Klemm KR - 702-2 - 2008

TECHNICAL MANUAL
Description
Operation
Maintenance
for
Hydraulic crawler drill rig

KR 702 - 2
KLEMM Bohrtechnik GmbH

Wintersohler Str. 5
D- 57489 Drolshagen
Tel: +49 (0) 2761 705- 0
Fax: +49 (0) 2761 705- 50
SCOPE OF LIABILITY
Information and data in this operatio-
nal manual may be changed without
prior notice
Although compiled with all care, the
manual may be incomplete.
KLEMM Bohrtechnik will not any ac-
cept claims resulting from missing
data in this manual.
Technical specifications and data
subject to modifications.
In case of doubt, the German text
shall prevail.
COPYRIGHT REGULATIONS
Layout and content of this manual is
subject of international copyright re-
gulations.
KLEMM Bohrtechnik 2008
Reproduction or use in any form

whatsoever, except within the legal
limits of copyright laws, and without
prior written permission of the com-
pany KLEMM Bohrtechnik is not
permitted.
KLEMM Bohrtechnik GmbH

Wintersohler Str. 5
D- 57489 Drolshagen
Tel: +49 (0) 2761 705- 0
Fax: +49 (0) 2761 705- 50
04/2008 KR 702- 2 / Serial no. 19104 2

Bei Anfragen und für schnelle und When making enquiries or orde-
reibungslose Ersatzteillieferung ring spares, please specify the fol-
bitte stets folgende Informationen lowing data to ensure prompt and
angeben: reliable delivery:
1. Maschinennummer 1. Number of Rig
2. Maschinentyp 2. Type of Rig
3. Ersatzteilmenge 3. Quantity required
4. E.Nr. 4. P/No.
Für elektrische Bauteile bitte zu- For electrical components please

sätzlich: state also:
5. Spannung (V) 5. Voltage (V)
6. Frequenz (Hz) 6. Frequency (Hz)
7. Leistung (kW) 7. Power (kW)
Durch Weiterentwicklung bedingte We reserve the right to modify

Konstruktionänderungen behalten equipment in the process of deve-
wir uns vor. lopment.
Crawler drill rig type : KR 702- 2
Serial no. : 19104
Year of manufacture : 04/2008
04/2008 KR 702- 2 / Serial no. 19104 3

Table of Contents
1 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.1 General references to the avoidance of accidents, damages
and excessive wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.2 General safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.3 Safety instructions for operation the drill rig . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.3.1 Special requirements and recommendations for combined drill rigs
with connected mobile power- packs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.3.1.1Disconnecting the Power Pack PP- 95 - DS from the drill rig KR 702- 2 17
1.3.2 Safety recommendations for tramming operations of drill rig KR 702- 2 18
1.4 Safety instructions for maintenance of the drill rig . . . . . . . . . . . . . . . . . . 21
2 Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3 Technical description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.1 Base frame with crawler tracks and boom . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.1.1 Crawler undercarriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.1.2 Boom assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.1.2.1Special swivel head (6 x 90°) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.2 Drill mast 164 and attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.2.1 Safety instuctions for roller chains for drill feed system
(only drill mast with feed chain) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3.3 Engine and central hydraulics (Power Pack PP- 95 - DS) . . . . . . . . . . . . . 31
4 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
4.1 Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
4.1.1 Hydr. rapid couplings on connection plate KR 702- 2 . . . . . . . . . . . . . . . . 33
4.1.2 Hydr. rapid couplings on connection plate Power Pack PP- 95 - DS . . . 34
4.2 Control elements on Power Pack PP- 95 - DS . . . . . . . . . . . . . . . . . . . . . . 35
4.2.1 Engine control box PP- 95 - DS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
4.2.2 Engine control system Power Pack PP- 95 - DS . . . . . . . . . . . . . . . . . . . . 41
4.2.3 Electronic engine regulator (EMR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
4.3 Prior to start- up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
4.4 Engine start- up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
4.4.1 Starting procedure of an Power Pack in cold ambient
temperature conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
4.5 Tramming the crawler drill rig . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
4.5.1 Tramming the drill rig on slopes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
4.5.2 Manoevrability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
4.6 Setting up and alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
4.6.1 Safety instructions for operation with telesc. drill mast
type 164 and lateral slidable glide slide . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
04/2008 KR 702- 2 / Serial no. 19104 4

