Dynamic Probing / Window Sampling Rig with folding mast on rubber chain crawler GTR790

Dynamic Probing / Window Sampling Rig with folding mast on rubber chain crawler GTR790

Contents: 1. Description 2. Safety Instructions 3. Pre-Start CHECK-LIST 4. Driving/tracking the GTR790 5. Dynamic Probing / Window Sampling Operations 6. Rod extraction procedure 7. Maintenance procedures 8. Spare parts list 9. Component documentation 10. General information (technical data, specification, wiring diagram, hydraulic circuit, CE certificate) 1. Description The GTR 790 is designed for dynamic probing and window sampling 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.

2. Safety Instructions The operation of th GTR 790 rig is strictly limited to the dynamic probing and window sampling operations; any other use of this machine can be very dangerous and is forbidden. Furthermore in this case any guarantee claim will be rejected. The GTR 790 rig may only be operated by trained and capable personnel familiar with this manual. For any components like petrol or Diesel engine, hydraulik breaker, rotary drives, winches etc. the relevant manufacturer s operation manual(s) form integral parts of this manual. To operate the GTR 790 it is mandatory to read beforehand and follow the instructions given therein! 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. IMPORTANT! Due to the exhaust gases it is strictly forbidden to operate this machine in enclosed rooms or without necessary ventilation! IMPORTANT! Due to the risks involved it is strictly forbidden to use the GTR 790 as a personnel carrier. Sitting or riding on the unit is dangerous! Rigs originally delivered by with a riding platform at the rear end may be used by one person during tracking. If a hydraulic leakage or failure is noticed stop the unit immediately. Take up any oil spilling and dispose of properly. CAREFUL: oil contaminates soil and water! 3. Pre-Start CHECK-LIST IMPORTANT: Before operating 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 internet: www.geotool.de

screening under the chrome filling 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 manufacturer s specifications as laid out under item 9. - Check tightness of all allan screws on the drop weight carriage. - 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 7. - Use hard hat, gloves and earplugs for the personal protection of everybody close to the workplace.

- Before starting the engine make sure that all control valves are in neutral position.

4. Driving/tracking the GTR 790 HYDRAULIC VALVE FUNCTIONS ON CONTROL CONSOLE (LH side of the rig; from right to left): Valve 1 Valve 2 Valve 3 Valve 4 Valve 5 erect/lower mast adjust mast vertically hydraulic rod extraction cylinder (autoreverse function) mast chain/drop weight mechanism up, down optional, for hydraulic breaker, rotary drives 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 manufacturer s instructions as laid out in item 9 and let it run on 1/3 throttle. To gain necessary ground clearance for the mast 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!

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. 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 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 1 person on the riding platform at the rear end of the unit (when delivered by OEM)! 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!

5. Dynamic Probing / Window sampling Procedures HYDRAULIC VALVE FUNCTIONS ON CONTROL CONSOLE (LH side of the rig; from right to left): Valve 1 Valve 2 Valve 3 Valve 4 Valve 5 erect/lower mast adjust mast vertically hydraulic rod extraction cylinder (autoreverse function) mast chain / drop weight mechanism optional, for hydraulic breaker, rotary drives 5.1 Move the rig to the borehole location as described under 4. 5.2 Set up the rig at the borehole location. Use a wooden plank for 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.

5.3 Erect upper part of mast as follows: 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. 5.4 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! 5.5 Now apply the two winged nuts and secure the connection safely. 5.6 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. 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. 5.7 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.). 5.8 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. 5.9 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. 5.10 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. 5.11 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. 5.12 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). 5.13 IMPORTANT! Before commencing operation make sure that the rig is set up in a stable position, the rod with it s 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. 5.14 Increase engine speed by using the throttle lever to ½ 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 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. 5.15 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. 5.16 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. 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.

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 rig s 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 jack s 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!

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 jack s operation by setting valve 3 to neutral, undo length of rod and continue.

7. Maintenance procedures Engine: Rubber chain crawler: Mast chain: Please proceed according to the relevant manufacturer s instructions as per item 9. 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 manufacturer s instructions as per item 9. 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: Drop weight carriage: Mast guiding profile: Hydraulic system: Clean weeekly and oil daily; grease top of latch daily. Clean and lightly spray oil chrome guiding rod daily (MoS2 spray preferably) Clean and grease once a week 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: BP Biohyd 46 SE 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.