
contact the toxic gas from burning the hydraulic oil.
Do not dispose the waste hydraulic oil at discretion on purpose to protect the
environment from pollution.

3.1.5 Warning for Possible Damage to Lifting Hole

Warning!
When lifting the oil tank with oil filled, the lifting hole or oil tank may be
damaged and life injury may occur. Lifting shall not be performed before
letting out all the oil in the tank and confirming the status.

Failure to follow the operation specifications or the warning may result in

serious accidents, or even life injury. Hereby we remind you that you will bear all
the responsibility in case of such accident.

3.1.6 Warning on High-pressure Gas

Warning:
Inside there is high-pressure gas! Do not contact with flame, welding is
not allowed, drilling hole is not allowed to avoid explosion or life injury.
Release the pressure before relieving the gas.
About the operation of charging or relieving the high-pressure gas, if you need
you can consult with TYSIM sale service

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 KR160M OPERATION AND MAINTENANCE MANUAL

3.1.7 Warning on the High-Pressure Oil Cylinder

High-pressure oil cylinder! Before the pressure is completely released, do

not discharge any part from the machine on purpose to avoid possible life
injury. The relief valve can be loosened by one round maximum.

3.1.8 Not to Use Ether Warning

Do not use ether! Not applicable to any machine equipped with ether
supplementary starting mechanism. Do not spray ether toward air intake
tube as this machine is equipped with air intake heater, otherwise severe
accident may happen.

3.1.9 Engine Speed Automatic Electronic Control (AEC) Warning

Warning!
When switch of the engine speed auto-control (AEC) is positioned at ON
(operating), if you operate the operation lever or the drive pedal, the
engine speed automatic control (AEC) will increase engine speed
automatically. While the machine is mounting up or dismounting from a
transportation truck, or operating in a narrow site, the AEC switch must
be in OFF position, in order to prevent the machine from sudden moving
and from severe injury accident.

3.1.10 Battery Safety Warning

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 KR160M OPERATION AND MAINTENANCE MANUAL

Warning!
The battery must be connected correctly. Incorrect connection may result
in explosion and severe life injury. The fluid in the battery cell is a kind of
corrosive liquid. Only the operator well dressed with armor or specialist is
allowed to perform inspecting or repairing the battery in case it is truly
necessary. Note that safety is your primary responsibility.

3.1.11 Warning for Fan Blades

Warning!
During inspection, service or dismounting of the engine, please be sure to
shut down the engine until no sound can be heard from the engine. If it is
necessary to open the engine hood, take special care of the fan blade or
other slewing parts(some times it is not obvious that they are in motion) on
purpose to avoid possible life injury or death.

3.1.12 Warning for Others

Warning!
Check daily the oil level of the lubricating oil in the rotary table case, and
whether or not the lubrication pump works normally. Check daily the
wearing condition of hoist cable for possible damage. The specified
gradient stipulated in the operation manual shall not be exceeded.
Smoking or lighting must be kept away from the fuel tank and hydraulic oil.

3.2 Major Safety Precautions

To make the users operate the rig safely and reliably, a series of safety precautionary
measures are provided in this chapter. It is sure that operation and service work can be
performed without equipment damage and life injury only if you follow the safety
precautions during working or servicing on the rig.

3.2.1 General Hazard Information

 Attach a “Do Not Operate”warning tag or a similar
warning tag to the start switch or to the controls
before you service the equipment, to prevent any
maloperation, so avoid damaging the machine and
hurting worker body.

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 KR160M OPERATION AND MAINTENANCE MANUAL
 Get to know the width of your equipment in order to maintain proper
distance with the surrounding fences or obstacles, when you operate the
equipment
 Be aware of high voltage power lines and power cables that are buried. If
the machine comes in contact with these, hazards, serious injury or death
may occur from electrocution.
 Wear a hard hat, protective glasses, and other protective equipment, as
required.
 Do not wear loose clothing or jewelry that can snag on controls or on other
parts of the equipment.
 Make sure that all protective guards and all covers are secured in place on
the equipment.
 Keep the machine clean without sundries. Remove debris, oil, tools and
other items from the deck, from walkways, and from steps.
 Secure all loose items such as lunch boxes, tools, and other items that are
not a part of the equipment.
 Be familiar with applied gestures, and note that who gives the gesture.
Accept only one person for directing gestures.
 No smoking during operation and maintenance working.
 Necessary maintenance, service and repair work can be performed only
after the machine stops and cools down completely.
 Dispose every kind of the liquids according to relevant code of the local
government.
 Unless otherwise specified, any equipment to be serviced should be put in
a proper position before performing the service.
 Any person other than the one in charge shall not enter the operator cabin
without permission.
 Maintenance work of the rig must be performed following the regulations.
 When the machine is not in use, it should be put on even and firm ground. Every
controller must be in OFF position; hydraulic operation levers in close position; ensure
the engine stopped and remove the key from the switch; cut off the main switch.
 During lifting operation, the loading capacity provisions must be observed.
 A special lock pin is provided on this machine for preventing the machine
from slewing during handling it for transportation; Make sure the lock pin is
inserted in the notch and locked before handling and transporting the
machine.
 Grease in the track tensioner oil cylinder has great pressure. If any grease
of high pressure leaks from the relief valve, it will adhere to the skin and

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 KR160M OPERATION AND MAINTENANCE MANUAL
cause severe even fatal injury.

3.2.2 Compressed air and pressure water

 Compressed air and / or pressurized water can
cause debris and/or hot water to be blown out.
This could result in personal injury.
 The maximum air pressure for cleaning purposes
must be below 205kPa; the maximum water
pressure for cleaning purposes must be below
275kPa.

3.2.3 Trapped pressure

Pressure can be intercepted in the hydraulic system; releasing trapped pressure can
cause sudden machine movement or attachment movement. Use caution if you
disconnect hydraulic lines or fittings. High pressure oil that is released can cause a hose to
whip. High pressure oil that is released can cause oil to spray.

3.2.4 Fluid penetration

 Fluid penetration can cause serious injury and
possible death.
 Pressure can be trapped in the hydraulic circuit
long after the engine has been stopped. The
pressure can cause hydraulic fluid or items such
as pipe plugs to escape rapidly if the pressure is
not relieved correctly. (E.g. plugs).
 Do not disassemble any hydraulic components or parts until pressure has
been relieved or personal injury may occur.
 Always use a board or cardboard when you check for a leak. Leaking fluid
that is under pressure can penetrate body tissue.
 If fluid is injected or eroded your skin, you must remove the liquid as soon
as possible, and go to get treatment. Seek treatment from a doctor that is
familiar with this type of injury.

3.2.5 Asbestos information

There are no asbestos parts on the rig. TYSIM recommend only authentic TYSIM
parts for replacing the old ones.

3.2.6 Beware of Equipment dropping down and Other

Mechanical Injury
 Any equipment must be supported firmly if

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 KR160M OPERATION AND MAINTENANCE MANUAL
operations will be performed underside. Do not depend on the hydraulic
cylinders to hold up the equipment. Equipment can fall if a control is moved,
or if a hydraulic line breaks.
 Do not work beneath the cab of the machine unless the cab is properly
supported.
 Unless you are instructed otherwise, never attempt adjustments while the
machine is moving or while the engine is running.
 Never jump across the starter solenoid terminals in order to start the engine.
Unexpected machine movement could happen.
 Whenever there is equipment control linkages the space in the linkage area
will change with the movement of the equipment or the machine. Don’t stay
at the spaces that may have a sudden change with machine movement or
equipment movement.
 If it is necessary to remove guards in order to perform maintenance, always
install the guards after the maintenance is performed.
 Keep objects away from moving fan blades. The fan blade will throw objects or
cut objects.
 Do not use a kinked wire cable or a frayed wire cable. Wear gloves when
you handle wire cable.
 When you strike a retainer pin with force, the retainer pin can injure you.
Make sure that there is nobody at the areas when you strike a retainer pin.
To avoid injury to your eyes, wear protective glasses when you strike a
retain pin.

3.2.7 Coolants
Cooling system conditioner contains alkali. Alkali can cause personal injury. Do
not allow alkali to contact the skin, the eyes, or the mouth.

3.2.8 Battery
Electrolyte is an acid. Electrolyte can cause personal injury. Do not allow
electrolyte to contact the skin or the eyes. Always wear protective glasses for
servicing batteries. Wash hands after touching the batteries and connectors. Gloves
are recommended.

3.2.9 Prevention of Fire and Explosion

 All fuels, most lubricants, and some coolant
mixtures are flammable.
 Flammable fluids that leak or spill onto hot
surfaces or onto electrical components can
cause a fire. Fire may cause personal injury

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 KR160M OPERATION AND MAINTENANCE MANUAL
and property damage.
 Remove all flammable materials such as fuel, oil, and debris from the
machine.
 Do not operate the machine near any fire.
 Do not weld on lines or on tanks that contain flammable fluids. Don’t weld
and cut lines or tanks that contain flammable fluid. Clean any such lines or
tanks thoroughly with a nonflammable solvent prior to welding or flame
cutting.
 Every junction of electric circuits should be clean, and connection should be
firm.
 Check daily all the cables, wires for possible loose, disconnection or
damage. Before starting any electric appliance of the machine, every
loosened wire must be fastened, damaged wire repaired, by way such as
fastening, repairing or replacing. Clean and tighten up every electric
connection and make all the cables, wires work reliably.
 Never check the battery charging by way of putting a metal piece between
connecting poles; use voltage meter or hydrometer instead.
 Do not charge the frozen battery, this may cause an explosion.
 In case of pipeline or connector cracking, make use of protective hood or
proper covering to isolate the high-temperature components from exhaust
fume, fuel, oil material and so on.

3.2.10 Tubes, Pipelines and Hoses

 Do not bend or strike high pressure lines. Do not install any lines that are
bent or damaged.
 Repair any lines that are loose or damaged. Leaks can cause fires. Consult
TYSIM Customer Service for repair or for replacement parts.
 Check lines, tubes and hoses carefully. Do not use your bare hand to check
for leaks. Use a board or cardboard to check for leaks. Tighten all
connections to the recommended torque.
Replace the parts if any of the following conditions are present:
 Terminal fittings are damaged or leaked.
 Outer coverings are chafed or cut.
 Wires are exposed
 .Outer covers are ballooning.
 Flexible parts of the hoses are kinked
 Outer covers have embedded armoring.
 Terminal fittings are displaced.
 Make sure that all clamps, guards, and heat shields are installed

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 KR160M OPERATION AND MAINTENANCE MANUAL
correctly. During machine operation, this will help to prevent from
vibration, rubbing against other parts, and excessive heat.

3.2.11 Track information

 Track adjusting system use either grease or oil under high pressure to keep
the track under tension.
 Grease or oil under high pressure coming out of the relief valve can
penetrate the body causing injury or death. Do not watch the relief valve to
see if grease or oil is escaping. Watch the track or track adjustment cylinder
to see if the track is being loosened.
 The pins and bushings in a dry track pin joint can become very hot. It is
possible to burn the fingers if you contact with these components for long
time.

3.2.12 Thunder Injury Prevention

 When thunder is striking in the vicinity of the machine, the operator should
never mount or dismount the machine.
 If you are in the cab during thunder, stay in it. If you are on the ground
during thunder, stay away from the vicinity of the machine.

3.2.13 Mounting and Dismounting

 Mount the machine and dismount the machine
only at locations that have steps and/or
handholds. Before you mount the machine, clean the
steps and the handholds. Inspect the steps and
handholds. Make any necessary repairs.
 Face the machine whenever you mount or
dismount the machine. Maintain a three-point
contact with the steps and with handholds.
(Note: Three-point contact can be two feet and one hand. Three-point
contact can also be one foot and two hands.)
 Do not mount or leave the machine while the machine is traveling and/or
turning, much less jump down from the machine.
 Do not try to carry instruments or commodities while mounting or stepping
down the machine; they should be lifted up to or dropped down from the rig
platform by a rope.
 While entering or leaving the operator's cabin, do not hold any operation
lever as a handrail.

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 KR160M OPERATION AND MAINTENANCE MANUAL

3.2.14 Before Starting the Engine

 Start the engine only from the operator compartment. Never short across
the starter terminals or across the batteries. Shorting could damage the
electrical system by bypassing the engine neutral start system.
 Inspect the condition of the seat belt and of the mounting hardware.
Replace any parts that are worn or damaged. Regardless of appearance,
replace the seat belt after three years of use.
 Adjust the seat so that full pedal travel can be achieved with the operator’s
back against the back of the seat.
 Ensure the lighting system equipped on the machine with all the lights in
working order.
 Construction site must be ensured with adequate lighting system, with light
fittings properly adjusted.
 Make sure that the worksite is clean and wide enough, without other
persons or obstacles.

3.2.15 Starting the engine

 If a warning tag such as “do not start the
machine” is attached to the engine start
switch or to the controls. Also, do not move
any controls.
 Move all hydraulic controls to the HOLD
position before you start the engine. Move the hydraulic activation control
lever to the LOCKED position.
 Diesel engine exhaust contains products of combustion which can be harmful to
your health. Always run the engine in a well ventilated area. If you are in an
enclosed area, vent the exhaust to the outside.

3.2.16 Before Operating the Rig

 Clear all personnel from the machine and
from the area.
 Clear all obstacles from the machine’s path.
 Pay special attention to wires, ditches and
other dangerous place.
 Be sure that all windows are clean. Secure
the doors and the windows in the open position or in the shut position.
 Adjust the rear-view mirrors (if equipped) for the best visibility close to the

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 KR160M OPERATION AND MAINTENANCE MANUAL
machine.
 Make sure that the horn, the travel alarm and all other warning devices are
working properly.
 Fasten the seat belt securely.
 Warm-up the engine and the hydraulic oil before operating the machine.
 Before moving the machine, check the position of the undercarriage. The
normal travel direction is with the idler wheels to the front under the cab and
the drive sprockets to the rear. When the undercarriage is in the reversed
direction, the directional controls must be operated in opposite directions.
 Slowly move the rig to an area without people and obstacles, and examine whether
all the controller and safety equipment works in order.
 Every safety operation measure must be observed.

3.2.17 Operating the Rig

 Operator can work only by sitting in the cab, controlling the rig performance,
and preventing the rig from being out of control.
 Safety belt must be fastened during the machine working. Various kinds of
operation levers can be operated only when the engine is running.
 Drive the machine slowly on an unenclosed ground; examine all the control
system and protector in normal working order.
 While the machine travels, especially on rough ground or rocky ground, the
mast may swing up and down or horizontally. Pay attention to the hunting
range of the mast and not to let it surpass the limit value.
 Before starting the machine, operator should make sure that nobody is in the
dangerous area, and ensure that no life danger will occur. Any one other than
the operator is allowed on the machine.
 While slewing the slewing platform and the upright mast, make sure that
the mast is at least 10cm above the ground.
 While lowering the mast, ensure that the cable will not bump against any
person or objects.
 During operation, pay attention to malfunction symptoms and be ready to
solve them promptly.
 During operation, pay attention to make record of any machine breakdown,
and be ready to proceed with necessary repairing.
 While the machine travels, keep the attachment about 40cm above the
ground. Do not drive the machine near any projecture, cliff edge and edge
of the excavation area. Keep the machine away from cliff, crag or falling
place at a safe distance.

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 KR160M OPERATION AND MAINTENANCE MANUAL
 In case that the rig body is raised because of rotary table compressing or hoist
lifting, the rig operation should be stopped immediately.
 Take care to avoid any abnormal ground condition which may result in the
machine tilting.
 Whenever possible, perform the operation in longitudinal slope direction,
and try to avoid operation in crossfall direction.
 While working in hillside, slope or inclined ground, or across a trench ridge
or other obstacles, prevent the rig from rolling over. In case the machine
begins to sideslip, unload the machine immediately.
 It is allowed for the rig to work in a longitudinal slope no more than 2º
, and perform drilling.
 Prevent the rig from out of control; make sure that the rig is working with a
loadage within the rated value.
 Do not turn the machine while traveling in slopy field, otherwise the
machine may tip over or sideslip.
 During traveling, or before the upper turnplate slewing, the mast should be
retreated 200 backward to increase its stability.
 Take special care while the rig travels in floppy ground. If the ground is
floppy and the rig is caving in, pave with timbers or steel plates
underside tracks.
 The lifting capacity will decrease while the machine loadage distance
increase from the machine.
 For the minimum distance from an obstacle, please check with relevant
national or local regulations.
 Before operate the machine, consult with the local utility departments for
underground pipeline and cable locations.
 Seal the drilled pile holes in time if they will not be poured with concrete
immediately.
 Fill in the ready pile holes in time.

3.2.18 Parking the Machine

 Park the machine on a level surface. If you must park the machine on a
grade, chock the tracks of the machine.
 Move the hydraulic activation control
lever to the LOCKED position, and all
parts of the rig rest in unloaded and
steady status. For instance, let down the
Kelly bar, the drilling tool and let them

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 KR160M OPERATION AND MAINTENANCE MANUAL
touchdown; retreat mast to 20°so that to increase its stability.
Warning!
Hanging load on the parked rig is absolutely forbidden.

3.2.19 Stopping the Engine

 Turn the engine start switch to OFF position and remove the engine start
switch key.
 Turn the battery disconnect switch to OFF position.

3.2.20 Operator's Workbench

 CAT operator cabin is equipped on the KR160M drilling rig, in conformity
with the following standard: SAE J154, ISO 3411, EN 474 - 1, EN 23411.
 In the operator cabin, no improvement shall encroach the specified space.
Specified space must be kept while installing fire extinguisher or other
equipments.

3.2.21 Guards (Operator Protection)

 There are different types of guards that are used to protect the operator.
 A daily inspection of the guards is required.

3.2.22 Rig Working Area

Warning!
Before operating the rig, make sure that no persons are within the range of
the rig (for instance 10m). Any operation is prohibited before the area is
evacuated completely.

 While the mast is 60º upright, the rig can travel at a longitudinal slope of 5º
maximum; transverse slope of 5º maximum.
 When the rig is working in longitudinal or transverse slopy area, stretch the
track frame wider as far as possible, with the allowable maximum ground
slope being 2º. Here the ground slope is only referred to firm, hard to cave-
in ground.
 During traveling down slope, do not slowdown suddenly. We would like to
remind you that you should survey the gradient when you are passing the
uneven ground.

Warning!

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 KR160M OPERATION AND MAINTENANCE MANUAL

Surpassing the specified gradient is prohibited.

3.2.23 Mast inclination

 When the rig undercarriage inclination does not exceed 2º, the mast verticality
can be adjusted to work without stopping the machine for shaving the ground
surface.
 In order to prevent accidents, it is not allowed to incline the mast before the
mast and Kelly bar are lifted off the ground.

3.2.24 Winch Operations

 Winch of the drilling rig is equipped specially for hole-forming operation
(such as Kelly bar, buckets, power plant and other drilling tools). It should
not be used for other purpose. During operation, relevant national
regulations shall be observed.
 In case the drilling rig is used for operations (such as for common lifting
operations) other than the above mentioned contents, possible accidents
resulted will not be borne by TYSIM corporation.
 Keep the drilling rig stability when the Auxiliary winch is working.
 For lifting purpose, the load should be positioned strait ahead to the mast,
with the included angle no greater than 15º; when the load is in an angle to
the mast front and side, the rig should be turned to make the load
positioned at the longitudinal axis extension line. Or else, the machine body
may be in serious risk of tip-over.
Warning!
Hoist equipped for the rig is provided as specialized facility for hole-
forming; it is prohibited to use the hoist as a lift or loader for other
operations.

3.2.25 Moving the rig

Warning!
Never move the mast while moving the rig at the same time.

 Before the rig operation, examine the area around the rig whether or not in
conformity with working requirement, and safe (such as ground stability
degree).
 Do not park the machine near the pressure pipelines charged with high

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 KR160M OPERATION AND MAINTENANCE MANUAL
pressure.

3.2.26 Passing through Bridges and Tunnels

 When passing through bridges and tunnels, make sure that the bridge
maximum load is greater than the maximum weight of the rig; and tunnel
permitted passing dimensions are greater than the rig size.
 When transporting the rig by towed vehicle on highways, fix the rig to the
vehicle according to the method provided in this manual.
 Apply special devices for fixing the turntable and rotary table.

3.2.27 Moving the Rig with Mast Upright

Warning!
The following requirements must be met for moving the rig, or else
dangers like electric shock and overturn may happen!

While moving the rig with mast upright, or

raising the mast upright, make sure that there are
no air obstacles such as high tension line,
telephone wire, and so on, in the space the mast
will sweep over.

3.2.28 Prevention of Dropping Down

Operators may be faced with danger of dropping down while working at high
level for servicing, repairing or installation; therefore, effective safeguard must be
ensured such as fastening safety belt, or use of special dropping preventing device.

Warning!
Dropping down danger may happen for working high above the ground,
therefore effective safeguard must be adopted.

3.2.29 Connecting of the Steel Ropes

For connection of steel ropes with hook or steel
rope connector, lift related regulations of the lift trade

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 KR160M OPERATION AND MAINTENANCE MANUAL
must be observed strictly.

3.2.30 Safeguards for Operators

According to the safe work practices provisions, operation crews must wear
safety equipment such as safety helmet, labor protection shoes, goggles, gloves,
mask, and others specified. Work clothes must be proper in size, without disturbing
to operations.

3.2.31 Emergency Stop

Emergency stop push button of the rig is located under the seat.

Warning!
Under emergency situation, so long as to press emergency stop push
button, the rig engine will stop. While the engine is to be started again,
you must reset the emergency stop push button to exit stop status.

