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Operating ManualRH900

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CONTENTS Description of the product page 2 General Safety Instructions page 8 Transport page 16 Assembly of the product page 17 Putting into operation page 21 Operation of the product page 24 Trouble shooting page 29 Maintenance page 32 Placing out of operation page 39 Additional Information page 41 Annexe (technical data) (TA) page 42

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Description of the product type: RH 900 weight: approx. 280 kg (without mounting plate) serial no.: 090066 year of construction: 11 / 2012 Address: EURODRILL GmbH Industriestraße 5 D – 57489 Drolshagen Germany �: ++49 (0) 2763 / 21228 – 0 Fax.: ++49 (0) 2763 / 21228 – 22 e-mail: [email protected]

internet.: http://www.eurodrill.de Eurodrill reserve the right of amendment regarding all data, information and drawings mentioned in this operating manual due to further technical development without any previous announcement thereof. In case of doubt the German version is always applicable.

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1. Remark of copyright protection acc. to DIN 34 Forwarding and copying of this operating manual as well as using and informing of the contents thereof is strictly forbidden; unless for competent people who are trained and personnel who has to maintain, service and operate the machine may use this manual for the purpose as directed unless it is especially approved. Violators will be sued for damages. In case a patent is granted or copyright in design is issued all rights are reserved. 2. Name plate All Eurodrill products are equipped –directly in our workshop- with name plates for distinct identification with the following data.

The removal of the name plate causes complete loss of warranty claims.

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3. Application Eurodrill hydraulic drifters / rotary heads are exclusively determined for drilling purposes in special civil engineering or similar applications. They are only determined to be used in combination with a suitable carrier / drill rig. Eurodrill hydraulik drifters / rotary heads are only to be used for purposes they are originally intended to – this is considered to be improper use. Proper use of the equipment also requires careful reading of this operating manual as well as taking care of all instructions – in particular to watch all safety instructions. Furthermore all inspection- and maintenance intervals have to be properly followed as indicated. In case there is no proper use of the Eurodrill hydraulic drifters / rotary heads a safe operation of the Eurodrill hydraulic drifters / rotary heads cannot be guaranteed. When injuries of persons or material damages resulting from improper use of the equipment occur, the user/operator is taken responsible and the manufacturer of the hydraulic drifters / rotary heads is not responsible.

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4. Warranty Eurodrill is taking over the warranty of all hydraulic drifters / rotary heads and spare parts of 12 months effective after shipment of the goods. In case Eurodrill hydraulic drifters / rotary heads operate in several shifts a day the warranty period is reduced according to the shift intervals. Due to extreme stressing/load caused by operations and applications different components are subject to high wear and these parts –as listed below- are not subject to any warranty: • accumulator diaphragms • bearing bushings • pistons • shank adaptors (striker bars) • thrust rings • seals ONLY Eurodrill spare parts are allowed to use. Using other spare parts will cause immediate loss of warranty. Furthermore Eurodrill do not undertake any liability for: • damages at the rig itself by improper use of Eurodrill hydraulic drifters / rotary heads, • damages at Eurodrill hydraulic drifters / rotary heads by improper connection of the

hydraulic components, • using the components non complying with the intended use as determined, • wrong and improper handling, • use of non admissable working materials and fuels, • unsufficient and improper maintenance. Warranty is also reduced in case unproper and extended stock is the result of corrosion and in case prior to putting into operation the device has not been properly inspected. The same applies in case of illegal operation at the hydraulic drifters / rotary heads, during the time of warranty, if not approved by Eurodrill. Eurodrill’s General Terms of Sale and Delivery are valid. Special agreements are only valid in writing, verbal agreements are not valid at all and are not considered to be binding. Any changes of the warranty terms have to be fixed in writing with the purchase order. Removal of the name plate causes immediate loss of warranty.

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5. Technical devices DRICON DRICON is a control system to realize different working speeds and torques by combining different hydraulic motors. Flawless function is only guaranteed by watching the following points:

• control acc. to hydraulic connecting diagram! • control pressure: p control = 38 bar ! • Switching-over ins ONLY allowed at complete stop or in a condition under NO

LOAD. Working disorder or even considerable damages is caused in case of not watching this warning! Hydraulically switchable gear stages Eurodrill hydraulic drifters / rotary heads –e.g. of the series HD 4008 / RH 800 and HD4011 / RH11 can be equipped with a hydraulically switchable gear stage increasing an easy operation and reducing the shifting times because there is no more shifting in another gear by hand. The result is a much more efficient operation. STOP first and ONLY switch the gear stages at stop! Control acc. to hydraulic connecting diagram! Working disorder or even considerable damages is caused in case of not watching this warning! 2 – speed hydraulic motors, hydraulically switchable Different Eurodrill hydraulik drifters / rotary heads e.g. HD4008, RH11-4 or VDW 1608 / 1206 / 6035 / 3525 can be equipped with 2 – speed hydraulik motors. Switching from one speed to the other is ONLY permitted in COMPLETE STOP ! Controlling acc. to hydraulic connecting diagram ! Working disorder or even considerable damages is caused in case of not watching this warning!