4.7 Drilling controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
4.7.1 Drilling controls on base drill rig . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
4.7.2 Drilling controls on slewable control panel . . . . . . . . . . . . . . . . . . . . . . . . . 53
4.7.2.1Safety Instructions for rope winches mounted on drill masts . . . . . . . . . 55
4.8 ESS control box on slewable control panel . . . . . . . . . . . . . . . . . . . . . . . . 56
4.9 Telescopic function of the drill mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
4.10 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
4.10.1 Drilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
5 Crawler tracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
5.1 Adjusting Track Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
5.2 Repairs on crawler chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
5.3 Controls on tramming gear box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
6 Care and maintenance of the KLEMM crawler
drill rig type KR 702-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
6.1 Maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
6.2 Recommended Oil- and grease- types for drill rig KR 702- 2
with Power Pack PP- 95 - DS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
6.2.1 Characteristics of different hydraulic oils for Klemm drill rigs . . . . . . . . . 67
6.3 Filters and filter inserts for KR 702- 2 and PP- 95 - DS . . . . . . . . . . . . . . . 69
6.3.1 Filter and filter inserts for KR 702- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
6.3.2 Filter and filter inserts for Power Pack PP- 95 - DS . . . . . . . . . . . . . . . . . . 70
6.4 Scope of the 100 hour inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
6.5 Lubrication Chart Maintenance and Service Intervals . . . . . . . . . . . . . . . 76
6.5.1 Maintenance of piston rods of hydraulic cylinders . . . . . . . . . . . . . . . . . . 78
6.6 Special instructions for Deutz Diesel engine TCD 2012 L04 2V . . . . . . 78
6.6.1 Permitted fuels for DEUTZ diesel engine . . . . . . . . . . . . . . . . . . . . . . . . . . 78
6.6.2 Dark coloration of diesel fuel due to oil ingress . . . . . . . . . . . . . . . . . . . . . 78
6.6.3 Cooling liquid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
6.6.4 First filling and refilling of cooling liquid on Deutz diesel
engine type TCD 2012 L04 2V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
6.7 Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
6.7.1 Hydraulic oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
6.7.2 Filtration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
6.7.3 Oil Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
6.7.4 Repairs and maintenance of the hydraulic system . . . . . . . . . . . . . . . . . . 84
6.7.4.1Trouble shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
6.7.5 Reference to repairs at the hydraulic system . . . . . . . . . . . . . . . . . . . . . . . 87
6.7.5.1Special guarantee remarks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
6.8 Special Remarks (Welding Instructions) . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
04/2008 KR 702- 2 / Serial no. 19104 5

6.9 Maintenance of the starter battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
6.9.1 Cold start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
6.9.2 Installing the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
6.10 Accumulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
6.10.1 Introduction and precaution instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
6.10.2 Works at accumulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
6.10.3 Assembly of cpl. Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
6.10.4 Putting into operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
6.10.5 Using of accumulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
6.11 Conservation of hydraulic piston rods and machine components . . . . . 93
7 Attachment points for truck transport . . . . . . . . . . . . . . . . . . 94
7.1 Attachment points for drill rig KR 702- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
7.2 Attachment points for Power Pack PP- 95 - DS . . . . . . . . . . . . . . . . . . . . . 95
8 Rope attachment points (1-4) on the drill rig type
KR 702-2 for loading with the help of a crane . . . . . . . . . . . 96
9 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
9.1 Technical data KR 702- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
9.2 Technical data Power Pack PP- 95 - DS . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
9.3 Technical data of sound level measurement
acc. to DIN EN 791 and 2000/14/EC (Outdoor- Noise - Directive) . . . . . 99
10 Kinematic possible mast movements
KR 702-2 basic version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
04/2008 KR 702- 2 / Serial no. 19104 6