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 KR160M OPERATION AND MAINTENANCE MANUAL

4 TECHNIQUE INSTRUCTION

4.1 KR160M Drilling Rig overall dimensions

Principal view, front view and transportation position view of KR160M Drilling
Rig are shown respectively as follows:

Fig 1 Transportation position view

Fig. 2 working status view

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 KR160M OPERATION AND MAINTENANCE MANUAL
4.2 Major Technical Data of KR160M Drilling Rig

Item Unit Data Item Unit Data

Max torque kN.m 165 Pilot pression MPa 4
1500/700
Pile max dia. mm Chassis type CAT 326D
（CFA）

58/46
/
Depth max. m Engine type CAT C7.1
16（CFA
）

Engine nominal
Working speed rpm 5~26 kW 159
power
Max push kN 155
Extended width
Max pull kN 160 mm 4100
of crawler
Main winch pulling
force(the first kN 160 Width of crawler mm 700
layer)
Main winch pulling Overall width in
m/min 80 mm 4100
speed drilling position
Auxiliary winch
pulling force(the kN 60
first layer)
Overall width in
Auxiliary winch
m/min 70 transport mm 3100
pulling speed
position
Stroke of crowd
mm 13000
system
Overall height in
Mast sidewards
° 5 transport mm 3197
rake
position
Mast front rake ° 5 Traction power kN 230
Operating
Weight with
Mast back rake ° 90 t 49
standard Kelly
bar
System pressure MPa 35

4.3 Major Components

KR160M Drilling Rig is a large size pile foundation construction machinery and

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 KR160M OPERATION AND MAINTENANCE MANUAL
highly efficient filling pile forming-hole equipment. It is able to move to the pile
position automatically, high efficiently and conveniently and carry on drilling task
rapidly. By means of slab transport vehicle it is convenient to be transferred to other
work site and it has the advantage of disassembling quickly to adapt to different
kinds of operating mode.
KR160M Drilling Rig mainly consists of chassis and working equipment. Major
components of KR160M Drilling Rig include:
Traveling Mechanism, slewing Drive, derricking gear, main which, auxiliary
winch, mast, rotary table, rotary table pressurized structure as well as drill stem,
drilling tool and so on. Drill mainframe assembly designed and manufactured by
Beijing TYSIM Heavy Industry Limited Company.
For major components of KR160M Drilling Rig please see Fig. 4.

Fig.4 Structure sketch of the rig

1、Tracked undercarriage 2、Chassis 3、 Mast support 4、 Auxiliary winch

5、Main winch 6、Crowd winch 7、 Mast 8、CFA auger 9、Rotary table

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 KR160M OPERATION AND MAINTENANCE MANUAL
4.3.1 Power system (Engine)
In this machine, a diesel engine (model CAT C7.1) electronic-spray
turbocharging with medium cooling is incorporated, which is the most advanced
power unit globally at present. It is able to induct load change and correspondingly
modulate the power output. The engine noise is low, vibrates slightly, protects the
environment effectively, its performance is stable and reliable, which has reached
EPA Tier Ⅲ effluent standard and can export to Europe, North America etc.
(Performance parameters are instructed in the engine specification)

4.3.2 Hydraulic system

CAT main control loop and pilot control loop have been adopted for the
hydraulic system, which makes it possible that the flow distributes according to
need by relevant working equipment, so to realize optimum matching under various
operating condition. The pilot control operations are more flexible, safe, comfortable
and precise. The system emits heat by itself. All the pumps, motors, valves and
pipe fittings are imported products which ensure the system reliability.

Pressurized cylinder
Pressurized tank connected to the mast and pressurized cylinder piston rod
connected to the power head bracket. Through the expansion of pressurized
cylinder piston rod to drive reciprocating movement of the driving head and

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 KR160M OPERATION AND MAINTENANCE MANUAL
pressurized feed or pull out when drilling. Balance valve is along with the oil circuit,
which can be reliable power to lock the power driving in arbitrary position of the
pressurized stroke when not supply oil to the pressurized cylinder.

4.3.3 Electrical system

On this machine 24V DC is provided for the electrical system, with major
functions including engine start-up, flameout monitoring, electromagnetic
commutation, mast angle measuring, manual/automatic adjustment, switching,
automatically up and down the mast, alarming, drilling depth monitoring and
adjustment, various liquid level monitoring, main and auxiliary winch, as well as
mast tilting angle limiting, Engine fault detection, alarm monitoring and display
system for system parameters. Electrical system components are used imported
products.
Adopted advanced REXROTH manual operation and automatic interactive
switching electronic leveling device, which can proceed real-time monitoring and
keep the mast vertical during the construction operation to ensure effectively the
verticality of the pile.

4.3.4 Traveling Mechanism

This mechanism functions for the whole machine traveling and moving,
composed mainly of hydraulic motor, reductor, driving wheel and tensioner, tracks,
bogie wheel, carriage wheel, guide wheel and so on. Via the hydraulic system
control, the mechanism is enabled to move advance, reverse, leftwards, rightwards
and around a point.
There are hydraulic cylinders inside the left and right vertical beams, the
stretch-out or retreat-back of the cylinders enable the track traveling gear extending
or retreating. The function of the rig enables the machine to increase its working
stability with wider track, while to reduce the width of the whole machine during
transportation with the tracks retracted back.

4.3.5 Working Equipment

The working equipment includes mast, rotary table, Kelly bar, mast support,
main/ auxiliary winch, drill bucket, pressing oil cylinder and so on.

4.3.5.1 Derricking gear

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 KR160M OPERATION AND MAINTENANCE MANUAL

Mast cylinder

Tripod

Boom

Derricking cylinder

Knighthead

Derricking gear is the mounted component for mast. Mast fix thereon, while
mast and slewing gear of drilling chassis linked by it ,and through the action of
derricking cylinder and mast cylinder ,mast keeps away or approaches chassis and
changes the inclination fore-and-aft, which can regulate the amplitude in working
position and the height of whole machine in transport position..
Derricking gear is comprised of the following parts: overhang beam, tripod,
stand bar, derrick cylinder, and mast cylinder and so on. The soffits of overhang
beam , stand bar and derricking cylinder separately swing joints to the leading ends
of revolving dial, and the upper extremes separately swing joints to the two corner
ends of tripod, while the other corner of the tripod swing joint with mast underpart
through turntable.
Revolving dial, arm, knighthead and tripod form one parallelogram mechanism
through the swing joint of axis pin. Mast and tripod only fluctuate parallel translation
when derricking cylinder flex to change work amplitude ,which assure the mast
inclination and rod system drilling angle unchanging while the mast fluctuates.

4.3.5.2 Kelly bar

KR160M matched 377-5×12.5 friction Kelly bar with effective drilling depth up
to 64 meters when delivered. It also can match 377-4×12.5 interlocking Kelly bar,
which can be considered for the pattern of rock drilling with effective drilling depth
up to no more than 58 meters.

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 KR160M OPERATION AND MAINTENANCE MANUAL

Following frame

Kelly bar

The Kelly bar is an importance assembly, which is used for transferring torque
and pressure to drilling bucket from the rig. It realizes the progressive movement of
drilling rig for working by the cutting force of the drilling teeth while the Kelly bar is
slewing; Or when the rock blocks for drilling are greater than 10MPa, the rotary
table driven by pressurized tanks to make the pressure movement, which pass the
axial force to the drilling bucket by drill stem through inner spline of quill spline to
achieve the progressive movement of the drilling rig.

4.3.5.3 Winch

Main Winch

Main winch is comprised of the following parts: hydraulic motor reductor, spool,
winch bearing, wire rope, rope slings and so on. Function of the main winch is to
hoist and lower the Kelly bar, and as the importance constituent of drilling, it is
realized by hydraulic system. When the rig proceed drilling task, main winch detent
should be released to make the hoist system in floating position, which can assure
unconfined drilling progressing and operating the pressurized structure to
pressurized the Kelly bar that make Kelly bar pore-forming favorably.

Auxiliary winch
Auxiliary winch is comprised of the following parts: hydraulic motor reductor,
spool, hoisting, and wire rope, rope slings and so on. Auxiliary winch parks in the
tripod and the function of it are that lifts drilling tool and other heavies no bigger
than 11 tons in the pile foundation site, so it is the auxiliary hoisting equipment
when the rig works normally.

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 KR160M OPERATION AND MAINTENANCE MANUAL

4.3.5.4 Rotary table

Rotary table is the most important actuating unit for rig. It drives Kelly bar
slewing to complete drill feed movement. With external toothing mode, 2 hydraulic
motor reductor drive one barrel-type main arbor, which joined by slewing support of
external gear, and output torque through meshing engagement about the drive
screwing die of barrel-type main arbor inwall and the rectangle bond of Kelly bar, at
the same time, the friction drag produced by positive pressure would pressurize the
drilling bucket when transfer torque.
Rotary table matching low rotation speed of high pulling torque can be used for
pore-forming drilling operation.

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 KR160M OPERATION AND MAINTENANCE MANUAL
4.4 Operation handle button
All the functional parts of KR160M Drilling Rig are driven by hydraulic system;
every system operation is performed by hydraulic pilot system control; and working
condition of every part is monitored by the electrical system. All the operating and
monitoring devices of the whole machine are arranged in the operator's cab.
Specific position of respective parts are shown in Fig. 7A and 7B:

1. left operation lever 3. screen 4. engine functioning monitor panel

5. travel operation lever 6. mast adjusting lever 7. Pressure gauges
8. Right operation lever 9. engine start switch 10. gasoline throttle operation
lever
11. hydraulic system putting through switch 12. supplementary supervisory panel
13. work hour meter
Fig. 7A KR160M Piling Rig control and monitoring system layout

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 KR160M OPERATION AND MAINTENANCE MANUAL

B A E F

C D G H

LEFT HANDLE RIGHT HANDLE

Notes to left lever front and back
A PWM button B Front upside switch button
C Front underside switch button D Back switch button
2. Notes to right lever front and back:
E PWM button F Front upside switch button
G Front underside switch button H Back switch button
Fig. 7B Levers sketch

4.4.1 Left operation handles

Left handle PWM button A: push-up for slewing; Pull-down for slewing reset.
Front upside switch button B: Manual/automatic slewing positioning.
Front underside switch button C: Horn.
Back switch button D: Depth reset.

4.4.2 Right operation handles

Right handle PWM Button E: push-up for floating, pull-down for switching
between main and auxiliary winch, which can also be performed by pressing key 2
in the 2nd page of the display screen.
Front underside switch button G: Idle speed.
Back switch button H: crowd amplitude switch over. Likewise you can perform
the "pressing amplitude switch over" by pressing button 1 in the 2nd page of the
display screen.

4.5 Operating procedure

4.5.1 Left operation lever

While switching over to the main winch, pulling back the lever will cause the
main winch pulling Kelly bar up; when pushing forward the lever, the Kelly bar
down.

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 KR160M OPERATION AND MAINTENANCE MANUAL
When switched to the auxiliary winch, pushing the lever forward will cause the
auxiliary winch ropes down;
When unlocking the auxiliary winch, pulling the lever backward will cause
lifting. Pushing button A leftward and upward will enable the turret left turning;
Pushing button A rightward and upward, the turret turns rightward.

4.5.2 Right operation lever

Pushing leftward will enable the rotary table turning forward (namely move
forward into the ground with cutting and drilling). Pushing rightwards will enable the
rotary table reverse turning (namely Kelly bar unlock or sand drill bucket door
close).
While switching to pressing, pushing forward will cause pull-down cylinder
piston rod extending out, so to press the Kelly bar; Pulling back will enable the pull-
down cylinder piston rod retreating, and to lift the rotary table.
While switching to amplitude, pushing forward will enable the mast parallel
moving forwards; pulling back will enable the mast parallel moving backwards.

4.5.3 Switch over procedure

pressing the button 2 in the 2nd page of the display screen, or pulling down
the front switch E button on right operation lever will enable switching over the main
or the auxiliary winch; pressing the button 1 in the 2nd page of the display screen,
or pressing down the button H on the back of the lever will switch over the
amplitude pressing.

4.5.4 Floating Manual lever

Push-up button E on the right handle will enable
Kelly bar free floating. Or floating can be performed via
pressing the button 3 in the 2nd page of the display
screen, and you can switch back to the original function
in the display screen after the operation.
Pedal
4.6 Travel operation levers (pedals)
Two controlling modes are provided for the traveling
control: by manual levers and by pedals. Both the
control modes are interlocked, either of them can be
chosen for the control in practice, but the traveling
must be unlocked first.
While the operation lever is pushed forward, the machine advances; pulling
the operation lever backward, the machine goes reverse; one-sided lever operation

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 KR160M OPERATION AND MAINTENANCE MANUAL
for one-sided track movement, with the other track remaining fixedly; the machine
turning (e.g., left side lever is pushed forward, the machine advances turning right;
left side lever pulled back, the machine reverse turning right, vice versa); if one
lever is pushed forward while the other pulled backward, the machine will do zero
forward speed rotation (e.g., the left side lever forward while the right side lever
backward, the machine does only clockwise rotating; On the contrary, only anti-
clockwise rotating).
Note: Hereby mentioned "advance" or "reverse" refers to the driving wheels in
rear of the cab. If the driving wheel is located in front of the cab, the machine will
run in the opposite direction.

4.7 Mast Adjusting Lever

Operating this lever will adjust the mast angle;

pushing the operation lever forwards will enable the
mast to incline forwards; pulling it backwards will
enable the mast to incline backwards; pushing it
leftwards will enable the mast to incline leftwards;
Pushing it rightwards will enable the mast incline
rightwards.

Note: Pay attention to the operation. The speed of movement of each functional
part is directly related to the displacement of its operating lever; the smaller the
displacement, the lower the speed; the greater the displacement, the higher the
speed; when the displacement reaches the maximum position, the speed of
movement of the controlled mechanism will be the fastest, i.e., the movement
speed of the controlled mechanism can be controlled by the lever displacement.
Additionally, the moving speed of the lever could not be too fast.

4.8 Hydraulic System Putting Through Switch

Connect Close

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 KR160M OPERATION AND MAINTENANCE MANUAL
While this operating lever is pushed down, the hydraulic system is put through,
and the whole hydraulic system can work normally; while this operating lever is
pulled up, the hydraulic system is cut off, and the whole hydraulic system stops
working. When passing in and out the cab, this lever must be pulled up in order to
cut off the hydraulic system to prevent the lever from being mis-touched which
cause the rig operation resulting in unnecessary loss.
4.9 Pressure gauges
The three pressure gauges display respectively oil pressures of the two main
pumps and that of the auxiliary pump.

4.10 Display System

4.10.1 Boot screen

After starting the rig and showing the display, the display screen powered on
will first enter the boot screen (Picture-1), then wait for a few seconds, and
automatically enter the initial page (Picture-2). Press any key to enter the system

Picture-1 Boot page

Picture-2 The initial page

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 KR160M OPERATION AND MAINTENANCE MANUAL

4.10.2 Main action page

Picture-3 The initial page

(See the following picture-3), there are main information of working condition and
operation.
Main information includes: Drilling Depth, Drill Position, Single Depth, Mast Angle,
Slewing Angle, Left Pump
Pressure, Right Pump Pressure, Auxiliary Pump Pressure and Alarm Display.
Selection of working conditions; running time, operation of leg and soil remover, etc.
Information Bar:
is the maintenance information prompt icon that appears and flashes when the
running time reaches the specified time;

The icon (main winch) appears when the machine is in the main winch state. It

indicates the machine is in the auxiliary winch state when the icon ( auxiliary
winch) appears;

The icon appears when the machine is under pressure. It indicates the

machine is in the variable amplitude state when the icon appears, it;

The running time icon ( running time) records the running time of
the controller, which is equivalent to the rotary drilling time.
Key Functions:
F2: Working condition selection : Press to switch to CFA working mode,
and press again to return to the rotary working mode;
F4 :“Operation” :the display interface into “Operation”. (See the following
picture-4)

F7 Switch :of main winch and auxiliary winch: only when opening this
switch, the switching key of

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 KR160M OPERATION AND MAINTENANCE MANUAL
main winch and auxiliary winch can be used.

F8: Travelling Switch : When starting the rig, the beginning condition is
closed. When press this switch, it
will become open, and push travelling plate to make crawler walk.

F9 Touching ground protection switch: When starting the rig, the beginning
condition is open; when
close this switch, the function of main winch touching ground is closed.
F13: Leg Stretch : Reset switch, press fixedly, Leg cylinder stretch, loosen
this switch and the operation ends.
F14: Leg Shrink : Reset switch, press fixedly, Leg cylinder shrink, loosen
this switch and the operation ends.

F15: Cleaners Stretch : Reset switch, press fixedly, Cleaners cylinder

stretch, loosen this switch and the operation ends.

F16: Cleaners Shrink : Reset switch, press fixedly, Cleaners cylinder

shrink, loosen this switch and the operation ends.

4.10.3 AUX-Operation page

Press “F4 Operation” on the home page to enter (Picture-4)

Picture-4 AUX-Operation page

Key Functions:
F3: Tensioning Stretch : Reset switch, press fixedly, Tensioning cylinder
stretch, loosen this switch and the
operation ends.
F4 ： Tensioning Shrink : Reset switch, press fixedly, Tensioning cylinder
shrink, loosen this switch and the
operation ends.

F12: Limit switch: When the rig begins, the limit switch is on working
condition; if press the switch to
close, the rig’s limit switch has no effect (main winch and mast left & right limit);

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F13: IO check : Used to monitor input and output points of the controller in
real time;
F14: INFO : Used to check the machine maintenance information;
F15: SET : Press to enter the "Parameter Determination" page (Picture-16-
Picture-20)

F16: Back : Press to return to the main operation page;

1.3.1 Several operation modes of mast

Mast operating interface: Continuously press the Key F7 to switch between

"Manual" → "Auto". （Picture-5 and Picture-6）

Picture-5 Picture-6
"Manual" state: operate the mast only through the mast control lever, as shown in
Picture-5
"Auto" state: press F8 to switch between "Standing" → "Level" → "Down" three
automatic operation statuses,
as shown in Picture-6.
"Sanding" state: press F9 “START” to start the automatic mast erection function,
and press it again to stop the
automatic mast erection, as shown in Picture-7.
"Level" state: press F9 “START” to start the automatic leveling, and press it again to
stop automatic leveling; at
the “Sanding” state, when mast angle is Y ≥ -5 degrees, the system will enter the
automatic leveling state automatically, as shown in Picture-8.
"Auto" state, press F9 “START” to start the auto mast lowering function and press it
again or when the mast angle Y ≤ -90 degrees, the automatic mast lowering stops

Picture-7 Picture-8

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Before the automatic mast erection, it is a must to confirm that the

boom is raised to be higher than the cab, the mast is not limited, the drill pipe has
enough space to move without hitting the ground, the wire rope is tensioned and
not loose, and there are no wires, buildings or other obstacles above the machine.
Otherwise, there is a risk of accidents.
For the automatic mast erection operation, must be turned
on.
For the automatic mast erection operation, it must be ensured that the
ground is flat and solid, and the inclination of the chassis cannot exceed 1 degree.
Otherwise there is a risk of losing control.
In the process of the automatic mast erection, the operator cannot
leave the cab and should always pay attention to the state of the mast. Otherwise,
immediate stop is impossible in case of an accident and thus result in a safety
incident.
The angle in X direction should be controlled within ±0.5 degrees
during the automatic mast erection. The mast should be manually adjusted to the
vertical status during construction.
No other page can be entereed in the automatic state. It is necessary

to adjust to the “manual” state before exiting or switching to another page.

Before the mast erection operation, first confirm the state of wire
ropes of both main and auxiliary winches to make sure there is no interference
while the mast is moving.

4.10.4 IO Check page

Press F13 on the “Operation” page to enter

Input and output states of the controller are detected and whether the controller
executes the command correctly is judged. Press to enter the “IO Check” page.

Picture-9

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Picture-10
The status of each input port of the controller is displayed. indicates there is no
signal input, while indicates the controller receives signals.
The valid signals that are receivable to the controller are not only 24V,
but also 0V.

4.10.5 Maintenance information inquiry

Press F14 on the “Operation” page to enter. This page mainly

provides maintenance information inquiry. When the running time is arrived, will
appear and flash in the information bar on the main operation page. And the icon

will flash as well.

Picture-11, Picture-12, Picture-13,Picture-14,Picture-15.

Picture-11

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Picture-12

Picture-13

Picture-14

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Picture-15

When the running time comes to the maintenance time, the texts above
the relevant switch buttons will flash for quick
finding of the relevant maintenance information.

4.10.6 Parameter determination

Press F15 on the “Operation” page to enter.

Picture-16 Parameter Setting

Parameters of each sensor at set, as shown in Picture-16, Picture-17, Picture-18,
Picture-19 and Picture-20.
The first to enter are the depth calibration, the ground contact of the main winch,
the pull of the main winch, and the drill pipe depth calibration under CFA working
condition.

4.10.6.1 How to enter values on the display screen

By pressing first, a cursor will appear around the red values on the screen.

By pressing continuously, the cursor will switch back and forth among

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several red numbers. To adjust a value, move the cursor to this value, press

to determine the figure to be modified, press or to allow the figure

indicated by the cursor to switch between “0-9” and “decimal point and minus sign”.

Press to confirm the figure desired, then press or to move

the cursor and enter figures of other digits. Press after all of them are
entered.
The default digit of the cursor is the highest digit. For example, to enter

“150”, the cursor starts at the hundreds place “1”, press to move to tens
place and the units place.
The decimal point also occupies one place. For instance, “1.5” actually
needs the input of three places, namely ‘1’, ‘.’, and ‘5’.

