Sany SR200C Rotary Drilling Rig Safety, Operation & Maintenance Manual – PDF DOWNLOAD

Sany SR200C Rotary Drilling Rig Safety, Operation & Maintenance Manual – PDF DOWNLOAD

FILE DETAILS:

Sany SR200C Rotary Drilling Rig Safety, Operation & Maintenance Manual – PDF DOWNLOAD

Language : English
Pages : 514
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Sany SR200C Rotary Drilling Rig Safety, Operation & Maintenance Manual – PDF DOWNLOAD

Introduction
1 1 Overview 1-3
1 2 Your Documentation Package 1-4
1 2 1 Recommendations on Using the Documentation 1-4
1 2 2 Documentation Storage 1-5
1 3 Organization of This Manual 1-5
1 3 1 Table of Contents 1-5
1 3 2 Introduction 1-6
1 3 3 Safety 1-6
1 3 4 System Functions 1-6
1 3 5 Operation 1-6
1 3 6 Maintenance 1-6
1 3 7 Troubleshooting 1-6
1 3 8 Specifications 1-7
1 3 9 Appendix 1-7
1 4 Your Sany Machine 1-8
1 4 1 Special Tips 1-8
1 4 2 Application of Rotary Drilling Rig 1-8
1 4 3 Machine Directions 1-9
1 4 4 Machine Information 1-9
1 4 5 Product Nameplate 1-10
1 4 6 Chassis Nameplate 1-11
1 5 Contact Information 1-11
2 Safety
2 1 Foreword 2-3
2 2 Hazard Words 2-4
2 2 1 Hazard Word Levels 2-4
2 2 2 Other Signal Words 2-5
2 3 Safety Decals and Plates 2-6
2 3 1 Locations 2-6
2 3 2 Meaning 2-8
2 4 Safety Equipment 2-19
2 4 1 Hydraulic Lock Lever 2-19
2 4 2 Extinguisher 2-19
2 4 3 Emergency Exit 2-20
2 4 4 Seat Belt 2-20
2 4 5 Emergency Stop Switch 2-21
2 5 Safety Precautions 2-22
2 5 1 Be Cautious of High Pressure Fluid 2-22
2 5 2 Dust Hazard 2-23
2 5 3 Mechanical Injury 2-24
2 5 4 Battery Hazards 2-26
2 5 5 Fire Prevention 2-27
2 5 5 1 Away from Fire 2-27
2 5 5 2 Daily Checks 2-28
2 5 5 3 Fire Treatment 2-29
2 5 6 Scald Prevention 2-30
2 5 7 Safety Information of Hose 2-31
2 5 8 Fluid Leakage 2-32
2 5 9 Crawler Safety Information 2-33
2 5 10 Lightening and Strong Wind Precautions 2-34
2 5 11 Falling Protection 2-34
2 5 12 Noise Protection 2-35
2 5 13 Vibration 2-35
2 5 14 Wire Rope Safety Information 2-35
2 5 15 Climbing on/off Drilling Rig 2-37
2 5 16 Kelly Bar and Drilling Tools 2-38
2 5 17 Working at Areas with Underground Pipelines 2-39
2 5 18 Working at Areas with High Voltage Power Lines 2-40
2 5 19 Electrical Accident 2-41
2 6 Safety during Operation 2-42
2 6 1 Staff 2-42
2 6 2 Personal Protective Equipment 2-44
2 6 3 Keeping the Drilling Rig in Good Service Condition 2-46
2 6 4 Safety on Construction Site 2-47
2 6 5 Signals to Control Operation 2-49
2 6 6 Drilling Rig Danger Area 2-55
2 6 7 Avoiding Tipping 2-56
2 6 8 Before Entering the Cab 2-58
2 6 9 Before Starting the Engine 2-59
2 6 10 Before Operating the Drilling Rig 2-60
2 6 11 Drilling Rig Operation 2-61
2 6 12 Construction of Drilling Rig 2-63
2 6 13 Drilling Rig Dismantling 2-65
2 6 14 Parking Safety 2-65
2 6 15 Transporting Drilling Rig 2-67