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General Safety Instructions 1. Operator’s duty of care Eurodrill hydraulic drifters / rotary heads were designed and built on the basis of a risk analysis and under consideration of all relevant harmonised standards as well as further national standards and technical specifications. The machine thus conforms to the current level of technology and guarantees the highest possible degree of safety. This level of safety can only be achieved in practice if all necessary measures are observed in dealing with the machine. It is therefore part of the duty of care of the machine's operator to plan these measures and check that they are executed correctly. In particular the operator must ensure that - the machine is used only as directed (see chapter "Product description") - the machine is operated only in a fault-free, operational condition and in particular the

safety devices are regularly checked to ensure that they function as directed - any necessary protective equipment or work clothes for the operating, maintenance

and repair personnel is available and is used - the operating manual is always legible and is available in full at the machine's location - the machine is operated, maintained and repaired only by sufficiently qualified and

authorised personnel - this personnel is regularly instructed in all matters relating to occupational safety and

environmental protection and are familiar with the operating manual and in particular with the safety instructions as directed

- all safety instructions and warnings on the machine are visible and legible and are not

removed. Always keep this information available! This operating manual must be kept close to the machine. It must be ensured that all persons working with Eurodrill hydraulic drifters / rotary heads have to read the operating manual at any time. In addition to the operating manual, job control statements within the meaning of the Health and Safety at Work Act and the regulation governing the use of tools and equipment must also be provided. All labels on the machine displaying safety and operating instructions must always be kept legible. Worn or damaged labels must be replaced immediately

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2. Safety instructions Requirements of personnel Eurodrill hydraulic drifters / rotary heads may only be operated by persons who have been specially trained, briefed and authorised. These persons must be familiar with the operating manual and act accordingly. The respective areas of authority of the operating personnel must be clearly defined. Furthermore, the following activities require special qualifications: - Putting into operation - may only be performed by experts. - Instruction may only be performed by experts. - Eliminating of failure may only be performed by Eurodrill personnel/ by personnel especially trained by Eurodrill. - Servicing may only be performed by Eurodrill personnel/ by personnel especially trained by Eurodrill. - Maintenance may only be performed by Eurodrill personnel/ by personnel especially trained by Eurodrill. - Repair may only be performed by Eurodrill personnel/ by personnel escpecially trained by Eurodrill. - Withdrawal from service may only be performed by experts. Operating personnel who has to be trained first, may only work on Eurodrill drifters/hydraulic rotary heads under the supervision of an experienced person. Successful completion of the training/instruction period should be confirmed in writing. All control and safety devices must be operated only by persons who have been suitably instructed. All personnel working at the machine have to read the operating manual first and then have to confirm with their signature that they really understand this operating manual. Personal safety equipment During the operation with Eurodrill hydraulic drifters / rotary heads all operating personnel is obligated to wear personal safety equipment: - safety helmet - safety shoes and -boots - working gloves - ear protection - safety glasses - breathing protective mask

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2. General Safety Instructions Before starting: Familiarise yourself sufficiently with - the machine's operating and control elements - the machine's equipment - how the machine works - the safety devices of Eurodrill hydraulic drifters / rotary heads During regular operation Eurodrill hydraulic drifters/rotary heads may only be started from the prescribed control stand on the drill rig. During operation of the hydraulic drifter/rotary head, no safety devices may be removed or deactivated. The operating personnel must make sure that no unauthorised persons remain within the operating area of the hydraulic drifter/rotary head. Once the machine has been switched off, the operating personnel must wait until all mobile parts have come to a standstill and the function lamps have been extinguished before leaving the carrier/drill rig. At least once a day the following check-up must be performed: ... - check if there are any visible damages at the Eurodrill hydraulic drifters / rotary heads - check all functions of the safety devices - check all hydraulic hose connections if they are tight and properly connected

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2. General Safety Instructions During maintenance: The servicing/maintenance work defined in the operating manual - tuning, cleaning, lubrication, maintenance, inspection must be performed when due. Before starting to service please note the following: - Switch off the central power supply with the master switch of the carrier / drill rig,

lock the master switch and put up a warning sign prohibiting switching it on again - Make sure that all machine parts have cooled down to room temperature - Make sure that suitable lifting gear and weight-carrying equipment is available for replacing large machine parts - Block off access to the operating area of the machine, make sure no person is trespsassing the operating area - Replace all defective machine parts immediately - Use only original spare parts or spare parts allowed by Eurodrill (on agreement) - Make sure to have enough suitable collecting containers for materials (like oil, cooling liquids, etc) what might pollute the ground water. After completing the servicing work at the Eurodrill hydraulic drifter / rotary head and before starting the machine again, note the following points: - Double-check all previously loosened screws to make sure they are tightly secured - Check that all previously removed protective devices, covers, container lids, screens,

filters, valves ........ have been replaced correctly - Make sure that all previously used tools, materials and other equipment are removed

from the operating area - Clean the operating area and remove any liquids or similar substances which may

have leaked out - Make sure that all the machine's safety devices are properly working again

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2. Genereal Safety Instructions

Working on hydraulic equipments: As a matter of principle, all works on the hydraulic equipment of Eurodrill hydraulic drifters/rotary heads may ONLY be done by experts especially trained for this kind of work. Before starting work, depressurise all hydraulic and pneumatic installations/installation parts. During maintaining the damaged hoses should preventively be exchanged (see instructions of the hose manufacturer). Changes at the equipment Due to safety reasons it is strictly forbidden to make any unathorized change on Eurodrill hydraulic drifters / rotary heads. Any intended change has to beconfirmed in writing with the company Eurodrill. Use ONLY original spare parts / original wearing parts / original accessory / all these parts are especially designed for Eurodrill hydraulic drifters / rotary heads. There is no guarantee using non-original parts that they are designed and manufacured acc. to stress-proof and safety rules. Any parts and/or any special design -not supplied by Eurodrill- are NOT released and approved by Eurodrill to be used on Eurodrill hydraulic drifters / rotary heads. Environmental protection During all work on and with Eurodrill hydraulic drifters / rotary heads carefully note the regulations to avoid waste and proper waste disposal or recycling. In particular when setting up, servicing and withdrawing the machine from operation, make sure that substances which can contaminate ground water - such as grease, oil, coolants, solvent-based cleaning fluids etc. - do not soak into the ground or enter the drainage system. These substances must be properly collected, stored, transported and disposed in suitable containers.

