SUNWARD SWDE120B-3 Manuale
SWDE120B-3 DOWN-THE-HOLE DRILLING RIG
Operation & Maintenance
Manual
SUNWARD INTELLIGENT EQUIPMENT CO., LTD.
March, 2022
FOREWORD
The manual shall be read carefully and understood correctly to help you operate and
maintain your machine safely and properly, otherwise, personal injury and machine damage
may occur.
The safety attentions and labels are mentioned in the manual and fixed on the machine
providing the instructions of potential risks and the way to avoid that.
It’s impossible for SUNWARD to predict all the potential risks. Thus, the safety rules
are mentioned in the manual and on the machine only referring to the basic safety rules
instead of all possible safety precautions. Necessary measures should be taken by you to
ensure the safety if there’s no specified, recommended or allowed methods or actions in the
manual.
The forbidden usages or operations in the manual shall be observed strictly under any
circumstances.
The machine is designed according to the metric system, all the data presented are
metric, even if the inch size is lined out, which is still transformed by the metric size. Besides,
only metric parts and tools can be used.
The manual should be regarded as the permanent part of your machine and kept in the
cab for consultation at any time. Please contact SUNWARD or authorized dealers to
purchase a new one if it’s damaged or lost. Meanwhile, it should be attached when the
machine is transferred or sold.
Only qualified, experienced operators or who received an official license after a
standard training can operate, check or maintain this machine.
The instructions, data and charts covered by this manual are the latest product
information as of its date of issue. The manufacturer SUNWARD reserves the right to make
any modification or amendment of any nature from time to time and without prior notice,
deemed useful or necessary, to any machine component, without any obligation to amend the
content of this manual accordingly. Pictures and data contained in this manual are not
binding. Consequently, no claim raised in this respect will be considered.
Please contact SUNWARD or authorized dealers for any questions about the latest
material or the material referred in the manual.
SUNWARD INTELLIGENT EQUIPMENT CO., LTD.
OPERATION & MAINTENANCE MANUAL SWDE120B-3
Table of Content
1. Safety Rules...........................................................................................................................1
1.1 Safety Mark................................................................................................................. 1
1.2 Safety Label................................................................................................................. 1
1.3 General Safety Instruction........................................................................................... 1
1.4 Preparation for Emergency.......................................................................................... 2
1.5 Wear Safety Protective Gear....................................................................................... 2
1.6 Check Machine Before Start-up.................................................................................. 3
1.7 Adjust Operator Seat....................................................................................................3
1.8 Enter or Leave Machine Correctly.............................................................................. 3
1.9 Start Engine Correctly................................................................................................. 3
1.10 No Passenger Allowed In The Cab............................................................................4
1.11 Keep Machine Away From Power Line.................................................................... 4
1.12 Move Machine Safely................................................................................................4
1.13 Prevent Accidents While Backing Up or Swinging.................................................. 4
1.14 Safe Operation........................................................................................................... 5
1.15 Avoiding Runaway Accidents................................................................................... 5
1.16 Parking Machine Safely.............................................................................................6
1.17 Safe Maintenance.......................................................................................................6
1.18 Supporting Machine Correctly.................................................................................. 7
1.19 Trash Cleaning...........................................................................................................8
1.20 Preventing Battery Explosion.................................................................................... 8
1.21 Storing Spare Parts Safely......................................................................................... 8
1.22 Preventing Splashing Attacker.................................................................................. 9
1.23 Preventing Parts From Flying Off............................................................................. 9
1.24 Keep Away From Transmission Parts....................................................................... 9
1.25 Prevent Inhaling Asbestos Dust.................................................................................9
1.26 Beware Of Inhaling Smoke or Exhaust Gas............................................................ 10
1.27 Beware of scalding.................................................................................................. 10
1.28 Be Careful Of Pressured Liquids.............................................................................10
1.29 Avoid Heating near A Pressured Oil Pipe............................................................... 11
1.30 Avoid Heating Flammable Liquid Pipe...................................................................11
1.31 Remove Paint before Welding or Heating...............................................................11
1.32 Liquid Disposal........................................................................................................12
1.33 Chemical Disposal................................................................................................... 12
1.34 Fire Prevention.........................................................................................................13
2. CAB..................................................................................................................................... 14
2.1 CAB........................................................................................................................... 14
2.2 CAB CONTROL HANDLE & DASHBOARD LAYOUT...................................... 15
2.3 Electric Control Section of Cab.................................................................................16
2.4 Main Operating Interface...........................................................................................17
