operation and safety manual · 2018. 12. 13. · this manual provides information to operators on...

OPERATION AND SAFETY MANUAL

Rev.01/17

GEAX s.r.l.

EK75CFAJ160

Serial number : 160J075E

GEAX s.r.l via Campoceraso,13

60027 Osimo (AN) ITALY

Tel. +39/0717131953

Fax. +39/071715199

www.geax.it [email protected]

GEAX s.r.l Chapter 1

OPERATOR TRAINING 1

Chapter 1

OPERATOR TRAINING

1.1 Foreword This manual provides information to operators on the features and operation of the EK75 track-mounted drilling rig. It also describes the hazards relating to the rig's operation and what to do to minimize the risks. The purpose of this manual is to prepare safety-minded operators; accordingly, as well as listing the required procedures, it is designed to raise the reader’s awareness on the importance of working safely. Our is that it will contribute to eliminate superficial, careless and uncritically repetitive behaviours, which are ultimately the main causes of jobsite accidents.

1.2 Physical and mental conditions of operators Operators must have past experience in the sector, be familiar with the general safety rules and have proven their attitude to recognize and handle potentially dangerous situations. Before using the (EK751) drilling rig for the first time, new operators must read this OPERATION AND SAFETY MANUAL completely. Once they are sure they have understood it, they can proceed to use the rig with the assistance of an experienced colleague. The introductory period should last as long as necessary, depending on the operator’s past experience. At the time of starting a work shift, operators must be in good health and in sound physical and mental conditions. Their blood alcohol content must be within the levels prescribed by motor vehicle regulations. 1.3 Operators' equipment Operators must wear the protective equipment required by jobsite safety regulations and relating to the specific activities carried out, e.g.:

• type-approved helmet

• type-approved safety shoes

• comfortable, appropriately-sized work overalls

• close-fitting, type-approved protective gloves

• type-approved safety glasses

• type-approved earplugs or earmuffs

• protective face masks (when required by working conditions)

1 Make sure the serial number on the drilling rig is the same as the number printed in the manual.


OPERATOR TRAINING 2

All protective clothing and devices must be in good conditions and clean enough not to affect their protection capacity or wearing comfort. In particular, heavy clothing must be used as required by the temperature on the jobsite: thermal comfort contributes to keeping the attention threshold high. Overalls should have no loose flaps that might hamper the operation of controls or get caught on edges or rotating shafts. Gloves are necessary to protect the hands from cuts and abrasions that can be produced when gripping wire ropes or metal parts, but they should not reduce finger mobility nor get caught on edges or on the controls. Avoid wearing rings or jewellery. 1.4 Safety signs A poster should be placed in the jobsite with safety signs reminding to wear the protective devices described above, as required by law. Figure 1.4.1 shows a few of these mandatory signs.

Fig. 1.4.1


OPERATOR TRAINING 3

1.5 Symbols used in this manual Danger (or other) signs are used at various points in the manual to call the reader’s attention to issues regarding potentially dangerous activities.

Situation, procedure, context or other factor that can lead to increased risk.

Situation, procedure, context or other factor that can lead to increased risk of electrocution.

Situation, procedure, context or other factor that can lead to increased risk of getting caught and dragged by rotating parts.

Situation, procedure, context or other factor that can lead to increased risk of fire.

Situation, procedure, context or other factor that can lead to increased risk of scalding on parts that become hot during operation.

Situation, procedure, context or other factor that can lead to increased risk of intoxication or poisoning by harmful substances.

Situation, procedure, context or other factor that can lead to increased risk of intoxication or poisoning by harmful substances.

Situation, procedure, context or other factor that can lead to increased risk of burning by corrosive substances.

Situation, procedure, context or other factor that can lead to increased risk of loss of balance and falling.

Situation, procedure, context or other factor that can lead to increased risk of crushing hands.

Situation, procedure, context or other factor that can lead to increased risk of being hit by suspended loads falling down.

Improving safety measures is a never-ending task; should you encounter a potentially hazardous situation that is not adequately covered in this manual, please let us know.

GEAX s.r.l. Chapter 2

TRANSPORTING THE DRILLING RIG 1

Chapter 2

TRANSPORTING THE DRILLING RIG

2.1 Operations preparing transportation

2.1.1 Removing the tool

The auger tool (two parts + the tip) can only be disassembled with the mast upright. Disassemble the tip, the lower part and then the upper part. Proceed as follows to disassemble the tip:

Lower the tool to the ground.

Disassemble the centring device using the winch 2° to handle the parts (70 kg.) fig. 2.2.3.1.

Hook the tip to the rope of the secondary winch.

Command a slight tensioning of the rope.

Loosen the recessed safety bolt and slip the pin off.

Lift the rotary so that the joint slips off and the tip remains hanging on

the rope of the winch.

Move the rope of the secondary winch down.

Place the tip on the ground and move it.

Proceed as follows to disassemble the central part of the auger fig.2.1.1.1:

Lower the tool to the ground.

Lean the ladder against the mast.

When a second operator at the base guarantees the stability of the

ladder by holding it with both hands, climb up to the height of the joint and secure the safety belts to the eyebolt on the mast.



Hook the tool (lower element) to the rope of the secondary winch.

Command a slight tensioning of the rope.


Climb down the ladder and remove it.

Go to a safe area.

Lift the rotary-tool so that the joint slips off and the auger part remains

hanging on the rope of the winch.


Place the tool on the ground and move it. Proceed as follows to disassemble the upper part of the auger fig.2.1.1.2:

Rest the tool on the ground, moving the rotary to the intermediate position.



ladder by holding it with both hands, climb up to the height of the rotary joint and secure the safety belts to the eyebolt on the mast.

Hook the tool (upper element) to the rope of the secondary winch.

Command a slight tensioning.



Go to a safe area.

Lift the rotary-shaft so that the joint slips off and the auger remains

hanging on the rope of the winch.


Place the tool on the ground and move it.



fig.2.1.1.1 fig.2.1.1.2

2.1.2 Disassembly of mast support extension. Before folding the mast, the support extension must be disassembled



2.1.3 Closing mast for travel configuration Proceed as follows to fold the mast:

1. Lower the rotary to the point indicated in fig.2.1.3.1.

2. Position the pin V1 on the rotary guide to block downward sliding fig.2.1.3.2;

3. Deactivate the down limit switch of winch 1°. 4. Lower the rotary until it rests on the pin V1. 5. Further loosen the rope (30 cm.) to avoid problems when folding the

mast. 6. Position the pin V2. 7. Fold the mast forwards, acting alternately on the joystick D1 and

selector D2. 8. Reach the position shown in fig.2.1.3.3.

fig.2.1.3.1 fig.2.1.3.2



9. Remove the bolts and two pins B between the two parts of the mast fig.2.1.2.3.

fig.2.1.3.3

10. Make sure no one is in the trajectory of the folding mast fig.2.1.3.4.

11. Act on the selector D3 to fold the mast.

fig.2.1.3.4

12. Insert the bolt A to block movement of the mast fig.2.1.3.4. 13. Take on the configuration shown in fig.2.3.2.1 to load the machine onto

the transportation vehicle.



2.2 Setting up drilling rig at jobsitesite

2.2.1 Opening mast for work configuration Proceed as follows to open the mast:

Remove the bolt A between the two parts of the mast.

Make sure no one is in the trajectory of the opening mast.

Act on the selector D3 to open the mast.

If the mast has difficulty moving, the operator can intervene to detach it making sure his body remains outside of the trajectory of the mast fig.2.2.2.1.

fig.2.2.1.1

Make sure the ropes are not damaged while the mast is rotating.

When the mast is aligned, insert the pins B and the bolts between the

two parts and secure them fig.2.1.2.3.

Make sure the ropes are positioned correctly on the pulleys.

Lift the rotary slightly to be able to pull the blocking pins off.

Pull off the blocking pins.



Align the mast vertically by acting alternately on the joystick D1 and on the selector D2, being careful not to scrape the base of the mast against the ground.