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3. Dangers Mechanical danger: Always keep away from suspended loads. During operation of the hydraulic drifter / rotary head never reach out to the drill rods or to parts of the drill rods, this could cause severe injuries. Also watch carefully when working with Eurodrill hydraulic drifters / rotary heads; it is always dangerous because fluids can be spouted out under very extreme pressure. Thermical danger: When working with Eurodrill hydraulic drifters / rotary heads there is always the risk of getting burnt by getting in contact with: - parts of the drifter / rotary head, - parts of the percussion mechanism, - parts of the drill string, - hydraulic hoses. Danger from noise: Depending on the local conditions,during work with Eurodrill hydraulic drifters / rotary heads high sound levels can occur, which can cause deafness, loss of balance or diminished alertness. In this case the operating personnel must be provided with adequate personal protective equipment. Also watch that due to the noise of the operating Eurodrill hydraulic drifters / rotary heads the communication among each other and listening to acoustic warning signals is getting more difficult (for example listening to the horn of a car). Watch the rules and regulations of noise pollution in this operating manual and use the prescribed personal protective equipment.

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3. Special dangers Dangers from “residual“ energy: Note that various forms of energy can still be present after the machine has been switched off or has come to a standstill. For example: - machine parts which continue to run for a while after deactivation - raised machine parts - hydraulic components - live power cables Make sure you also provide adequate information being introduced to the equipment and in the job control statement. Danger from unexpected faulty functions: Working on Eurodrill hydraulic drifters / rotary heads watch the risk of unexpected faulty functions resulting from: - failure of or faults in the control system - restoring the power supply after an interruption - external influences on the electric system

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4. How to deal with danger while working with hydraulic drifters/rotary heads in combination with carriers/rigs. See the safety/warning signs and symbols:

excessive noise

bad weather conditions

bad soil conditions

high dust pollution

percussive hoses/components

risk of fire

low visibility

unsufficient lights

risk of falling down from higher positions

danger of explosion

danger ofhigh pressure fluids and gases

excessive vibrations

faulty function of componentsunprotected, movable

equipment parts

contact with heated components

crash down ofparts of drilling equipment

ejection of drilling material

mechanical failure or

leakage of fluids( oil, fuel, etc. )

fall over, slipping off of the drill rig

ear

risk of tripping over

Safety gasses

Safety gloves

Put on ropesnseilen

use

lifting tools

safety helmet

safety boots

Hanging

loads

noise

falling parts

danger / warning

Mechanical

danger

Risk of falling

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Transport 1. Safety instructions for the transport Watch out for the following special dangers when transporting the machine, to avoid deadly injuries during transport of Eurodrill hydraulic drifters / rotary heads: - ONLY qualified personnel is allowed to transport the equipment watching all safety

instructions - Eurodrill hydraulic drifters/rotary heads may ONLY be lifted at the lifting points as

directed - Watch the proper transporting points/lugs acc. to the weight of the Eurodrill hydraulic

drifters/rotary heads during transport - Protruding sharp edges can cause cuts. - Suspended loads can fall, your life will be endangered. Never stand under suspended

loads! - Parts which have been piled up too high can collapse. - Watch carefully that the accumulators are empty during air freight otherwise there is a

high risk of explosion (see also the chapter: accumulators) - Also read carefully the chapter: “general safety instructions“

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Assembly 1. General instructions for assembly Safety instructions To avoid damage at the equipment and/or deadly injury during mounting of the Eurodrill hydraulic drifters / rotary heads it ismandatory to note the following points: - ONLY qualified personnel is allowed to mount the Eurodrill hydraulic drifters/rotary

heads carefully oberserve all safety instructions. - Prior to mounting the Eurodrill hydraulic drifters / rotary heads FIRST check them if

there are any transport damages at the equipment. - It is very important to watch very carefully and follow the tightening torques as directed. - Put the drill mast in a horizontal position. - Also read the chapter: “general safety instructions“. Special instructions to avoid danger Watch out for the following special dangers when setting up the Eurodrill hydraulic drifters or rotary heads: - Machine parts which have been put down/mounted incorrectly can fall over/off, causing

injury. - Open and accessible sharp-edged machine parts can cause injury. - Live cable ends and components can cause injury through electric current. - Parts placed loosely on top of each other can slip and fall. - Welding work carries a risk of fire. - Improperly laid cables (e.g. bending radius too small) can cause smouldering and

cable fire - Leaking lubricants, solvents, preservatives, .... can cause cauterization if they come

into direct contact with the skin. - Incorrect screw-tightening torque can cause serious injury to persons and damage to

property. - Faulty pressure pipes and connections can cause serious physical injury.

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2. Mechanical– and hydraulical mounting Mechanical assembly During assembly of the Eurodrill hydraulic drifters / rotary heads the drill mast should preferably be in horizontal position. Lifting tools and fittings must be available acc. to the weight of the components. Tighten all screws with the proper tightening torque(see table next page). Eurodrill hydraulic drifters / rotary heads must ONLY be mounted on Eurodrill mounting plates using the proper original fixing elements. In case other mounting plates will be used this is only possible to comply with the main connecting dimensions and it must be agreed with Eurodrill because correct guiding and clearance have to be guaranteed. It is important to mount all existing fixing- and supporting elements. Eurodrill hydraulic drifters / rotary heads must NOT be connected resistant of deflection with the mounting plate, i.e.: do NOT screw it on and do NOT weld it on. It is mandatory to use a casing guide during assembly of Eurodrill hydraulic drifters / rotary heads. The inner diameter of the casing guide should approx. be 5 mm larger than the diameter of the drill string. Eurodrill hydraulic drifters/rotary heads must be properly aligned to guarantee proper function and to avoid any damage, i.e: the center lines of

hydraulic drifter / rotary head ► drill string ► casing guide

must be properly aligned. Check these center lines during operation and if necessary re-adjust them. Lifting tools and fittings must be available acc. to the weight of the components. Tighten all screws with the proper tightening torque.

