GTR790 rig Operators Manual

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Dynamic Probing / Window Sampling Rig
with folding mast on rubber chain crawler

GTR790/RHB






































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GTR790 rig Operators Manual
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0. General, Handbook


- Handbook:
Make sure a copy of the GTR 790 Instruction and Maintenance Manual
is always accessible to the operator in case of need.

- Limitation of Liability:
GEOTOOL as the manufacturer declines all responsability for damage to
things and persons resulting from the incorrect use of the machine.

- Limitation of use:
The operation of the GTR 790 RHB rig is strictly limited to dynamic
probing, (window) sampling, and core drilling operations; any other use of
this machine can be very dangerous and is forbidden. Furthermore in this
case any guarantee claim will be rejected.

- Trained personnel:
The GTR 790 RHB rig may only be operated by trained and capable
trained expert operators.
These shall be familiar with the GTR 790 Instruction and Maintenance
Manual in accordance with machine driving licenses or other licenses
issued in conformity with the laws of the country in which the machine is
entrusted to the operator.
The manufacturers customer, the owner, the leasing purchaser, the hirer,
the driver, or any other rightfully entitled party, without restrictions or
exclusions, having the right to use the machine shall be obliged to
ascertain beforehand on his own account and responsability that the
operator is in possession of the qualifications indicated.

- Maintenance:
Before taking the machine in operation the operator shall be obliged to
make sure that all maintenance procedures have been performed in
conformity with the provisions of the manufacturers instruction manual
and that these have been noted on a suitable maintenance sheet.
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- O.E.M. component instructions:
For any components like Diesel engine, hydraulic rubber chain crawler
carriages, winches etc. the relevant manufacturers operation manual(s)
form integral parts of this manual. To operate the GTR 790 RHB it is
mandatory to read beforehand and follow
the instructions given therein!




1. Introduction to the machine and its control elements

The GTR 790 is designed for dynamic probing, window sampling and light rotary drilling
operations.

It is mounted on a rubber-chain crawler carrier. Its main components include a petrol or Diesel
engine, the hydraulic system with pumps, tank, control valves, steel frame and mast
assembly.

The unit is equipped with a chain driven drop weight hammer system for dynamic probing
operations following DIN, SPT or AFNOR standards with drop weights of 10/30/50/63,5 kg or
23/64/96/128 kg and drop heights of 500 and 750 mm.

Optionally hydraulic breakers, rotary drives, diamond coring devices, manual/hydraulic/electric
winches with mast pulley head and tool change beam can be employed.

Extraction of rods, samplers etc. is carried out by means of hollow hydraulic cylinders (jacks)
in conjunction with tapered wedge clamps (slips) or ball clamps..


All functions of the rig are controlled from two control consoles:

- One at the rear of the rig for engine and tracking features
- One on the front lefthand side of the rig for mast and rig positioning as well as for
sounding and drilling operations
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2. General Safety Instructions

- Changes:
Any changes to the rig and especially its hydraulic system i.e.
changes of the settings of the overload valves can be very dangerous and
is forbidden. Furthermore in this case any guarantee claim will be
rejected.

- Exhaust gases:
Due to the exhaust gases it is strictly forbidden to operate this machine in
enclosed rooms or without effective ventilation !

- Riding on the rig:
Due to the risks involved it is strictly forbidden to use the GTR 790 RHB
as a personnel carrier. Sitting or riding on the unit is dangerous !
Rigs originally delivered by GEOTOOL with a riding platform at the rear
end may be used by one person during tracking.

- Hydraulic leakage:
If a hydraulic leakage or failure is noticed stop the engine immediately.
Take up any oil spilling and dispose of properly.
CAREFUL: oil contaminates soil and water!

- Lighting:
When moving or operating the machine make sure that proper lighting is
provided at all times!

- Fire:
In case of fire: The machine and its accessories do not have contra-
indications with regard to fire fighting equipment of any type.

- Hydraulic fluid hazards:
In case of being drenched by oil or hydraulic fluid under pressure seek
medical attention immediately.

- Underground use:
The use of this machine for underground work is forbidden.




3. Protective Clothing, Personal Positioning,
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Safety Awareness,

- Protective clothing:
The operator and anyone having access to the work area of the machine
shall be obliged to wear suitable accident-prevention clothing: protective
helmet, work gloves, safety footwear, ear plugs, tight clothing that does
not risk becoming trapped in moving parts.