Act on the joystick D1 to achieve the perfect upright position of the mast.

Re-activate all limit switches.

2.2.2 Assembling tool The auger tool (in two parts + the tip) can only be assembled with the mast upright. Assemble the upper part, the central part and then the tip. Proceed as follows to assemble the upper part:

1. Move the rotary to the intermediate position P2 fig. 2.2.2.1.

Fig. 2.2.2.1



2. Hook the tool (upper element) to the rope of the secondary winch. 3. Go to a safe area.

4. Lift the tool until the two parts of the joint are aligned. 5. Lean the ladder against the mast.

6. When a second operator at the base guarantees the stability of the

ladder by holding it with both hands, climb up to the height of the rotary joint and secure the safety belts to the eyebolt on the mast.

7. Push the tool so that the male and female parts of the joint are aligned

both axially and with the surfaces of the hexagon. 8. Lower the rotary-shaft to compose the joint. 9. Insert the pin and secure the safety bolt. 10. Climb down the ladder and remove it.

Proceed as follows to assemble the central part of the auger fig.2.1.1.1:

Position the rotary at the up limit switch.

Hook the tool (lower element) to the rope of the secondary winch.

Lift the tool until the two parts of the joint are aligned.



ladder by holding it with both hands, climb up to the height of the joint and secure the safety belts to the eyebolt on the mast.

Push the tool so that the male and female parts of the joint are aligned

both axially and with the surfaces of the hexagon.

Lower the rotary to compose the joint.

Insert the pin and secure the safety bolt.




Proceed as follows to assemble the tip:

1. Hook the tip to the rope of the secondary winch.

2. Lift the tip a bit off the ground. 3. Rest the tip on the ground so that the parts of the joint are aligned both

axially and with the surfaces of the hexagon.

4. Lower the rotary-tool so that the parts of the joint meet. 5. Insert the pin and secure the safety bolt. 6. Unhook the rope of the winch.

In the work configuration, the winch 2° rope must be hooked to the specific eyebolt and slightly tensioned.

2.2.3 Assembling mast extension and centring device When the drilling rig has been set up, before beginning the work shift the lower mast support extension and the centring device of the tool must be assembled. Use the winch 2° to handle the components (70 kg).



Fig. 2.2.3.1

2.3 Loading, unloading and anchoring the rig on a semitrailer

2.3.1 Positioning the semitrailer

The trailer must be placed on level ground, firm enough to allow using the loading ramps and performing the manoeuvres required to align the rig to the ramps. The climb must be straight and in line with

the trailer. Make sure there are no obstacles or overhead cables inside the drilling rig’s manoeuvring space, paying special attention if the mast must be positioned vertically (fig.2.4.1.2).

2.3.2 Loading and unloading

When loading or unloading the rig on/from the trailer, the rig’s configuration must be as shown in fig. 2.3.2.1 with the tool detached and the mast folded down. This configuration is similar to the

transport configuration, except that the boom is slightly raised to prevent the rotary's bottom flange from scraping on the ground or on the deck (a 20-30 cm clearance is sufficient).

Figures 2.3.2.1-2-3-4-5-6 show the loading operation sequence.



fig.2.3.2.1

fig.2.3.2.2

Figures 2.3.2.2 and 2.3.2.11 show the approximate point where the rig changes inclination when passing from the ramp to the deck or vice versa. In this stage the rig should travel at its lowest speed so that the change occurs as gently as possible.

fig.2.3.2.3



fig.2.3.2.4

fig.2.3.2.5

fig.2.3.2.6



Figures 2.2.2.7 -8-9-10-11 show the unloading operation sequence.

fig.2.3.2.7

fig.2.3.2.8

fig.2.3.2.9



fig.2.3.2.10

fig.2.3.2.11

To climb the slope use the ramps supplied, placing them so that their length and rigidity are compatible with the rig's gradeability and weight. Place the trailer on a sufficiently wide, flat area, free from overhead cables (power lines or other) that might interfere with loading/unloading.

Making contact with power lines is particularly dangerous because (in addition to the mechanical aspects described below) it can cause an electric shock to persons who are touching metal parts (e.g., the

trailer or the drilling rig) and the ground at the same time. In case of contact with power lines do not touch the vehicles involved (especially the trailer, as it has rubber tires). If the cable remains in contact with the rig, the operator should stay inside and await the intervention of the power company personnel. If the operator tries to get off the rig there is a chance that he might come in contact with the vehicle and the ground at the same time, receiving a dangerous electric shock. The risk is greatest when the rig is on the trailer, because the rubber tires provide insulation from the ground and allow very high voltages. If the rig is on the ground the risk is smaller, since the drilling rig is mounted on metal tracks. Non-electric cables pose risks of a mechanical nature. They might be strong enough to topple supporting



structures before breaking, causing danger to bystanders. After breaking, they might whip around violently as they release the elastic energy

accumulated. During loading and unloading, persons on the ground should stay at a safe distance.

2.3.3 Anchoring The drilling rig must be anchored to the semitrailer with strong stay wires capable of preventing any movement. 2.4 Transportation 2.4.1 Configuration for transportation on semitrailer

During transportation the drilling rig must be arranged in the configuration shown in figure 2.4.1.1 or with the mast facing backwards. The front part of the mast should rest on the deck of the

semitrailer in order to minimise the load on the boom’s hydraulic cylinders and increase overall stability. The tool must be detached. The engine must be turned off and the key on the dashboard turned to OFF. The door must be secured shut to avoid it opening during transportation.

fig.2.4.1.1

Figure 8.4.2.1 shows the overall dimensions of the rig in its typical transport configuration.

When the drilling rig is on the trailer deck, rotating the cab with respect to the crawler must be done with the mast held vertical and close to the cab, as shown in fig.2.4.1.2.



fig.2.4.1.2

Clockwise rotation A to B Before taking on transport configuration with mast in the rear

Anticlockwise rotation B to A Before starting unloading fig.2.3.2.1

2.4.2 Centre of gravity In the transport configuration the rig’s centre of gravity is located approximately 60-70 cm in front of the fifth wheel-cab axis. 2.4.3 Road transport The truck and trailer must be adequately sized to carry the drilling rig, both in terms of dimensions and load capacity. Make sure the rig is arranged compatibly with the maximum allowable load of every axle. Also, make sure that the planned route is large enough in width and height (narrowings in the road, bridges, low overhead cables, traffic signs, etc.). Check the capacity of any bridges along the route. The truck should proceed at a speed that is compatible with the conditions of the road and such as to not compromise the stability of the load at any time.



2.5 Replacing extension shaft and relative support rod 2.5.1 Disassembling extension shaft Do as follows to disassemble the extension shaft:

1. Place the rotary as low as possible. 2. Move the hook of the winch 2° near the eyebolt at the top of the

extension shaft (slightly below). 3. Tilt the mast (acting alternately on the lever D1 and on the selector D2) until

reaching the position used to fold it fig.2.1.2.3. 4. Hook the rope of the winch 2° with the eyebolt at the top of the manifold

(connected to the shaft by means of the rotary joint). 5. Bring the mast back to the upright position. 6. Go to a safe area.

7. Move the cable of the winch 2° up and pull the shaft off the rotary drag

device. 8. Move the rope of the secondary winch down and rest the shaft on the

ground. 2.5.2 Disassembling extension shaft guide support Do as follows to disassemble the guide support from the shaft:

Lower the rotary to the point P1 indicated in fig.2.5.2.1.



fig.2.5.2.1

Fold the mast forwards by acting alternately on the lever D1 and selector D2

fig. 2.5.2.2.

An operator must be at the end of the support ready to sustain the weight (40 kg.) to pull the first bolt off fig.2.5.2.2.



fig.2.5.2.2

Loosen the upper bolt 1 and remove it.

Rest the end of the support on the ground.

Support the weight of the rod and remove the second bolt 2.

Place the support on the ground and move it.

2.5.3 Assembling extension shaft guide support Do as follows to assemble the guide support to the shaft:

Fold the mast forwards by acting alternately on the lever D1 and selector D2

fig. 2.5.2.2.