1 Safety instructions
All personnel involved in operating and/or maintaining this equipment must first
read and thoroughly understand the operating instructions before attempting to
operate or perform maintenance on the drill rig. Non- authorised or untrained per-
sonnel must not under any circumstances attempt to operate or repair the machine.
Safety first must always be the primary consideration of all personnel while opera-
ting or maintaining the drill rig under normal and especially in unusual conditions.
Since these safety precautions cannot cover every possible situation, everyone is
expected to exercise good judgement, foresight and common sense while operating
or working with, on, or near the drill rig.
The signs CAUTION and PLEASE NOTE

are to be defined as follows :
CAUTION
This word is used to point out that inadequate or

non - compliance with operating manuals, working instructions, operational
sequences etc. will substantially damage property or cause severe
personal injury which could be fatal.
PLEASE NOTE
PLEASE NOTE is used to make people aware of installations

and gives hints for operation and maintenance which are important but not
hazard related. It generally indicates an operational aid.
04/2008 KR 702- 2 / Serial no. 19104 7

1.1 General references to the avoidance of accidents, damages
and excessive wear
1 Drill rig
The drill rig has multiplicity kinematic degrees of freedom for positioning of the basic
rig and particularly the drill mast.
But not each kinematically possible configuration is meaningful or permissible. This
particularly depends on the mounted drill mast, the drilling unit and drilling equip-
ment.
Therefore among other things the permitted drilling positions given in the stability
calculations, the setting- up sequences and the specific ground pressure as well as
all other references in the manual must be observed.
KLEMM Bohrtechnik refers to the fact, that not each theoretically possible drilling
position can be described.
If other drilling positions are to be aligned, then this lies in the technical discretion
of the operator. Otherwise consultation with KLEMM Bohrtechnik must be taken.
The following points must be particularly considered:
1.1 Extreme displacement of the center of gravity
Special attention must be paid when setting- up the drill mast with far out overhan-
ging center of gravity. The center of gravity of the drill mast with its attachments e.g.
drill heads and hydr. drifters, drilling equipment and if necessary rod magazines
must be placed as near as possible to the ground contact area of the drill rig. The
ground contact area of the drill rig is defined by the tipping edges of the crawler
tracks.
1.2 Collision
Causes of the multiplicity of kinematic possibilities, the setting- up of the drill rig has
to be done with maximum attention, appropriate speed and if necessary with a se-
cond instructing person.
With inattentive setting- up operations, collisions e.g. between the drill mast and
parts of the boom or the basic rig are possible.
1.3 Overlay of the degrees of freedom
The kinematic degrees of freedom are for example realized by hydraulic cylinders
or slewing drive units. The degrees of freedom can be redundant in certain positions,
that means for example, that a tilting motion around a certain spatial axle can be
achieved by two or more methods. Within the methods, the most favorable method
regarding endangerment and damage must always be selected.
04/2008 KR 702- 2 / Serial no. 19104 8

2 Extreme environmental condition
If the drill rig is to be operated under extreme or outside the of KLEMM Bohrtechnik
specified site conditions, previous clarification with KLEMM Bohrtechnik is necessa-
rily. These are e.g.:
- Extremely low or high temperatures and or humidity

- Special geographical altitudes
- Particularly high dusty condition
- Operations in tunnels or underground
3 Changeable equipment
3.1 Equipment from KLEMM Bohrtechnik
For the drill rigs of KLEMM Bohrtechnik many equipment components, which can
be changed or additional mounted are available.
For example these are rotary drill heads, hydr. drifters, rod magazines, drill masts
and drill mast extensions, flushing pumps, lubricants and fuels and other compo-
nents. All combinations of changeable equipment with the drill rig cannot be descri-
bed. To avoid endangerments and damages, the following points must be strictly ob-
served when self changes of the drill rigs equipment are made:
- permissible stabilities und strengths

- permissible pressures in the hydraulic system
- permissible flow rates in the hydraulic system
- permissible operation modes of hydraulical and electrical components
(e.g. preferred rotation direction of hydraulic motors)
- electrical control- and monitoring functions
- use of safety devices or safety components
- permissible contamination for lubricants and operating materials
- conformity with the european regulation for machines when substantial
changes are done (only in the marketing area of the European union).
3.2 Adaptation at or of equipment of other manufacturers
Fundamental the same points as being considered above are to be observed.