4.10.6.2 Parameter calibration

4.10.6.2.1 Depth calibration:

Method:
1. First ground the drill rod, clear the depth, and the raise the rotary drive.
2. Lift the drill pipe, raise the main winch, measure with a tape measure, and let
the drill pipe rise to 1m high.
3. Compare the depth value on the display screen and the value measured with
the tape measure.
4. Adjust the value. If it is less than “1m”, first enter the value “50” to see if the
value altered in

Picture-17

is close to the measured value “1m”. If it is close to “1m”, increase the

value until is “1m”. If it is greater than “1m”, enter a negative value and

adjust continuously to make “1m”.

4.10.6.2.2 Setting of pull

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 KR160M OPERATION AND MAINTENANCE MANUAL
Set the threshold value of the ground contact protection. When the value set is
smaller than the pull measured, the ground contact protection acts and the main
winch stops falling. Otherwise, the main winch can be normally lowered.

The default set value of is 3 tons.

This value is determined by the weight of the drill pipe, which must be
greater than the weight of the core rod (the innermost rod) of the drill pipe plus the
drill bucket. Otherwise, the main winch can happen to pause or suspension in the
air due to lowering failure.
If the weight of the drill pipe is not known, it can be estimated based
on the weight displayed by . If the weight displayed is 8t (including drill
pipe and drill bucket, suspended), it can be estimated that the drill bucket is 1t, and
the core rod of the drill pipe (4 sections) 1.5t, roughly estimated 3t.

4.10.6.2.3 Calibration of pull

Pull of the main winch is calibrated;

Calculation formula: L 实(actual) is the actual display value;
L is the value displayed after calibration;
V1 is input value;
P= P 实×(1+ V1 /1000)
P= P(actual) × (1+ V1 /1000)
For instance: P 实(actual)=400
P = 420 (value measured by the flow meter);
V1 =（（420/400）-1）×1000；
V1 =50;

4.10.6.3 Mast calibration

Press to enter the calibration of mast rate. The running speed of the mast
is controlled by entering different values.

Picture-18

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The default values are:

The minimum current cannot be greater than the maximum current,

otherwise it will run at the fastest speed and pose a safety risk.
The maximum current input must not exceed 1000 to avoid damage to
the controller.
The values cannot be modified unless under special circumstances.
For any doubt, please consult after-sales department of Tysim Piling Equipment
Technology Co., Ltd.

4.10.6.4 Calibration of tilt sensor

Press to enter, where the tilt sensor is calibrated, generally with the
theodolite.

Picture-19

Original value measured of the tilt sensor

The calibrated value to be entered

Value after calibration

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Quickly calculate the set value: The set value is equal to the negative value before
setting
For example, the value of the X axis displayed before setting is -0.5, the set value
entered is 0.5, and then the final value displayed is 0.
The value of the Y axis displayed before setting is 0.5, the set value entered is -
0.5, and then the final value displayed is 0.
Despite that the tilt sensor has been calibrated before the machine is
delivered from the factory, it still needs to be calibrated after some time. It is
recommended to calibrate the tilt sensor once every three months.
The calibration of the tilt sensor directly affects the perpendicularity of
boreholes drilled by the rig. It is recommended to record original values before
entering new values.

4.10.6.5 Mast handle calibration

The mast control handle is calibrated.

Picture-20

The default calibration values are as below:

255 255

0 0

126 126

4 4

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The value cannot be altered freely. Unauthorized alteration will affect

the control of the handle over the mast. For alteration, please contact after-sales
service department of Tysim Piling Equipment
Technology Co., Ltd. first.
4.10.7 Mast adjusting handle
The mast angle can be adjusted by controlling
the handle and pressing the handle operation
enable button on the mast adjusting handle, as
shown in Picture-21
When the control handle is pushed forward, the
mast leans forward;
When the control handle is pulled backward, the mast leans backward;
When the control handle is pushed leftward, the mast leans leftward;
Picture-21
When the control handle is pushed rightward, the mast leans rightward;

There is a point to be noted about the control part. The moving

speed of each functional part is directly related to the displacement of the
control handle. When the displacement of the handle is small, the moving
speed of the controlled mechanism is low; when the displacement of the handle
is large, the moving speed of the controlled mechanism is fast. When the
displacement of the handle reaches the maximum position, the moving speed
of the controlled mechanism is the fastest. That is, the speed of movement of
controlled mechanisms can be controlled by controlling displacement of the
handle. It should also be noted that the handle cannot be moved too fast.
Before the mast erection operation, it must be confirmed that the
ground is flat and solid, and the inclination of the chassis cannot exceed 2
degrees. Otherwise there is a safety risk.

Before the mast erection operation, first confirm the state of wire
ropes of both main and auxiliary winches to make sure there is no interference
while the mast is moving.

Before the mast erection operation, it is a must to confirm that the

boom is raised to be higher than the cab, the mast is not limited, the drill pipe has
enough space to move without hitting the ground, the wire rope of the main which is
tensioned and not loose, and there are no obstacles above the machine. Otherwise
there is a risk of accidents.

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4.10.8 Instructions for Left and Right Control Handles

4.10.8.1 Right handle

4.10.8.2 Left handle

4.10.9 Wire Number Correspondence Table

No. Wire Function No. Wire Function
No. No.
1 TM1.1 Left mast extending 28 TM2.1 Main/auxiliary switchover
(output)
2 TM1.2 Left mast retracting 29 TM2.2 Slewing (output)
3 TM1.3 Right mast extending 30 TM2.5 Auxiliary winch limit (input)
4 TM1.4 Right mast retracting 31 TM2.6 Handle effective
5 TM1.7 Soil remover extending 32 TM2.8 Main winch limit (output)
6 TM1.8 Amplitude switchover 33 TM2.9 Auxiliary winch limit (output)
(output)
7 TM1.1 Handle input Y axis 34 TM2.1 Ground contact protection
2 0 (output)
8 TM1.1 CFA mode 35 TM2.1 Handle input X axis
4 2
9 TM1.1 Tension switchover 36 TM2.1 0V
5 3
10 TM1.1 Alarm lamp 37 TM2.1 Slewing brake
6 6
11 TM1.1 Rotary drive high speed 38 TM2.1 Floating
7 (output) 7
12 TM1.1 Crowd/amplitude 39 TM2.1 Main winch limit (input)
8 switchover (input) 9
13 TM1.2 Left mast limit 40 TM2.2 Rotary drive high speed
0 1 (input)

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14 TM1.2 Right mast limit 41 TM2.2 Floating brake
1 2
15 TM1.2 Soil remover retracting 42 TM2.2 Service unlock
2 3
16 TM1.2 Leg switchover 43 TM3.2 Slew effective
3 0
17 TM3.2 5V 44 TM3.2 Main/auxiliary switchover
1
18 TM3.3 0V 45 TM3.2 Depth reset
2
19 TM3.5 Main pump pressure 1 46 TM3.2 Floating button
3
20 TM3.6 Main pump pressure 2 47 TM4.1 0V
21 TM3.7 Auxiliary pump pressure 48 TM4.2 CANH
22 TM3.8 Main winch pull 49 TM4.3 0V
23 TM3.1 0V 50 TM4.4
2 P1
24 TM3.1 CFA sounding A 51 TM4.5
6 P1
25 TM3.1 CFA sounding B 52 TM4.6
7 CANL
26 TM3.1 Sounding A
8
27 TM3.1 Sounding B
9

If you need to handle mast with display screen, before operation,

you must choose operating mode, then you can click and handle mast. Jog means
touching and clicking button. Holding down means operation, releasing means
stop.

Before using the function of down/raise the mast automatically,

please check weather the display of mast regular is normal and height of mast is
higher than the height of cab. In the process of down/raising the mast automatically,
please pay attention to mast regulai all time. If an exception occurs, please turn off
the engine immediately(not pilot switch)

The above pictures are for reference only; please in kind prevail
if those pictures are inconsistent with the product. the specific text and
operation sequence will be subject to change due to the system upgrading
without notice.

4.11 Engine Working Monitor Panel

The electronic monitoring system consists of the action alarm, alert indicator,
gauges, message display, keypad and a controller.

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Fig. 8 Engine working monitor panel

(1) Alert indicator (2) Engine speed dial indicator (3) Gauges (4) Message display
(5) keypad

Note: If an alarm is given, immediately check from the monitor, implement

operations indicated on the monitor screen, or perform maintenance.
Engine Speed Dial Indicator: This digital display indicates the current
position of the engine speed dial.
Gauges: The gauge cluster contains gauges for the engine coolant
temperature, hydraulic oil temperature, and fuel tank level.
Message display: The message display consists of a graphic display in
order to show information that pertains to various machine functions.
Keypad: The keypad has eight keys that are used to input information into the
electronic monitoring system.

Up key: press this key to move the cursor upward.

Right key: press this key to move cursor rightwards or to decrease the value.
Set key: press this key to set again or to set value.
Menu key: press this key to access master menu.
Left key: press this key to move leftward cursor or to increase thee value.
Down key: press this key to move downward cursor.
Cancel key: press this key to reject an instant choice or to reject a design
value. Depressing this key can regain display by default.

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OK key: press this key to choose an item entered from the list.
The electronic monitor and control system is used to worn the operator that
there is failure occurred or approaching failure. Malfunctions may happen in several
systems.

4.11.1 Pre-start Monitoring Function

Turn the engine start switch to ON (start) position. The alert indicator and
gauges turn on. After approximately two seconds, images and characters will
appear in the message display.
The coolant temperature, the hydraulic oil temperature, the fuel level, and the
position of the engine speed dial are now indicated.
The monitoring system checks the level of the engine coolant, the engine oil,
and the hydraulic oil before the engine starts.
When the fluid level check operation is performed, FLUID LEVEL CHECK
ACTIVATED appears in the message display.
When the fluid level check operation is finished, FLUID LEVEL CHECK
COMPLETED appears in the message display.
If the fluid level check operation detects a low fluid level, the appropriate
message will be displayed and pictograph will be shown to indicate the fluid level
that is low.

Notes: If more than one fluid level is low, the display will cycle through the
low fluid levels in one second increments. The low fluid level indicators will
disappear after five seconds when the engine is started.
Note: While machine is on a slope, precise liquid level check can not be
performed. Liquid level checking should be done on level ground.

If engine starts during the liquid level checking," FLUID LEVEL CHECK
CANCELLED"appears on the message display.
After checking the filter working hours, check the liquid service hours. If a filter
or liquid is found over the recommended exchange cycle, “CHECK FILTR / FLUID
INFO"appears on the message display.
After the systematic check is finished, the message display will show the
default display. The default display shows current time and the status of the travel
speed control switch.
4.11.2 Warning Categories

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The Electronic Monitor System (EMS) provides three warning categories.

The first warning category requires only the operator awareness. The second
warning category requires a change to the machine operation or a change to the
maintenance of the machine. The third warning category requires immediate
shutdown of the engine.
If multiple warnings are present in the system, the most important problem is shown
first. Press the up key or press the down key in order to view all of the warnings that are
present in the machine. If no keys are pressed within five seconds, the display will return
to the most important problem.
Note: The menu is still functional by pressing the menu key.
 Warning category 1
In this category, only a warning will be shown in message display. This
category alerts the operator that the machine system needs attention. Failure of
these systems will not endanger the operator. Failure of these systems will not
cause serious damage to the machine components.
Battery Voltage--this warning is presented in message display, indicating that
there is malfunction in the electric charging system. The warning will also be
presented in normal starting procedure. The machine can keep working while the
warning is displayed. If the warning remains, you should check immediately the
electrical parts of charging circuit immediately, and perform necessary repairs.
Electronic Controller--in case the controller function is found out of order, or
communication between the controller and the monitor with problem, the alarm will
be presented in message display. Malfunction may occur out of electronic
controller.
Stop the engine, and restart it after a few minutes. If the warning will not be
presented again in message display, then the malfunction does not exist. In case
the warning is presented again, then problem exists. Please consult TYSIM user
service center for necessary service.
In case it can not be repaired immediately, you may use the backup switch to
MANUAL position and continue operating the machine.
While the backup switch is in MANUAL position, information" BACKUP
SWITCH ON" will be presented in message display. The message display will no
longer work.

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The backup switch is only temporary procedure. Perform any necessary
repairs as soon as possible.
Monitor Panel—This warning is displayed in message display, a problem may
exist in the monitor panel. The problem might exist in the data communication lines.
Consult TYSIM service center for the necessary repairs
Restricted Fuel Filter - while fuel filter restricting, this warning indication will be
presented in message display. If fuel filter is restricted, engine output will be
decreased. You should immediately check the fuel filter. Replace the fuel filter if
necessary.
Restricted Air Filter -- while air filter restricting, this warning indication will be
presented in content indicator. If air filter is restricted, engine output will be
decreased. You should immediately check air filter and clean it. Inspect air filter
condition, and replace air filter if necessary.
Restricted Hydraulic Return Filter – This warning is displayed in message
display when the hydraulic return filter (capsule filter) is restricted. A restricted
hydraulic return filter will cause hydraulic components to malfunction. Turn the engine
start switch to OFF position and then turn the engine start switch to the ON position.
If the warning disappears the filter is good. Operate the machine on flat ground for at
least ten minutes. If warning reappears, replace the return filter cartridge.
Note: hydraulic pressure back flow clogging alarm will disappear after 3
minutes display.
Water separator-- when water separator is full, this warning indication will be
presented in message display. Water in the separator should be discharged as
soon as possible.
fuel level-- if fuel oil in the fuel tank is below the specified level, this warning
indication will be presented in message display. You should immediately add fuel
oil.
engine oil height-- if engine oil in the engine is below the specified level, this
warning indication will be presented in message display. You should immediately
add engine oil.
Hydraulic oil height-- if hydraulic oil in the oil tank is below the specified level,
this warning indication will be presented in message display. You should
immediately add hydraulic oil.
Engine coolant height-- if engine coolant in the engine is below the specified
level, this warning indication will be message display. You should immediately add
coolant.
 Warning Category 2
In this category, the warning is displayed in message display and the alert
indicator comes on. This category requires a change in machine operation in order

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to reduce excessive temperature in one of the machine system or more.
Hydraulic oil temperature-- this warning indicates that the hydraulic oil
temperature is too high. If this warning indication is presented in message display,
you should lower machine working speed. Keep engine running in idle speed until
hydraulic oil temperature decrease to normal level. The engine is to run in idle
speed for a period. If this warning remains exist, you should stop engine. You
should check hydraulic oil level and check hydraulic oil cooler for debris. Perform
any necessary repairs as soon as possible.
Coolant temperature-- this warning indicates coolant temperature too high. If
this warning indication is presented in message display, you should lower machine
working speed. Keep engine running in idle speed until engine cools down. Keeps
the engine running in idle speed for a period, if this warning remains existing, you
should stop engine. Check engine coolant, and check radiator for debris.
 Warning category 3
The following movement will occur with warning of this category:
 The warning is displayed in message display.
 The alert indicator comes on.
 The action alarm sounds.
This category requires immediate shutdown of the machine in order to prevent
injury to the operator and/or severe damage to the machine.
Note: If lubricating oil insufficient warning appears, it is recommended to
shutdown the machine and informs TYSIM service workers in time for
directions and service.
Engine oil pressure—while the engine oil pressure is too low, this warning
indication will be presented in message display. Stop the machine immediately if
this warning appears. Stop the engine and find out break-down causes. Do not
operate the machine before clearing off a fault.
 Others
Air inlet heater-- if engine coolant temperature is too low, air inlet heater will
work. When engine start switch is in"ON" position, this indication will be presented
in message display. The engine can be started after this indication disappears from
the message display.

4.11.3 Gauges

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Fuel level (1) -- this gauge displays oil level in the fuel oil tank. With this gauge
operator can determine the fuel quantity in the fuel tank. When fuel gauge indicates
that oil level is in the white range, fuel oil should be added immediately.
Engine coolant temperature (2) -- this gauge displays engine coolant
temperature. The green range means normal working temperature. While red
range means overheating.
Hydraulic oil temperature (3) -- this gauge displays hydraulic oil temperature.
The green range means normal working temperature. If the meter reaches the red
range, you should relieve system load. If the gauge stays in the red range, stop the
machine and investigate the cause of the problem.

4.11.4 Main menu

The main menu allows the operator to view information concerning the
machine. The main menu also allows the service technician to perform adjustments
to the machine.

(1) up key (2) right key (3) set key (4) menu key
(5) left key (6) down key (7) Cancel key (8) OK key

Press menu key when the default display is active.

After the menu key is pressed the following four options are displayed:
PREFERENCES, SELECT TOOL, FLTR / FLUID INFO and SERVICE OPTION.
Press up key (1) or press down key (6) in order to highlight the desired menu.
Press OK key (8). Press the Cancel key (7) in order to exit the main menu and
return to the default display.

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Note: If no keys are pressed within 30 seconds, the main menu will be
cancelled and default display will be shown.
FLTR /FLUID INFO—this menu allows the operator or the service technician
to view the current service hours and the recommended service intervals on a
variety of maintenance items.
SERVICE OPTIONS—this menu allows the service technician to reset the
filter/fluid information. This menu requires the use of a password. The password
can be changed by using this menu. Machine information can also be obtained with
this menu.
 1) Language selection
 Press menu key (4).
 Press up key (1) or down key (6) in order to highlight the PREFERENCE
menu. Press OK key (8).
 Press up key (1) or press down key (6) in order to highlight the SELECT
LANGUAGE menu. Press OK key (8).
 Press right key (2) or left key (5) in order to scroll through available
languages. Press set key (3) in order to select the desired language.
Note: Press Cancel key (7) in order to return to the default display.
 2) Clock adjustment
 Press menu key (4).
 Press up key (1) or press down key (6) in order to highlight the
PREFERENCE menu. Press OK key (8).
 Press up key (1) or press down key (6) in order to highlight the SET CLOCK
menu. Press OK key (8).
 Press right key (2) or press left key (5) in order to select the hour or the
minute. Press up key (1) in order to increase the number. Press down key
(6) in order to decrease the number.
 When the clock is set to the desired time, press set key (3).
Note: Press cancel key (7) in order to return to the default display.
 3) Display adjustment
This display adjustment menu is used to adjust the contrast of the message
display. This menu is also used to adjust the brightness of the display backlight.
There are two settings of the backlight. One setting is for operation during the day
when the lights are off. The other setting is for operation at night when the lights are
on.
 4) Contrast
 Press menu key (4).
 Press up key (1) or press down key (6) in order to highlight the

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PREFERENCES menu. Press OK key (8).
 Press up key (1) or press down key (6) in order to highlight the ADJUST
DISPLAY menu. Press OK key (8).
 Press up key (1) or press down key (6) in order to highlight the CONTRAST
menu. Press OK key (8).
 Press up key (1) or press down key (6) in order to adjust the contrast.
Note: Press Cancel key (7) in order to return to the default display.
 5) Brightness
 Press menu key (4).
 Press up key (1) or press down key (6) in order to highlight the
PREFERENCES menu. Press OK key (8).
 Press up key (1) or press down key (6) in order to highlight the ADJUST
DISPLAY menu. Press OK key (8).
 Press up key (1) or press down key (6) in order to highlight the
BRIGHTNESS menu. Press OK key (8).
 BRIGHTNESS—Select this menu in order to change the brightness of the
display during the day when the lights are off. Press up key (1) or press
down key (6) in order to adjust the brightness.
Note: Press Cancel key (7) in order to return to the default display.
BRIGHTNESS—Select this menu in order to change the brightness of the display at
night when the lights are on. Press up key (1) or press down key (6) in order to
adjust the brightness.
Note: Press cancel key (7) in order to return to the default display.
 6) Filter / fluid maintenance information
This menu allows the operator and the service technician to view the
accumulated service hours and the recommended change intervals for the following
filters and lubricants.
Engine oil
Engine oil filter
Fuel filter
Swing drive oil
Pilot hydraulic oil filter
Case drain oil filter
Return hydraulic oil filter
Final drive oil
Hydraulic oil
Engine coolant
 Press menu key (4).