Lift the support rod from the side of the bolts and insert the first one.

Lift the other end of the support rod (40 kg.) until the holes are aligned.

Insert the second bolt fig.2.5.2.2.

Tighten the bolts. 2.5.4 Assembling extension shaft Do as follows to assemble the extension shaft:

1. Move the rotary as low as possible fig.2.5.4.1.

2. Hook the rope of the winch 2° to the eyebolt on the upper manifold of the shaft.

3. Lift the extension shaft slightly higher than the inlet of the drag device on the rotary.



fig.2.5.4.1

4. Push the lower part of the shaft to align it with the pass-through hole of

the drag device. 5. Align the shaft so that the sliding guide can be inserted onto the support

rod. 6. Turn the shaft so that it blocks on the inserts of the rotary (detail of

fig.2.5.4.1).

7. Move the winch 2° down to insert the shaft in the drag device of the

rotary until the rope is loosened. Keep your hands away from the inlet zone.

8. Lower the mast as in point 1 to unhook the rope of the winch 2°.


DRILLING RIG WORKSITE OPERATIONS 1

Chapter 3

DRILLING RIG JOBSITE OPERATIONS 3.1 Moving the rig in the jobsite 3.1.1 Pre-planning the route

Before moving the drilling rig in the jobsite you should survey (on foot) the area where the rig is to be placed, and plan the path of travel by which to get there. The ground along the route must be

firm enough to support the weight of the rig, with forward or lateral gradients (which vary according to the rig's configuration) within the limits described below. The tool should be held at 20-30cm from the ground, but not so low as to risk scraping on uneven ground. This might damage the rig structure. When moving the drilling rig the mast must always be held vertically , with the exception of the configuration for transportaton. On sloping surfaces, turret rotations must be very slow to prevent as much as possible the inertial effects of the movement, that may trigger off dangerous unbalance. When the crawler controls are enabled, an intermittent acoustic warning is sounded.



• Maximum downward slope 6° (10% gradient), with mast held vertically and cab aligned with the direction of travel, facing forward (fig. 3.1.1.1).

• Maximum upward slope 6° (10% gradient), with mast held vertically and cab aligned with the direction of travel, facing forward (fig. 3.1.1.2).

Climb the slope along the line of maximum gradient (<10%). This will prevent the rig from tilting sideways.

fig.3.1.1.1 fig.3.1.1.2

Drive the rig at a low, steady speed.



• Maximum upward slope 18° (30% gradient), with mast lowered and cab aligned with the direction of travel, facing forward (fig. 3.1.1.3); maximum downward slope 18° (30% gradient), with mast lowered and cab aligned with the direction of travel, facing backwards (in reverse) (fig. 3.1.1.3).

fig.3.1.1.3

Climb the slope (<30% gradient) along the line of maximum gradient. This prevents the lateral tilt.

When travelling in reverse, use the rear-view mirrors and check both sides frequently. In case of poor visibility, stop the rig and inspect the path from a better viewpoint. Keep the travelling speed at minimum.



• Maximum lateral slope 5° (8% gradient), with mast held vertically and cab aligned with the direction of travel, facing either way (fig. 3.1.1.4).

fig.3.1.1.4

Drive the rig at a low, steady speed. The recommended gradient limits must never be exceeded. If the rig is subjected to rapid changes in inclination due to uneven ground while travelling, stop the rig and change the configuration and/or route in favour of a safer one.



When travelling in reverse, use the rear-view mirrors and check both sides frequently. In case of poor visibility, stop the rig and inspect the path from a better viewpoint.

• Maximum lateral slope 9° (15% gradient), with mast lowered (as in

fig.3.1.1.3) and cab aligned with the direction of travel, facing either way (fig.3.1.1.5).

fig.3.1.1.5

When travelling in reverse, use the rear-view mirrors and check both sides frequently. In case of poor visibility, stop the rig and inspect the path from a better viewpoint.



• Maximum lateral slope 5° (8% gradient), with mast held vertically, cab turned sideways to the direction of travel and unstable centre of gravity (fig. 3.1.1.6).

fig.3.1.1.6

Drive the rig at a low, steady speed. The recommended gradient limits must never be exceeded.

Bear in mind the protruding counterweight at the back.



• Maximum lateral slope 5° (8% gradient), with mast held vertically, cab turned sideways to the direction of travel and stable centre of gravity (fig. 3.1.1.7). Along the way maximum slope could rise up to 10° (18% gradient) on the sole condition that turret rotations are made only when the slope is <5°.

•

fig. 3.1.1.7

Bear in mind the protruding counterweight at the back.



• When travelling over flat areas, use the configuration shown in fig.3.1.1.1-2; do not use the configuration shown in fig. 3.1.1.8 except for very short transfers (i.e., getting over an obstacle). This configuration applies a heavy stress on the crawler's front drive wheels and on the mast guides. Do not use this configuration when travelling downhill.

fig.3.1.1.8

In general, when the rig is moving, the tool should be held as low as possible (as shown in the figures), but not so low as to risk scraping on uneven ground. This might damage the rig structure or make the rig unstable. Inspect the path of travel before shifting the rig, checking for narrow or low passages, overhead cables or any other obstacles that might interfere with the moving rig.

The speed of travel depends on the terrain's roughness and gradients: slow down to minimum speed when approaching the gradient limits described above, to avoid destabilizing the rig. The

angles of inclination shown in the figures must not be exceeded at any time, not even for a few moments. 3.2 Setting up the drilling rig 3.2.1 Work area

The place of installation should be adequately wide and flat, so that the crawler tracks have enough support to prevent dangerous swaying during rig operations. The surface of the standing area

may also be non-horizontal. In this case the angle of inclination, measured along the line of maximum slope, should be less than 5° (8% gradient). If the rig is to be used in an indoor location, install a system for extracting the exhaust fumes and discharging them outside.



3.3. Prior safety assessment of working conditions 3.3.1 Manoeuvring space

Make sure there is a safe distance between the drilling rig and nearby structures or non-removable objects, in order to prevent possible contacts. Check the distance from overhead cables; no rig

manoeuvre – even if done by mistake – should lead to any contact (see fig.

8.4.3.1). Make sure there is an adequate passageway for the mechanical shovel that will be removing the material dug out by the drill. Make agreements with the ground operator on the route to be followed by the mechanical shovel and on its waiting place, which should be visible from the rig’s cab. 3.3.2 Borehole drilling hazards Consult the jobsite supervisor or chief of operations to make sure:

• that no underground distribution networks (gas, power, telephone, water, sewage, etc.) are present in the planned drilling sites;

• that drilling a borehole in the vicinity of a structure will not affect its stability;

• that no unauthorized persons can come close to the rig during its operation (if this safety requirement is not ensured, halt all operations until it is);

• that the work area is not contaminated by hazardous substances.

3.4 Precautions when drilling a borehole 3.4.1 Borehole drilling operations

During drilling operations, care should be taken that no one comes close to the rig’s work area. Should this occur, halt operations until safety conditions are restored.



3.4.2 Removing excavated material When unloading the excavated material, the person in charge of removing it should wait at a safe distance and move in to remove the material only when the rig, completed the bore, extracts the tool (without rotating it). The material removal from the tool has to be done gradually, using a shovel or similar, during the tool extraction. Depending on the bore depth, pauses will be carried out during which the land in accumulation will be moved using an excavator or similar. 3.4.3 Rig stability during drilling operations Both the initial thrust on the tool and the first rotation of the turret should be done at slow speed in order to verify the rig’s stability. If the rig does not appear to be stable, halt operations and improve the supporting surface. 3.5 Risk management in case of unexpected obstacles inside borehole 3.5.1 Damaging buried installations

In case the tool hits and damages a buried installation, due to wrong information received, proceed as follows.