The adaptations takes place in the discretion of the operator if they are not coordina-
ted with KLEMM Bohrtechnik.
In principle the in the manual and further attached documentation

contained safety and warning reference must be observed.
If there is none or a contradictory information to a specified question in
the documentation, KLEMM Bohrtechnik must be consulted before
operation or conversion.
04/2008 KR 702- 2 / Serial no. 19104 9

1.2 General safety instructions
F Directive of application
The KLEMM drill rig must be used only as directed in DIN EN ISO 12100- 1
(safety of machinery), and as described in the operators manual for drilling
operations. Another using of the drill rig as directed (e.g. for lifting operations
as a crane or ground moving operatios) is striktly forbidden.
F Make sure all persons are clear of the machine before moving or starting any
drilling operation.
F All personnel involved in operating and maintaining this equipment

must first read and thouroughly understand the operating instructions.
F Operating instructions
Operating instructions for the KLEMM Bohrtechnik drill rig must be

complied with for operation, maintenance, service, repairs and transport. The
contractor is obliged to amend safety regulations to meet local requirements.
Operating instructions and amendments must be kept securely on the working
site.
F Personal Safety Equipment
Wear Personal Safety Equipment - Working gloves

- Safety boots
- Safety hat
- Hearing protection
- Safety glasses
- Nose mask (only if dust)
Wear tight clothes (protection clothes according to DIN).

Keep hands, arms, legs and clothing away from all moving parts.
Do not touch heated up parts with your bare hands. Wear protection gloves.
F Vibrations
The weighted value of the vibrations of the body (feet, seat face) of 0,5m/s2,
which can shake the operator during the drilling work, is not exceeded. The
value of the hand/the arm vibrations, which shake the operator during the dril-
ling work, is under 2,5m/s2.
04/2008 KR 702- 2 / Serial no. 19104 10

1.3 Safety instructions for operation the drill rig
1. Operation and maintenance of KLEMM drill rig
Independent and unassisted operation (operator) and maintenance

(fitter) is to be entrusted only to persons who:
1.1 Are at least 18 years of age (Check for local stipulations)
1.2 Are physically and mentally suited
1.3 Have been instructed in operating and maintaining

the crawler drill rig and have proven their ability to the
contractor / user
1.4 Can be expected to perform responsibly
And are designated for the job by the contractor/user.
2. Danger zone
Be sure that no one is within the drill mast’s danger zone.

The danger zone is the area around the drill rig within which persons may be
endangered by the rig’s slewing range or its components working movements.
The operator must work the machine only if no one is within the danger zone.
In case of danger the operator must give warning signals. Warning signals are
generally given with horns.
Pre - determined hand warning signals must be used if on- site noise is liable
to drown audible signals.
If persons do not leave the danger zone despite having been warned the ope-
rator must stop working immediately.
3. Safety distance
A safety clearance of min. 0,5 metres must be kept from buildings, scaffolding
and other equipment to prevent the danger of being squashed.
Keep in mind the drill rig’s slewing facilities.
If the safety clearance cannot be complied with the area must be cordoned off.
04/2008 KR 702- 2 / Serial no. 19104 11

4. Safety devices
Safety devices and protective equipment of moving machine components

must be opened, removed, or disabled only with the rig’s engine stopped and
secured against inadvertent or unauthorised start- up.
Safety devices are e.p. ESS- system (System KLEMM), engine cover doors,
protective gratings, coatings.
All safety devices and protective equipment must be reinstalled after comple-
tion of maintenance service and repairs.
5. Transport of persons
The transport of persons on the drill rig is strictly forbidden!!