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 KR160M OPERATION AND MAINTENANCE MANUAL
 Press up key (1) or press down key (6) to in order to highlight the FLTR /
FLUID INFO menu. Press OK key (8).
 Press right key (2) or left key (5) in order to scroll through the available
service items.
Note: Press Cancel key (7) in order to return to the default display.
The service hours cannot be reset by using this menu. Refer to Operation and
Maintenance Manual,”Filter/Fluid Hours Reset”for the procedure to reset the service
hours.
 7) Password entry
A password is required in order to access the service options menu and the
tool selection menu. Follow the procedure in order to enter the password.
 Press menu key (4).
 (2) Press up key (1) or press down key (6) in order to highlight the SERVICE
OPTIONS menu. Press OK key (8).
 (3) Press right key (2) or left key (5) in order to select the desired position.
Press up key (1) or down key (6) in order to input password.
Note: The password is alphanumeric. You may choose from 0 to 9. You may
also choose from A to F. The initial password is "0001".
 Press OK key (8) when you finish entering the password.
Note: Press cancel key (7) in order to return to the default display.
 The monitoring system checks the password. If the password is correct; you
will have access to the service options menu.
 If the password is incorrect, INVALID PASSWORD will be displayed.
 Press OK key (8) in order to retry the password or press Cancel key (7) in
order to exit.
Note: Consult TYSIM user service center if you forget your password.
 8) Password change
 Press menu key (4).
 Press up key (1) or press down key (6) in order to highlight the SERVICE
OPTIONS menu. Press OK key (8).
 You will be prompted to enter a password. Refer to Operation and
Maintenance Manual, “Password Entry”for information on entering a
password.
 Press up key (1) or press down key (6) in order to highlight the CHANGE
PASSWORD menu. Press OK key (8).
 Press right key (2) or left key (5) in order to select the desired position.
Press up key (1) or down key (6) in order to select the new password.
Note: THE password is alphanumeric. You may choose from 0 to 9.You may

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 KR160M OPERATION AND MAINTENANCE MANUAL
also choose from “A” to “F”.The initial password is"0001".
 Press set key (3) when you finish entering the new password.
Note: Press cancel key (7) in order to return to the default display.
 After set key (3) is pressed you are asked to confirm you selection. Press OK
key (8) in order to save the password in memory and return to the default
display.
Note: Press cancel key (7) in order to return to the default display without
saving the password.
 9) Machine Information
This menu allows the operator or the service technician to view the engine speed,
the main pump delivery pressure, and other options as well.
 Press menu key (4).
 Press up key (1) or press down key (6) in order to highlight the SERVICE
OPTIONS menu. Press OK key (8).
 You will be prompted to enter a password. Refer to Operation and
Maintenance Manual,”Password Entry”for information on entering a
password.
 Press OK key (8) in order to select MACHINE INFO.
 You may now view the following information.
 Engine speed
 Implement pump pressure (drive pump)
 Implement pump pressure (idle pump)
 Power shift pressure (implement pumps)
 10) Filter / fluid hours reset
This menu allows the operator and the service technician to reset the
accumulated service hours for the following filters and lubricants.
Engine oil
Engine oil filter
Fuel filter
Swing drive oil
Pilot hydraulic oil filter
Case drain oil filter
Return hydraulic oil filter
Final drive oil
Hydraulic oil
Engine coolant
 Press menu key (4).
 Press up key (1) or press down key (6) in order to highlight the SERVICE

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OPTIONS menu. Press OK key (8).
 You will be prompted to enter a password.
 Press up key (1) or press down key (6) to in order to highlight the RESET
FLTR / FLUID HR menu. Press OK key (8).
 Press right key (2) or left key (5) in order to scroll through the available
service items.
 Press set key (3). After set key (3) is pressed you are asked to confirm your
selection. Press OK key (8) in order to reset the service hours.
Note: Press Cancel key in order to return to the default display without
resetting the service hours.

4.12 Service hour meter

Service hour meter—this display indicates the total operating hours of the
machine. Use the display to determine the service hour maintenance intervals.

Fig. 9 Service hour meter

4.13 Supplementary control panel

Fig. 10 Supplementary control panel

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Light switch—push the switch in order to turn on the work lights.

Whenever you push the switch, you change the pattern of the work lights that
are turned on. The indicator lights that are in the cab indicate the pattern of the
work lights that are turned on.
Pattern 1--when you press the light switch once, indicator light (1) turns on.
When indicator light (1) is on, the following work lights are turned ON: work light (A)
on the chassis and work lights (B) are mounted on cab.
Pattern 2--when you press the light switch twice, indicator light (1) and
indicator light (2) are turned on. When indicator light (1) and indicator light (2) are
on, the following work lights will be ON: work light (A) that is mounted on the
chassis, work lights (B) that are mounted on the cab, and work light (C) that is
mounted on the left side of the boom.
Off-- when both of indicator lights are off, all of the work lights off.
Note: Cab lights (B) and a light on the right side of the boom are optional.

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5 USE AND OPERATION OF THE DRILLING RIG

Before using and operating the KR160M Drilling Rig, our corporation hereby
reminds you to follow the safety precautions in Part II of these manual and relevant
precautions of safety use and operations.

5.1 Start-up the Rig

5.1.1 Before starting

 Look around and under the machine for defilement clogging, loose bolts, oil
leakage, and coolant leakage, damaged or worn parts.
 Check the condition of all the parts in the hydraulic system.
 Check all the engine oil level, coolant level, fuel oil level and hydraulic oil
level.
Note: Engine crankcase oil insufficient or overfill, both the two cases will
result in engine damage.

5.1.2 Start-up
 Turn the battery disconnect switch to the ON position.
 Make sure that the reset button for the circuit breaker remains depressed.
 Move the hydraulic controls lockout lever to the LOCKED position.
 This machine is equipped with engine neutral starting system. The engine
can be started only when the hydraulic controls lockout lever is in LOCKED
position.
 Turn engine start switch (1) to the ON (start) position.
 The monitoring system starts.
Note: If the engine start switch is held in the On position for two seconds or
more, the pre-start check of the monitoring system will be activated. If any
fluid levels are low, the low fluid level will be shown on message display (3). If
the fluid level is too low, and the corresponding fluid to the specified level
before you start the engine.
Ensure that on the message displays there is such message" INTAKE AIR
HEATER ON". If this message is shown on the message display 3), that indicates
engine coolant temperature too low, and the engine can not start properly.

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Message display
If the engine coolant is at lower temperature, air intake heater will start. The
message display will display the message" INTAKE AIR HEATER ON". The engine
should be started only after the message disappeared (Make the warning buzzer
before the engine start-up to call the working personnel's attention) .Turn the
engine speed switch (2) to medium speed position"5"or"6".
Note: Starting the engine shall not exceed 16 seconds. In case that the
engine will not start, the engine start switch must be turned to OFF position
before restarting the engine.
Turn engine start switch (1) to the START position. Release the engine start
switch key after the engine starts.
With standard specifications, this machine’s engine can start in areas where
temperature is as low as - 18º C. For areas that are cooler, two types of starting
kits are available, and the ether starting aid.
Make the engine zero-load running in idle speed for 15 ~ 20 minutes; after the
machine is preheated, various components of the rig become suitable for
operations.

5.2 The rig shutdown and the engine shutdown

Note: Immediately stopping the engine after working with load will result
in engine overheat and engine components fast worn-out. Make reference to
the following shutdown procedure to enable engine cooling, and to prevent
turbocharger shell overheat, which will result in engine oil pyrogenic
problem.
Stop the machine and enable the engine idle running for 5 minutes.
Note: While the engine is running, do not turn the battery cut-off switch to
OFF position, or else serious damage of the electrical system may be resulted
in.
 Turn the engine start switch to OFF position and remove the engine start
switch key.

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 Turn the engine start switch to OFF position. In case the engine will not stop,
make the following procedure.
 This switch is located left-hand underside the operator seat.
 Raise the cover (1).
 Push down switch (2), and that will stop the engine.
Note: First of all, stop the engine by the engine start switch. Using the engine
stop controller is another way to stop the engine.
 Push back the switch to the original position. Ensure the engine restarting.
 If the engine can not be stopped with the above steps, use the following
method.
 Stop the engine if electrical malfunction appears.
 Turn the engine start switch to OFF position. In case the engine will not
stop, make the following procedure.
 Turn oil disconnect valve clockwise to cut-off fuel oil supply. The engine will
stop after fuel oil in the fuel pipeline is exhausted.
Note: The engine may perhaps remain in operation for a few minutes.

5.3 The Rig Entering Worksite

The rig entering worksite is enabled by slab transport vehicle transportation;
after the rig entered the site, select level and firm position, let down the gangway
(angle of the gangway and the ground surface shall not exceed 15°) . Start the
engine, then operate the steer operation levers, let the track direct to the gangway,
then drive the rig slowly down from the vehicle. During driving the rig from the
transport vehicle, mast height shall be adjusted at any moment, in order to prevent
the equipment from touchdown and parts damage.

Fig. 12 Sketch of the rig approach to or leaving the flat bed truck

The drilling equipment can be installed after the rig driving down to the ground.
Only two kinds of operations should be performed for the rig equipment
installation: Stretch track shoes, and raise the mast upright from travel position to
working condition; Fix the Kelly bar.
 Drive the rig to level, solid and clean ground, pull out the four track set pins,
extend the track to maximum width and insert the set pins.

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 Pull out the set pin between the upper mast and master mast (in
transportation position this pin is used to fix the folded upper mast and the
master mast). Extend the upper mast together with the lift cathead to a
position direct to the master mast. Fasten the upper mast and the master
mast reliably together by bolts.
 Connect the cathead transverse fixing beam with oil cylinder piston rod by
locking rope. Operate the lever (see the lever operating function), and
stretch out the pressing cylinder piston rod, and lift the cathead. Enable the
cathead seat close to the upper end of the upper mast and fasten the both
together by bolts. (as shown in Fig. 13)

Fig. 13
 Install the wire rope of main winch according to the schematics

Fig. 14
 Extend the main winch rope until it is long enough to install the lifting Kelly
bar.

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 Alternately operate the luffer operation lever and the mast operation lever to
raise the mast gradually to upright status. (as shown in Fig. 15)
 In the above mentioned procedure, as lower end of the middle mast touches
the upper end of the lower mast, immediately stop the operation lever
controlling the mast (or else machine parts will be damaged) ; Fasten the
both masts together reliably. (as shown in Fig. 16)

Fig. 15 Fig. 16
 Remove the supporting link rod of the lower mast.
 Operate the pull-down cylinder, extend the pull-down cylinder piston rod to
rotary table bracket ear, connect the pull-down cylinder piston rod and
rotary table bracket together by dowel pin.
 Adjust the rig direct-axis and the Kelly bar to the same straight line position,
and make the upper end of the Kelly bar direct to the rig.
 Connect the main winch rope with the Kelly bar upper end swivel element
reliably by dowel pin, and curb the dowel pin by a split pin. (as shown in
Fig. 17)
 Adjust the mast to 4°angle tilt forward. Slowly start the main winch, and lift
the Kelly bar slowly. While lifting the Kelly bar, move the rig close to the
Kelly bar. Right before the Kelly bar leaving the ground; enable the Kelly
bar positioned vertically to avoid it from discharging after it leaving the
ground. (as shown in Fig. 18)

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Fig. 17

Fig. 18

 Keep lifting the Kelly bar to a height above the rotary table, and then
stop lifting. And then adjust the Kelly bar to vertical status in a
extremely slow speed (Note: movement must be extremely slow, or else
discharging Kelly bar may result in parts damage and life injury) .Here,
a worker is needed working on the rotary table, assisting to fix the Kelly
bar. The rotary table is located in the middle-lower part of the mast; lift

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the rotary table to a certain height with reference to the Kelly bar, adjust
the Kelly bar position in the rotary table, and lay down the mast. Insert
the Kelly guide head close to the mast guide rail and fix them with a
coupling pin, thus the Kelly guide head can be accurately installed to
the mast guide rail.
 Complete upper preparations, try to operate the rig.

Warning!
Rotary table wheel set the whole friction and interlocking Kelly bar key
groove, must assemble the Kelly bar corresponsively, otherwise, the
facilities would be damaged easily.

5.4 Construction Operation of the Rig

5.4.1 Working equipment test running

 Main winch testing
 Operate the main winch for moving the Kelly bar up and down by
operation levers in the cabin; after releasing the operation lever, the
Kelly bar should immediately stop moving, and be locked at the
position. Operate the rig slowly to prevent operation failure and avoid
accident in danger to personnel and the equipment.
 Mast inclining testing
 Lift the mast to upright position; enable the mast incline slowly; mast
heeling angle 6° and inclining forward angle 5°; exceeding these angles
will be mechanically limited. The mast inclines backward angle is 90°.
Check for normal movement.
 Mast luffering testing
 Raise the mast to upright position; higher and lower the boom cylinder
and pull-down cylinder; check for normal movement.
 Auxiliary winch testing
 Operate the auxiliary winch, with moving heavy objects up and down by
relevant levers; after releasing the operation lever, the heavy object
should immediately stop moving, and then be locked at the position.

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Warning!
Operate the rig extremely slowly during testing; function test must be
performed with extreme care in order to avoid possible operation failure and
accident danger to personnel and machine parts.

5.4.2 Preparation for Construction Work

 Equipment inspection
Fill in lubricating grease to every point; check hydraulic oil level and oil
quality; check hoist, rotary table, upper mechanism slewing reduction gear oil
level and quality; check the oil in the engine and check the oil quality; check
filter for possible replacement; check drill teeth for possible replacement,
check the drill bucket whether it opens and close normally.
 Confirm the geologic data
The strata from the ground surface down are respectively cement
hardened layer, miscellaneous fill, clay, fine sand, medium coarse sand,
pebble, medium airslaked lithosphere.
 Drilling tool selecting:
Determining drilling tool gauge according to engineering release requirements.
Normally required drilling tool gauge should be 1cm ～ 2cm smaller than the
diameter of the specified drill hole. Ensure the filling coefficient is not too
large .During drilling, drilling in cement hard layer prefers auger (clay layer prefers
ordinary drill bucket without baffle plate). For sand and pebble layers, choose
special sand bucket drill. If it is unable to drill in the medium airslaked harder
lithosphere, it is possible at first to choose auger for crushing, then use drill bucket
to dredge for scraps.
 Bucket features and the adapting earth layers
The bucket is actually a cylinder vessel to hold soil, but with cutter blade or
cutting edge underside the bucket and welded. As fast as rotary drilling technology
is deployed, it has been found that the drilling operations have some restriction in
its way during drilling in basal ground such as sand layer, hard rock substratum or
pebble- gravelly layers. It has been found that selecting different buckets for drilling
in based on the geological report on site can raise operating efficiency meanwhile
save production costs.

5.4.3 Drilling Operations

 Survey and setting out lines
Determine the pile position according to the assigned red line point and
direction, by means of theodolite or laser ranger and ranging rod. According to the

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construction pile position drawing, to calculate the angle and distance from red line
points, by polar coordinates.
 The Rig taking its place:
The mast should be under the state of mast leveling, while the rotary table
should be lowered under the articulated point of tripod and mast
the point of auger against the pile position mark.
Here the rig position slewing center is3～4 m distant from the pile position.
If possible, luffer oil cylinder should retreat the mast as far as
possible，thus to decrease rig deadweight and the influence to the hole by
up and down alternate tension. Check in radius of slewing for any obstacles
to influence the slewing.
 Start to drive
After breaking into the cement hard layer, move the main winch lifting lever,
raise the drill from the hole opening to a certain distance, then stop. Move the
upper mechanism commutation switch to turn the machine, and stop when it arrives
at the earth unload position, unload earth. (For the correct unloading earth method,
please read the sixth section in the manual).
 Build in casing
Remove the auger after breaking through the hard layer, and change with
ordinary drill bucket plus underreamer for drilling ahead; when the depth is suitable
for a casing, lift a casing by auxiliary winch and locate it into the hole. Check the
pile position and casing center position for conformity by means of theodolite and
joint spider. In case of disconformity, adjust casing correction; and after correction,
fill earth around the casing and then make compaction. Now casing in-built is
accomplished.。
 Drill in
(1) Horizontal adjusting: Driving the rig to pile position vicinity and keep the
bodywork level as best as you can. If there is a slope over size, setting sand
and stone can be performed, and lock the track after position determination.
(2) Turn the machine and the luffer oil cylinder for precision contraposition; point
the slewing zeroize button on the screen; Self-adjust the mast vertical status;
in case the drill is too high from the hole center, it is possible to lower it with
floating Kelly bar, thus it becomes easier for the workers to do contraposition.
(3) Locate the drill bit exactly at the same level with the casing, and set up zero on
the depth gauge.
While operating the rotary table for drilling slewing, place the Kelly bar to the
hole bottom; press main winch floating button, and you can perform pressing
drilling, meanwhile you must fill in encasing slurry. When drilling mud collected to a

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certain quantity (quantity depending upon the geologic condition, general
recommendations are limited within 70% of the gross capacity), pull out the bucket.
While pulling out, reversal turn the Kelly bar by 1 ～ 2 rounds with the drill
bucket door closed. While raising the rotary table, operate the main winch to pull
the Kelly bar and drilling tool out of the hole, and turn the Kelly bar to earth unload
position, lift the Kelly bar, bump the bucket door open for dropping the drilling mud.
Operate the upper mechanism turning to pile position, point the touch screen for
turning angle reset; It turns for next round drilling operation. Thus move in cycles,
until pile drilling depth meets the requirement.
 Drilling in clay
Drilling in clay layer is performed with strong resistance, high absorbability and
hard pull-out. Therefore the rotary table torque should not be great; control by the
lever drilling in properly at 23MPa hydraulic pressure. During drilling in, keep
pressing continuously; the footage quantity depends on the height and diameter,
normally for diameter below 800mm, 60% － 90% bucket capacity will be suitable;
For diameter over 800mm, it should not be more than 60% bucket capacity. As the
clay is with strong adsorption force it is not easy to drop down.
 drilling in sand layer
As sand layer, especially medium coarse sand layer without cementing nature,
is relatively coarse and dispersed, so, during lifting, the sand inside the bucket
tends to spill out; besides, the resistance during drilling in is also relatively strong.
For higher drilling efficiency, let the rotary table provide maximum torque for drilling
in; meanwhile keep pressing; When the rotary table reaches rated value, raise
rotary table and relieve pressure and drill in repeatedly, until a certain scrap is
collected in the bucket for unloading; Then the next drilling in begins. As 80% of
bury-in-hole accidents with rotary drilling rig are happened in sand layer, that
reminds us of special care of the operation; In particular, when constructing with big
diameter hole, wild operation shall never be performed. Deep drill-in plus the sand
melted in the slurry falling back, bury-in-hole is easy to occur. While drilling in sand
layer, double bottoms door bucket is preferred as that can farthest avoid bury-in-
hole accidents.
 Drilling in pebble layer
As pebble is sorted in lithosphere, footage is achieved by the drill teeth slewing
and cut-in pebble broken joint, and then broken granules are picked in drill bucket.
While drilling in this layer, keep pressing continuously with maximum torque
provided until the pressure drilling unable to advance. After pulling out and
dropping scrap, the next round drilling in begins. As the pebble layer is relatively
complicated and unexpected events happen frequently, special care should be
taken.

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 Position change and leaving
When the rig finished a hole and ready to change or leave the pile position, the
procedures are the opposite with the entering process. The rotary table should be
under the articulated point of triangle and mast, and then lowering.
 Locking and unlocking the interlocking Kelly bar
Bar locking-the Kelly bar is lowered until the auger touches the hole bottom, then
rotate the Kelly bar clockwise; meanwhile, thrust down the rotary table slowly,
(adjacent) external bar (or rotary table) internal key slides along with the direction of
adjacent internal bar external key; the process of lower end of external bar internal
key sliding and pressing the bearing point of internal bar external key is called bar
locking. The locking process must rotate the Kelly bar clockwise and thrust down
the rotary table. Never quit the Kelly bar rotating with only thrusting down the rotary
table.
Kelly bar unlocking-after finishing the drilling, the interlocking Kelly bar must be
unlocked before lifting.
Notice: 1. During lifting, it should be always rotating.
2. When drilling into the rigid strata, the bigger angle between 70 degree and
90 degree is choosed under the state of angle position of derricking cylinder and
horizont with meeting the requirement of drill diameter will be good for realizing
greater crowd force. When the angle is smaller than 70 degree, the track shoe may
be tilted with making the unlocking to be difficult, also the Kelly bar will be caused to
damage.
3. During lowering or lifting the mast, the ratory table must be under the
articulated point of triangle and mast, and then lowering or lifting slowly to avoid
damage.
4. During operation, it is prohibited to press the casing by mast; disobey the
requirement, you will be responsible for the damage!

5.5 The Rig Retreating from Worksite

The steps for the rig retreating is by the reverse steps of entering worksite.
Drive the rig to level, solid and clean ground for disassembling the rig
equipment.

5.5.1 Rig equipment disassembling

Only two steps of operations should be performed for the rig disassembling:
dismount the Kelly, retreat the mast to transportation position and retreat the track
shoes to transportation width.
 Lay down the mast; remove the coupling pin on the Kelly guide head and on

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the mast guide rail, enable the Kelly guide head separate from the mast.
 Operate the main winch: lift the dismounted Kelly bar, enable the lower end
depart from the rotary table, and the upper end ear depart from mast guide
rail, and slowly enable the mast tilt forward up to a 4°angle. (Pay attention
to operate slowly enough to avoid damage of the machine parts by the
Kelly swing). (as shown in Fig. 19, Fig. 20)

Fig 19 Fig 20

Fig 21
 Keep lowering the Kelly, after the lower end touches the ground, move the rig
backwards while lowing the Kelly, until all the rod falling down to the
ground. (as shown in Fig. 21)

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 Remove the coupling pin of the main winch rope and the Kelly upper end
swivel element, separate the main winch rope from the Kelly bar.
 Retreat the main winch rope to a length suitable for transportation, and fix
the pigtail.
 Place the rotary table to mast underside, remove the coupling pin of the
rotary table with pull-down cylinder, and retreat pull-down cylinder piston
rod. (as shown in Fig. 22)
 Adjust mast inclination in order to install the supporting link rod of the lower
mast (as shown in Fig. 23)
 Remove the connecting bolt of the master mast and the lower mast. (as
shown in Fig. 24)
 Retreat the mast to horizontal position, and let the mast rest on the support.
(as shown in Fig. 25)
 Hang the cathead by hoisting equipment, remove the coupling bolt of the
cathead and upper mast; put down the cathead, and hang the cathead with
hanging rope (or hanging rod).
 Remove the connecting bolt of the upper mast with the master mast;
dismount the upper mast with the cathead to master mast side, and fix
them together with dowel pin. (as shown in Fig. 26)

Fig. 21 Fig. 22 Fig. 23

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Fig. 24 Fig. 25

 Remove track set pin; retreat the track to transportation width, and insert the
track set pin. Shipment of the rig can be performed after finishing the rig
retreating.
5.5.2 Loading the Rig onto Truck
Adjust the rig and the transport vehicle to the same axial position. Enable the
rig guide wheel close to the truck, while the driving wheel far away from the truck.
Enable the rotary table and the driving wheel on the same side, namely, enable the
rig directing forward (based on related position of the guide wheel and driving
wheel) for climbing the truck. (As shown in Fig. 12)
Lockup the truck wheels reliably and let down the gangway; the angle between
the gangway and the ground should not exceed 15°. Drive the rig slowly up to the
truck under the superintendent direction. This procedure must be made slowly and
carefully, ensuring the rig park in the middle of the truck, without departing from the
truck axis line. The rig should be fixed by ropes after mounting up. Adjust the mast
height at any moment during climbing the truck, on purpose to avoid machine parts
being damaged.
5.6 CFA operating condition
5.6.1 Install the long spiral drill bit
If CFA operating method is used after installation, the

installation process of the long spiral drill bit working device

is as follows:

1. Select and install a special pulley yoke wedge used in the CFA method.
2. Ensure that the upper buffer device and lower pressure plate of the rotary drive
have been removed and installed and that the internal key used in the rotary
excavating drill has also removed and installed, as shown in Fig. 26.
3. Check that the soil-cleaning device installed on the lower mast, the mast support
and the base plate have installed properly, as shown in Fig. 26.
4. Install the auxiliary winch wire rope, with the connection of the end of wire rope in
accordance with the “connection between wire rope and rope clip”.