- Emergency STOP switch:
Before each work shift check emergency devices for proper operation.


- Safety Distance:
During movement the operator is to keep a safe distance of min. 300 mm
away from the machine to prevent feet being crushed by the tracks.
No other person is allowed near the machine while moving.

- Second Person:
When the need for a second person exists to work inside the work or
hazard area of the machine this must be carried out as follows:

Two people must always be present both of whom authorized, trained and
instructed to safety procedures in a way that one monitors from his
position the safety of the other who is carrying out the task.
The main operator must have immediate access to the emergency
devices.
The work area must be suitably lit.
Communication between the two must be established in a reliable way.




4. Personal Awareness when starting the machine


- Emergency devices:
Before each work shift check emergency devices for proper operation.

- Work area:
Never stand or allow some other person to stand in the work area.

- Access:
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Before starting the probing or drilling operation mark prohibited access
areas around the machine with suitable forbidden access notes.

- Safe distance:
The operation of mast positioning, mast pull-push, drop weight system,
hydraulic winch, and rotary drilling head is forbidden when anyone is close
to the unit.





5. Pre-Start Checking, Start-up


Before starting the GTR 790 unit carefully check the following parts and components for
correct setting and remediate any possible damage:

- Check hydraulic fluid level in oil reservoir centrally mounted in the
rig frame. With all hydraulic cylinders fully retracted the oil level
should be visible on top of the screening under the chrome filler
cap on top of the tank. If necessary, remove the wooden table
plate above the reservoir to have better access.

- Check the hydraulic system as well as the petrol or Diesel fuel
tank and motor sump of the engine for any leakages.

- Check engine oil level according to the relevant manufacturers specifications as laid
out in the handbook.

- Check tightness of all screws on the drop weight carriage, rotary drivehead, breaker
carriage or diamond coring device

- Check screw fastenings and bolt connections (for the rig and all the ancillary
components, if applicable).

- Check safety fork and/or pin(s) for condition and availability.

- Check the lubrication and maintenance condition in
accordance with item 11.

- Use hard hat, gloves and earplugs for the personal protection
of everybody close to the workplace.
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START THE ENGINE:

IMPORTANT:
With the engine running the hydraulic system is
under working pressure. Therefor make sure that all
control valve levers are in neutral to avoid
unexpected moves.






IMPORTANT! At any irregularity occuring the hydraulic system has to be set to neutral and
the engine stopped by activating the EMERGENCY STOP BUTTON or the relevant engine
stop switch/ignition key.



Now start the engine according to the manufacturers instructions and let it run on 1/3 throttle.

To stop the engine turn the ignition key counter clockwise to the 0 position.

IMPORTANT: Never shut off the main battery switch when the engine is still running.
This will severely damage the battery charging system!



6. Control Functions, Hands-On by trainees



HYDRAULIC VALVE FUNCTIONS ON CONTROL CONSOLE
(LH side of the rig; from right to left):
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Valve 1 erect/lower mast
Valve 2 adjust mast vertically
Valve 3 hydraulic rod
extraction cylinder
(autoreverse function)
Valve 4 mast chain / drop
weight mechanism
Valve 5 optional, for hydraulic
breaker, rotary drives




HYDRAULIC VALVE FUNCTIONS ON
TRACKING CONSOLE
(at the rear of the rig):

Valve 6 rubber chain crawler, LH side

Valve 7 rubber chain crawler, RH side







7. Transport of Machine, Strapping

- Loading:
When loading the machine onto the vehicle never exceed the
maximum gradient indicated by the manufacturer by using suitable ramp-type
chutes.
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- Strapping:
During transport on or in a vehicle stabilize the machine by using adequate
means of retention in order to prevent it from moving and jeopardizing the
stability of the vehicle whilst moving.

- Mast:
Never move the machine with the mast in vertical position and/or with the drop
weight carriages moved up on the mast.

- Gradients:
Never move the machine over terrain exceeding the maximum gradients
indicated by the manufacturer: 25 degrees to the front and to the rear, 15
degrees laterally

WARNING: If the machine is parked on an incline place suitable wedges behind the tracks
for extra safety.