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2. Mechanical– and hydraulical mounting Table tightening torques

* Quality identification of screws 6.6, 8.8, 10.9 + 12.9 ** Quality identification of nuts 6, 8, 10 + 12

tightening torque / Nm of metric regular threads tightening torque / Nm of Verbus Ripp screws for

material: cast iron

solidity class solidity class

dimension 8.8* / 8** 10.9* / 10** 12.9* / 12** dimension 10.9*

M 4 2,7 4 4,8 M 12 115

M 5 5,5 8 9,4 M 14 200

M 6 9,4 14 16,5 M 16 300

M 8 23 34 39

M 10 46 68 78

M 12 79 117 135

M 14 126 185 216 tigthening torque / Nm of lock nuts (Securit)

M 16 194 279 333

M 18 270 387 459 solidity class

M 20 387 558 648 dimension 10**

M 22 522 747 873 M 12 x 1,5 88 M 24 666 954 1116 M 14 x 1,5 130

M 27 990 1395 1665 M 16 x 1,5 220

M 30 1350 1890 2250 M 20 x 1,5 440

tigthening torque / Nm of metric fine threads

solidity class tigthening torque / Nm of UNC-threads

dimension 8.8* / 8** 10.9* / 10** 12.9* / 12**

M 8 x 1 24,5 36 43 solidity class

M 10 x 1 52 76 89 dimension 8.8*

M 10 x 1,25 49 72 84 3/8“ - 16 UNC 46

M 12 x 1,25 87 125 150

M 12 x 1,5 83 122 145

M 14 x 1,5 135 200 235

M 16 x 1,5 205 300 360 tigthening torque / Nm of UNF-threads

M 18 x 1,5 310 440 520

M 20 x 1,5 430 620 720 solidity class

M 22 x 1,5 580 820 960 dimension 8.8* 10.9* 12.9*

M 24 x 2 730 1040 1220 1/2“ - 20 UNF 100 150 175 M 27 x 2 1070 1500 1800

M 30 x 2 1490 2120 2480

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2. Mechanical– and hydraulical assembly Hydraulic assembly The hydraulic assembly must be properly done acc. to the hydraulic connecting diagram. All hydraulic hoses of the carrier/drill rig must be laid acc. to the hydraulic connecting diagram. Hydraulic hoses must indicate the following marks: - name of manufacturer - date of manufacture - type/model - nominal width - max. admissable operating pressure Hydraulic hoses must never be tied up and the nominal diameter must be acc. to the specifications of the hydraulic connecting diagram. Due to safety reasons hydraulic hoses must be exchanged every 6 (six) years even if there are not any technical defetcs. It is absolutely forbidden to work with used hydraulic hoses. Prior to the first operation and -at least once a year- an expert has to inspect all hydraulic hoses. All defects have to be removed immediately. In case any additional hydraulic valves are needed they have to be integrated and connected acc. to the hydraulic circuit of the carrier/drill rig. In case Eurodrill drifters are equipped with DRICON a special supply valve has to be provided (see annexe/techncal data TA). It also is necessary to ensure that the pressure line of the percussion mechanism –being disengaged- is connected with the tank without any pressure. This can be achieved by using a hydraulic valve acc. to the hydraulic control symbol shown in the annexe/technical data TA.

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Putting into operation 1.General Safety Instructions Check-ups and safety control prior to putting into operation When putting Eurodrill hydraulic drifters/rotary head into operation, you must observe the following safety instructions in order to avoid lethal injury, damage to the machine and other material damage. The machine may only be put into operation by qualified persons always watching the safety instructions. The following special qualifications are required: - Only authorised persons are allowed to put the machine into operation watching the

safety instructions at all times. - Make sure that no authorised persons remain in the operating area of the machine and

that no one is endangered by putting the machine into operation. - Before starting the machine for the first time, make sure that all tools and foreign parts

have been removed from the machine. - Before putting the machine into operation, activate all safety devices and emergency

stop switches. - Make sure that allpersonnel is wearing the protective outfit. - Before putting into operation check the direction of the motor of the drifter/rotary head. - Before putting into operation check the function of the percussion mechanism of the

Eurodrill drifters. - Prior to start the drifter/rotary head check the lubrification (see technical data in the

annexe: TA) - Before starting the machine for the first time, check all technical special devices (see

description). - Before starting operation check the tight seat of all screw connections. - Before starting operation check all hose connections on tightness and leakage. - Read the chapter "General safety instructions". - Furthermore the instructions of the rig manufacturer prevail.

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2. Special instructions of putting into operation Operating temperature Eurodrill hydraulic drifters / rotary heads may only be put into operation -after careful warm up- when the hydraulic oil in the operating circuit of the carrier/drill rig has reached its operating temperature. You have to take special care of this during winter and operating with the machine in cold areas. In case you do not watch this instruction sealing elements in the Eurodrill hydraulic drifters or rotary heads might get defective or completely damaged. Furthermore if you do NOT follow these instructions immediate loss of warranty will be caused. Testing the functions Test the functions of rotary mechanism and percusison mechanism by enganging the corresponding valves of the carrier/drill rig for a short time. The percussion mechanism should never be operated longer than 20 %/min due to hazardous empty blows. These blows could be absorbed by the damping device but this device is only provided for working in intermittend operation (see description). All other sepcial designs like DRICON, KHVE (hydraulic piston stroke adjustment), switchable gear stages can be tested and controlled by the mandatory control valves of the drill rig acc. to the hydraulic connecting diagram. Drilling accessory Installing flushing heads or similar drilling accessory to the shank adptor (striker bar) it is necessary to take care that the components are free of grease and oil. This prevents that the thread connection might get loose during breaking the drill pipes. It mostly is difficult to handle drill string components and there is always a high risk of getting hurt due to their heavy weight, their size and form.