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5. Wind the main winch wire rope onto the pulley yoke and follower pulley, and
connect the end to the triangle frame reliably, as shown in Fig. 14; for
connection of ends of wire rope, please refer to “GB / T5976 Wire Rope Clip”.

1. Rotary drive 2. Soil-cleaning device 3. Casing 4. Outrigger cylinder 5.

Base pressure plate

Fig. 26 Installation of all parts for CFA operating method

5.6.2 Install the long spiral drilling rig

Main structure of long spiral rig is shown in Fig. 5-4 and Fig.

5-5; the installation process of rig is as follows:

1. Connect the guide frame (guide frame B) to the

follower frame.

2. Connect the return bend to the extended drill rod

(extended drill rod B).

3. Assemble the extended drill rod (extended drill rod B)

into the follower frame.

4. Assemble the transition plate onto the lower end of the

extended drill rod B.

a) Connect the extended drill rod (extended drill rod B)

to the three sections and more of spiral drill bit.

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 KR160M OPERATION AND MAINTENANCE MANUAL
b) Connect the drill bit.

1. Return bend 2. Guide frame 3. Extended drill

rod 4. Spiral drill bit 5. Drill bit

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KR160M OPERATION AND MAINTENANCE MANUAL

Fig. 27 Long spiral drill used in the CFA operating method

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 KR160M OPERATION AND MAINTENANCE MANUAL
Spiral Kelly Bar
When the spiral kelly bar is installed with this machine, the maximum drilling depth
can arrive 16m. Besides, differet length spiral kelly bars can be formed according to
the actual situation .

Different length spiral kelly bars are formed

Spiral drill pressure rod

The spiral pressure rod of this machine has two pressure tables , they are
located at both ends of the pressure rod . When the pressure rod for drilling is slow,
moving power head to the position of pressure table, then compressing the
pressure table to give kelly bar pressure and increase the effective of drilling .

When giving kelly bar pressure by power head , it must be slow and
inching operation . Continuous pressure is not allowed. This operation
may damage the spiral kelly bar and machine.
Pressure table
Pressure table

Lock catch

When lifting the spiral kelly bar, don’t pull the bucket teeth beyond the
retaining cylinder, because the bucket teeth may damage the
retaining cylinder. The retaining cylinder can be opened and let the drill auger pass.

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 KR160M OPERATION AND MAINTENANCE MANUAL

danger

Excessive lifting of kelly bar may damage the retaining cylinder

5.6.3 Turn rotary method to CFA method

1、Remove the damping device on the power head and the lower pressure plate at
the lower part

absorber

presser

2、Installing tail mast, cleaning machine, and connecting the oil pipe.

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 KR160M OPERATION AND MAINTENANCE MANUAL

Cleaning machine

Tail mast

3、Lifting faucet and pressure rod

Firstly, the faucet is connected with pressure rod. Secondly, using the crane to lift
pressure rod to the power head position . Thirdly, rotating power head and making
the pressure rod carded in the first pressure table. Fourthly, guiding rod through the
faucet fixed hole, and fixed on the power head.

Guiding rod
Faucet Pressure rod

Installation of pressure rod and guiding rod

4、 Installation of Spiral Kelly Bar
Connecting the kelly bar on the ground and adjusting the adjustable lever which is
in the guarding-cylinder to the maximum position, with a crane lifting pressure rod.
The drill auger part through the guarding-cylinder and then connected with a
pressure rod.

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 KR160M OPERATION AND MAINTENANCE MANUAL

Spiral kelly bar

Connection of Spiral Kelly Bar

In connecting the spiral kelly bar, it should be paid attention to the

direction . So that the blade helix is whole and without any
dislocation .

In the installation of spiral kelly bar, please attention to the position of

power head on the mast. It can not be too front or back, or the mast
cylinder is unable to move the mast. If this situation happens, please move the
power head suitably and make the gravity of mast move forward.

In the installation of spiral kelly bar, please push the adjusting lever
which is in the guarding-cylinder to the maximum position in advance so
as to ensure sufficient space to let kelly bar enter into the protected casing.

To adjust the maximum position

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 KR160M OPERATION AND MAINTENANCE MANUAL
5、The main winch wire rope is connected with the connecting seat of power head.
Under CFA method, main winch wire rope only play a supporting role to enhance
the kelly bar. According to the actual construction of formation, the main winch wire
rope can be selective used . During the construction, the main winch wire rope must
not be hung on the faucet.

Right ： main winch wire Wrong：main winch wire rope

rope

6 、Stand the mast and adjust the adjustable lever of the guarding-cylinder to the
suitable position. Move machine and adjust the amplitude, then to align the piles
position. At last, starting drilling construction after putting down the leg cylinder for a
reliable supporting

When the mast is tilting behind, it must make sure that the guarding-
cylinder is locked, or the retaining cylinder may roll backward. There
is a possibility of damage to the personnel and damage to the machine

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 KR160M OPERATION AND MAINTENANCE MANUAL

Loc
ked

Before mast tilts behind, please check if the guarding-cylinder is locked or not

5.6.4 Drill operation using a CFA operating method

行走定位 放支腿支撑 旋转钻进 钻到目标深度 旋转，边上提边泵浆

Traveling and positioning Erect outriggers to support Spirally drill Drill to the Rotate, and pump the slurry while
target depth lifting

5.6.5 Process flow under CFA operating condition

1. Surveying and setting out

The construction pile location plan is measured with a

theodolite or laser range finder according to the given red

line point and direction, and the angles and the distances to

the red line point can be calculated with polar coordinates,

and the pile location is determined with a theodolite and a

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ranging rod.

2. Drill rig in position

The mast shall be in the tilt backward state when the drilling

rig moves to the pile position. The keyway on the extended

drill rod shall be mounted onto the internal key of the

follower frame before tilting backwards, to avoid the long

spiral drill bit from slipping down in the rill movement

process. The maximum safety tilt backward angle of the mast

is 15° when the long spiral drill is installed. The road where

the drill travels to the pile position shall be sufficiently rigid

and flat, with the group slope of not exceeding 3°, and the

20m space above the ground is free of any obstruction, and

the rotary drive shall lower down as far as possible to reduce

the height of center of gravity of the entire machine, to

prevent tipping, as shown in Fig. 5-7.

Mast shall be tilt backwards at least 15 degrees during the

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hole location is transferred

Move the drill near the pile position slowly, and slowly erect the mast, allowing that
the tip of the drill bit aligns with the marking point on the pile location.
The distance from the center of rotation of drill to the hole position shall be ranged 3
to 4m. If conditions allow, the luffing cylinder shall be extended as far as possible,
so that the influence on the hole by the weight of drill and the alternate tension in
the lifting and lowering processes can be reduced. Check that there is no any
barrier within the rotary radius to affect the rotation.
Check that the bottom outrigger cylinder can work normally and that soil-cleaning
device can also work normally.
Check that the movable door at the lower end of the drill bit can be opened and
closed normally (the door can be closed in the drilling process and opened normally
in the pile grouting process).
3. Check the drill status
Before the construction with a rotary drill using a CFA method, stop the machine
and check that all relative parts are installed according to the “Installation of long
spiral drill bit using a CFA operating method”; power on the drill and switch the
display control interface to the CFA operating method interface.
4. Drill forward
① Move the drill near the pile position, and keep the drill

body at the level state as far as possible; the gravels are

padded for leveling if the slope is too steep, and the left

and right extended traveling frames are locked with pins

after determining the position.

② Adjust the mast to the vertical state through the

automatic vertical state adjustment. By luffing and rotary

actions, the drill bit tip aligns with the pre-determined pile

position through adjustment, with the depth set to zero.

③ Extend the outrigger cylinder at the bottom of the mast

and support it on the ground, and select a solid steel

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plate or sleeper with large area to level the bottom of the

o u t r i g g e r c y l i n d e r, t o r e d u c e t h e g r o u n d p r e s s u r e a p p l i e d

b y t h e m a s t c y l i n d e r, e n s u r i n g a g o o d d r i l l i n g p e r f o r m a n c e

of drill.

④ Switch the operation program to the C FA o p e r a t i n g

m e t h o d o p e r a t i o n p r o g r a m i n t e r f a c e o n t h e d i s p l a y, a n d

p r e s s t h e " C FA " S t a r t b u t t o n .

⑤ Rotate the operation rotary drive forwards.

⑥ Lower the pressure winch and press the float button to

drill. The drilling pressure used in the C FA operating

method is provided by the drill and the pressure winch.

With the moving forward of the drill, the gradually

increasing of the pressure provided by the rotary drive

c a n b e o b s e r v e d o n t h e d i s p l a y. W h e n t h e r o t a r y d r i v e

pressure increases, the drilling speed will decrease; at

this time, stop (or slow down) and lower the drill. (If the

torque of rotary drive increases to the maximum value in

the drilling process, this can not play the best

performance of the machine; furthermore, the operation at

maximum torque can result in the reduction of equipment

life.)

⑦ With the rotary drive rotating forwards, the engine is

working at maximum speed to increase the speed of the

rotary drive; at this time, drill chips will be conveyed to

the ground through the spiral blades. With the increased

speed of the rotary drive, the drill chips conveying speed

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is also increased.

⑧ With the output of drill chips, the displayed torque of

the rotary drive will reduce; at this time, drill can lower to

dill forwards. Repeat steps (6), (7) and (8) until drilling to

the predetermined depth in the pile hole.

⑨ P l e a s e r e m o v e c h i p s c o n v e y e d t o t h e o r i f i c e t i m e l y, t o

ensure that the drill chips can quickly and easily output to

the ground in the next drilling process.

⑩ When drilling to a predetermined depth, grout the pile

u s i n g a C FA o p e r a t i n g c o n s t r u c t i o n p r o c e s s . O p e r a t e t h e

equipment to pull out the drilling tool, and keep the rotary

drive rotate forwards in the pulling process. the pulling

speed shall be consistent with the pile slurry conveying

speed, to avoid pile shrinkage, breakage and other

defects.

⑪ When the pile is poured to the predetermined position,

move the equipment away for next construction process

u s i n g a C FA o p e r a t i n g m e t h o d .

Notes: 1. Please remove drill chips output to the orifice

around timely.

2. To lift the drill, please keep the drill rotate

forwards.

3. The backward tilt angle of the mast can not exceed 15° in the mast
lowering or erecting process for drilling rig equipping with a long
spiral drill, and mast shall lower or erect slowly, to prevent damage to
the machine.

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5.7 Daily Maintenance of Drilling Rig

NOTE: Our Company reminds again our customers of strictly following the
safety precautions for maintenance and service of drilling rig described in
“Safety Precautions”, Part III of this manual before carrying out any
maintenance and service for KR160M Drilling Rig.

5.7.1 Inspect before operation of drilling rig

 Check all the tanks for sufficient oil quantity and normal oil quality.
 Check all the reduction gears for sufficient oil quantity and normal oil quality.
 Check for oil leakage.
 Check main and auxiliary ropes for any possible broken wire, and if they are
safe, reliable and good connection, and ropes stretcher for sufficient force.
 Check swivel element for free slewing and internal grease for freedom of
contamination.
 Check steel structure for freedom of crack, corrosion, tip-off and other
damages, and repair it if any.
 Fasten loose rubber pipe and bolt.
 Apply grease to the moving parts in all mechanisms. For example, do apply
sufficient grease to the whole slewing faces on the portions with large
slewing faces, such as turret slewing once after slewing a given angle.
 Lubricate main and auxiliary ropes with each strand fully greased.
 Apply grease to the three sides of mast guide.
 Check Kelly guide head slewing bearing
 Check circuit relay is aged or not, if circuit was damaged.

5.7.2 Daily lubrication maintenance for the rig

Note: Fill grease to the grease nipple on one side of elevator with other
grease nipple opened. This is good for expelling out the previous grease.
Otherwise, it may cause damage to the seal in elevator and easy ingression of
dirty water with fine sand and mud, resulting in wear to bearing and further
decrease of sensitivity of elevator.

Schematic Diagram for Lubrication Points and Their Lubrication Frequencies for
drilling rig (as shown in Figure 26)
serial
number Lubrication position points frequency
s

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 KR160M OPERATION AND MAINTENANCE MANUAL
1 CFA swivel 1 portions once a week
2 Minor pulley shaft for cathead 2 portions once a week
3 Major pulley shaft for cathead 2 portion once a week
Shaft connecting cathead and 1 portions once a week
4
upper mast
5 Crowd system pulley(upper) 2 portions once a week
Shaft connecting upper mast and 3 portions once a week
6
middle mast
Bearings at both ends of mast 2 portion1 once a week
7
cylinder
8 Outside bearing of crowd winch 1 portion once a week
turnplate press block and 10portions once a week
9
turnplate
Shaft connecting turnplate and 1 portion once a week
10
triangle
Shaft connecting middle mast and 2 portions once a week
11
winch frame
Outside bearing of auxiliary 1 portions once a week
12
winch
13 Outside bearing of main winch 1 portions once a week
Bearings at both ends of boom 2 portions once a day
14
cylinder
Connecting shafts at both ends 4 portions once a day
15
of boom
Connecting shafts at both ends 4 portions once a day
16
of support rod
17 Swing bearing 1 portion once a week
18 Extention cylinder 1 portion once a week
19 Support cylinder 1 portion once a week
20 Crowd system pulley(lower) 1 portion once a week
21 Powerhead pulley 2 portions once a week
22 Mast guide 2 portions once a shift

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Fig. 26
Caution: If the filling-up area and the number changes, please consult TYSIM
Customer Service.

5.8 Key parts periodic maintenance

You should maintain drilling rig daily during engineering, and also must
maintain key parts termly as required. As for maintenance to diesel machines,
please obey the statement about CAT C9 HHP.

5.8.1 Steel rope

Steel rope is one of the key parts and an easily-damaged part in KR160M
drilling rig. Correct selection, reasonable use and maintenance and service may
improve the service life of steel cable to avoid accident.
The standard that KR160M drilling rig is GB8918-2006 important use of steel

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 KR160M OPERATION AND MAINTENANCE MANUAL
rope.
Steel rope for main winch 26NAT-35W×7-1770-ZS（83m） .
Steel rope for auxiliary winch 14 NAT-6×29Fi＋IWR-1770-ZS（55m）.
Steel rope for crowd winch(lifting) 16 NAT-6×29Fi ＋ IWR-1770-
ZS（53.5m）.
Steel rope forcrowd winch(pressing) 16NAT-6×29Fi ＋ IWR-1770-
ZS（35.5m）.
You must remember to choose the above type of steel rope, lower the standard
is not allowed.

5.8.1.1 Use of steel ropes

The steel rope should be installed on the

equipment correctly according to the requirements in
order to prolong its service life and ensure safe and
reliable operation.
 Fixation of steel rope end
When rope clamp is used for fixation and
connection (refer to Figure 6b), the regulations in
GB/T5976 rope clamp should be met. Its fixation and
connection strength in correct installation should not be less than 85% of the break
pull force for the steel rope.
 Method for Use of steel ropes GB/T5976 rope clamp
 Arrangement of rope clamp:
The steel rope is installed as shown in Figure 7.
The clamp holder is fixed on operating segment of the
steel rope and the U-screw on its tail segment. The
rope clamps cannot be arranged on steel rope in
opposite directions alternatively.
 Quantity of rope clamps:
The number of steel rope camps is related to the diameter of steel rope. The
minimum number of rope clamps required by the steel ropes in different diameters
is recommended in Table 1.
Table 1 Recommended Minimum Quantity of rope clamps
Nominal Diameter
＞
of Steel Rope ≤18 ＞18~26 ＞26~38 ＞38~44
44~60
mm
Minimum 3 4 5 6 7
Quantity of Rope

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 KR160M OPERATION AND MAINTENANCE MANUAL
clamps

 Distance Between rope clamps: The distance between rope clamps is equal
to 5-6 times of steel rope diameter.
 Fastening of rope clamps: Check the rope clamp that has been bear load
once or twice in practical use. In most cases, the nuts are requirement to
be fastened further. The reasonable force bearing for each rope clamp
should be considered when the steel rope is fastened. The rope clamp
closest to the ring should be close to the ring as possible but must be
correctly fastened. It should be ensured that there is no damage to the
steel wire on the external layer of steel rope.
 Fixation and connection with wedge and wedge sleeve, if adopted, should
be in conformity of the regulations in GB/T5973 Wedge Joints for Steel
Rope. The fixation and connection strength should not be less than 75% of
break pull force for steel cable.

5.8.1.2 Use of Steel Ropes

If steel rope with no load has friction with a certain portion of machine, make a
suitable protection to the contact portion after it is installed according to the
requirements. Before steel rope is put into use, ensure that all the devices related to
operation of steel rope are installed well and operate properly. In order to position
steel rope stably, operate the machine with the load about 10% at low speed for
several times.
Generally, the newly used steel rope should be the same as the previously
installed one in type and specification. If the steel rope in different type is to be
used, the user should ensure that the performance of the new steel rope is not
lower than originally selected steel rope.

5.8.1.3 Maintenance and Service and Discard Judgment of Steel Rope

Maintenance and service of steel rope is determined in accordance with its

purpose, operating environment and type. In possible condition, timely clean steel
rope and apply grease to it, especially to the portion bent as passing pulley when
the machine operates in corrosive environment and cannot be lubricated due to
some reason related to work. The applied grease should be corresponding to that
used in steel rope manufacturer.

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 KR160M OPERATION AND MAINTENANCE MANUAL
5.8.1.3.1 Inspection
 Daily Observation
Often observe any visible portion on steel rope on every working day in order to
find damage and deformation. Special attention should be paid to fixed portions of
steel rope. When any defect, such as, broken wire, worn, corrosion or deformation
is found, make judgment according to the regulations in GB/T9572 Practical
Specification for Inspection and Discard of Steel rope on Hoisting Machine.
 Periodic Inspection
For the cycle of periodic inspection, consider the following:
 Requirements in state laws, regulations and rules
 Machine type and operating environment
 Machine operating grade
 Results and defect occurrence in previous inspections
 Used time of steel rope
Inspect the segment of steel rope led out from fixation and connection end
because it is very dangerous if fatigue, broken wire or corrosion occurs at this
portion.
Inspect the fixation device itself for deformation or wear.
Inspect the removable devices (wedge joint, rope clamp, press plate, etc) for
internal condition and steel cable end for internal broken wire. Ensure the security
of wedge joint and rope clamp.
Check and make sure that the steel rope end devices meet the requirements
in corresponding standards.
Visually inspect at any time the other portions of joint for broken wire.
If broken wire occurs near or in steel cable end device, shorten the steel cable
and reinstall it to its fixation device for reuse. But the length of the steel cable must
meet the requirement for minimum number of winding turns on winch drum. Usually
the number of safety turns is 1.5-2, and 3 turns are used in most cases.

5.8.1.3.2 Storage and Identification of Steel Rope

In order to prevent spare steel rope from damage, keep it in a clean and dry
warehouse, and provide the inspection results or the method for clearly identifying
the specification for steel rope.

5.8.1.3.3 Discard of Steel rope

 Factors for Discard of Steel Rope
When broken wire occurs in or near steel rope end, timely take action and do
not use it further.

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 KR160M OPERATION AND MAINTENANCE MANUAL
Discard the steel rope on which broken wire is concentrated within the steel
rope length less than 6d.
If it is found that broken wire occurs and increases in quantity after use for a
certain period, timely make judgment for discard according to the standard.
Discard the steel rope with a whole strand broken.
Discard the steel rope of which the diameter is reduced due to damaged steel
rope core.
Discard the steel rope when some event occurs due to its reduced elasticity in
accordance with the standard.
Discard the steel rope when wear to its outside layer reaches 40% of its
diameter. Discard the steel rope of which the diameter is reduced by 7% or more.
Discard the steel rope with visible deformations.
Timely discard the steel rope with external corrosion.
Discard the steel rope with broken wire, reduced gap between strands and
expanded diameter, etc, due to internal corrosion.
 Caution for Inspection and Discard of Steel Rope
To conduct inspection and judgment, make account of the above-mentioned
factors and follow the regulations in respective standards. However, damage to
steel rope is often caused by accumulation of many factors. This requires the
person in charge to judge and decide whether the steel rope is to be discarded or
further used.
In all cases, the inspector should make sure whether the damage to steel rope
is caused by the defect in machine and make recommendation for removing the
defect before use of new steel rope.