8. Positioning of Machine, Gradients of operation

Start the engine according to the manufacturers instructions and let it run on 1/2 throttle.

To gain necessary ground clearance for the mast foot lift the mast structure by using control
valve 2.

Take into consideration that the center of gravity is higher and apply the neccessary caution
while negotiating inclines.

The drop weight carriage is to be in the bottom position during tracking at all times.


To move the rig stand behind the control bar at the rear end and apply gentle pressure onto
the two control levers into the desired direction.

If necessary, open the throttle for higher speeds and use the tortoise/hare valve where
applicable.

To stop the machine quickly just let the levers go.

RECOMMENDATION:
in difficult situations or curves: medium throttle and little control valve opening
straight course on even surface: full throttle, full valve opening

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To bring the machine to a standstill reduce engine speed by the throttle lever first.



EMERGENCY STOP: Let go levers and take hands off the
controls: The rig stops immediately and
the brakes apply.


CURVES:

Right hand side: use left hand control valve for LH side crawler
Left hand side: use right hand control valve for RH side crawler


CAUTION: Avoid curves at high speed due to sudden lateral moves of the chassis.








CAUTION!

No persons are allowed on the rig while driving
except for one person on the riding platform at the
rear end of the unit (when supplied by
GEOTOOL).

IMPORTANT! Especially when moving
backwards or in narrow walkways make always
sure that nobody is under risk getting caught
between the unit and walls or other obstacles !

IMPORTANT! Always make sure the way
you want to go is clear of any obstacles and the
inclination does not exceed safe levels !

WARNING: Never move the machine with the mast in vertical position and/or with the drop
weight carriages moved up on the mast.

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WARNING: Never move the machine over terrain exceeding the maximum gradients
indicated by the manufacturer: 25 degrees to the front and to the rear, 15
degrees laterally

WARNING: If the machine is parked on an incline place suitable wedges behind the tracks
for extra safety.



A towing attachment is mounted to the back end of the machine to pull a small size accesory
trailer (max. weight 400 kg).

WARNING ! During tracking with a trailer attached beware of sharp turns! Serious injuries or
damage to the machine or the trailer can occur if the angle between the
machines back end and parts of the trailer exceeds 90 degrees!




5.1 Move the rig to the borehole location as described under 4.





WARNING: Before erecting the mast make sure no obstacles or persons are in the range of
action of the machine. During mast positioning carefully check that there are no
obstacles in the way of the hydraulic hoses and that these
are not damaged.
When lowering the mast to its transport position
make sure the winch does not collide with the engine
housing.



Erect upper part of mast as follows:
Mast type With engine throttle set to approx 1/3 bring
bottom mast section forward by using valve 1 until it
reaches a forward angle of about 25 degrees to vertical.
This facilitates the erection of the top mast section. If
ground clearance for the mast foot is not sufficient bring up
mast by using valve 3. Remove R-clip and securing
bolt at the back of the mast folding bracket.
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Bring top mast section forward and upward until mast is straight
(look for the wing nuts swivels not to interfere). CAREFUL: Do not try to
erect the top mast section from the front of the rig; stand to one side
of the unit and bring the mast top in the required position. Keep your
hands clear of the joint to avoid being caught and possibly injured
during this procedure!
Now apply the two winged nuts and secure the connection safely.


Check mast chain tension for proper drop weight operation.
To bring the mast into the vertical position set it up longitudinally first by using valves 1 and
2. Use valve 2 to lift the front end of the rig for about 2/50 mm depending on the floor
conditions to ensure proper standing during operation.










Set up the rig at the borehole location. Use a
wooden plank or timber to support the mast foot if
ground conditions do not provide enough stability
to ensure proper standing. If set up correctly the
rig reaches a stable three-point suspension
provided by the mast foot and the two crawler
back ends.

During drilling and probing operations the mast
foot must rest firmly on the ground to give the
machine a stable operation position.





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WARNING: Never set up the machine exceeding the maximum gradients
15 degrees to the front and to the rear, 10 degrees laterally



By means of the spindle ratchet on the front LH side of the
rig the lateral adjustment of the mast is achieved whereas
the water level indicator on the mast assists to find the
final upright position.