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3. Summary for putting into operation

Checking Putting into operation

first time Daily weekly Devices/instructions of preventing accidents

● ●

Checking the visibility ● ● Fixing elements ● ● Fixing screws ● ● Hydraulic hoses ● ● Supply of lubricants ● ● Alignment of drill string ● ● Rotating direction of gear ● Function of percussion mechanism

●

Switchable gear stages ● Hydraulic piston stroke adjustment (KHVE)

●

DRICON ● Repeated putting into operation After larger repairs and modifications at the drill rig or at Eurodrill hydraulic drifters / rotary heads do all check-ups as listed before due to safety reasons and to avoid damages.

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Operation 1. General safety instructions To avoid damages at the rig/drifter/rotary head or dangerous injuries during operatiion you have to watch the following points: - Eurodrill hydraulic drifters/rotary heads must ONLY be used acc. to their proper

application as directed. - Before turning on the Eurodrill hydraulic drifters/rotary heads you first have to be

thoroughly informed how to react when trouble/failure occurs. - Before turning on the Eurodrill hydraulic drifters/rotary heads check all functions at the

device for instructions of preventing accidents. - In case the rig/drifter/rotary is not used acc. to its proper purpose as directed people

can badly and dangerously be injured and the equipment can get damaged. - Dangerous injuries happen by not taking care of and being negligent of the personal

protective outfit (boots, glasses, helmet, etc.). - False reaction during failure/trouble causes severe personal injuries. - Watch carefully all instructions of the operating manual when you work at the

rig/drifter/rotary head. - Eurodrill hydraulic drifters / rotary heads must only be used at the places of work as

directed. - After an emergency stop the carrier/drill rig and the Eurodrill hydraulic drifter/rotary

head must be secured against turning on again by unauthorised third people. - Also read the chapter: “General safety instructions“.

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2. Operating elements and drilling progress Places of work of the operating personnel Read carefully all instructions of the carrier/drill rig about the places of work for the operating personnel. Additional operating elements have to be installed acc. to the instructions as directed. Additional operating elements The following operating elements for controlling the Eurodrill hydraulic drifters/rotary heads have to be added in case they have not been installed at the carrier/rig. These are the standard control valves used by Eurodrill. In case other control valves are used they have to be in accordance with the hydraulic connecting diagram. Working disorder or even considerable damages are caused in case of not watching this warning!

technical devices part number

Hydraulic piston stroke adjustment

609997

Hydraulic switch-over in series / parallel

400616

Hydraulic switch-over DRICON

615952

Hydraulic switch-over motor type: D

615952

Hydraulic switch-over 2-stage motor

400616

Operation and drilling progress To achieve an optimal drilling progress in using Eurodrill hydraulic drifters/rotary heads it is very important to adjust them acc. to the hydr. connecting diagram with the hydraulic circuit of the carrier/drill rig. It is very important to watch carefully all hydraulic devices and their controls (please see the techncial data (TA) in the annexe)

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2. Operating elements and drilling progress Influences on the drilling progress The right choice of the drill rig and the drilling method considerably influences the drilling progress. Please note the following listing where different influences are described but this is only a recommended selection and not a complete listing: - carrier/drill rig - geology/soil formations - drilling method - drilling equipment - cutting geometry of the drill bits - flushing - push-down forces

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3. Important instructions of operation Drilling with mast directed upwards (over head) While drilling with the mast directed upwards (angle > 90° to the vertical) and the use of water flushing, dirt can get into the driving unit by rinse water what pours down the drill string what will cause severe damage. While drilling with hydraulic drifters / rotary heads which have the gear box oil lubricated, gear oil can escape via the filter/breather when the mast is directed upwards. This can cause an insufficient lubrication and severe damage as a result. In such case it is required to contact Eurodrill for coordination of accordant arrangements. In case you do not follow these instructions you will cause severe damage resulting in immediate loss of warranty. Drilling with DTH While drilling with DTH (down-the-hole-hammer) it is mandatory that the driving unit or better its bearing system will not be damaged by the backlashes of the DTH hammer. This can be ensured by using an additional device such as a Shock Absorber or a Floating Spindle. In case you do not follow these instructions you will cause severe damage resulting in immediate loss of warranty.

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3. Important instructions of operation DRICON To achieve a high life time and also high performance when working with DRICON it is absolutely necessary to read all issues about DRICON very carefully in the following chapters: • hydraulic connecting diagram -product description - fuels change over of the motors with DRICON must ONLY be done when the drifter/rotary is in full stop or without any load. To avoid severe damages you must absolutely note the instructions in chapter „product description“. In case you do not follow these instructions you will cause severe damage resulting in immediate loss of warranty. Hydraulically switchable gear stages When working with Eurodrill products what are equipped with hydraulically switchable gear stages you have absolutely to note that switching must ONLY be done at complete stop of the drifter/rotary head. Also the following chapters have to be followed: - hydraulic connecting diagram - product description In case you do not follow these instructions you will cause severe damage resulting in immediate loss of warranty.

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TROUBLE SHOOTING 1. General safety instructions You have to follow the points as listed below to avoid severe damages at Eurodrill hydraulic drifters/rotary heads and also to avoid severe personal injuries: - ONLY qualified persons are permitted to eleminate faults and malfunctions. - First of all you have to secure the carrier/drill rig and the Eurodrill hydraulic drifters /

rotary heads that no one re-starts the rig/drifter/rotary head unintentially. - Be sure -at all times- that the safety stop of the drill rig and the drifters/rotary head is

guaranteed by a second person. - Secure the operating area of all moving parts of the drill rig and the drifter/rotary head. - Also read very carefully the chapter: „general safety instructions“.