2 6 16 Drilling Rig Maintenance 2-68
2 6 17 Winch Operation 2-69
2 7 Maintenance Safety 2-70
2 7 1 Maintenance Personnel 2-70
2 7 2 Risks in Maintenance 2-70
2 7 2 1 Preparing for Maintenance 2-73
2 7 2 2 During Maintenance 2-75
2 8 Environment Protection 2-78
2 8 1 Proper Waste Disposal 2-78
2 8 2 Mud Pollution 2-79
2 8 3 Fuel Emissions 2-79
3 System Function
3 1 General Structure of Rotary Drilling Rig 3-3
3 2 Function Description 3-5
3 2 1 Undercarriage 3-5
3 2 2 Upper Carriage 3-5
3 2 3 Hydraulic System 3-6
3 2 5 Main Winch 3-8
3 2 6 Auxiliary Winch 3-9
3 2 7 Mast 3-10
3 2 8 Rotary Drive 3-11
3 2 9 Kelly Bar 3-12
3 3 Components Explanations 3-13
3 3 1 General View of the Operator Cab 3-13
3 3 2 Chassis Monitor System 3-15
3 3 2 1 Screen Introduction 3-15
3 3 2 2 Screen Display and Operation 3-21
3 3 3 Hydraulic Lock Lever 3-23
3 3 4 Operation Control Assistant 3-24
3 3 5 Air Conditioning System 3-27
3 3 6 Radio 3-33
3 3 6 1 Control Panel 3-33
3 3 7 Traveling Lever/pedal 3-39
3 3 8 Left and Right Operation Handle 3-40
3 3 8 1 Left Operation Handle Button Function 3-40
3 3 8 2 Right Operation Handle Button Function 3-40
3 3 8 3 Left Operation Handle Directional Function 3-41
3 3 8 4 Right Operation Handle Directional Function 3-42
3 3 9 Mast Adjusting Lever 3-43
3 3 10 Display 3-45
3 3 10 1 Start-up and Language Select Interface 3-45
3 3 10 2 Drilling Operation Main Interface 3-46
3 3 10 3 Alarm Interface 3-48
3 3 10 4 Operation Interface 3-48
3 3 10 5 Calibration Interface 3-50
3 3 10 6 Setting Interface 3-51
3 3 10 7 Oil Pressure Interface 3-51
3 3 10 8 Mast Vertical Adjusting Interface 3-52
3 3 11 Anti-collision Function of the Operator Cab 3-54
3 3 12 Slack Rope Switch-off 3-55
3 3 12 1 Display Protection 3-56
3 3 13 Seat 3-57
3 3 14 Limit Switch 3-60
3 3 15 Level 3-61
3 3 16 Alarm Lamp (optional) 3-61
4 Operation
4 1 Basic Operation 4-3
4 1 1 Job Preparations 4-3
4 1 2 Visual Checks 4-3
4 1 3 Job Set-up 4-5
4 1 4 Checks Before Starting the Engine 4-7
4 1 4 1 Checking Coolant Level 4-7
4 1 4 2 Checking Engine Oil Level 4-7
4 1 4 3 Draining Water and Sediment in Fuel Tank 4-7
4 1 4 4 Checking Fuel Amount and Refuel 4-7
4 1 4 5 Checking Hydraulic Oil Level 4-7
4 1 4 6 Checking Water Oil Separator 4-8
4 1 4 7 Checking the Electrical Circuit 4-8
4 1 4 8 Checking Horn Function 4-9
4 1 5 Starting the Engine 4-10
4 1 5 1 Normal Start-up 4-10
4 1 5 2 Starting The Engine in Cold Weather 4-12
4 1 6 After Starting the Engine 4-13
4 1 6 1 Breaking in a new Machine 4-13
4 1 6 2 Warming-up Operation 4-13
4 1 7 Shutting down the Engine 4-15
4 1 8 Checks after Each Workday 4-18
4 1 9 Traveling 4-19
4 1 9 1 Traveling Operation 4-20
4 1 9 2 Traveling up and down Slopes 4-25
4 1 10 Upper Carriage Swing 4-26
4 1 11 Adjusting Drilling Center Distance 4-28