5.8.2 Engine

5.8.2.1 Engine Cooling System

5.8.2.1.1 Replace the coolant

Note: This machine was fully filled at factory CATERPILLAR Extended Life
Coolant.
 (1) Unlatch the engine hood and raise it.
 (2) Slowly loosen pressure cap that is on the radiator in order to release
pressure from the cooling system.
 (3) Remove the pressure cap.
 (4) Remove the access cover that is underneath the radiator.
 (5) Open the drain valve and allow the coolant to drain into a suitable
container. The drain valve is located on the bottom of the radiator.

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 (6) Flush the cooling system by following steps in order to properly flush the
cooling system.
 Close the drain valve.
 Fill the cooling system with clean water.
 Install the pressure cap.
 Start the engine and run the engine until the engine reaches operating
temperature.
 Stop the engine and make it cool.
 Loosen the pressure cap slowly in order to relieve any pressure in the
cooling system.
 Open the drain valve that is underneath the radiator and allow the
coolant to drain into a suitable container.
 Flush the radiator with clean water until the draining water is
transparent.
 (7) Close the drain valve, and install the access cover underneath the
radiator.
 (8) Add the coolant which have long valid period. Refer to the following
topics.
 (9) Start the engine. Operate the engine without the cooling system pressure
cap until the water temperature regulator opens and the coolant level
stabilizes.
 (10) Maintain the coolant level within 13 mm (0.5 inch) from the bottom of
filler pipe.
 (11) Inspect the gasket of the cooling system pressure cap. If the gasket is
damaged, replace the pressure cap.
 (12) Install the cooling system pressure cap.
 (13) Stop the engine.
 (14) Open the left access door.

 (15) Check coolant reservoir. Maintain the coolant level between ”Full” mark
(1) and “Low” mark (2).
 (16) If additional coolant is necessary, remove the reservoir cap and add
CATERPILLAR coolant solution.
 (17) Install the reservoir cap.
 (18) Close the engine hood and latch the engine hood. Close the left access
door.

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5.8.2.1.2 Add coolant extender
When CATERPILLAR extended life coolant (ELC) is used, 119-5152 coolant
extender must be added to the cooling system.
Use an 8T-5296 Coolant Conditioner Test Kit to check the concentration of the
coolant.
 Park the machine on level ground.
 Stop the engine.
 Unlatch the engine hood and raise the engine hood.
 Make sure that the cooling system has cooled down. Loosen the cooling
system pressure cap slowly in order to relieve system pressure. Remove the
pressure cap.
 It may be necessary to drain some coolant from the radiator so that
Caterpillar Extender can be added to the cooling system.
 Add 119-5152 Coolant Extender to the cooling system. Please consult the
engineer in TYSIM Customer Service.
 Inspect the gasket of the cooling system pressure cap. If the gasket is
damaged, replace the pressure cap.
 Install the cooling system pressure cap.
 Close the engine hood and latch the engine hood.
Caution: Mixing ELC with other products will reduce the effect of the coolant.
This could result in damage to cooling system components. If Caterpillar
products are not available and commercial products must be used, make sure
they have passed the Caterpillar EC-1 specification for pre-mixed or
concentrate coolants and Caterpillar Extender.

5.8.2.1.3 Inspect and replace the hoses

 Unlatch the engine hood and raise the engine hood.
 Inspect all hoses for leaks due to cracking, for softness next to the clamps,
and for loose clamps.
 Replace hoses that are cracked or soft and tighten any loose clamps.
 Loosen the cooling system pressure cap slowly in order to relieve any
pressure. Remove the pressure cap.
 Drain the coolant from the cooling system to a level that is below the hose
that is being replaced.
 Loosen the hose clamps and disconnect the damaged hose.
 Replace the damaged hose with a new hose.
 Replace the hose clamps and tighten the hose clamps.
 Add the appropriate coolant solution to the cooling system.

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 KR160M OPERATION AND MAINTENANCE MANUAL
 Close the engine hood and latch the engine hood.

5.8.2.1.4 Check the coolant level

(1) FULL Level (2) LOW Level

 Open the left rear access door.
 Check the coolant level of the coolant tank. Maintain the coolant level
between the “FULL” mark and the “LOW”mark. If the coolant tank is empty,
follow the Steps
 Unlatch the engine hood and raise the engine hood.
 Slowly loosen the cooling system pressure cap in order to relieve
system pressure. Remove the pressure cap.
 Add the appropriate coolant solution to the cooling system.
 Start the engine. Operate the engine without the cooling system
pressure cap until the water temperature regulator opens and the
coolant level stabilizes.
 Maintain the coolant level within 13 mm (0.5 inch) of the bottom of the
filler pipe.
 Inspect the condition of the gasket on the pressure cap. If the gasket is
damaged, replace the pressure cap.
 Install the cooling system pressure cap.
 Stop the engine.
 Close the engine hood and latch the engine hood.
 (3) If additional coolant is necessary, remove the tank cap and add the
appropriate coolant solution.
 (4) Install the tank cap.
 (5) Close the left access door.

5.8.2.1.5 Clean/replace air filter primary element

If a warning and a pictograph is displayed on the message display or if the
exhaust is black, check the primary filter.
 Open the access door on the left side of the machine.
 Squeeze the outlet tube slightly in order to purge the dirt from the outlet tube.

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 Loosen the four cover latches and remove the air cleaner cover.
 Remove the primary filter element from the air cleaner housing.
 Clean the air cleaner cover and the inside of the air cleaner housing.
 Inspect the O-ring seal on the air cleaner cover. Replace the O-ring seal if
the O-ring seal is worn or damaged.
Caution: Do not clean the air filter elements by bumping or tapping. Do not
use elements with damaged pleats, gaskets, or seals. Engine
damage could result. Make sure that the clean filter element is
dried fully before it is reinstalled into filter housing. Any water in
the filter elements will result in incorrect indication of
contamination in test result for periodic oil sampling analysis.
 Clean the primary filter element. Check the primary filter element. Clean the
primary filter element with low pressure compressed air.
 Direct the airflow to blow the inside and outside of the pleated wrinkling part
in primary filter element. Prevent the fold wrinkling part and air nozzle from
contact to each other.
 Check the primary filter element after cleaning.
 Wrap the clean primary filter element, and keep it at a clean and dry place.
 Install the clean primary filter.
 Install the air cleaner cover and close the latches securely.
Note: Install the air cleaner cover properly. The arrows must point upward.
 Change the filter if any of the following conditions occurs:
 Restricted Air Filter indicator on the monitor panel still comes on.
 Exhaust smoke is still black after the installation of a primary filter.
Note: Replace the primary filter that has been used for a year.
 Close the access doors.

5.8.2.1.6. Replace fine air filter secondary element

Caution: Always replace the secondary filter element. Never attempt to reuse
the secondary filter element by cleaning the element. When then
primary filter element is replaced, the secondary filter element
should be replaced. The secondary filter element should also be
replaced if the air filter restriction warning appears on the message
display after the installation of a clean primary filter element or if the
exhaust smoke is still black.
 Open the access door on the front left side of the machine.
 Remove the secondary filter element.
 Cover the air inlet opening. Clean the inside of the air cleaner housing.

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 Remove the cover from the air inlet opening.
 Install the new secondary filter element.
 Install the primary filter element.
 Install the air cleaner cover and close the latches securely.
 Close the access door.

5.8.2.2 Engine lubricating system

5.8.2.2.1 Check engine oil level

Check the oil level while the engine is stopped. Do not check oil level while the
engine is running.
 Open the engine hood.
 Remove the dipstick. Wipe the oil off the dipstick and reinsert the dipstick.

 (3) Remove the dipstick and check the dipstick. The oil level should be
between the “FULL “mark and the“ADD”mark.
Caution: Do not fill above the “FULL”mark on the dipstick. If the oil level is
above the “FULL”mark, the crankshaft might dip into the oil during
engine operation. This will lead to excessively high oil temperatures.
High oil temperatures can reduce the lubricating characteristics of
oil.
 (4) Remove the oil filler plug in order to add oil, if necessary.
Note: If the oil is deteriorated or badly contaminated, change the oil
regardless of the maintenance interval.
 (5) Clean the oil filler plug. Install the oil filler plug.
 (6) Close the engine hood.

5.8.2.2.2 Replace engine oil and oil filter

 Selection of the oil change interval.
Caution: A 500 hours engine oil change interval is available, provided that
operating conditions and recommended multigrade oil types are
met. When these requirements are not met, shorten the oil change
interval to 250 hours, or use an S.O.S oil sampling and analysis
program to determine an acceptable oil change interval. If you select

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an interval for oil and filter change that is too long, you may damage
the engine. Recommended multigrade oil types are listed in the
following Table. Do not use single grade oils.

CAT engine change oil period (1)

operation condition
oil high- overload operation
multi oil type load oil with
normal2 parameter altitude over
sulfur0.3
(3)
higher 1830 ㎜
%～0.5%
than 37.8L (4) (6000ft)

first choice CAT DEO 250h 500h 500h 250h (6)

first choice API CH-4
250h 500h 250h 250h (6)
TBN(4) the lowest 11.0
API CH-4 TBN lower
250h 500h 250h 250h (6)
than 11.0
API CG-4 250h 250h (5) 250h (5) 250h (6)
API CG-4 (5) 250h (6) 250h (6) 250h (6) 250h (6)
N
ote as follows:
（1）The traditional oil change interval for the engine is 250 hours, if operation
condition and with the recommendation oil, the interval might be 500 hours. If
you change the rig, it will change the oil period.
（2）Normal conditions include these factors: fuel sulfur below 0.3%, altitude
below 1830 m (6000 ft), and good air filter and fuel filter maintenance. Normal
conditions do not include high load factor, harsh operating cycles, or harsh
environments.
（3）High load factors can shorten the service life of the engine oil. Continuous
heavy load cycles and very little idle time result in increased fuel consumption
and oil contamination. These factors deplete the oil additives more rapidly. If

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the average fuel consumption of your CAT336D exceeds 37.8 L (9.8 US gal)
per hour, follow the “High Load Factor” recommendations in Table .To
determine average fuel consumption, measure average fuel consumption for a
period of 50 to 100 hours. If the application of this machine is changed, the
average fuel consumption may change.
（4） For sulfur content exceeds 0.5%, please consult TYSIM Customer Service.
（5） To determine 500 hours change oil period, please take procedure A as
reference:
Procedure A: Inspect the 500 hours interval for changing oil
This procedure includes three 500-hours changing oil periods, sampling and
analyzing the oil respectively at 250 hours and 500 hours, so there are 6 samples,
analyses the viscosity and IR. If the result is satisfactory, so you can change oil with
500 hours interval. If there is any change with the application of the rig, please
make the procedure again.
（6） If the sample did not pass the inspection, shorten the oil interval to 250
hours, please read procedure B:
Procedure B: optimize oil interval
From the beginning of 250 hours oil interval, by gradually increasing method to
adjust the interval, each interval adds 50 hours, then periodically take sample and
analyze, including viscosity and IR. If there is any change with the application of the
rig, please make the procedure again. If the sample did not pass the inspection,
shorten the oil interval, or choose the above recommendation multilevel oil.

5.8.2.2.3 Oil gradation plug

Oil gradation plug distinguish from labels, which locate the wire of the Oil
gradation plug.

(1)10W30 (2)15W40

Oil gradation plug is used to accelerate the C7.1 engine start in cold day. While
changing Oil gradation, the driver must assure that insert corresponding oil

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gradation plug into wiring harness. If use some specifically Oil gradation plug,
hereinafter Oil gradation plug to be used for informing ECM.
 Insert Oil gradation plug (1) into“10W30” wiring harness;
 Insert Oil gradation plug (2) into“15W40” wiring harness;
 Insert the Oil gradation plug (2) , using electronic maintain tool to program for
oil gradation;
 Utilize programmable screen for clients;
 Select oil gradation through electronic maintain tools;
 Input corresponding necessary number with oil gradation.

5.8.2.2.4 Procedures for changing Engine Oil and Filter

Caution: If the sulfur content in the fuel is greater than 1.5 percent by weight,
use the oil that has a TBN of 30 and reduce the oil change interval by
one-half.
 Park the machine on a level surface. Stop the engine.
Note: Drain the crankcase while the oil is warm. This allows waste particles
that are suspended in the oil to drain. As the oil cools, the waste
particles will be settled to the bottom of the crankcase. The particles will
not be removed by draining the oil and the particles will recirculate in
the engine lubrication system with the new oil.
 The drain valve for the engine crankcase oil is located under the rear of the
upper structure.
 Open the crankcase drain valve. Allow the oil to drain into a suitable
container.
 Close the drain valve.
 Open the access door at the right side of the machine.
 Remove the oil filter with a strap type wrench.
 Clean the filter housing base. Make sure that all the old filter gaskets are
removed.
 Apply a thin coat of engine oil to the gasket of the new filter.
 Install the new filter by hand. When the gasket contacts the filter base, turn
the filter by 3/4 turn more. This will tighten the filter sufficiently.
 Every new oil filter has rotation index marks that are spaced by 1/4 turn. Use
the rotation index marks as a guide for tightening the oil filter.
 Close the access door.
 Unlatch the engine hood and raise the engine hood.
 Remove the oil filler plug. Fill the crankcase with new oil.
Caution: Do not under fill or overfill engine crankcase with oil. Either

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condition can cause engine damage.
 Start the engine and allow the oil to warm. Check the engine for leaks. Stop
the engine.

 Wait for 30 minutes in order to allow the oil to drain back into the crankcase.
Check the oil level with the dipstick. Maintain the oil between the
“FULL”and”ADD”marks on the dipstick. If necessary, add oil.
 Close and latch the engine hood.

5.8.2.3 Engine Fuel System

5.8.2.3.1 Replace the fuel filter

Warning!
Personal injury or death can result from a fire. Fuel leaked or spilled onto hot
surfaces or electrical components can cause a fire. Clean up all leaked or spilled
fuel. Do not smoke while working on the fuel system.
Turn the disconnect switch OFF or disconnect the battery when changing fuel
filters.
Notice: Do not fill fuel filters with fuel before installing them. Contaminated fuel
will cause accelerated wear to fuel system parts.

 Open the access door on the left side of the machine.

 Position a suitable container for the used fluid under drain hose.
 Open the drain valve. Allow the fuel in the filter to drain into the container.
 Securely tighten the valve.
 Remove the fuel filter.
 Inspect the fuel filter for debris by cutting the fuel filter open.
Note: This fuel filter is a cartridge type filter. This type of filter cannot be
reused.
 Clean the mounting base of the fuel filter. Make sure that the old seat is
removed from the mounting base.
 Apply a thin coat of clean diesel fuel to the sealing surface of the new fuel

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filter.
 Install the new fuel filter by hand. When the seal contacts the filter mounting
base, tighten the filter by an additional 3/4 turn. The filter has rotation index
marks that are spaced by increments of 1/4 turn. Use these rotation index
marks as a guide for proper tightening.
 Prime the fuel system.
 Close the access door on the left side of the machine.

5.8.2.3.2 Drain water from water separator

 Open the front access door on the left side of the machine.
 Provide a suitable container for used fluid.
 Check bowl (2) in the bottom of the water separator. Open drain valve (1).
Drain the water and sediment in the bowl.
 Close the drain valve.
 Close the front access door.

(1) Drain Valve (2) bowl

5.8.2.3.3 Replace water separator element

Warning!
Personal injury or death can result from a fire. Fuel leaked or spilled onto hot
surfaces or electrical components can cause a fire. Clean up all leaked or
spilled fuel. Do not smoke while working on the fuel system.
Turn the disconnect switch OFF or disconnect the battery when changing fuel
filters.
Notice: Do not fill fuel filters with fuel before installing them. Contaminated
fuel will cause accelerated wear to fuel system parts.

 Open the front access door on the left side of the machine.
 Turn drain valve (1) counterclockwise in order to open. The drain valve is

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located on the bottom of the water separator.
 Drain the water and the sediment into a suitable container.
 Close drain valve (1).
 Remove filter (3) from filter base (4).A filter wrench may be used to loosen
the filter.
Note: The water separator element is a cartridge type filter. The filter cannot
be reused.
 (6) Remove filter (3) from bowl (2). Discard the used filter.
 (7) Clean the inside surfaces of filter base (4) and bowl (2).

(1) Drain Valve (2) bowl (3) Filter (4) Filter base
 (8) Remove cap (5) from the bottom of new filter (3). Remove seal (6) from
cap (5).
 (9) Install seal (6) in the groove of bowl (2).
 (10) Install bowl (2) to a new filter (3) .Securely tighten bowl (2) to filter (3).
 (11) Install filter (3) in filter base (4) .Securely tighten filter (3) to filter base
(4).
Note: Do not start the engine until all service to the fuel system is completed.
 (12) Close the access door.

5.8.2.3.4 Clean fuel tank cap and strainer

 Remove the fuel cap.
 Inspect seal (4) for damage. Replace the seal if necessary.
 Remove screw (1), filter assembly (2), drain valve (3) and the gaskets.
 Remove the strainer that is located in the filler opening.
 Wash the strainer and the fuel tank cap in a clean, on-flammable solvent.
 Install a new cap filter kit. Install the gaskets, drain valve (3), filter assembly
(2) and screw (1).
 Install the strainer into the filter opening.
 Install the fuel tank cap.

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5.8.2.3.5 Drain water and sediment from fuel tank
 The fuel tank drain valve is located underneath the fuel tank.
 Open the drain valve by turning the valve counterclockwise. Allow the water
and the sediment to drain into a suitable container.
 Close the drain valve by turning the valve clockwise.

5.8.2.3.6 Fill the fuel tank

Other engine maintenance and service things please follow Engine operation
statement manual.

5.8.3 Electrical system

5.8.3.1 Cleaning and Replacement of Battery and Recycle of Waste Battery

 Battery - Cleaning
Clean the battery surface with a clean cloth. Keep the terminals clean and
keep the terminals coated with petroleum jelly. Install the post cover after you coat
the terminal post with petroleum jelly.
 Battery - Recycle
Always recycle a battery. Never discard a battery.
Always return used batteries to one of the following locations:
(1)A battery supplier, (2) An authorized battery collection facility (3) 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 Circuit Breaker – Replacement

Warning!
Personal injury can result from battery fumes or explosion. Batteries give off
flammable fumes that can explode. Electrolyte is an acid and can cause
personal injury if it contacts the skin or eyes. Prevent sparks near the
batteries. Sparks could cause vapors to explode. Do not 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.

 Turn the engine start switch key to the OFF position. Turn all of
switches to the OFF position.
 Turn the battery disconnect switch to the OFF position. Remove the
key.

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 Disconnect the negative battery cable at the battery.
 Disconnect the positive battery cable at the battery.
 Disconnect the battery cables at the battery disconnect switch. The
battery disconnect switch is connected to the machine frame.
 Connect the battery cable at the battery disconnect switch.
 Connect the positive battery cable of the battery.
 Connect the negative battery cable of the battery.
 Insert the key and turn the battery disconnect switch to the ON position.

5.8.3.2 Check that the circuit breaker is reset

Alternator circuit – This circuit breaker is designed to protect the alternator. If

the batteries are installed with reversed polarity, the circuit breaker would prevent
the alternator from damaging the rectifier.
The circuit breaker has a capacity of 80 A.
Circuit breaker reset – Push in the button in order to reset the circuit breaker. If
the electrical system is working properly, the button will remain depressed. If the
button does not remain depressed, check the appropriate electrical circuit. Repair
the electrical circuit, if necessary.
5.8.3.3 Replace fuse

Open the front access door on the left side of machine.

The fuse panel is located on the circuit breaker panel. Open fuse access cover
to check the fuse.
Fuse – Fuse protects the circuit system from damage due to overload.
Replace the fuse if burnt. Check and/or repair the circuit if the new fuse is burnt.
Caution: For replacement, use a new fuse the same as the replaced one in type
and capacity. Otherwise, the circuit system may be damaged.
Caution: If the fuse is burnt frequently, there is trouble in the circuit system.
To replace fuse, use the fuse puller on fuse panel. On the fuse panel, there are
spare fuses, 3 at 5 A, 4 at 10 A, 2 at 15 A and 1 at 30 A.
The fuses for circuit protection are listed below. Each circuit is attached with

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the ampere value for every fuse.
(1) Spare – 5 A (2) spare – 10 A
(3) Spare – 10 A (4) spare – 10 A
(5) Spare – 15 A (6) spare – 30 A (7) spare – 30 A
(8) Engine controller – 15 A
(9) Horn – 10 Amps
(10) Timing relay – 10 A
(11) Cab light – 10 A
(12) Engine starting switch – 10 A
(13) Jib indicator – 10 A
(14) Engine controller and pump controller – 10 A
(15) Attached device valve controller – 15 A
(16) Roof light and memory – 10 A
(17) Air conditioner fan – 15 A
(18) Electrical refueling pump – 30 A
(19) Spare – 5 A (20) spare – 5 A
(21) Spare – 10 A (22) spare – 10 A
(23) Fuel pump – 10 A
(24) Windscreen washer and windscreen wiper – 10 A
(25) Chassis light – 10 A
(26) Spare switch and monitor – 5 A
(27) Heater base – 5 A
(28) Low windscreen washer and low windscreen wiper – 10 A
(29) Cigarette lighter – 10 A
(30) Switch console and radio equipment – 5 A
(31) Accessory solenoid – 10 A
(32) 12V, 7V commutator 1 – 10 A
(33) 12V, 7V commutator 2 – 10 A
(34) Air conditioner – 15 A
(35) Fast coupling – 5 A
(36) Signal light – 15 A
(37) Cab fan – 5 A
(38) Auxiliary circuit – 10 A

5.8.4 Air Filter and Air Conditioner in the Cab

5.8.4.1 Test of Air Conditioner

Warning!
Inhalation of coolant gas or smoke generated from the inflammable containing

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coolant gas may cause injury to human. Smoking is prohibited when air
conditioner is repaired or where there is coolant gas probably.
C Caution: To fill or replace coolant, only the coolant recommended by CATERPLILLAR can be
d. O can be used. Otherwise, it will cause damage to the system.