5.8.1 After reaching a stable and safe position of the rig you may now commence to
start dynamic probing or window sampling operation. Firstly, place the reinforced
wooden base plate for later rod extraction close to the front of the mast in a way
that the rods or samplers can be guided straight through the hole (For rod
extraction please refer to item 5.9).






9. Preparation of Machine for various drilling modes

Tool change


WARNING: When lifting loads with the winch make sure the load beam is attached
correctly and the load does not exceed the max. winch capacity.

Never unwind the total length of winch rope. Always leave at least three turns of
rope on the winch drum. Never use any other part of the machine like mast or
drop weight carriage for lifting purposes.




10. Operating in various drilling modes

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Start



After reaching a stable and safe position of the rig you may now commence to start
dynamic probing or window sampling operation. Firstly, place the reinforced wooden base
plate for later rod extraction close to the front of the mast in a way that the rods or samplers
can be guided straight through the hole (For rod extraction please refer to item 6.).

To bring up the drop weight carriage insert key bolt
fully through the covered hole in the safety basket and
the two brackets at the connection rods. Secure key bolt
in this position by using the R clip.



Lift drop weight carriage to the
top of the mast with valve 4 and
secure it by using the safety fork
with R-clip to prevent weight frame to come down.

Open rod guide at the front bottom of the mast and insert probing rod
with point (or window sampling tube), apply brass cap and lower drop
weight mechanism halfway onto the rod after removing safety fork with
R-clip by using valve 4 (After some time it might be necessary to lift up the drop weight
carriage before pulling the safety fork since the drop weight sits on it). The brass cap is fully
taken up by the anvil.

Close rod guide at the front bottom of the mast (use proper guiding elements to fit the rod
or sampler diameter), adjust rod fully parallel to the mast and lower drop weight carriage
completely.




At this moment recheck the vertical position of the mast and readjust if necessary. Reset
the blow counter to 0 by pushing the button (if applicable).

IMPORTANT! Before commencing operation make sure that the rig is set up in a stable
position, the rod with its brass piece is fully taken up by the anvil, no persons are close to the
operating machine and the rig is kept under severe supervision at all times.

Increase engine speed by using the throttle lever to speed and use valve 4 to set the
chain in upward motion. The chain blocks mounted on the drive chain take up the weight body
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until it is released at the top end of the drop weight frame and freely drops onto the anvil. The
drop energy is transmitted to the rod, the point or the cutting shoe. By setting the engine
speed through the throttle lever the number of blows per minute can be adjusted from ca. 15-
35.


IMPORTANT! Do not manipulate any part of the unit whilst in operation! In case of
irregularities immediately set valve 4 to neutral, put the throttle to idle position and stop the
engine. The Emergency cut-off switch stops the engine immediately. Make sure the weight
body is not resting on a chain block but is lowered onto the anvil before you work on the
rig.


With the rod fully sunk in and the drop weight frame in its bottom position the chain blocks
do not catch the weight any more. This is to prevent the weight from hammering onto the mast
foot. Please note that the blow counter remains in function disregard of the position of the drop
weight. Therefore set valve 4 to neutral, and cut down engine speed.

To insert a new length of rod lift up drop weight carriage by fully inserting the key bolt with
R-clip and proceed as described under 5.8. Add next rod, connect the rods tightly and carry
on as described under 5.9 above.


IMPORTANT! During daily operation check the tightness of all allan screws on the drop
weight carriage from time to time while the engine must be shut off.








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6. Rod Extraction procedure

A hollow hydraulic cylinder (jack) serves to extract rods or sampling tubes from the soil. It
is employed in conjunction with a steel-reinforced wooden base plate to enlarge the area
preventing it from being drawn into the ground.
The rigs hydraulic system comprises an autoreverse valve to control the up-and-down
movement automatically. The rod or sampling tube is held by either tapered wedge clamps
(slips) or ball clamps.

To pull the rods proceed as follows:

6.1 If not done before as laid out under 5.8
place the wooden base plate close to
the front of the mast in a way that the
rods or samplers can be guided straight
through the hole (It is adviseable to do
this before starting the window sampling
procedure since it may be difficult later
especially with larger sampler
diameters).

6.2 Bring the drop weight carriage fully up
and secure it in top position as
described above.

6.3 Move the mast backwards by activating
valve 2 downwards which means that
the front end of the rig is lifted further.
The general position of the rig is not
changed by doing so. This gives enough
room for the jack and the clamps in front
of the mast and for the rods to negotiate
the drop weight carriage above.