4 1 12 Crowd Control 4-30
4 1 13 Main Winch Operation 4-32
4 1 14 Auxiliary Winch Operation 4-36
4 1 15 Rotary Drive Control 4-38
4 1 16 Depth Measuring Control 4-39
4 1 17 Calibration 4-40
4 1 17 1 Depth Measurement Calibrating 4-40
4 1 17 2 Swing Angle Calibrating 4-41
4 1 17 3 Verticality Calibration 4-42
4 1 18 Crawler Extending and Retracting 4-43
4 1 19 Parking the Drilling Rig 4-44
4 1 19 1 Regular Parking 4-44
4 1 19 2 Checks During Parking 4-46
4 1 19 3 Machine Locking 4-46
4 1 19 4 Long-term Storage 4-47
4 1 20 Operation in Cold Weather 4-48
4 1 20 1 Checks in Cold Weather 4-48
4 1 20 2 Operation Tips in Cold Weather 4-50
4 1 20 3 After Daily Operation 4-53
4 1 20 4 After Cold Season 4-53
4 2 Drilling Rig Construction 4-54
4 2 1 Construction Preparation 4-54
4 2 1 1 Drilling Rig Checks 4-54
4 2 1 2 Drilling Tool Selection 4-56
4 2 2 Drilling Rig in Place 4-57
4 2 3 Drilling 4-58
4 2 3 1 Drilling in Clay Layer 4-58
4 2 3 2 Drilling in Sand Layer 4-58
4 2 3 3 Drilling in Pebble Layer 4-59
4 2 3 4 Drilling in Shale Layer 4-60
4 3 Rigging & Derigging 4-62
4 3 1 Requirements for Rigging and Derigging 4-62
4 3 1 1 Guidelines for Rigging and Derigging 4-62
4 3 1 2 Notes on Rigging and Derigging 4-63
4 3 1 3 Preparation for Rigging and Derigging 4-64
4 3 2 Rigging Drilling Rig 4-65
4 3 2 1 Removing Swing Locking Connecting Rod 4-65
4 3 2 2 Extending the Crawlers 4-66
4 3 2 3 Mounting Counterweight 4-66
4 3 2 4 Connecting Upper Mast and Middle Mast 4-68
4 3 2 5 Connecting Pulley Yoke 4-70
4 3 2 6 Installing Main Winch and Lower Mast 4-72
4 3 2 7 Mounting Rotary Drive 4-73
4 3 2 8 Connecting Hoses 4-74
4 3 2 9 Connecting Electric Device 4-77
4 3 2 10 Connecting Middle Mast and Lower Mast 4-78
4 3 2 11 Installing Wire Ropes 4-80
4 3 2 12 Drilling Rig Test Run 4-84
4 3 3 Installing Drilling Tool 4-86
4 3 3 1 Connecting Rope Swivel to Kelly Bar 4-86
4 3 3 2 Connecting Kelly Guide to Kelly Bar 4-87
4 3 3 3 Aligning Drilling Rig with Kelly Bar Upper End 4-88
4 3 3 4 Connecting Wire Rope and Rope Swivel 4-89
4 3 3 5 Installing Kelly Bar 4-89
4 3 3 6 Installing Drilling Bucket 4-93
4 3 4 Disassembling Drilling Tool 4-94
4 3 4 1 Disassembling Drilling Bucket 4-94
4 3 4 2 Removing Kelly Bar 4-95
4 3 5 Disassembling Drilling Rig 4-99
4 3 5 1 Disconnecting Pulley Yoke and Upper Mast 4-99
4 3 5 2 Disconnecting Upper and Middle Mast 4-100
4 3 5 3 Removing Rotary Drive and Crowd Cylinder Connection 4-101
4 3 5 4 Disconnecting Middle Mast and Lower Mast 4-102
4 3 5 5 Removing Rotary Drive 4-103
4 3 5 6 Removing Main Winch and Lower Mast 4-104
4 3 5 7 Removing Counterweight 4-105
4 4 Wire Rope 4-107
4 4 1 Installing Wire Rope 4-107
4 4 2 Unloading and Storing Wire Rope 4-114
4 4 3 Discarding Wire Rope 4-116
4 5 Drilling Rig Transport 4-118