1. If the buried object is a power cable, pull the tool out of the hole to

eliminate the contact. While the contact lasts, the cab operator should not get off the rig and the ground operator should not touch it. If it is not possible to move the tool there is the risk that the buried cable is touching it, meaning that the rig may be electrified (the voltage depends on the nature of the soil). The operator should remain on board because if he tries to get off the rig he might touch the ground and the rig at the same time and receive a powerful electric shock. Immediately inform the power company and wait for their personnel to cut the power and remedy the problem.

2. If the buried object is a gas pipe (natural gas or other fuel), stop the rig immediately, turn off the engine and inform the gas company (or other authority). While waiting for the maintenance crew to arrive, isolate the area and remove any source of flames or sparks. Move the rig only after the maintenance personnel ensures that the flow of fuel has been stopped. If a fire erupts try to extinguish it using the on-board fire extinguisher, but only if the fire is a small one.

3. If the buried object is a telephone cable, pull the tool out (very slowly in order not to increase the damage) to eliminate the contact and verify



the extent of the damage. As a rule, the voltage circulating through telephone cables is not high enough to represent a hazard for operators. As a precaution, however, avoid touching the conductors in the cable or the rig while the contact lasts. Inform the telephone company and move the rig to make room for repairs to be carried out. Isolate the area.

4. If the buried object is a water or sewage pipe, pull the tool out (very slowly in order not to increase the damage) to verify the extent of the damage and inform the relevant authority to organize repairs. Move the drilling rig away from the spilling water and isolate the area. Be aware that wet ground can be slippery and lose bearing capacity.

5. If the buried object is a pipe carrying an unknown fluid (whether gaseous or liquid) proceed as in point 2.

3.6 Hazards posed by boreholes inside work area 3.6.1 Operation in the presence of boreholes

As soon as the borehole is completed and the required depth is reached, it must be made safe by setting up barriers preventing access to the hole. Placing the reinforcement cage inside the hole

increases safety by contrasting the collapse of the hole’s edges, but it does not replace barriers. If drilling is suspended for any reason before reaching the required depth (to be resumed at a later time), leave the tool on the mouth of the hole for protection.

3.7. Auxiliary winch 3.7.1 Using the auxiliary winch

The auxiliary winch is intended to be used by the operator only for attaching or detaching the tool or to move material required for drilling the hole once it has been placed close to

the rig using suitable means. This material should be lifted only next to the borehole, therefore moving the rig while the winch is in use is not allowed. To lift an object use the hook at the end of the rope, fastening it to a part that is strong enough not to break and in such a manner that it will not unhook during hoisting. The operator should have both the load and the rope in view at all times. The rope should not touch or be hindered by any other object or obstacle. The ground operator should stay at a safe distance and never stand below the suspended load.



The suspended load should never come into contact with the rig itself, to prevent either or both from being damaged or dangerously tangled to each other. When lifting a load, the cab operator should bear in mind that once the load gets off the ground it might begin to sway and injure the ground operator. For that reason loads should be completely lifted only for a short time and only when absolutely necessary for the work being carried out. The weight of the load must be within the winch’s carrying capacity. The load limits are shown in Par. 6.4.1. Is absolutely forbidden to use the mast movements to increase the winch 2 lifting capacity.

3.8. Working in bad weather 3.8.1 Lightning

The drilling rig’s metal structure provides intrinsic protection for the operator at the controls (like an automobile). The risks for the ground operator are generally greater, especially

during operations involving the auxiliary winch. Blasts of air caused by lightning striking the rig can cause a dangerous loss of balance to assistants working nearby. Suspend rig operations until the lightning hazard is over. 3.8.2 Wind

The hazards caused by wind are also greater for the ground operator. Halt operations if the wind is strong enough to compromise the ground operator’s balance or

cause dangerous oscillations when using the auxiliary winch. 3.9 Visibility 3.9.1 Poor visibility due to fog

In case of fog, work can continue provided the field of vision of both the cab operator and ground operator is wide enough not to increase the risk factors.

More specifically:

• The cab operator should be able to see the area in where the ground operator is working.

• The cab operator should be able to see a sufficient space around the rig in order to avoid hitting objects during operations.



• When shifting the rig, the operator should be able to see vertical points of reference standing out of the ground (buildings, poles, etc.) in order to prevent alterations of his sense of balance.

• When shifting the rig, the operator should be able to view the planned route and have perfect visibility of the ground around the rig.

3.9.2 Poor visibility due to darkness, bad weather or dust

When ambient darkness is such as to increase the risk factors, work with the rig must be halted. The electric spotlights installed on the drilling rig should be used to improve visibility in the work area

when the ambient light is in itself enough to ensure safe operations.

3.10 Parking the drilling rig

3.10.1 Parking in the jobsite Park the drilling rig on a flat surface, leaving enough space around it to carry out inspections. Leave the rig in the transport configuration. In the winter, make sure the cooling circuit is provided with sufficient antifreeze fluid. Remove the keys from the ignition switch and lock the cab door.

GEAX s.r.l. Chapter

INSPECTIONS AND IRREGULAR RIG BEHAVIOUR 1

Chapter 4

INSPECTIONS AND IRREGULAR RIG BEHAVIOUR

4.1 Inspecting the drilling rig 4.1.1 Periodic inspections Inspect the drilling rig following the instructions in Manual No. 2 (EK75 Drilling Rig Service Manual), which describes the frequency of the inspections to carry out depending on the operating hours, the work environment and the rig’s age. The maintenance personnel should be trained as required by the manufacturer in the manual. 4.1.2 Checks before every work shift

Before you start a work shift visually inspect the drilling rig walking around it in a complete circle. Look for abnormal traces of oil or grease, check the hoses and make sure they are well fastened to

the structure, make sure every part is firmly attached and check the conditions of the ropes on both winches. In particular, before bringing the mast to its vertical position, check the location of the ropes: their proper placement within the throats of the pulleys and fasten the hook on the auxiliary winch rope. Furthermore, remove any object completely or partially laying on the rig or in its work area. Make sure there are no foreign objects inside the control cab and that the cab itself is adequately clean, i.e., with nothing that might interfere with using the controls (hand or foot controls). Make sure the cab windows are clean and do not reduce the extent or quality of the field of vision. 4.1.3 Starting the drilling rig Turn on the engine and wait a few minutes for the fluids in the machine (coolant, lubricating oil, hydraulic oil) to reach their operating temperature. The machine that operate in cold climates are fitted with an independent heater of fluids (lubricating oil and hydraulic oil). If the ambient temperature is below 0° it must be turned on in advance in respect of the engine according to the following table:

GEAX s.r.l. Chapter

INSPECTIONS AND IRREGULAR RIG BEHAVIOUR 2

Ambient temperature Advanced turning on [min]

Working mode

-10°<temp.<0° 60 Turning off after the engine starts

-15°<temp.<-10° 120 Working simultaneously

temp.< -15° 360 Working simultaneously

Then, move the rig from its parking area or from the place where it was unloaded from the transport vehicle (see chapter 2) to the drilling site (see chapter 3), then straighten the mast (see chapter 5).

4.1.4 Checks after every work shift The inspections to make at the end of a work shift are the same that were done at the start. The reason is twofold: there will be more time to remedy any problems that may be found, and traces of anomalies may be wiped away if the rig is washed down after a work shift (see Par. 4.1.2). 4.2 Anomalies

4.2.1 Anomalies during operation

Should you detect any anomaly during the rig's operation, trace its origin and determine whether the safety levels have changed. If that is the case, halt work immediately, stopping the rig in a safe

and stable configuration, and contact the maintenance service at once. Note down the incident on a logbook that can be consulted by the maintenance service. 4.3 Maintenance 4.3.1 Maintenance procedures For information on scheduled maintenance and repairs, please consult Manual No. 2 (EK75 Drilling Rig Service Manual). On the jobsite, any emergency repair equipment should be kept on service vehicles and not on the drilling rig. Simple inspection equipment (e.g., electric torch, paper towels for cleaning, etc.) can be stored in the compartment on the rig.