6.4 Place the jack over the rod and if necessary add a new length of rod .
Place the clamp over the rod and on top of the jacks adaptor plate.

6.5 Start extracting operation by setting engine to full speed and engage valve 3.
CAREFUL: During pulling of the rods or tools never touch jack or clamp to avoid
injury risks. The jack can apply forces of up to 20 metric tons!
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CAREFUL: Since the hydraulic control of the jack works automatically make sure that the
rig is under supervision at all times. It might happen that the jack extracts meters of rods
which are liable to touch overhead structures such as roofs, trees, power lines etc. creating
considerable safety hazards.


6.6 When one length of rod is fully extracted stop the jacks operation by setting
valve 3 to neutral, undo length of rod and continue.


IMPORTANT:

ALWAYS follow these instructions to avoid damage or injuries!

Do not undertake any manipulations during operation!

Always use safety fork and key bolt with R-clip when drop weight carriage and/or drop weight
body is not completely lowered.

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7. Maintenance procedures

It is not supposed to instruct the operator to carry out special maintenance operations; it is
recommended to employ specialized personnel.


WARNING: The installation and use of non-original spare parts is forbidden unless being
authorized in written by GEOTOOL.

WARNING: The use of toxic hydraulic fluids is forbidden; use only type of fluid as prescribed
by GEOTOOL.

WARNING: Use only hydraulic hoses that conform to the specification and pressure rating of
GEOTOOL.

WARNING: Before each work shift check emergency devices and acoustic/luminous
indicators for proper operation.

WARNING: It is mandatory to timely carry out the maintenance procedures and safety
checks as laid out in this manual including the O.E.M. instructions covering the
Diesel engine, crawler undercarriage, and hydraulic winch.
For future reference the safety and maintenance jobs carried out must be
indicated in the safety and maintenance sheet.

WARNING: During any maintenance work the machine must be shut off and the emergency
switch must be engaged to prevent it being started by another person.

WARNING: All maintenance operations must be carried out by skilled and professionally
trained personnel using suitable tools, means for removing or refitting of
heavy mechanical parts etc. .

WARNING: Changing the setting of hydraulic valves is strictly forbidden.

WARNING: Never tamper with the emergency devices.



Engine: Please proceed according to the relevant
O.E.M.s instructions
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Rubber chain crawler: If necessary the rubber chain tension can be
increased by removing the lateral metal cover
plates and grease the nipple inside with a
grease gun. The nipples can be easily
reached from the back end inside the
crawlers. The grease pressure pushes the
front wheel forward increasing the tension on
the chain. Please proceed according to the
relevant O.E.M.s instructions.

Mast chain: Check chain tension daily with drop weight
carriage fully down. Attach spring scale to the
chain in the front of the mast in the middle
between drive and return sheeve. At a pull
force of 4-5 kg the distance between chain
and mast profile shall be 8 mm.

Tensioning procedure (as you would do on a
bicycle):
Undo lateral 19 mm bolt at the return pulley
axle at the bottom of the mast.
Undo 19 mm securing nut in the front mast
foot.

Increase chain tension by fastening the 19
mm tensioning nut above the securing nut
until correct setting is reached.

Fasten securing nut and the return pulley axle
bolt.

Clean and lubricate chain once a week with
machine oil. Grease chain blocks daily.


Latch mechanism: Clean weeekly and oil daily; grease top of
latch daily.
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Drop weight carriage: Clean and lightly spray oil chrome guiding rod
daily (MoS2 spray preferably)

Mast guiding profile: Clean and grease once a week

Hydraulic system: The unit is delivered with a bio-degradable oil
as per specification attached. The correct oil
level with all hydraulic cylinders fully retracted
should be visible on top of the screening
under the chrome filling cap on top of the
hydraulic oil tank. If necessary, remove the
wooden table plate above the reservoir to
have better access.

Never fully top up the tank! The hydraulic fluid
expands with rising temperature and could
flow over !

Only use the recommended type of fluid:

Ernergol HLP - HM

Electric system: The electric system is powered by a
maintenance-free 12 Volt battery.



IMPORTANT! During daily operation check the tightness of all allan screws on the drop
weight carriage from time to time while the engine must be shut off.