4 5 1 Transport Requirements 4-118
4 5 2 Safety Guidelines for Transport 4-118
4 5 3 Transport Parameters 4-120
4 5 3 1 Transport Status (A) 4-120
4 5 4 Loading and Unloading the Machine 4-124
4 5 4 1 Requirement for Loading and Unloading the Machine 4-124
4 5 4 2 Loading the Machine 4-126
4 5 4 3 Fastening Method 4-127
4 5 4 4 Unloading the Machine 4-127
4 5 5 Requirements for Sea Transportation 4-128
4 5 5 1 Hoisting the Machine 4-129
4 6 Kelly Bar 4-131
4 6 1 Instructions 4-131
4 6 2 Welding 4-133
4 6 3 Transport and Storage 4-138
4 7 Drilling Tool 4-140
4 7 1 Overview 4-140
4 7 2 Kelly Box 4-140
4 7 3 Drilling Tool Categories 4-142
4 7 3 1 Drilling Bucket Single-edge 4-142
4 7 3 2 Drilling Bucket Double-edge 4-144
4 7 3 3 Cone Auger 4-146
4 7 3 4 Straight Auger 4-148
4 7 3 5 Core Barrel 4-150
4 7 3 6 Double-layer Core Barrel 4-152
4 7 3 7 Core Barrel With Centralizer 4-153
4 7 3 8 Underreamer Bit 4-154
4 7 3 9 Casing Drive Adapter 4-155
4 7 3 10 Easily Worn Parts of Drilling Rig 4-156
4 7 4 Drilling Tool Operation 4-157
4 7 4 1 Drilling Bucket 4-157
4 7 4 2 Auger 4-157
4 7 4 3 Core Barrel 4-158
4 7 4 4 Belling Tool 4-159
5 Maintenance
5 1 Maintenance Precautions 5-3
5 2 Maintenance Information 5-5
5 2 1 Lubricating the Lube Points 5-8
5 2 2 Drilling Rig Oil 5-11
5 3 Maintenance Schedule 5-14
5 4 Maintenance Procedures 5-26
5 4 1 Every 10 Service Hours 5-26
5 4 1 1 Crawler Tension – Check and Adjust 5-26
5 4 1 2 Hydraulic Cylinders- Check 5-29
5 4 1 3 Gearbox Gear Oil Level- Check 5-32
5 4 1 4 Shock Absorbing Device for Rotary Drive – Check 5-33
5 4 1 5 Crawler Track – Visual Inspection 5-37
5 4 1 6 Wire Rope – Inspect 5-38
5 4 1 7 Wire Rope – Maintain 5-39
5 4 1 8 Rope Swivel Flexibility – Check 5-40
5 4 1 9 Rope Swivel – Lubricate 5-41
5 4 1 10 Engine Oil Level – Check 5-43
5 4 1 11 Water and Sediment in Fuel Tank- Drain 5-45
5 4 1 12 Hydraulic Oil Level – Check 5-46
5 4 1 13 Cooling System Coolant Level – Check 5-48
5 4 1 14 Fuel Amount – check and Refuel 5-51
5 4 2 Initial 50 Service Hours 5-53
5 4 2 1 Engine Oil and Filter – Change 5-53
5 4 2 2 Fuel Filter – Replace 5-57
5 4 2 3 Filter of Water Oil Separator – Replace 5-59
5 4 2 4 Fuel Tank Strainer – Clean 5-60
5 4 3 Every 50 Service Hours 5-61
5 4 3 1 Winch Reducers Oil Level – Check 5-61
5 4 3 2 Switches, Buttons and Operation Handles – Check 5-62
5 4 3 3 Rope Hold-down Rollers – Check 5-62
5 4 3 4 Rotary Drive Mounting Bolts – Check 5-63
5 4 3 5 Driver Strip – Check and Change 5-64
5 4 3 6 Rotary Drive Sliding Strip – Check and Replace 5-65
5 4 3 7 Crawler Track Mounting Bolts – Check 5-66
5 4 3 8 Air Intake and Exhaust System – Visually Check 5-67
5 4 3 9 Window Wiper – Check 5-67
5 4 3 10 Window Washer – Check 5-67
5 4 3 11 Kelly Guide Swing Bearing – Replace 5-68