 Start the engine, and set engine speed knob to MEDIUM SPEED position.
 Open the front access door on the left side of machine.
 Observe from accumulator-drier view window, and note the quantity of
coolant.
 A few bubbles in view window (A) only means sufficient coolant.
 Many bubbles in view window (B) mean lack of coolant.
 A few bubbles in view window (C) means no coolant almost.
 If (B) or (C) is found from the view window, consult TYSIM customer
service.
 Operation of air conditioner without enough amount of coolant will
cause damage to the compressor.
 Maintain air conditioner well for years. Run the air conditioner for
several minutes once a week to rotate the compressor. This may
prevent coolant from leakage. The dried seal on compressor may cause
leakage.
 Close the view door.

5.8.4.2 Check and Replacement of Air Conditioner/Cab Heater Filter

Caution: Blockage of air circulating filter element may decrease the

performance of air conditioner or cab heater and shorten their life.
To prevent their performance from decrease, clean the air filter
element according to the requirement.
The circulating filter is located at the lower part on the left side of cab.
 Remove the filter element by directly pulling it upwards.
 Consult TYSIM Customer Service before cleaning air filter element with the

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compressed air.
 Clean the filter element with the compressed air at maximum pressure of 200
kPa (2 bar).
 Inspect the filter element after cleaning. If the filter element is damaged or
severely contaminated, replace it with a new one. Make sure that the filter
element is dry.

5.8.4.3 Cleaning and Replacement of Cab Air Filter (Fresh Air)

The fresh air filter is located behind the cab.

 Loosen bolt (1), and open filter cover (2) and air filter (3).
 Remove the air filter (3) from filter cover (2).
 Clean the air filter with a maximum of 200 kPa (2bar) pressure air.
 After you clean the air filter, inspect the air filter. If the air filter is damaged or
badly contaminated, use a new air filter.
 Install the air filter and the filter cover.
Note: Make sure that the arrow on top of the air filter is facing forward.

5.8.4.4 Test of the Indicator and Instrument

 Check instruments for broken glass cover, broken indicator light and
damaged switch and cab for other damaged component.
 Start the engine.
 Check for inoperative instrument.
 Switch on all the lights in the machine. Check for normal operation.
 Drive the machine to move forward. Release the control lever and pedal, and
check that the machine stops moving.
 Stop the engine.
5.8.5 Hydraulic System

5.8.5.1 Check hydraulic system oil level

Caution: Never remove the fill/vent plug from the hydraulic tank if the oil is
hot. Air can enter the system and cause pump damage.
 Park the machine on level ground.
 Open the access door on the right side of the machine.
 For a cold machine, maintain the hydraulic oil level in the low temperature
range. For a machine that is at normal operating temperature, maintain the
hydraulic oil level in the high temperature range.

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 Close the access door.
Note: Perform Step 5 through Step7 if the oil level is low.
 Slowly loosen the fill/vent plug in order to relieve any pressure. Add oil, if
necessary.
 Check the O-ring seal of the fill/vent plug. Replace the O-ring seal is
damaged.
 Clean the fill/vent plug and install the fill/vent plug.
5.8.5.2 Clean hydraulic tank screen.

 Park the machine on level ground.

 Unlatch the engine hood and raise the engine hood.
 Remove bolts (1), washers (2) and cover (3) from the top of hydraulic tank.
 Clean the area thoroughly in order to keep dirt out of the screen cover .Clean
the area thoroughly in order to keep dirt out of the fill/vent plug.
 Relieve the internal pressure from the hydraulic tank by loosening the fill/vent
plug. After the pressure is relieved, remove the fill/vent plug.
 Remove bolt (8), washer (9) and cover (10).
Note: Do not allow spring (11) to fall into the tank.
 Remove spring (11) and filter screen (12).
 Wash the screen in a clean nonflammable solvent. Replace the screen, if the
screen is damaged.
 Remove O-ring seal (13) from screen (12).
 Inspect O-ring seals (13) and (14). Replace the O-ring seals if wear or
damage is evident.
 Install O-ring seal (13) on screen (12).
 Install screen (12) and spring (11). Then install cover (10), washers (9) and
bolts (8).
Note: Make sure that the O-ring seals and the spring are properly positioned
during installation.
 Inspect the O-ring seals on the filler plug for damage. Replace the O-ring, if
necessary. Clean the filler plug. Install the filler plug.
 Install cover (3) with bolts (1) and washers (2).
 Close the engine hood and latch the engine hood.

5.8.5.3 Replacement of Hydraulic Oil Filter

5.8.5.3.1 Replace case drain filter.

 Park the machine on level ground.

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 Move the hydraulic controls lockout lever to the UNLOCKED position.
 Turn the engine starting switch to the ON position.
 Move the joysticks and the travel levers/pedals to the full stroke positions in
order to relieve the pressure in the pilot lines.
 Turn the engine start switch to the OFF position, and return the hydraulic
controls lockout lever to the LOCKED position.
 Slowly loosen the fill/vent plug on top of the hydraulic tank in order to relieve
the internal pressure of the hydraulic tank.
 After the pressure is relieved, tighten the fill/vent plug.
 Open the access door on the right side of the machine.
 Clean the area in order to keep dirt out of the filter base.
 Remove the used case drain filter from the filter base.
Note: This element is a cartridge type filter .The element cannot be reused.
 Clean the filter base.
 Coat the seal of a new case drain filter with clean hydraulic oil. Install the
new case drain filter in the filter base. Tighten the case drain filter hand tight.
 Start the engine and operate the machine slowly for 10 to 15 minutes. Move
each cylinder evenly through several cycles.
 Return the machine to the position that is shown in illustration. Check the
machine for oil leaks.
 Stop the engine.
 Maintain the oil level in the low temperature range for a cold machine.
Maintain the oil level in the high temperature range for a machine that is at a
normal operating temperature.
 Slowly loosen the fill/vent plug in order to relieve any pressure. Remove the
fill/vent plug in order to add oil, if necessary.
 Clean the fill/vent plug. Install the fill/vent plug.
 Close the access door.
5.8.5.3.2 Replace pilot system filter.
 Park the machine on level ground.
 Move the hydraulic controls lockout lever to the UNLOCKED position.
 Move the joysticks and the travel levers/pedals to the full stroke positions in
order to relieve the pressure in the pilot lines.
 Turn the engine starting switch to OFF position, and move the hydraulic
control lever back to LOCKED position.
 Slowly loosen the fill/vent plug on top of the hydraulic tank in order to relieve
the internal pressure of the hydraulic tank.
 Open the access door on the right side of the machine.

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 Clean the area in order to keep dirt out of the filter base.
 Remove the used pilot filter element from the filter base.
 Clean the filter base.
 Coat the seal of a new pilot filter with clean hydraulic oil. Install the new pilot
filter in the filter base. Tighten the pilot filter hand tight.

5.8.5.3.3 Replace oil return filter.

The oil return filter is a cartridge type filter.
By using a cartridge type filter, the amount of foreign material that enters the
hydraulic system is reduced when the filter element is replaced.
Note: If the message display shows that the hydraulic return filter is plugged,
turn off the machine.
 Loosen the fill /vent plug in order to relieve the hydraulic tank pressure.
Tighten the fill/vent plug after the hydraulic tank pressure is relieved.
 Remove the filter cartridge.
 Remove bolts (1), washers (2) and cover (3).
 Remove plug (4) in order to release the pressure in filter cartridge (5).
 Pull up the handle at the top of filter cartridge (5) until the filter cartridge
contacts guide (A) on filter case (6).
 Turn the filter cartridge (5) counterclockwise by 180º in order to align the
projection of the filter cartridge (5) with the notch of the filter case. Pull out
the filter cartridge (5).
 Inspect the cover and O-ring (7).If either part is damaged, replace the part.
Inspect the filter cartridge for debris and for damage. If necessary, replace
the filter cartridge.
 Remove the filter element. Perform Step a through Step f in order to remove
the filter element.
 Make sure that plug (4) is removed. Make sure that all of O-ring (18) is
removed from plate (8).
 Remove spiral retaining ring (9).
 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.
 Remove O-ring (11) from plate (8).
 Lift filter element (12) from shell (10).
 Pour the remaining oil into a suitable container.
 Repeat Step a through Step f for the other filter groups.
 Clean the shell of the filter cartridge. Perform Step a) through Step d) in
order to clean the shell of the filter cartridge.
 a} Turn shell (10) upside-down.

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 b} Remove screws (15).
 c} Remove filter pads (14) from slide plate (13).
 d} Wash the following parts in a clean nonflammable solvent :
plug(4),plate(8),spiral retaining ring(9),shell(10),and filter pads(14). Dry
the parts.
 Install the filter elements. Perform Step a) through Step k) in order to install
the filter elements.
 Apply spray type oil to the inside of shell (10) in order to prevent rust.
 Apply grease to a new O-ring (11).
 Plate (8) will contact the inside of shell (10).Apply grease to this point.
 Apply grease to O-rings inside ports (19) at the bottom of shell (10).
 Install new filter pads (14). Tighten the screws to a torque of 0.4 N·m
(3.5 lb in) .
 Apply spray type oil into the clearance between shell (10) and slide
plate (13).
 Turn over shell (10).Apply grease to the two O-rings on new element
(12).Install element (12) into shell (10).
 Move boss (16) in alignment with notch (17). Install plate (8) into shell
(10).
 Install spiral retaining ring (9) into the groove in shell (10).
 Apply grease to new O-ring (18). Install O-ring (18) on plug (4).
 Insert plug (4) into plate (8).
 Install the filter cartridge. Perform Step a) through Step e) in order to install
the filter cartridge.
 Check if ports (B) at the bottom of the filter case are closed.
Note: If the ports are open, rotate slide plate (C) counterclockwise to the
stopper in order to fully close the ports. When the ports are fully
closed, any remaining oil in the filter case should be completely
removed.
 Check that ports (D) of the filter cartridge are fully closed.
Note: The filter cartridge cannot be installed unless the ports are fully closed.
If the ports are open, rotate slide plate (E) counterclockwise to the stopper in
order to fully close the ports.
 Check that O-rings (F) have been installed and that oil has been applied
to O-rings (F).
 Install the filter cartridge into the filter case. Turn the filter cartridge
clockwise by 180º and push down the filter cartridge when the filter
cartridge contacts guide (A).

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 Install plug (4), cover (3), washers (2) and bolts(1) Tighten bolts (1) to
the torque of 29±5 N·m .

5.8.5.4 Replacement of Hydraulic Oil

5.8.5.4.1 Precaution for Replacement of Hydraulic Oil

The first oil change interval is 500 hours, and the hereafter is each to change
the oil a time when using 1500 hours, The first time to change the hydraulic oil is
125 hours, later change the oil one time with the interval of 250 hours, and then the
oil change interval can prolong if the imported high quality hydraulic oil will be used.

5.8.5.4.2 Replacement of hydraulic oil of hydraulic system

The interval of replacement of it is 4000 hours.
The interval of replacement of it is 4000 hours. The 4000 hours maintenance
interval of hydraulic oil is acceptable. If you want to prolong the interval, it needs
have SOS test, the SOS test interval is 500 hours, and the maintenance period of
the hydraulic filter didn’t change. If you did not carry out the test, the maintenance
period must be 2000 hours.
The interval of the rig operation with mal-condition does not include the 4000
hours maintenance plan.
The lubricate agent wants to get the 4000 hours interval to change the oil, must
use the hydraulic oil which has been approved.

5.8.5.4.3 Use Instruction of Oil Quality

Operating Viscosity Range
To acquire the best efficiency and service life, it is recommended to select the operating
viscosity (within operating temperature range) with the following range:

Vopt = optimal operating viscosity 16-36mm2/s

Viscosity limit range Vmin=5mm2/s

Transient at maximum permitted temperature T=115℃

Caution: It cannot exceed 115℃ Vmax-1600mm2/s in partial area (e.g.,

bearing area).
Transient cold starting (n<1000r/min,Tmin=-40℃)

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5.8.5.4.4 Precaution for Selection of Hydraulic Oil
To select hydraulic oil correctly, understand the operating temperature in the
loop (close loop) related to the environmental temperature.
The hydraulic oil should be selected in accordance the following: The
operating viscosity (Vopt) is within optimal range within operating temperature range
(refer to the shaded part in the selection diagram). We recommend the oil of high-
grade viscosity.

Example: When the operating temperature in loop is 60℃ at the

environmental temperature of X℃, the viscosity grade corresponding to the
operating viscosity range (Vopt) is VG46-VG68. So VG68 should be selected.

Caution: The temperature of leaked oil (leaked from housing) is always

higher than that in loop due to the impact of pressure and
rotary speed of pump. However the temperature at any point in
loop should not exceed 90℃.

5.8.5.4.5 Lubricate oil on the market

You can use 900ppm diesel engine lubricate oil with min. zinc-bearing (heavy
machine uses)

Caution:
It is prohibited to mix the hydraulic oils in different brands and types.

5.8.5.4.6 Procedure to change the hydraulic oil

 Park the machine on level ground.
 Remove bolts (1), washers (2) and cover (3) from the top of hydraulic tank.
 Clean the area thoroughly in order to keep dirt out of the screen cover. Clean

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the area thoroughly in order to keep dirt out of the fill/vent plug.
 Relieve the internal pressure from the hydraulic tank by loosening the fill/vent
plug. After the pressure is relieved, remove the fill/vent plug.
 Remove the hydraulic tank access cover that is located under the upper
structure. This will allow access to the drain valve.
 Remove plug (4).
 Loosen drain plug (7) in order to drain the oil.
 Drain the oil into a suitable container.
 After the oil has been drained, tighten drain plug (7) to the torque of
110±15N·m
 Clean and install plug. Tighten the plug to the torque of 75±5N·m (55±48lb ft)
.
 Open the access door on the right side of the machine.
 Clean the pump, the hydraulic lines and the hydraulic tank.
 Remove the plug from the tube. Allow the oil to drain into a container.
 Inspect the O-ring. Replace the O-ring if wear or damage is evident. Install
the plug and the O-ring into the drain port.
 Remove bolts (8), washers (9) and cover (10).
Note: Do not allow spring (11) to fall back into the tank.
 Remove the spring (11) and screen (12).
 Wash the screen in a clean nonflammable solvent. Allow the screen to dry.
Inspect the screen. Replace the screen, if the screen is damaged.
 Remove O-ring seal (13) from the screen.
 Inspect O-ring seals (13) and (14). Replace the O-ring seals if worn or
damage is evident.
 Install O-ring seal (13) on screen (12).
 Install screen (12) and spring (11). Then install cover (10), washers (9) and
bolts (8).
Note: Make sure that O-ring seals and the spring are properly positioned
during installation.
 Clean the screen in the rubber flashing line of the pump. The screen is
located inside the right side door.
 Use a wrench with a span of 24mm in order to remove case.
 Remove screen (16) and seal (19) from head (11).
 Clean inside of the head.
 Remove seal (17) from case (18). After washing screen (16) and case (18)
with a nonflammable solvent, allow the screen and the case to dry.
 Inspect screen (16). Replace the screen if the screen is damaged.

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 Lubricate new seal (19) with small amount of clean hydraulic oil. Install the
seal in head (15). Do not damage the seal when installing it to cylinder head
(15).
 Lubricate the new seal (17) with a small amount of clean hydraulic oil. Install
the seal in the case.
 Install tank case (18) in head (15). Tighten the case to a torque of 30±5 N·m .
 Fill the hydraulic system oil tank.
 Inspect the O-ring seal on the filter plug for damage. Replace the O-ring, if
necessary. Clean the filler plug. Install the filler plug.
 Remove the pressure cap.
 Inspect the pressure cap. Clean the pressure cap. Replace the pressure cap
if damage is evident.
 Replace the pressure cap.
Note: Make no attempt to start the engine until the pump has been filled with
hydraulic oil. Or serious damage to the hydraulic components can
result.
 When the hydraulic oil has been replaced, the air must be removed from the
hydraulic oil system. Use the following procedure to remove the air from the
hydraulic oil system.
 While the engine is stopped, remove the vent plug on the top of the
pump. Leave the vent plug unattached for several minutes until the
pump is filled with hydraulic oil. After the pump is filled with hydraulic oil,
tighten the vent plug. Start the engine.
 Stop the engine. Slowly loosen the vent plug for several turns until the
hydraulic oil flows out of the opening from the vent plug. This indicates
that the air has been released from the pump. Tighten the vent plug
again.
 Start the engine. Operate the engine at idling speed for five minutes.
 Operate the joysticks in order to circulate the hydraulic oil. Stop the engine.
 Maintain the oil level between the marks on the sight gauge in the
appropriate temperature range.
 Close the access door.
 Close the engine hood and latch the engine hood.

5.8.5.5 Clean the radiator core

 Raise the engine hood and open the access door on the left side of the
machine.

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 Check all the core fins for debris.
 Remove dust and debris from all of the core fins and from the screens.
 Compressed air is preferred, but high pressure water or steam can be used
to remove dust and general debris from a core.
 Close the engine hood and close the access door.

5.8.5.6 Inspect oil filter

Inspect a used filter for debris

Use a 4C-5084 Filter Cutter or a 175-7546 Oil Filter Cutter to cut the filter
element open. Spread the pleats and inspect the element for metal and for
other. .Excessive debris in the filter element can indicate possible failure.
If metals are found in the filter element, metals must be differed from
nonferrous parts by magnet. Ferrous metals can indicate worn on steel parts and
on cast iron parts. Nonferrous metals can indicate wear on the aluminum parts of
the engine.
Small amounts of debris may be found in the filter element. This could be
caused by friction and by normal worn.

5.8.5.7 Quick coupler- Lubricate

Wipe all fittings before you apply lubricant.

Apply lubricant through the four fittings on the quick coupler. The quick coupler
has two fittings on each side.
Note: Do not lubricate the wedge and the wear plates. Friction is needed in
order to hold the wedge in place during backfilling.

5.8.6 Swing Gear

5.8.6.1 Swing bearing-Lubricate

Wipe the fittings before you lubricate the swing bearing. The swing bearing is
under the base of the boom. Apply lubricant through the fittings until the lubricant
overflows the bearing seals.

5.8.6.2 Change swing drive oil

 Remove the access cover that is located below the swing drives.
 Remove drain hose (2) from holder (1) on the upper frame. Face the end of
the hose toward the container.

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 Use a universal joint with a socket extension to loosen the drain valve in hole
(3).Drain the oil into a suitable container.
 Tighten the drain valve. Hook the drain hose (2) to the holder (1).Make sure
that the end of the hose is facing upward.
 Remove dipstick (4).
 Add the specified quantity of oil through the dipstick tube.

FULL

ADD
 Maintain the oil level between the tip of the dipstick and the mark on the
dipstick (4).
 Check the oil if has been drained for metal chips or metal particles.
 Do lever the drain liquid according to the local laws and regulations.

5.8.6.3 Check swing drive

 The dipstick for the swing drive oil is on the swing drive at the rear base of
the boom.
FULL

ADD

 Check the dipstick. Maintain the oil level between the tip of the dipstick and
the mark on the dipstick. Add oil through the dipstick tube, if necessary.
 Insert the dipstick.

5.8.6.4 Lubricate swing gear

Caution: Improper lubrication can cause damage to the machine components.

To avoid damage, make sure that the proper amount of grease is
applied to the swing drive. When the amount of grease in the
compartment becomes too more, the agitation loss becomes large,
thereby accelerate grease deterioration. Grease deterioration can
cause damage to the pinion gear of the swing drive and swing
internal gear. Not enough grease will result in poor gear lubrication.

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 Remove the inspection cover that is located near the boom base. Inspect the
grease.
 Remove bolts (1) and washers (2). Remove cover (3) and gasket (4).
 Inspect gasket (4). Replace the gasket if there is damage.
 Check the level of the grease. The grease should be evenly distributed on
the floor of the pan.
 Check for contamination and for discolored grease.
 If the grease is contaminated or discolored with water, change the grease.
Remove bolts (5), washers (6), cover (7) and gasket (8) in order to allow the
water to drain. When you reinstall cover (7), inspect gasket (8).Replace the
gasket if there is damage.
 Raise the boom and turn the upper structure by 1/4 turn.
 Repeat above steps at every 1/4 turn.
 Install gasket (4), cover (3), washers (2) and bolts (1).

5.8.7 Track driving

5.8.7.1Check the track

Check the track for wear and for excessive dirt buildup.

5.8.7.2 Measuring track tension

 Place a straight edge on the tracks. The straight edge should be long enough
to reach from the idler to the carrier roller.
 Measure the maximum amount of sag in the track. The sag is measured from
the highest point of the track grouser to the bottom of the edge. The track
that is properly adjusted will have a slack of 40 to 55mm.
5.8.7.3 Track Adjustment

WARNING!
Grease under high pressure may cause injury and death to human. The
grease at high pressure, which is spurted out from relief valve, may
pierce human organs to cause injury and death to human. The relief
valve can be loosened for one turn only. If the track cannot be released,
close the relief valve and consult the TYSIM Customer Service.
Caution: Proper adjustment of track may prolong the service life of
track and the components in drive device.