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2. Trouble shooting and eliminating faults

Rotary head doesn’t work at all or only at reduced power

Possible reason Remedy Performerr

Carrier/drill rig doesn’t achieve the indicated driving power

Check motor speed / if necessary increase speed

Qualified person Service engineer Eurodrill service man

Unsufficient pump power of drill rig Check pumps or increase adjustment/renew


Wrong integration in hydr. circuit of drill rig

Check hydr. integration (hydraulic diagram)


DRICON doesn’t transfer any and too little power

Check hydr. control (hydraulic diagram)

Qualified person Eurodrill service man

Hydr. switchable gear stages can’t be switched

Check hydr. control (hydraulic diagram)


Reduced torque of rotary head Check oil leakage of hydr. motors/if nec. exchange


Unsufficient drilling progress

Possible reason remedy Performer

Unsufficient flushing Check flushing (media, pressure, volume etc.)

Qualified person Operating personnel

Unsufficinet feed at the drill mast (risk of damage by empty blows) Correct the feed Qualified person

Operating personnel

Drill string components aren’t aligned with drifter/rotary head

New aligning of all components

Qualified person Operating personnel

Drilling equipment is not suitable for the application

Be sure that equipment is suitable for application

Qualified person Expert

Different direction of drill hole Adjust the casing guide Qualified person Operating personnel

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3. Severe trouble or damages General instructions Severe trouble / damages at Eurodrill hydraulic drifters / rotary heads must only be repaired by qualified personnel or in suitable repair shops. Severe trouble or damages In case Eurodrill hydraulic drifters / rotary heads have to be dismantled or major parts have to be exchanged this has to be considered as severe trouble or damage: - breakage of pistons - destroyed anti-friction bearings - destroyed gear wheels - stuck pistons - renewal of complete seal kits - exchange or work at accumulators Qualified personnel To guarantee the original function of Eurodrill hydraulic drifters / rotary heads it is absolutely necessary that only qualified persons do these works: - Eurodrill service men - Experts trained by Eurodrill - Service men of the carrier/rig manufacturer trained by Eurodrill Appropriate work shops To guarantee the original function of Eurodrill hydraulic drifters / rotary heads after repair works or maintence works oder dismantling larger works repairs should only done in appropriate work shops being very clean and supplying necessary technical equipment, tools (lifting tools, machines, correct tools, etc.).

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Maintenance, servicing and repair 1. General saftey instructions To avoid damages at the equipment or personal injuries during maintaining the Eurodrill hydraulic drifters / rotary heads it is mandatory to follow the points as listed below: - First you have to secure the area before starting maintenance/servicing. - Only qualified personnel is allowed to do the works at the hydraulic equipments of the

machine. - Turn off all all pressure units so that they are out of any pressure. - Only use the indicated materials as directed. - Only use original Eurodrill spare parts listed in Eurodrill spare parts lists. - Only qualified personnel is allowed to do the cleaning-, lubricating-, servicing- and

repair works. - Strictly follow all screw tightening torques - Strictly take care to ensure that all material, lubricants and auxiliary material will be

disposed acc. to environmental rules and regulations. - Also read very carefully the chapter: „General safety instructions“.

33

2. Material and fuel, gas and oils Hydraulic valves The needed hydraulic valves for the control of the technical devices (DRICON, hydraulic piston stroke adjustment, etc.) have to be acc. to the connecting diagram. Hydraulic hoses All hydraulic hoses needed for the integration of the Eurodrill hydraulic drifters / rotary heads into the hyraulic circuit of the carrier/drill rig have to be acc. to the hydraulic connecting diagram and have to be maintenained acc. to the instructions. Oil filter To avoid damages at Eurodrill hydraulic drifters / rotary heads the user has to guarantee an oil quality acc. to cleanlines requirement ISO 4406 18/13. This can be achieved – under regular circumstances – with a p-line filter of 15 µm. Gear oil You absolutely have to note that you choose the correct lubricants acc. to the indicated instructions as directed. In case you do not follow these instructions you will cause severe damage resulting in immediate loss of warranty (filling volume please see lubricating diagram). Eurodrill hydraulic drifters / rotary heads are originally filled with gear oil of the class as listed below:

SAE 80W 90 In case Eurodrill hydraulic drifters / rotary heads are used under extreme conditions, e.g.: at hot/cold temperatures it might be required to use a different gear oil. Using a different gear oil must be agreed in writing with Eurodrill.

34

2. Material and fuel, gas, oil Hydraulic oil To guarantee the function of Eurodrill hydraulic drifters / rotary heads it is absolutely required to use appropriate hydraulic oil. Eurodrill recommend mineral oil with a guaranteed viscosity of 20-43 cSt regarded as a regular and typical operating temperature of the carrier/drill rig. Other brands of hydraulic oils – same as synthetic oils and mineral oils with VI - improved or with a special additive (EP) – may only be used after written agreement with Eurodrill. In case you do not follow these instructions you will cause severe damage resulting in immediate loss of warranty. Lubricants To increase the life time of the mainly stressed parts of the Eurodrill hydraulic drifters / rotary heads (like there are: shank adaptors, bushing, liners, flushing heads, etc.) it is mandatory to lubricate these parts acc. to the intervals indicated in the lubricating diagram Due to our experience Eurodrill use a lubricant made by the company Fuchs Lubritech during fitting and initial lubricating of hydraulic drifters/rotary heads. Furthermore we can also recommend the alternative lubricant made by the company: Klüber. Adresses of the companies are Listed in chapter additional info. In case other lubricants will be used by you it causes loss of warranty if you don’t have Eurodrill’s agreement in writing. Gas It is only allowed to use nitrogen (N) with purity class 99.8% when charging the accumulators (see accumulator). There is the risk of explosion and it is absolutely not permitted to use gases other than directed.