5 4 3 12 Impact Ring – Check and Replace 5-69
5 4 3 13 Spring of Kelly Bar- Check and Replace 5-69
5 4 3 14 Shock Absorbers – Check 5-70
5 4 4 Initial 250 Service Hours 5-71
5 4 4 1 Aux Pump Filter Element – Change 5-71
5 4 4 2 Winch Reducer Oil- Change 5-72
5 4 4 3 Gear Oil for Swing Reducer – Change 5-73
5 4 4 4 Travel Reducer Oil – Change 5-75
5 4 4 5 Pilot Filter Element – Replace 5-77
5 4 4 6 Return Filter – Replace 5-79
5 4 4 7 Bolts Connecting Swing Bearing – Check 5-88
5 4 4 8 Reducer Gear Oil – Change 5-88
5 4 4 9 Oil Suction Filter – Clean 5-90
5 4 5 Every 250 Service Hours 5-91
5 4 5 1 Wire Rope Sheaves – Check 5-91
5 4 5 2 Rotary Drive Gear Oil – Check 5-91
5 4 5 3 Hoses – Check and Replace 5-92
5 4 5 4 Kelly Guide Sliding Strip – Check and Replace 5-93
5 4 5 5 Engine Oil and Filter – Change 5-93
5 4 6 Initial 500 Service Hours 5-94
5 4 6 1 Gearbox Gear Oil – Change 5-94
5 4 7 Every 500 Service Hours 5-94
5 4 7 1 Engine Crankcase Breather – Clean 5-94
5 4 7 2 Kelly Bar Baffle – Check 5-95
5 4 7 3 Kelly Bar Drive Gibs – Check 5-95
5 4 7 4 Kelly Bar Tube – check 5-96
5 4 7 5 Kelly Bar Locking Recesses – Check 5-96
5 4 7 6 Bolts Connecting Swing Bearing – Check 5-97
5 4 7 7 Fuel Filter – Replace 5-97
5 4 7 8 Filter for Water Oil Separator – Replace 5-97
5 4 7 9 Fuel Tank Strainer – Clean 5-97
5 4 7 10 Gearbox Gear Oil – Change 5-97
5 4 7 11 Winch Reducer Oil- Change 5-97
5 4 8 Initial 1000 Service Hours 5-98
5 4 8 1 Hydraulic Oil – Change 5-98
5 4 9 Every 1000 Service Hours 5-106
5 4 9 1 Hydraulic Hose – Check 5-106
5 4 9 2 Hydraulic Hose – Change 5-107
5 4 9 3 Battery – Clean and Recycle 5-108
5 4 9 4 Air Conditioner/cab Heater Filter (recirculation) – Inspect and Replace
5 4 9 5 Travel Reducer Oil – Change 5-111
5 4 9 6 Gear Oil for Swing Reducer – Change 5-111
5 4 9 7 Pilot Filter Element – Replace 5-111
5 4 9 8 Return Filter Element – Change 5-111
5 4 9 9 Aux Pump Filter Element – Change 5-111
5 4 9 10 Oil Suction Filter – Clean 5-111
5 4 10 Every 2000 Service Hours 5-112
5 4 10 1 Gearbox Gear Oil – Change 5-112
5 4 10 2 Hydraulic Oil – Change 5-112
5 5 Storage of Drilling Rig 5-113
5 5 1 Cleaning the Drilling Rig 5-113
5 5 2 Machine Storage 5-113
5 5 2 1 Maintenance to the Drilling Rig during Storage 5-113
5 5 2 2 Maintenance to The Drilling Rig before Moving from the Warehouse
5-115
6 Troubleshooting
6 1 Motor System Common Faults and Troubleshooting 6-3
6 2 Electrical System Common Faults and Troubleshooting 6-20
6 3 Hydraulic System Common Faults and Troubleshooting 6-22
6 4 Troubleshooting of Work Unit 6-28
6 5 Air Conditioning System Common Faults and Troubleshooting 6-40
6 6 SR150C/SR200C ( SY) Wear Parts List 6-43
7 specifications
7 1 Dimension Giagram 7-3
7 2 Overall Dimensions 7-4
Appendix
Common Misoperation 8-5