2.4.1 Parameter Interface.........................................................................................19
2.4.2 Settings Interface............................................................................................ 20
2.4.3 Inclination Interface........................................................................................21
2.4.4 Drilling Depth Detection Interface................................................................. 22
2.4.5 Fault Code Interface....................................................................................... 23
2.4.6 IO Port Interface............................................................................................. 24
OPERATION & MAINTENANCE MANUAL SWDE120B-3
2.5 STARTING SWITCH............................................................................................... 25
2.6 THROTTLE CONTROL KNOB.............................................................................. 25
2.7 EMERGENCY SWITCH.......................................................................................... 26
2.8 CATHODE SWITCH................................................................................................26
2.9 BUS PANEL..............................................................................................................27
2.10 ROCKER SWITCH.................................................................................................30
2.11 RADIO.....................................................................................................................31
2.12 SEAT ADJUSTMENT............................................................................................ 33
2.13 PILOT LEVER AND SWITCHES CONTROL......................................................34
2.14 THROTTLE CONTROL KNOB............................................................................ 40
3. RUNNING-IN..................................................................................................................... 41
3.1 WATCHING ENGINE RUNNING CAREFULLY..................................................41
3.2 EVERY 8 HOURS OR EVERY DAY......................................................................41
3.3 AFTER FIRST 50 RUNNING HOURS....................................................................41
3.4 AFTER FIRST 100 RUNNING HOURS..................................................................41
4. ENGINE OPERATION.......................................................................................................42
4.1 DAILY CHECK (BEFORE OPERATING)..............................................................42
4.1.1 Electrical System............................................................................................ 42
4.1.2 Drilling Boom, Kelly Bar, Metal Sheet Parts, Crawler Plates........................42
4.1.3 Fasteners......................................................................................................... 42
4.1.4 Fuel System.................................................................................................... 42
4.1.5 Hydraulic System............................................................................................42
4.1.6 Electrical Device.............................................................................................42
4.1.7 Air Filter......................................................................................................... 42
4.1.8 Oil Level of Hydraulic Oil Tank.................................................................... 43
4.1.9 Lubrication......................................................................................................43
4.1.10 Protection Device..........................................................................................43
4.1.11 Safety............................................................................................................ 43
4.2 ENGINE OPERATION.............................................................................................44
4.2.1 Check Diesel Engine.......................................................................................44
4.2.2 Before Starting Engine................................................................................... 44
4.2.3 Starting Engine............................................................................................... 44
4.2.4 Starting In Cold Weather................................................................................45
4.2.5 Adjusting Rev of Diesel Engine..................................................................... 45
4.2.6 Engine Shut-down.......................................................................................... 45
4.3 USING ACCESSORIAL BATTERY....................................................................... 47
5. TRAVEL..............................................................................................................................49
5.1 TRAVELLING OPERATION.................................................................................. 49
5.2 TRAVELLING POSTURES..................................................................................... 50
5.2.1 Correct and Wrong Travelling Postures on Level Ground.............................50
5.2.2 Correct and Wrong Travelling Postures on Upslope......................................51
5.2.3 Correct and Wrong Travelling Postures on Downslope................................. 52
5.2.4 Correct and Wrong Travelling Postures while Crossing Slopes.................... 53
5.3 TRAVELING SPEED............................................................................................... 54
5.4 TRAVELING BRAKE..............................................................................................54
6. DRILLING OPERATION...................................................................................................55
6.1 DRILLING OPERATION.........................................................................................55
OPERATION & MAINTENANCE MANUAL SWDE120B-3
6.2 ATTENTION DURING DRILLING........................................................................ 55
6.3 ASSEMBLY OF AUXILIARY KELLY BAR......................................................... 56
6.4 STOP DRILLING......................................................................................................57
6.5 DISASSEMBLY OF KELLY BAR.......................................................................... 57
6.6 NOTES OF DRILL FRAME RETURNING.............................................................57
6.7 MACHINE MAINTENANCE.................................................................................. 58
6.8 Others.........................................................................................................................58
7. MAINTENANCE................................................................................................................59
7.1 MAINTENANCE PROCEDURES........................................................................... 60
7.1.1Correct Maintenance and Inspection Procedures............................................ 60