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 Track adjustment

Note: Do adjust the degree of tension well according to the current operating
conditions. If the soil layer is thick, release the track as possible.

 Tightening the track

Clean the fitting before you add lubricant.
 Add lubricant through the fitting until the correct track tension is
reached.
 Operate the machine back and forth in order to equalize the pressure.
 Check the amount of sag. Adjust the track, as needed.
 Loosening the track
 Loosen the relief valve carefully until the track begins to loosen. One turn
should be the maximum.
 Tighten the relief valve to 34N·m (25 lb ft) when the correct track tension is
reached.
 Operate the machine back and forth in order to equalize the pressure.
 Check the amount of sag. Adjust the track, as needed.
Note: If you cannot achieve the correct adjustment, please consult the
TYSIM Customer Service.

5.8.7.4 Change the final drive oil

 Position one final drive so that oil drain plugs (2).

 Remove drain plug (2) and level plug (1). Allow the oil to drain into a suitable
container.
 Clean the plugs and inspect the O-ring seals. If wear or damage is evident,
replace the drain plug, the level plug, and/or the O-ring seals.
 Install drain plug (2).
 Fill the final drive to the bottom of the opening on level plug (1).
 Install level plug (1).
 Perform Step 1 to Step 6 on the other final drive. Use a different container for
the oil so that the oil samples from the final drives will be separate.
 Completely remove the oil that has spilled onto surfaces.
 Start the engine and allow the final drives to run through several cycles.
 Stop the engine. Check the oil level.
 Check the drained oil for metal chips or particles.
 Properly dispose of the drained material.

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5.8.7.5 Check the final drive oil level

 Position one final drive so that oil drain plug 2) is at the bottom.
 Remove oil level plug (1).
 Check the oil level. The oil should be near the bottom of the level plug
opening.
 Add oil through the level plug opening, if necessary.
Note: Overfilling the final drive will cause the seals on the travel motor to
allow hydraulic oil or water to enter the final drive. This may
contaminate the final drive.
 Clean oil level plug (1).Inspect the O-ring seat. Replace the O-ring seal if the
O-ring seal is worn or damaged.
 Install oil level plug (1).
 Repeat the procedure for the other final drive.

5.8.8 Rotary table

5.8.8.1 Replace oil for rotary table drive device

 Remove the view cover under the rotary table drive device.
 Remove drain pipe (2) from fixer (1) on upper frame with the hose end
pointing to a container.
 Loosen the drain valve in hole (3) by using the universal joint that is
extended with sleeve. Drain the oil into a suitable container.
 Tighten the drain valve. Hang drain hose (2) on fixer (1) with the hose end
placed upwards.
 Add certain amount of oil through filler.
 Keep the oil level at the middle line of oil mark.
 Check the drained oil for existence of metal chips or metal particles.
 Do with the drain liquid according to the local laws and regulations.

5.8.8.2 Check the oil for rotary table device

Caution: Improper lubrication may cause damage to the components of

machine. To avoid damage, make sure that the amount of grease
applied to the rotary table drive device is correct. Excessive grease
in the splined gear chamber for rotary table may increase slewing
consumption, resulting in accelerating grease deterioration. Grease

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deterioration will cause damage to the pinion and the ring gear of
rotary table drive device. Lack of grease may cause bad lubrication
for gears.
 Remove the view cover near rotary table base. Check the oil.
 Remove bolt (1) and washer (2). Remove cover (3) and gasket (4).
 Check gasket (4). Replace it if obviously damaged.
 Check the oil level. Check that the oil is distributed in groove bottom
uniformly.
 Check the grease for condemnation and discoloration.
 Replace the oil if contaminated or discolored due to water. Remove bolt (5),
washer (2), cover (7) and gasket (8) to drain the water. Check gasket (8)
when reinstalling cover (7). Replace the gasket if obviously damaged.
 Install gasket (4), cover (3), washer (2) and bolt (1).

5.8.8.3 Replace oil for splined gear of rotary table

 Turn oil drain plug (2) for splined gear of rotary table on one side to its
bottom position.
 Remove drain plug (2) and oil level plug (1). Drain the oil for splined gear of
rotary table into a suitable container.
 Clean the plug, and check O ring. Replace the drain plug, oil level plug
and/or O ring if obviously worn or damaged.
 Install drain valve (2).
 Fill the splined gear cavity of Rotary table with oil to enable the oil level to
reach to the bottom of opening in oil level plug (1).
 Install the oil level plug.
 Carry out the above Steps from 1 to 6 for the splined gear cavity of rotary
table on the other side. Use another container to separate the oil samples
from the two splined gear cavities for rotary table.
 Thoroughly remove the oil splashed to the surfaces.
 Start the rotary table, and rotate the splined gear of rotary table for several
revolutions.
 Stop the engine. Check the oil level.
 Check the drained oil for existence of metal chips or particles.
 Properly do with the drained material.

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5.8.8.4 Check the oil level for splined gear of rotary table

 Turn oil drain plug (2) for splined gear of rotary table on one side to its
bottom position.
 Remove oil level plug (1).
 Check that the oil level is near the middle of oil level view window.
 Add oil through the opening in oil level plug when necessary.
Note: Overfill of oil to splined gear cavity of Rotary table will cause leakage
from rotary table seal, resulting in ingression of hydraulic oil or water
into the splined gear cavity of rotary table. This may contaminate the
splined gear cavity of rotary table.
 (5) Clean the oil levels plug (1). Check O ring. Replace the O ring if was worn
or damaged.
 (6) Install the oil level plug (1).

5.9 Common Trouble shooting and maintenance material recommendation

5.9.1 Common Trouble shooting

S/N Symptom Analysis Remedy

1. Replace diesel oil and
Black smoke from 1. Oil pipeline blocked oil filter element.
1 engine,, power 2. Engine defective 2. Contact TYSIM
insufficient Service.
Strange sound at 1. Mast joint bolt loose 1. Tighten bolt.
2 2. Kelly bar servo bearing
front end of mast 2. Add grease.
lack of grease
1. Level sensor damaged
1. Replace.
3 Mast not vertical 2. Hydraulic lock of mast oil 2. Replace.
cylinder damaged
1. Engine output power 1. Replace three
insufficient filters.
Rotary table output
4 torque insufficient 2. Overload 2. Improve process.
3. Hydraulic oil pipeline 3. Check and repair oil
blocked pipeline.
1. Solenoid valve plug 1. Clean.
Main winch seized
5 2. Check related
inoperative 2. Solenoid valve out of circuit.
power
1. Joint screw loose 1. Tighten.
6 Pipeline joint leak 2. Seal damaged 2. Replace.
Swivel element out 1. Elevator lack of grease 1. Fill grease.
7 2. Elevator bearing worn 2. Replace.
of free swing 3. Elevator seal damaged 3. Replace.
Depth meter 1. Sensor angle improper 1. Adjust.
8 inaccurate 2. Sensor worn 2. Replace.
1. track worn due to long- 1. Fill stretcher oil
9 Track loose term running cylinder with oil.
10 Steel rope broken 1. Elevator out of free 1. Repair.

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slewing 2. Replace and check
2. Steel cable seriously frequently.
damaged
1. Wire end loose 1. Check.
11 Slewing not free 2. Electrical component 2. Replace.
module damaged

5.9.2 Lubricating oil

Lubricant Viscosity at Environmental Temperature

°C °F
Spacing Room or Oil Viscosity Min. Max. Min. Max.
System
Value Value Value Value
SAE 0W20 -40 +10 -40 +50
SAE 0W30 -40 +30 -40 +86
Engine SAE 0W30 -30 +30 -22 +86
Crankcase SAE 5W40 -30 +40 -22 +104
SAE 10W30 -20 +40 -4 +104
SAE 10W40 -15 +50 +5 +122
SAE 0W20 -40 +40 -40 +104
SAE 0W30 -40 +40 -40 +104
SAE 5W30 -30 +40 -22 +104
SAE 5W40 -30 +40 -22 +104
SAE 10W -20 +40 -4 +104
Hydraulic System SAE 30 +10 +50 +50 +122
SAE 10W30 -20 +40 -4 +104
SAE 15W40 -15 +50 +5 +122
Biodegradable
Hydraulic Oil -25 +43 -13 +110
(HEES)
SAE OW20 (1) -40 0 -40 +32
Final Drive, SAE 0W30 (1) -40 +10 -40 +50
Rotary Disc Drive SAE 5W30 (1) -30 10 -22 +50
Device, track SAE 10W -30 0 -22 +32
Carrying Wheel SAE 30 -25 +25 -13 +77
and track Driving SAE 50 -15 +50 +5 +122
Wheel
SAE 60 -10 +50 +14 +122

Note: These oils are the special oils that include synthetic base stock without any
polymerized viscosity index improver.

5.9.3 Solvents and Oil Dosage Table

Approximate Refill Volume

Component US Imperi
Lit. Recommended Type
or System Gal. al Gal
Cooling 35 9.2 7.7 CATERPILLAR extended-life coolant (ELC)
System
Coolant Tank 1.5 0.4 0.3 CATERPILLAR extended-life coolant (ELC)
Fuel Tank 618 163 136 No.1 or No. 2 diesel engine fuel (-10#~-20#)

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Engine CAT diesel engine lubricating oil (DEO)
Crankcase 35.5 9.4 7.8 multilevel API CH-4、API CG-4 or API CF-4
with Filter
CATERPILLAR hydraulic pressure oil
Hydraulic Oil 315 83 69 (HYDO) or CATERPILLAR biodegradability
Tank hydraulic pressure oil (HEES)(1)
CATERPILLAR hydraulic pressure oil
Hydraulic 410 108 90 (HYDO) or CATERPILLAR biodegradability
System hydraulic pressure oil (HEES)(1)
Track Final CATERPILLAR gear-box / drive system oil
15 4.0 3.3
Drive (TDTO)
Turnplate CATERPILLAR gear-box / drive system oil
19 5.0 4.18
drive device (TDTO)
Turnplate 29 7.7 6.4 multiduty grease lubricant with lithiumNLGI2
gear
Oil for Rotary Mobil vehicle gear oil Mobil VBE HD 80W－
Table Drive 18 4.8 3.95
Device. 90

Rotary table Mobil synthetical gear oil Mobil GEAR

lubricant 60 15.9 13.2
SHC220

Note: Before use of HEES, please consult the TYSIM Customer Service. The
HEES may be not applicable to your machine.

5.9.4 Stage maintenance for fittings

Note: please purchase the parts that will be required for maintenance, strictly
according to the statement of our company to maintain your equipment, keep
it in its best status, and reduce your operating cost.

5.10 Appendix 1 Table for Bolt Tightening Torque

Nominal Dia. d Tightening Torque N·m (Standard Value)

Pitch mm
mm Grade 4.6 Grade 8.8 Grade 10.9
M10 1.5 20 44 62
M12 1.75 38 78 110
M14 2 60 120 170
M16 2 95 190 265
M18 2.5 142 260 365
M20 2.5 188 370 520
M22 2.5 500 700
M24 3 640 900
M27 3 950 1350
M30 3.5 1300 1800

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6 KR160M ROTARY DRILLING RIG CORRECT OPERATION METHODS

The following introductive content is about the supplementary and renewal to

the drill rig's use and control and maintenance and service, which is the result of
our clients’ experience on use and operation drilling rig, and we also combine the
advanced construction working methods that we are actively promoting. Use correct
control methods to operate, you would get twice the result with half the effort and
decrease equipment damage and use cost.

Warning: Not following the correct operation, lubricating, maintenance and

service performance and carelessness will cause decrease the rig’s life time
and increase accidents. The early damages caused by uncorrected operation,
lubricating, maintenance and service performance are not included in our
warranty scope, you must pay for the maintenance and the replacement of
the parts.

Note: Our Company supplies the training to the operators, correct operation,
lubricating, maintenance and service performance and safety precautions are
important parts of the training content.

6.1 Unload earth operating mode

Unloading earth is an important operating mode and it possibly brings major
injure to KR160M drilling rig, so you must adopt correct operation method.

Warning: It’s forbidden to adopt normal-reverse circulation method (first

reverse circulation, then suddenly normal circulation or opposite operation)
to unload earth, the early damages due to it are not included in our warranty
scope, you must pay for the maintenance and the replacement of the parts.

Note: the cuttings in the drill bucket are not allowed to surpass 80% of the
bucket, especially remain some space for its top will conduce to drill,
pullback and unload earth.
The following is some kind of frequent and correct unloading earth operating
modes.

6.1.1 Scram unloading earth

 Exalt drill bucket with symmetrical speed, it should be revolution exaltation;
 Slew the rig to unloading earth place, unclose the door of the bucket bottom;
 Turn clockwise (the same with drilling bore) with faster speed;
 Stop the drill bucket's revolution suddenly, so you can demount the cuttings

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from the drill bucket

6.1.2 Up and down unloading earth

 Exalt drill bucket with symmetrical speed, it should be revolution exaltation;
 Slew the rig to unloading earth place, unclose the door of the bucket bottom;
 By the main winch exalting the drill bucket up and down, you can demount
the cuttings from the bucket.

6.1.3 Unloading-earth ware / Scraping-earth ware

You could very expediently make unloading-earth ware / scraping-earth ware
by yourself, or consult our sale service to get technical support.
 Exalt drill bucket with symmetrical speed, it should be revolution exaltation;
 Slew the drill rig to the place above the unloading-earth ware / scraping-earth
ware (which is fixed to at the unloading place ) unclose the door on the
bucket bottom;
 Dropping the drill bucket with revolution turn, unload the cuttings by the
unloading-earth ware / scraping-earth ware.

6.1.4 Gravitation unloading earth

This kind of unloading earth method mostly designed for the drill bucket whose
diameter is ≥1500mm.
 Exalt drill bucket with symmetrical speed, it should be revolution exaltation;
 Slew the rig to unloading earth place, unclose the door of the bucket bottom;
 The cuttings could demount by itself gravitation.

6.1.5 Assistance unloading earth

This kind of unloading earth method mostly designed for demounting the
cuttings that were left by using other unloading methods, and is used to get rid of
the cuttings which were inside the bucket for long time.
 Slew the rig to unloading earth place, unclose the door of the bucket bottom;
 Stop running the drill rig, by using the supplementary means to raze off the
cuttings from the inside of the bucket.

6.1.6 Form open type unloading earth

This kind of unloading earth method mostly designed for the bucket whose
diameter is about 500～800 mm side open type drill bucket.
 Exalt drill bucket with symmetrical speed, it should be revolution exaltation;
 Slew the drill rig to the unloading earth place, reverse rotate the drill bucket;
 Centrifugal force would unclose the drill bucket of the side open type rig to
demount the cuttings.

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6.2 Pressure operating mode

80% operating modes of KR160M drill rig in construction drilling progress don't
need use compressive oil cylinder, or small compressive force is ok for drilling.
Universal drilling progress relies on themselves gravitation of Kelly bar, drill
bucket, rotary table, and the cutting force of the drill bucket can satisfy the required
compressive force.
Using the compressive oil cylinder would increase the load to all parts of the
drill rig, aggravate the cutting teeth abrasion of drill bucket, at the same time also
could decrease pore-forming speed and pore-forming quality, increase pore-forming
cost.
Warning: General drilling progress using compression cylinder to pressurize
will cause the early damages to the rig and its parts, which are not included in
our warranty scope, you must pay for the maintenance and the replacement
of the parts.
Only in drilling progress encounter different kinds of weathered rock whose
hardness ≥ 10 MPa, can use compressive oil cylinder to proceed symmetrically, the
force should not be too much.

6.3 Kelly bar unlocking

Kelly bar (interlocking Kelly bar) has three states: Complete unlocking,
incomplete unlocking and complete not unlocking. The later two states do not allow
lifting drill stem and subsequent operation. After completing drilling operation, Kelly
bar must be complete unlocking to lift and make subsequent operation.

Warning The severe damages to the rig or some parts of the rig caused by
lifting drill stem and subsequent operation before complete unlocking will not
be wrapped within the scope of warranty, and the maintenance and parts
replacement is paid by yourself.
Correct unlocking methods for drill stem:
 Must not use main winch to lift drill stem and drill bucket after complete
drilling operation
 Rotate the rotary table a turn counterclockwise to close the bucket bottom
(do not lift the rotary table)
 Use the compression cylinder to lift the rotary table for 200mm ～ 300mm
(reduce the pressure of pressurization point)
 Rotate the rotary table counterclockwise and lift it (unlocking)
 Lift the drill bucket slowly, it should be rotated counterclockwise (avoid self-
locking during lifting the bucket)

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 In the process of lifting drill bucket, take care whether the mast and Kelly bar
make forth and down movement after instant increasing weight when lift
every 1 portion length. This action is called the “nodding” of the rig.
 If the“nodding”doesn’t happen, please stop the rig immediately, transfer the
bucket to the bottom of the bore, repeat previous operations.
Note: If it not unlocks through repeated operation, please consult Tysim
Piling Equipment Co., Ltd after service department. Do not try any savage
operation.

6.4 Drill bucket cutting teeth rake angle selection

Front angle of the bucket teeth selection.
Rotary drilling rig working pressure and torque transmitting:
Pressure: rotary table oil cylinder → rotary table → Kelly bar → bucket →
cutting tooth;
Torque: Rotary table motor → rotary table turntable → Kelly bar → bucket →
cutting rock or soil.
In view of the whole working process, rig power is turned to working pressure
and torque, which are settled before the machine leaves the factory. However,
utilization ratio of the pressure and torque during transmitting depends upon the key
parameters related to Kelly bar and drill bucket with different cutting teeth rake
angle. The drill-in effect can be analyzed from the table 5 below.
Regarding drilling in the same layer with the same drilling torque, drilling
efficiency differs from different cutting teeth rake angles. Therefore, cutting teeth
rake angle must be chosen properly for higher drilling efficiency. After intensive
testing, it is found that a little larger cutting teeth rake angle suits well relatively
floppy layers such as the fourth layer, largely airslaked layer, and less frozen soil,
45~60°is proper, while relatively harder layers, bucket cutting teeth rake angle to be
25~35°.

Fig 4 Design features and Adapting earth layers

Type Design features Suitable strata

Bucket Single door bucket Single layer bottom, Clay soil
large mouth
Double doors bucket Single layer bottom, Loose soil or
stable drilling in preferable bond
pebble
Semi-close bucket Halves cylinder, Adhesive earth in
convenient unloading whole layer

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Double side doors Single layer bottom, Clay soil or loose soil
bucket large mouth, stable with pebbles
drill -in
Single door sand Double layer bottom, Big diameter
bucket large mouth pebbles, frozen soil
or largely airslaked
bedrock
Double doors sand Double layer bottoms, Medium or small
bucket two mouths diameter pebbles,
frozen soil or largely
airslaked bedrock
Single start, Large mouth with Clay soil
single straight flight more earth taken,
good guidance quality
Double start, With more earth Frozen soil or
single straight flight taken, good guidance preferable bond
quality pebbles
Double start, Smooth drilling in, Clay with less water,
double straight good guidance quality or preferred bond
flights pebble
Auger
Single start single Large mouth, quick Hard frozen soil,
cone flight unloading shale, big diameter
pebbles
Double start, single Good guidance Hard frozen soil, big
cone quality, quick diameter pebbles, or
flight unloading airslaked bedrock
Double start, double Good guidance Hard frozen soil, big
cone flights quality diameter pebbles, or
airslaked bedrock
Bottomless, good Large boulder or
Core barrel lithology drilling solid bedrock
nature
Belling
bucket Top-open Belling Large enlarging Soil layer or bedrock,
bucket angle, smaller slewing stable layers
torque

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Bottom-open Belling Small enlarging angle, Soil layer or bedrock,
bucket great slewing torque suitable for bad
ground

Fig 5 Relation between Cutting teeth rake angle and drill depth.

Cutting Kelly bar Footage m / 10min

teeth rake torques Little frozen
Mudstone Clay Sandy soil
angle (°) (kN.m) soil
180 0.4 0.55 0.45 0.55
30 120 0.4 0.5 0.4 0.5
100 0.3 0.4 0.3 0.4
180 0.7 0.65 0.6 0.7
45 120 0.6 0.6 0.5 0.65
100 0.5 0.5 0.4 0.65
180 0.5 0.5 0.5 0.6
60 120 0.5 0.4 0.5 0.5
100 0.4 0.3 0.4 0.5

6.5 Full-length/segmentation machine and tools drilling method

Note: Beijing TYSIM Heavy Machinery Co., Ltd strongly recommends the full-
length/segmentation machine and tools drilling method.

Before entering the working site, you should make detailed drilling method plan
according to the coherent geologic report, the depth of hole and the features of the
rig, then allocate the drilling bucket and cutting tooth, different geologic layer using
different drilling bucket, matching different length and angle cutting teeth, you can
take the above two lists as reference, thinking of the specific geologic layer to
choose. According to different drill bucket and cutting teeth and geology, establish
the drilling speed in drilling progress , if need compression, what size of
compression force and so on, establish specific bore operational standard ( for the
specific site ) .

6.6 Lubrication gap (Breathing Space)

Each oil site ' s lubrication and method in Part four" Maintenance and Service "
had been detailed introduced, here what accentuate is breathing space , normal
space is conduce to extend the lubricating oil ,oleosol lubricate life-time and the
validity of lubricating effect.
Notice: incorrect lubricate method could decrease lubricate effect, speedup

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moving part abrasion, decrease service life.
 Where to adopt lubricating oil, should remain more than 50 % ~ 60 % space;
 Where to adopt oleosol, should remain 10 % ~ 20 % space.

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