producer product Fuchs Lubritech Lagermeister TS

KLÜBER Lubrication Lubrication

Microlube GL 261 / GL 262

35

3. Servicing and repair instructions Maintenance of the flushing head The lifetime of the seals in the flushing head is much longer when you exactly follow the instructions of the lubrification plan (lubrification is mandatory at least once a week). When you lubrify the point of lubrification in the front please take care that the opposite plug is turned out so the remaining oil can get out; otherwise the pressure in the flushing head will build up, and this damages the seals. Don’t forget to screw the plug back in. In case there is no plug on the opposite side, you have to turn out the grease nipple and after the remaining oil is let out, turn the plug back in again. You have the change the seals immediately when fluid is getting out of the control boring to avoid more damage in the flushing head.

front point of lubrification

plug control boring

36

3. Servicing and repair instructions Seals All seals used in Eurodrill products may ONLY be exchanged if really necessary, i.e.: when leaks are discovered and an exchange will become necessary Eurodrill recommend to exchange the complete seal kit of the component (gear, percussion mechanism, flushing head, etc.). It is mandatory during exchange of the seals to take care of having an extreme clean area and to follow the instructions of installing the seals. In case you do not follow these instructions you will cause severe damage resulting in immediate loss of warranty. Breathers Prior to operation always inspect, clean and/or exchange all breathers installed at Eurodrill drifters and heads. A flawless function has to be guaranteed. Oil filter Prior to the first operation you have to check, to clean and if necessary to exchange all oil filters of the carrier/drill rig what are in the hydraulic circuit of the Eurodrill hydraulic drifters/rotary heads. After putting into operation the oil filters have to be serviced acc. to the table as listed below: Furthermore you always have to follow the instructions/indications of the rig manufacturer. In case you do not follow these instructions you will cause severe damage resulting in immediate loss of warranty.

Operating hours (h) Oil filter control 50 1.

500 2. After that every 500 hrs / 4 times a year (at least)

37

3. Instructions for servicing and repair Hydraulic oil change Prior to the first putting into operation of the Eurodrill hydraulic drifters / rotary heads you must be absolutely sure that the hydraulic oil in the carrier/drill rig is free of any pollution or dirt and is acc. to its required quality. If this is not the case you have to change the hydraulic oil. In case you do not follow these instructions you will cause severe damage resulting in immediate loss of warranty. All other information about hydraulic oil changes are shown in the instructions of the rig manufacturer. Gear oil change and check up To keep wear and tear at gear parts as low as possible it is required to change the gear oil acc. to the intervals as listed below: When working in ranges of high speed and load the gear oil has a higher wear-out and the result is that the oil change intervals have to be adjusted to this special stressing and condition. You have to specify the oil class by taking an oil probe. You can take this oil probe -while the rotary head is running- at the provided screw (6L). You also can find out about the function of the central lubrication pump (position please see the lubricating diagram). In case the lubrication pump does not supply any oil you then have to check if the rotary head is filled with enough oil. You have to carefully open one of the oil-drain plugs – which has a red mark- and check the oil level. In case there is enough oil one of the lines of the lubrication circuit might possibly be clogged up or the central lubrication pump is defective. In case you do not follow these instructions you will cause severe damage resulting in immediate loss of warranty.

Operating hours (h) Oil change 500 1.

1500 2. After that every 1000 hrs/once a year (at least)

38

3. Instructions for servicing and repair Lubricating with grease Lubricating Eurodrill hydraulic drifters / rotary heads has to be done acc. to the lubricating plan (see technical data in the annexe). It is mandatory to follow these intervals carefully, this reduces wear and tear and increases the life time of the components what are used under extreme stressing. In case you do not follow these instructions you will cause severe damage resulting in immediate loss of warranty. 4. Spare parts depot 4. Eurodrill recommend a stock of spare parts at the job site to guarantee that Eurodrill hydraulic drifters / rotary heads work properly. We only guarantee the original spare parts provided and supplied by Eurodrill. Installing and/or using products not checked by Eurodrill can cause negative impairment at Eurodrill hydraulic drifters / rotary heads and the safety can also be impaired. Any liability and warranty is excluded by Eurodrill GmbH in case a damage/defefect is caused by using non-original spare parts and accessory. The use of lubricants as directed and following the instructions for exchange at intervals as directed is also subject of the warranty clause. Any illegal operation at Eurodrill hydraulic drifters / rotary heads during the time of warranty other than maintenance work the warranty immediately expires. Use the spare parts lists and spare part drawings for your orders of spare parts – as mentioned in the Technical Annexe (TA). Ordering spare parts please advise as follows: - type of hydraulic drifter see plate - type of hydraulic rotary head see plate - serial number see plate - number of spare part see Technical Annexe (TA) 5. Customer Service In ase you need a Eurodrill service man please inform us: Phone no.: ++49 – 2763 – 21228-0 Fax no.: ++49 – 2763 – 21228-22 e-mail: [email protected]

39

Placing out of operation 1. General safety instructions When Eurodrill hydraulic drifters / rotary heads are placed out of operation you have to follow the safety instructions as listed below to avoid severe personal injuries and damages at the equipment as well as environmental damages. - Only experts and trained personnel are allowed to place the Eurodrill hydraulic drifters /

rotary heads out of operation. - Watch out for disposing materials, fuel, gas, oils, lubricants and auxiliary material acc.

to environmental protective instructions. - Eurodrill hydraulic drifters / rotary heads may only be lifted at the lifting points

especially marked and provided for. - When lifting Eurodrill hydraulic drifters / rotary heads ONLY use suitable lifting devices

and lifting lugs/points. - Always consider the grand total weight when choosing the suitable lifting devices. - See also the chapter: „transport“. - See also the chapter“ general safety instructions“.