CONTROLS 1

Chapter 5

CONTROLS

5.1 Description of drilling rig controls

5.1.1 General information on drilling rig controls

The drilling rig is equipped with hydraulically servo-assisted electric controls that require very little effort to be operated, i.e., just enough to win the resistance of the return spring and actuate the electric contact. The red lever on the left (E) enables all the controls when turned horizontally (preventing the operator from leaving the cab) and disables the controls when turned vertically, except for the mast alignment controls which remain enabled; the mast alignment functions have their own safety control which is located on the panel on the left (C). Selector D5 enables the controls that operate the crawler and turns on an acoustic alarm that warns the persons on the ground that the crawler may begin to move. The external and internal emergency buttons stop the engine and consequently all machine functions. Hereafter, the directions "left" and "right" should be understood as referring to the point of view of the operator sitting at the controls (fig. 5.2.1.1). The icons also represent the rig as seen by the operator (cab side).


CONTROLS 2

5.1.2 Symbols identifying the controls

Fig. 5.1.2.1

A Joystick. Backwards-forwards controls the main winch; left-right controls cab rotation.

Ae Button. Emergency stop

B Joystick. Backwards-forwards controls the movements of the mast or of the rotary head or of the auxiliary which; left-right controls rotary head rotation.

L Undercarriage translation controls (look at Hitachi manual)

P1 Button. Controls the acoustic alarm

P2 Button. It increases winch 2 up-down and push-pull speeds.

P3 Button In addition to other controls it increases rotary head speed.

P4 Rocker switch. Controls external accessories.

P5 Button. Controls the floating of the main winch.

Pr Button. Resets the depth meter./ activates automatic alignment.


CONTROLS 3

fig.5.1.2.2

fig.5.1.2.2

C1 Button. Enables manual controls D1 and D2, as well as the automatic alignment of mast P6 and Pr.

F1 Selector. Allows associating mast or rotary table movements to joystick B.

F2 Selector. In central position enables the 'floating' of winch 1, Set to On (with further clockwise rotation) locks the rotary to the mast (remaining floating active).

D1 Joystick. Allows biaxial vertical alignment of the mast

D2 Rotating control. Allows raising-lowering the boom.

D3 Rotating control. Opening and closing upper mast extension (not active in Kelly configuration).

D4 Selector. Allows selecting various rotary head speeds.

D5 Selector. Allows locking the crawler during drilling operations.

D6 Selector. Allows activating one or two hydraulic circuit feeding pumps.

D7 Selector. Allows associating mast or rotary head movements (See F1), as well as auxiliary winch operation to joystick B.

P6 Button. Allows starting the automatic mast alignment.

P7 Button. Allows exclusion of all limit switches.

S Warning light. Indicates that one or more limit switches have been disabled.

S2 Warning light. Indicates that the mast has reached its vertical position while the automatic system is operating.


CONTROLS 4

5.1.3 Control-lock lever

Lifting lever E will disable all the controls except for the mast alignment controls, (D1-D2) which remain enabled.

Pressing button C1, located on panel C on the left, will enable the mast alignment controls D1-D2 and the automatic mast alignment.

Turning selector D5 to the position shown will enable the undercarriage controls L and turn on the acoustic alarm. It also reminds the operator to switch to stop position before starting drilling.

Turning selector D5 to the position shown will disable the undercarriage controls L; this is the position to use during drilling.


CONTROLS 5

5.1.4 Acoustic alarm control

Pressing button P1 on joystick A sounds the acoustic alarm.

5.1.5 Mast opening controls

Turn knob D3 anticlockwise to fold the mast laterally for transport position. This operation must be done only when the mast is in a horizontal position.

Turn knob D3 clockwise to fold the mast laterally for work position. This operation must be done only when the mast is in a horizontal position.


CONTROLS 6

5.1.6 Mast alignment controls The mast alignment control are on panel D, located on the right, and is labelled D1; the control is enabled only when simultaneously pressing safety button C1 on panel C, located on the operator’s left side (regardless of the position of lever E): Movements produced by D1 can be automatically activated until reaching full vertical position, by pressing buttons P6 or button Pr on joystick B.

Lower lever D1 to make the mast rotate backwards (the top moves close).

Lift lever D1 to make the mast rotate forward (the top moves away).

Positioning the rotary in transport position it is possible to reach almost 90° (horizontal).


CONTROLS 7

Move lever D1 to the left to make the top of the mast tilt to the left. (tilting).

Move lever D1 to the right to make the top of the mast tilt to the right. (tilting).

Button C1 (safety enabling) and button P6 (or Pr in the right joystick) control the automatic mast vertical extension procedure. The system activates both axes as does control D1. Warning light S2 flashes throughout the procedure and remains steady once the alignment is complete.

Button C1 (safety enabling) and button Pr control the automatic mast vertical extension procedure. The system activates both axes as does control D1(as above) Warning light S2 flashes throughout the procedure and remains steady once the alignment is complete. (as above)


CONTROLS 8

5.1.7 Mast boom movement control The mast movement control is on panel D, located on the right, and is labelled D2; the control is enabled only by pressing simultaneously safety button C1 on panel C, located on the operator’s left hand side (regardless of the position of lever E).

Turn knob D2 clockwise to raise the boom and the mast.

Turn knob D2 anticlockwise to lower the boom and the mast.


CONTROLS 9

5.1.8 Mast movement control The control to move the mast up and down is joystick B; this control is multifunctional; therefore, it must be set by selectors F1 and D7

(Pay attention to the position of F1: mast movement selected)

Push joystick B forward to lower the mast.


Push joystick B backward to lift the mast.


By using button P2 and joystick B together you can increase the mast’s upward and downward speed. Use this function only in rotary piling mode.


CONTROLS 10

5.1.9 Rotary head controls The main controls of the rotary head are grouped together on the multifunction joystick B, located on the right-hand side. Selector D4 and button P3 allow selecting the rotation speed and the corresponding torque.

1 - V1 low speed max. torque 7500 daNm; 2 - V2 medium speed, reduced automatically by increasing the torque; 3 - V3 high speed, reduced automatically by increasing the torque;

Move joystick B to the left (towards the seat) to make the rotary head turn clockwise. The tool digs. . With D4 in position: V1-low speed, max torque 7500 daNm; V2-medium speed, torque

automatically tends towards v1 when maximum torque is provided;

Move joystick B to the right to make the rotary head turn anticlockwise . Speeds V1 and V2 are slightly lower than in clockwise turn.


CONTROLS 11

By using button P3 and joystick B together you can increase the rotary head's rotation speed (V3). This is useful when unloading the tool. In CFA mode, do not use to download the auger.

5.1.10 Main winch and turret controls The main winch and turret controls are grouped together on joystick A, located on the left-hand side, and on pedal P5:

Push joystick A forward to unwind the main winch and thus lower the tool.

Pull joystick A back to wind the main winch and thus lift the tool.


CONTROLS 12

Pedal switch P5 activates the floating of the main winch; this way the tool lowers at the set speed. The button works only when enabled with selector F1

Move joystick A to the right (towards the seat) to make the turret turn clockwise.

Move joystick A to the left to make the turret turn anticlockwise.


CONTROLS 13

5.1.11 BPS control: mechanical locking system between rotary and mast.

This system is to be used when compact or hard soil occurs.

Selector F1 in left position enables mast movement. Selector F2 in central position (as shown) enables winch 1 floating. By pressing pedal switch P5 it is possible to lift the mast pushing joystick B backward, leaving the tool at the bottom of the bore to start the pull-down.

Selector F1 in left position enables mast movement. Maintaining selector F2 rotated clockwise (as shown) it activates the locking system between rotary and mast and, by pushing joystick B forward, the mast together with the rotary is lowered; doing this the mast pull-down moves to the tool. (floating has to remain active to allow any small sliding before the lock, still using pedal switch P5)


CONTROLS 14

5.1.12 Auxiliary winch controls The auxiliary winch is controlled by joystick B. This control is multifunctional; therefore, it must be set by selector D7 (A beep confirms the choice). Button P2 on joystick B sets the system to a higher speed when lowering and raising the auxiliary winch:

(Pay attention to the position of D7: a beep is activated when the winch is selected).