7.1.2 Daily Inspection before Startup...................................................................... 60
7.1.3 Often Check Working Timer.......................................................................... 61
7.1.4 Preparation before Maintenance..................................................................... 61
7.1.5 Correct Use of Fuel and Lubrication Oil........................................................ 61
7.1.6 Checking Discharged Oil and Used Filter Element........................................61
7.1.7 Inspection after Maintenance..........................................................................62
7.1.8 Maintenance for Electrical System.................................................................62
7.1.9 Maintenance for Hydraulic System................................................................ 63
7.2 OIL, COOLANT AND FILTER ELEMENT............................................................64
7.2.1 Lubricating Oil and Hydraulic Oil..................................................................64
7.2.2 Fuel Oil........................................................................................................... 64
7.2.3 Coolant in the Cooling System.......................................................................65
7.2.4 Lubricating Grease..........................................................................................65
7.2.5 Oil Storage...................................................................................................... 66
7.2.6 Filter Element................................................................................................. 66
7.2.7 Oil and Coolant for Different Environmental Temperature........................... 67
7.3 TORQUE TABLE OF SCREW THREAD............................................................... 68
7.4 MAINTENANCE GUIDE.........................................................................................69
7.4.1 Oil................................................................................................................... 69
7.4.2 Engine Oil.......................................................................................................69
7.4.3 Gear Oil.......................................................................................................... 70
7.4.4 Hydraulic System............................................................................................70
7.4.5 Fuel System.................................................................................................... 71
7.4.6 Air Filter......................................................................................................... 72
7.4.7 Cooling System...............................................................................................72
7.4.8 Air Conditioner Maintenance......................................................................... 73
7.4.9 Dust Collection System.................................................................................. 74
7.4.10 Regular Change of Hydraulic Hoses............................................................ 74
7.5 ROTARY HEAD.......................................................................................................76
7.6 LIST OF MAINTENANCE PARTS, QUICK-WEAR PARTS................................79
7.7 CRAWLER................................................................................................................80
7.8 ELECTRICAL SYSTEM.......................................................................................... 82
7.8.1 Battery.............................................................................................................82
7.8.2 Battery Replacement.......................................................................................84
7.9 Maintenance under Special Conditions..................................................................... 84
7.10 Protecting Measures for Long Term Storage...........................................................86
8. PROBLEM SHOOTING.....................................................................................................87
OPERATION & MAINTENANCE MANUAL SWDE120B-3
9. MACHINE TECHNICAL SPECIFICATION.................................................................... 90
9.1.1 SWDE120B-3 Technical Parameters............................................................. 90
9.1.2 Dimension.......................................................................................................91
10. STRUCTURE AND WORKING THEORY.....................................................................93
10.1 DRILLING FRAME................................................................................................93
10.2 SLIDE FRAME....................................................................................................... 93
10.3 ROTATING MECHANISM................................................................................... 94
10.4 FEED MECHANISM..............................................................................................94
10.5 ROD DISCHARGER.............................................................................................. 94
10.6 DRY-TYPE DUST COLLECTION........................................................................ 94
10.7 WET-TYPE DUST COLLECTION........................................................................95
10.8 TRAVEL MECHANISM........................................................................................ 96
10.9 MACHINE FRAME................................................................................................97
10.10 IMPACTOR...........................................................................................................97
10.11 DIESEL ENGINE & PUMP GROUP................................................................... 97
10.12 OIL TANK.............................................................................................................97
10.13 ROD CAROUSEL.................................................................................................97
10.14 OPERATING SYSTEM........................................................................................97
10.15 AIR COMPRESSOR SYSTEM............................................................................ 98
10.16 HYDRAULIC CONTROL SYSTEM THEORY................................................100
11. APPENDIX......................................................................................................................101
11.1 HYDRAULIC SCHEMATIC................................................................................101
11.2 ELECTRICAL SCHEMATIC...............................................................................102
11.3 SYSTEM SCHEMATIC OF AIR COMPRESSOR..............................................103
12 MANUFACTURER INFORMATION............................................................................ 104
OPERATION & MAINTENANCE MANUAL SWDE120B-3
1
1. Safety Rules
1.1 Safety Mark
The figure to the right is a safety
reminder. When you see this mark on the
machine or in the manual, it indicates
that you may be in danger of injury.