40

2. Temporary - and final placing out of operation Instructions für placing out of operation Watch the following points – as listed below- when placing the Eurodrill hydraulic drifters / rotary heads out of operation: - Place the drill mast in a suitable position and secure it. - Turn the carrier/drill rig off and secure it so nobody can turn it on coincidentally. - Make sure that the hydraulic circuit is pressureless. - Disconnect the hydraulic drifter/rotary head from the hydraulic circuit of the carrier/drill

rig. - Untie all fixing elements. - Lift the hydraulic drifter/rotary head only with the proper and suitable lifting devices. - You also have to follow the instructions of placing out of operation by the rig

manufacturer. Temporary placing out of operation In case Eurodrill hydraulic drifters / rotary heads have to be placed out of operation, e.g. for maintenance/service or repairs you again have to carefully follow the instructions of putting the machine into operation. Final placing out of operation / disposal In case Eurodrill hydraulic drifters / rotary heads are placed out of operation after their life time is expired all material, auxiliary material, machine parts have to be properly disposed by the user/operator acc. to environmental rules and regulations.

41

Additional Information 1. Suppliers for lubricants/grease Producers of used lubricants/grease used by Eurodrill Fuchs Lubritech Hans - Reiner - Straße 7-13 D - 67685 Weilerbach Tel.: 0049 (0) 6374 / 924 - 5 Fax.: 0049 (0) 6374 / 924 - 940 Suppliers for alternative lubricants/grease: Klüber Lubrication München KG Geisenhausenerstraße 7 81379 München / Germany Tel.: 0049 (0) 089 / 7876 - 0 Fax.: 0049 (0) 089 / 7876333 http:\\www.klueber.com Please ask at the main office of the company Klüber Lubrication KG for representatives and subsidiaries.

42

Technical Annexe - Technical Data - Main dimensions / main components - Hydraulic integration - Drawing of spare parts of complete assembly - Spare parts list of complete assembly - Drawing of spare parts of rotary mechanism - Spare parts list of rotary mechanism - Drawing of spare parts of flushing head - Spare parts list of flushing head - Drawing of spare parts of coupling - Spare parts list of coupling

- Lubricating plan

Technical Data – RH 900 Rotary mechanism

Motor type: 96 Gear 1 Gear 2

Oil capacity QS (l/min) 150 150

Operating pressure pa (bar) 200 200

Rpm n (min-1) 69 138

Torque M (daNm) 690 345

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Spare Part No. Quantity

1 710429 1 Grundgetriebe RH900 kpl Basic gear rh900

2 596725 2 Hydraulikmotor Hydraulic motor

3 734518 1 Mitnehmerflansch Flange

4 399754 8 Zyl. Schraube mit I-6-kant M16x050 Hex.socket head cap screw m16x050

5 735715 1 Spülrohr Flushing tube

6 735430 1 Verdrehsicherung Torsion safety

7 99929 2 Sechskantschraube Hexagonal bolt

8 623544 1 Rohrbogen Bend

9 530161 2 O-RING O-ring

10 692367 1 Anschlussflansch Flange

11 222389 2 O-Ring O-ring

12 227586 8 Sechskantschraube Hexagonal bolt / din 933-m10*030, a3c

13 537788 1 Spülkopf Swivel

14 540539 1 Kupplung Coupling

Ersatzteilliste / Spare Part List

Pos. Beschreibung Description

Artikelnummer Menge


1 539239 1 Getriebegehäuse Casing

2 539680 2 Antriebsritzel Pinion

3 532790 2 Nadellager Bearing

4 399952 6 Sechskantschraube Screw

5 464619 8 Sicherungsschraube Screw


7 20501 2 Sicherungsring Snap ring

8 240619 9 Verschlussschraube Screw

9 244774 1 O-Ring O-ring 280/3

10 530223 2 O-RING O-ring

11 696815 1 Wellenscheibe Shaft washer

12 12471 1 Axial-Zylinderrollenkranz Crane

13 696816 1 Gehaeusescheibe bearbeitet Disk/washer

14 692412 1 Abtriebswelle Shaft

15 692413 1 Zahnrad Gear wheel

16 632025 1 Axial Zylinderrollenlager Axial rollers


18 692364 1 Gehaeuseflansch vorne Flange

19 637289 1 Kassetten Dichtring Ring

20 692363 1 Halteblech Sheet


22 389070 1 V-Ring V-ring


24 80527 1 Sprengring Snap ring

25 600506 1 O-Ring O-ring 192/3

26 89550 1 O-Ring O-ring 13/2

27 692365 1 Gehaeuseflansch hinten Flange


29 614880 1 Kassetten Dichtring Ring

30 692366 1 Halteblech hinten Sheet

31 636905 1 V-Ring V-ring

32 20993 1 Flachdichtring Flat seal ring

33 617367 1 Ölstandschauglas Oil control window

34 616223 1 Entlüftungsventil Valve



37 244766 1 Flachdichtring Flat seal ring

38 802866 2 Scheibe Disk/washer



Artikelnummer Menge


1 538983 1 Spülkopfgehäuse Casing

2 538662 1 Gehäusedeckel Cover

3 539997 1 Spülwelle Shaft

4 538196 1 Distanzring Ring

5 540730 1 Halteblech Sheet

6 20871 2 Kegelschmiernippel Nipple




10 22080 1 Sicherungsring Snap ring

11 532717 2 Rillenkugellager Bearing

12 402112 1 O-Ring O-ring 59/2,5

13 28949 1 Wellendichtring Shaft seal ring

14 615742 1 V-Seal V-ring

15 530625 3 Nutring Notch ring

16 530198 1 O-RING O-ring 90/2




Artikelnummer Menge


1 569627 1 Gehäuse Housing

2 569626 8 Buchse für Kupplung Typ VC / VCV Bushing for coupling type vc / vcv

3 540467 1 Mitnehmerflansch Flange

4 569625 1 Scheibe Disk

5 570670 2 Dämpfungsscheibe Damping washer

6 31114 8 Sechskantschraube Screw


8 530602 1 Nutring Ring




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