Push joystick B forward to unwind the rope (and lower the load).

Pull joystick B back to wind the rope (and lift the load).

Activating button P2 and joystick B backwards-

forwards simultaneously increases the rope

lifting/lowering speed.


CONTROLS 15

5.1.13 Depth Meter

Press Pr to reset the depth meter.

The instrument measures the depth of the borehole by measuring the length of rope deployed by the main winch. The measure is not affected by the movements of the mast when applying thrust. Measuring borehole depth:

• Lower the mast until its bottom is at ground level; a. if the tool protrudes inferiorly

from the mast of a distance “s”, start to drill slowly lowering the mast while the tool is penetrating into the soil;

b. if the tool doesn't protrude from the mast, take its base to the same level of the mast;

• press button Pr on joystick B to reset the display, which will show 00.0;

• start to drill. The display shows the depth in metres (the two decimals are centimetres)1

reached from the base of the tool. If case “a” occurs, the length “s” has to be added to the total depth.

1 Instrument's minimum sensitivity: 47 [mm].


CONTROLS 16

5.1.14 Pump selection The number of hydraulic pumps that feed the hydraulic system can be selected: selector D6 allows choosing 1 or 2 pumps. By varying the capacity, the rotary head basic speed also varies:

• for normal foundation drilling operations two pumps are used;

• the use of a single pump slows down the rotary head speed considerably, thereby making it more suitable for compacted soil with rock formations (pointed buckets);

• the use of a single pump simplifies some rotary head rotation simultaneous controls (e.g. mast lifting and rotation)

• in CFA mode, is recommended to work with only one pump.

Rotate selector D6 to choose whether to feed the hydraulic system of the rotary table with one or two pumps.

5.1.14 Disabling the winch limit switches

By pushing button P7, all limit switches are disabled The light indicated by the letter S warns you that one or more of the following limit switches has been disabled:

• DOWN limit switch of main winch

• UP limit switch of main winch

• UP limit switch of auxiliary winch

The limit switches must be disabled only in particular cases:


CONTROLS 17

winch 2 UP limit switch can be disabled only to easily wind the winch safely when the machine is placed in transport configuration;

winch 1 UP limit switch can be disabled only to easily place the machine in safety conditions when it is locked due to a limit switch malfunction;

winch 1 DOWN limit switch can be disabled only to simplify rope replacement operations.

Make sure that warning light S is turned off in normal operation (limit switches enabled) see par 5.1.14

5.2 Emergency stop button

5.2.1 Using the emergency stop button

There are two emergency buttons: one installed on the front of the machine (see fig. 5.2.1.1) which can be easily accessed by an external operator, the other inside the cab (panel d - fig. 5.1.2.1) button Ae.

Pressing down the red mushroom-shaped button stops the engine and consequently all moving parts.

Once the emergency is over you will need to release the emergency button before you can restart the engine. Turn the button anticlockwise to release it and return it to its normal position.

Fig. 5.2.1.1


OPERATING THE DRILLING RIG 1

Chapter 6

OPERATING THE DRILLING RIG

6.1 Raising the mast 6.1.1 Vertical mast alignment To set the mast up vertically, press lever D1 on panel D with your right hand

while pressing button C1 with your left hand. The purpose is to bring the mast from the transport configuration to its working position (which is exclusively vertical) through a series of brief, coordinated movements, as follows:

1. Turn knob D2 clockwise to raise the boom by 20-30 cm. 2. Lower lever D1 to rotate the mast by a small angle, so that its top

moves toward you. 3. Repeat from step 3 until the mast is vertical. 4. If the crawler is tilted to one side (within the allowable limits) move lever

D1 left or right to compensate the inclination.

When the mast is within 5° of vertical, it can be set to vertical by means of the automatic system: The automatic vertical extension procedure is activated by pressing buttons C1 and Pr simultaneously. Warning light S2 on (not flashing) indicates that the goal has been achieved. Mast axis deviation from the vertical is shown on the colour display: front and side. The tool’s offset from the pivot cab's axis of rotation will vary according to the

final position chosen for the boom. Working with smaller offsets (i.e., boom in a higher position) means

greater stability. In these configurations, make sure the mast does not hit against the crawler while the cab

is rotating. Vertical alignment should be done at the beginning, before starting to drill the

borehole, and must not be changed until completion.



6.2 Testing the safety devices

6.2.1 Testing the main winch (1) up limit switch

At the start of the work shift, check that the warning light indicating disengagement of the limit switch is off, and then move the rotary up. Slow down towards the end of travel and wait for the automatic

stop. The up limit switch of the main winch (1) (and therefore of the rotary) is mounted at the highest end of the mast and is sensitive to the position of the rotary. If it does not stop automatically, immediately stop it by hand. Inform the maintenance service and interrupt the work session. If the rotary does not stop automatically, exceeding the end of travel damages the rope and pulley.

6.2.2 Testing the auxiliary winch (2) up limit switch

At the start of the work shift, check that the warning light indicating disengagement of the limit switch is off, and then move the auxiliary winch rope up (winch winding) to make sure the up limit

switch works properly. If any malfunction is observed do not use the auxiliary winch. The limit switch must never be disabled. Disable the limit switch only when folding down the upper part of the mast.

6.2.3 Operation of auxiliary winch (2) when lowering

There is no down limit switch on the auxiliary winch (2). Accordingly, never unwind the winch all the way, and stay within the limits described in Par. 6.4.1.



6.3 Drilling a borehole 6.3.1 Control sequence for making the borehole

1. Make sure that the mast is vertical. 2. Turn selector D5 to lock the undercarriage. 3. Place the rotary head at the maximum height on the mast (joystick A). 4. Move the right joystick B forwards (mast down) to bring the tool in

contact with the ground fig.6.3.1.1. 5. When it touches the ground, move the joystick B to the left to command

clockwise rotation of the rotary and then lower the mast (joystick B forwards) until the base comes in contact with the ground; if it is especially firm, recur to the procedure in paragraph 6.3.2, using the rotary-mast block.

6. Turn selector F1 to the winch 1 floating position. 7. Command clockwise rotation of the rotary (joystick B to the left) and

step on the pedal P5 activating “floating” of the main winch fig.6.3.1.2. 8. While drilling the borehole, the P5 button can be released for short

periods while the rotary continues to be activated; this assures you that the earth on the auger has been detached from that inside the hole (making extraction easier).

fig.6.3.1.1 fig.6.3.1.2

9. When the auger is almost fully in the ground, the rotary is blocked, the P5 button released and the extension shaft must be unhooked from the rotary: the rotary is lowered (joystick A) and a short anti-clockwise rotation (unscrewing) is commanded fig.6.3.1.3. Then the rotary is lifted



to the top of the extension rod; in this position the rod has a step on the guides fig.6.3.1.3 which discharges the weight of the rotary onto the tool.

fig.6.3.1.3

10. The rotary starts to turn once again (joystick B to the left), pressing the

P5 button to ensure floating. 11. Drilling of the borehole terminates when the rotary has reached its

lowest position (after having exploited the extension shaft as well).



fig.6.3.1.4

12. The tool is removed from the hole by commanding the upward

movement (joystick A back). The operation consists in two phases: during the first phase, stop when the auger protrudes about 1 m from the ground; in this phase the rotary is lowered (the tool remains still due to friction with the ground) to be hooked to the base of the extension rod (inverse operation than point 9); when the rod is hooked, the tool is extracted and tools are used to remove earth from the auger.

13. The last part of the auger is extracted, lifting the entire mast and therefore re-enabling the joystick A with the selector E1.

14. Do not rotate the tool to discharge earth.



6.3.2 Using thrust device (BPS) to drill hard soil Referring to the previous chapter, during point 7, the auger should move forward, screwing into the ground, pushed by the force of its weight. At times, this forward-screwing movement does not occur due to the firmness of the ground. In these circumstances, the rotary-mast thrust system can be exploited:

7a. Selector F1 in position to activate mast movement. 7b F2 in central position to enable floating of winch 1. 7c. With pedal button P5 pressed, move the joystick B back and lift the

mast 60-80cm from the ground (the tool however remains in contact with the bottom of the hole) fig. 6.3.2.1.