1.2 Safety Label
There are various labels at various places on the
machine indicating various risks, such as Danger,
Warning, Attention, etc (right figure), they have
the following meanings:
Danger---indicates an imminently hazardous situationwhich, if not avoided, will
result in death or serious injury.
Warning---indicates a potentially hazardous situation which, if not avoided,
could result in death or serious injury.
Attention---indicates a potentially hazardous situation which, if not avoided,
may result in minor or moderate injury.
Danger, Warning safety labels are placed at given locations of the machine in the
possible dangerous area. General attentions are listed on the “Attention” safety
label. In this manual, “Attention” is also used to remind of safety instruction.
1.3 General Safety Instruction
Read the manual carefully and
follow the safety instructions on
the labels and manual before
operating the machine.
Always keep the safety labels
clean. Change any lost or damaged
labels with new ones. If the labels
or manual are lost, you can contact
the dealer and indicate the model
of machine to purchase.
OPERATION & MAINTENANCE MANUAL SWDE120B-3
2
Only trained and qualified
operators are permitted to operate
this machine. Keep the machine in
good condition as per this manual
Do not modify the machine
without prior authorization,
otherwise it will affect the
performance and service life of the
machine, or may cause injuries to
human body.
ATTENTION: The safety instructions
in this manual include only the general
safety rules of the machine. Not all
possible danger is covered. Should any
problems occur, please report to your
superior before operating and
maintaining the machine.
1.4 Preparation for Emergency
All personnel related to operating the
machine should pay attention to prevent
accidents from happening. Always keep
a first-aid kit and fire extinguisher
nearby. Have phone numbers of a doctor,
ambulance, hospital and fire department
with you in case of emergency.
1.5 Wear Safety Protective Gear
Before operation, always wear protective
gear
as the work requires, this includes:
Tight work clothes
Hardhat
OPERATION & MAINTENANCE MANUAL SWDE120B-3
3
Safety gloves
Safety glasses, goggles, or shield
Dust mask or respirator
Earplug or earcap
1.6 Check Machine Before Start-up
Before each day or shift, check the
machine according to the “Check
machine before start-up” section.
1.7 Adjust Operator Seat
You may adjust seat to suit yourself, lean
your back on the back of seat and let
your feet reach the pedals at ease.
1.8 Enter or Leave Machine Correctly
Always face the machine when you use
the steps and handholds to enter or leave
machine
Never use any control lever as a
handhold
Never enter or leave machine when the
machine is traveling, swinging, or
drilling.
1.9 Start Engine Correctly
The operator must sit on cab seat to start
engine
Standing on the crawler to start engine is
not permitted.
Short circuit start of the engine
(including terminal start) is forbidden.
OPERATION & MAINTENANCE MANUAL SWDE120B-3
4
1.10 No Passenger Allowed In The Cab
When the machine is in operation or
traveling, no passenger is allowed to stay
on or in the machine except the operator.
1.11 Keep Machine Away From Power Line
Any part or load of the machine touching power line will cause human death or GBH
Prohibit machine or its load from operating in the proximity of any power line.
Keep the machine more than 5 meters away from any power line.
1.12 Move Machine Safely
Before the machine travels and swings, know the position of other people.
Before the machine travels or swings, warn other people by tapping the horn.
Hand signals should be used when operation or swinging is made in confined area,
which are agreed upon before machine start-up.
Know that the pedal/control levers are corresponding to the traveling direction before
operating the machine.
★★★★★ When discharging drill mast, make sure that no person front of machine
and operator is required to wear safety helmet. When working on drill frame, safety
belt is required.
★★★★★ When moving machine, extrude pendular cylinder and close the service
with main Kelly bar to avoid their falling if machine has both main and service Kelly
bar.
Raise drill mast and tool before moving machine. Stop the engine and take any necessary
measures should the Kelly bar fall.
1.13 Prevent Accidents While Backing Up or Swinging
In order to prevent accidents while
backing up or swinging, the operator
must:
Look around and confirm nobody is
there before backing up or swinging.
Ensure that other people are out of the
Indice
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