7d. Turn F2 further and keep it in this position during the entire duration of rotary-mast blocking fig.6.3.2.2.

7e. With the joystick B to the left, first rotate the tool clockwise and then, moving the joystick forwards, move the mast slowly downwards; when moving down, the rotary is blocked with the mast and its thrust has a repercussion on the tool fig.6.3.2.3. It must move slowly to keep the strength of the thrust from lifting the carriage and tilting the mast. The descent of the mast must not overtake advancement of the tool into the ground; (during the first movement of the mast, the pedal P5 should be pressed as

well in order to favour blocking without loosening the rope of the winch 1).

7f. When the mast rests on the ground, interrupt descent by moving the joystick B all the way back releasing rotation for a few seconds until the auger spins freely without gripping the ground.

7g. Move the selector F2 back to the central position to release the rotary from the mast (return of blocking pins) fig.6.3.3.5.

7h. Repeat the operation from point 7b if the hard layer of ground has not yet been overcome; otherwise continue on.

7i. If the firm ground has been overcome, go on from point 6 of the previous paragraph.

fig.6.3.2.1 6.3.2.2 6.3.2.3 6.3.2.4 6.3.2.5



6.3.3 Operations forbidden when drilling a borehole

During actual drilling (tool rotating) it is strictly forbidden:

• to move the rig by switching selector D5

• to rotate the pivot cab

• to modify the mast’s vertical alignment, especially when the mast rests on the ground.

The mast’s alignment should not be changed even during pauses as this would compromise the straightness of the borehole and/or make it difficult to pull out the tool.

6.3.4 Borehole drilling precautions

During the operations described in par. 6.3.1, care should be taken that no one comes close to rig’s work area. Should this occur, halt operations until safety conditions are restored. When unloading the excavated

material, the tool must not rotate, and the operator must use a suitable tool (e.g. shovel). 6.4 Operation of auxiliary winch

6.4.1 Operation and limitations of use of auxiliary winch

In order to use the winch you must first unlock the safety catch (lever next to the pedal), loosen the wire rope and unhook it from eyebolt B. Stepping down on the front part of

rocker pedal P4 makes the rope come down, while stepping on the back part of the pedal makes the rope go up. Loads should be lifted vertically or with a deviation from the vertical of no more than 20° (see figure 6.4.1.1. Furthermore, for safety reasons, the rope should not be used outside the area shown in figure 6.4.1.2 (the allowable work area is shaded in the figure), in order to prevent the hook from going out of the operator’s field of vision or exceeding the limit of 20° from the vertical. Hoisting or dragging loads at higher angles can create overturning forces that can be hazardous for the drilling rig's stability.



fig. 6.4.1.1. fig. 6.4.1.2

Simultaneously pressing button P2 increases the rope's rate of descent. This function should be used only when lowering a reinforcement cage inside the borehole to increase its downward speed and get past narrowings where the cage might get stuck. Perform this operation with caution, and only when at least 1/3 of the cage’s length has already been lowered into the borehole at normal speed. Otherwise the cage (suspended load) may tilt over dangerously and risk injuring the ground operator.



When the winch is not in use, the hook at the rope’s end must be secured to eyebolt B (Fig. 2.1.2.2) and the rope itself kept slightly tensioned.

This will ensure that the hook does not sway around with the risk of hitting persons or objects, and will prevent it from getting tangled in moving parts with disastrous results. It is strictly forbidden to move the mast to increase the lifting capacity of the winch 2°.

Once you have finished using the winch, lock the pedal (flipping the lever on the side) before you do anything else. For further information see Par. 3.7.1.

6.5 Disabling the limit switches 6.5.1 Disabling the rope up limit switch on the main winch

The down limit switch should be disabled only when replacing the rope on the main winch during rig maintenance.

6.5.2 Disabling the rope up limit switch on the auxiliary winch

The up limit switch should be disabled only when winding the rope while folding down the upper element of the mast.


CONTROLLING GENERAL HAZARDS 1

Chapter 7

CONTROLLING GENERAL HAZARDS

7.1 Fire prevention 7.1.1 Refuelling

The following precautions should be applied to reduce fire hazards during refuelling. Use type-approved dispensing systems when refuelling the drilling rig. Stop the engine when refuelling. Make sure that no one is smoking and that there are no open

flames nearby. The fire extinguisher is located inside the control cab. The rig is supplied with a fuel pump for refuelling purposes.

• Place the fuel container (can) on the ground in a stable position.

• Put the metal end (provided with a check valve) of the suction hose (fig.7.1.1.1) inside the can and make sure it is well immersed in the fuel.

• Switch on the electric pump (Fig. 7.1.1.2) and leave it on until the fuel indicator in the cab reaches F, meaning that the fuel tank is completely full; exceeding this limit may cause dangerous fuel spills.

• Stop the pump immediately if it is not intaking fuel. Alternatively, use the upper filler when refuelling by gravity with a dispenser nozzle.

• Place yourself so you can hold the nozzle comfortably.

• Introduce the nozzle well inside the filler making sure that there is a metal-to-metal contact.

• Refuel until the fuel indicator in the cab reaches F, meaning that the fuel tank is completely full; exceeding this limit may cause dangerous fuel spills.

fig.7.1.1.1 fig.7.1.1.2



The metal contact between the nozzle and the filler prevents sparking caused by electrostatic discharges. Do not carry fuel cans in or on the drilling rig. Pay attention to the hot parts of the rig and be careful not to splash them with fuel that may be accidentally spilled during refuelling. Use a cotton cloth to wipe off any fuel that may have spilled on parts that are not overheated. Do not use wool or synthetic materials. 7.1.2 Checking the battery fluid

To check the electrolyte level in the battery turn off the engine and wait a few minutes. Use a low-voltage electric torch to illuminate the area. Do not use open flames. When in use (either charging or discharging) batteries

develop hydrogen, which is a highly explosive gas. 7.1.3 Checking other fluids

Checking or topping up other fluids (e.g., lubricating oil, hydraulic oil) should be done when the rig is cold, before the start of a work shift (see Maintenance chapter).

7.1.4 Leaking of flammable liquids

If any leaks are observed in the fuel circuit, the lubrication system or the hydraulic circuit, stop the rig as soon as you can, turn off the engine and make sure the leaking fluid is

not falling on overheated or electric parts. Emergency repairs carried out on the worksite should be done following the servicing procedures prescribed by the manufacturer, and performed by expert, trained personnel. 7.1.5 Fire extinguisher Keep a fire extinguisher on hand in an easily accessible place. The extinguisher must comply with local regulations and be designed for use against fires involving solids, liquids and gas. The extinguisher is usually stored inside the control cab, fastened to a support.



7.2. Preventing burns from hot surfaces or toxic substances 7.2.1 General information

When the rig is working, certain parts reach high operating temperatures that can cause burns if touched. In descending order of danger, the hot parts to be careful of with reference to the

internal combustion engine are: the exhaust, the lubrication circuit, the cooling circuit and the cylinder head. With reference to the hydraulic system: the pumps, the hydraulic motors and the connection circuits. In case of problems, service personnel should intervene only after the parts have cooled down completely, bearing in mind that fluids take more time to cool than their containers or the hoses/tubes in which they flow. Do not attempt to speed up operations using protective screens of any kind, as they may prove ineffective against pressurized liquids or gases. In case of overheated solid parts, the thickness of the protections used would make it difficult or unsafe to perform servicing. 7.2.2 Cooling circuit

The cooling circuit is pressurized. Never loosen the cooling circuit cap when hot. Rapid depressurization would cause a large amount of steam to form that would violently escape causing extensive scalding. In addition, coolants are

composed of harmful substances that are irritating to the eyes and skin and toxic if swallowed.

7.2.3 Hydraulic actuating circuits

The hydraulic fluid is pressurized hydraulic oil. When the rig is working, the hydraulic oil can reach high operating temperatures that make it dangerous in case of contact. Before servicing a

hydraulic device in any way, it should be left to rest until it cools down, then depressurized and emptied of oil. Do not release oil into the environment.

7.2.4 Battery electrolyte

The rig's battery contains a sulphuric acid solution that can cause burns if it comes in contact with the body, especially the eyes. In case of contact, wash quickly with plenty of water and consult a

doctor.



7.3 Pressurized devices 7.3.1 Hydraulic actuating circuits

The parts of the rig that are hydraulically actuated are driven by pressurized oil. Before servicing any such device it must be depressurized, without loosening the fittings but following the

instructions in the service manual. A fluid that escapes from a pressurized device (even working at a small flowrate) and strikes the skin directly can cause abrasions and penetrate deeply, producing serious injuries. The risk of harming one's eyes is particularly serious. Even for simple inspections on pressurized devices, operators must always protect the uncovered parts of the body, wearing a see-through face mask, a helmet, gloves and full-body overalls. Likewise, maintenance personnel should also wear adequate clothing and use the same protection devices (see Manual No. 2). 7.3.2 Leaks in hydraulic circuits

If you discover a leak from a hydraulic circuit or device, stop the rig (in a stable configuration, if possible) and request maintenance. Continuing to use the rig would increase the risks both for the

operator (the machine might not respond to the controls as expected) and the rig itself (certain parts might work under excessive stress). Additionally, hydraulic fluid spillages contaminate the environment, and measures must be taken to limit them.

7.3.3 Checking tubes and hoses Regardless of the inspections carried out at the start of the work shift, the cab operator and ground operator – each from their own point of observation – must have an overall view of the drilling rig in order to warn one another of any change in configuration. For example, a broken hose clamp might lead to damages to the hose by crushing, cutting or stretching. Inspections must be carried out also after accidental impacts with foreign objects during work, although this should not happen if the work area has been adequately prepared.



7.4 Entering and exiting the drilling rig cab 7.4.1 Proper position and movements

Do not get on or off the machine when it is moving. Do not get on or off the machine when the hydraulic lock (E) is not activated. When passing by the controls, there is a risk of touching them inadvertently, starting dangerous movements. The left joystick A is

particularly exposed to this risk. Moving it may cause the sudden rotation of the cab with serious consequences:

• the operator may fall from the cabin;

• parts of the machine may hit external operators;

• damage may be caused to the machine in proximity of obstacles or of the rod when the bucket is in the borehole.

Get on the rig only using the footboards provided for the purpose. Make sure they are always well secured and not damaged by impacts or other events. Keep the footboards clean from mud or earth, in order to ensure a good grip between the shoes and the metal. Clean you shoes before entering the cab. Mud and earth can obstruct the proper operation of the foot controls. When getting on or off the rig, always maintain three points of contact with it, in order to prevent dangerous swinging. Do not get on or off the rig when it is moving.

7.4.2 Cab space The cab is designed to accommodate a single operator. Do not enter the cab in two or more, even if only to pick up an object. 7.5 Additional equipment 7.5.1 Worksite arrangement All the equipment required for work must be arranged in an orderly manner, if possible in a single place and outside the area occupied by the rig when in operation. The reason for this is that a ground operator who is busy preparing equipment cannot pay attention to the rig and all its moving parts. 7.5.2 Drilling rig arrangement Do not under any circumstances place equipment of any kind on the drilling rig, either on the sides (leaning) or on horizontal surfaces.



7.6 Using the emergency stop button 7.6.1 Handling a dangerous situation

The emergency button should be used only when the ground operator realizes that the cab operator may not be quick enough to act on the controls in the presence of a dangerous event. This may happen because of poor visibility, a sudden illness or other reason affecting the operator at the controls. In any other case, it can be safer to handle an emergency from the cab, using the functions that are still operational, than completely and prematurely blocking the whole rig in a moment of panic.

7.6.2 Operators' positions On the basis of the considerations made above, the cab operator and ground operator should remain each within the other's field of vision as much as possible, so that they may alert each other – even by gestures – of any dangerous situation that might arise. 7.7. Additional information on using the auxiliary winch 7.7.1 General considerations

The auxiliary winch should be used as described in Par. 3.7.1 and within the operating limits illustrated in Par. 6.4.1. In brief, the operator must not use the auxiliary winch for purposes

that are typical of a crane. The rig is provided with the auxiliary winch for two reasons only:

• to safely change the bucket or other drilling tool (the operation is performed better if controlled by a single operator);

• to move within a restricted area material strictly regarding the drilling of the borehole, avoiding the risks that would arise from having a second large machine in the same work area.

These operations can be carried out by the auxiliary winch with maximum operational safety. Moving material around the worksite is a task better performed by other equipment specifically designed for the purpose.


GENERAL DESCRIPTION OF DRILLING RIG 1

Chapter 8

GENERAL DESCRIPTION OF DRILLING RIG

8.1 Description of drilling rig The EK75CFA is a machine designed to drill boreholes using a continuous flight auger known as "CFA". The drilling rig presents an innovative articulation of the mast that allows a wide range of operative positioning. The mast is supported by a long, articulated boom which connects it to a tracked crawler. This architecture allows greater operational margins than traditional configurations. Rotatory and translational movements are driven by hydraulic systems. The only source of power on the machine is a diesel engine mounted on the crawler. 8.2 Identification data: Model EK75 Serial number 160J075E



8.3 Technical data 8.3.1 Mechanical specifications Rotary head Max. torque

7500

[DaNm]

Max. drilling depth: 16,5 [m]

Tool diameter

Max.

Min.

0.75 0.3

[m] [m]

Mast adjustment in working position:

Rotation on transverse plane

Rotation on longitudinal plane

±5 ±5

[°] [°]

Main winch

Max. pull

12000 x 3

[DaN]

Auxiliary winch

Max. pull

3700

[DaN]

Mass (without accessories) 24000 [kg]

Tracked crawler JCB JS160 NLC

Diesel engine power

93

[kW]

8.3.2 Noise levels

LwA Acoustic power level of airborne noise

102

dB(A)

LpA Noise level inside operator's control cab

70

dB(A)

Note: Measurements made in accordance with standard 2000/14/CE, UNI EN 791/1997

8.3.3 Vibration level Acceleration on operator's hands and arms

< 2.5

[ m/sec2 ]

Acceleration on operator's body < 0.5

[ m/sec2 ]

Note: Measurements made in accordance with standards ISO 2631/1, ISO 5349, SAE J1166



8.4 Dimensions 8.4.1 Working order

Symbol Dimension [mm] Note:

A 19600 Max height in working conditions

E 5000 Extension kelly stroke

Ip 2740 Tail swing

Ra 2300-3800 Front radius fifth–wheel axis – bucket axis

B 11000 Rotary stroke along the mast

D 410 Distance of auger axis from frontmost point of mast

fig. 8.4.1.1



8.4.2 Transport configuration

Symbol Dimension [mm] Note:

At 3100 Typical height (not including flexible parts). Horizontal position with mast entirely lying on loading deck is also acceptable.

Lt 10500 Length

C 3100 Cab height (including safety guards)

Resting point of mast bottom on loading deck (inside crawler tracks perimeter)

fig. 8.4.2.1

Dimensions At and Lt are subject to considerable variations depending on the

mast’s angle of inclination. Motor vehicle regulations require the topmost point of the drilling rig, when arranged on the transport vehicle, to be <4m (13.1 ft) from the ground (see official road user guide).

.4mheightdeckAt



8.4.3 Spatial requirements during positioning manoeuvres

fig. 8.4.3.1

The unbroken red line shows the maximum reach of the top of the rig during the positioning manoeuvres. The dashed line shows the positions that must not be assumed, as they would not be visible to

the operator and are not needed for any operation.

operation and safety manual · 2018. 12. 13. · this manual provides information to operators on...

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