6. Step on the drill rig
While operation the drill rig is forbidden to step on the machine. Before step-
ping on the machine the engine of the drill rig must be stopped and secured
against inadvertent or unauthorised start- up.
7. Stability
The stability (according to DIN EN 791 “Drill rigs - safety”) of the crawler drill
rig must always be assured.
Stability may be impaired by:
Excessive load, unsecure ground, jerky acceleration and stopping of tramming
and slewing movements, slopes.
The operator is responsible for the rig’s stability, and must, if necessary, modify
procedures to allow for special site conditions.
8. Truck loading process
In order to avoid chutes of the drill rig in the case of the loading process onto
the truck, ramps must be coated with skid- proof materials (e.g. wood slats or
rubber mats).
9. Securing against fall
To forestall danger of falling and crashing, the drill rig must at all times keep
a safe distance from ledges, pits and slopes.
It is the contractor’s responsibility to assess the ground’s bearing capacity, and
assert a safety distance for the rig.
Be sure of the bearing capacity of bridges, floors, and structures prior to
moving the basic rig on to them.
10. Alignment of the drill mast
If the drill rig is equipped with a telescopic drill mast type 164 / 2370mm long,
a cat head with rope winch, a hydr. drifter or a rotary drill head and a clamping
and breaking device, the rig should be preferably operated with driven out front
and rear support. It is to be paid absolutely attention, that the drill mast is prop-
ped with the front console on the soil during drilling operations.
04/2008 KR 702- 2 / Serial no. 19104 12

11. Signalling
If the operators vision is impaired during tramming and working, someone

must give signals for assistance, or the tramming / working area must be
cordoned off.
Only reliable persons must be designated to give signals.
They must be instructed as to their responsibility.
Communication must be co- ordinated and exclusively used between operator
and the person giving signals.
The signalling person’s attention must not be diverted by additional tasks.
12. Working in the area of utility lines (gas, water, electricity,...)
The contractor is responsible to ascertain if utility or not visible lines are buried
on the drilling site. The site’s owner is obliged to supply this information.
If utility or not visible lines are present their location must be clearly marked.
Plans clearly detailing the location (run and depth) of utility or not visible lines
must be kept for reference on the working site.
The operator must stop working immediately and inform the site manager if a
utility line or its protective cover should be found or damaged.
Uncovered utility lines must be secured against swaying or slipping.
13. Working near overhead electrical lines
The following minimal safety distances must be complied with if working near
overhead power lines, unless local or national stipulations require otherwise:
Rated voltage:
up to 1000 V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . safety distance = 1 m
above 1kV to 110 kV . . . . . . . . . . . . . . . . . . . . . . . . . . . safety distance = 3 m
above 110 kV to 220 kV . . . . . . . . . . . . . . . . . . . . . . . . safety distance = 4 m
above 220 kV to 380 kV . . . . . . . . . . . . . . . . . . . . . . . . safety distance = 5 m
or if rated voltage unknown . . . . . . . . . . . . . . . . . . . . . safety distance = 5 m
If a min. safety distance can not be respected, the contractor must arrange
other safety steps (e.g. cut off or move the electr. line) in accordance with the
owner or operator of the electr. lines.
14. Safety precaution trailer coupling.
The trailer coupling P/No. 40333 is approved for max. 40 kN = 4 tons
15. Guards and safety devices are for your protection. Do not remove or disable
them under any circumstances. The ESS requires particular attention. Mal-
function of the Emergency Stop System may cause delays in switching the drill
rig off, leading to severe or fatal injuries.
16. Replug the 2 mast slewing cylinders (option slew head 6 x 90°) only in
horizontal mast position.
04/2008 KR 702- 2 / Serial no. 19104 13

17. Operational intervals
The operator must park the crawler drill rig with Power Pack on bearing and
level ground, and secure against inadvertent or unauthorised movement, prior
to each operational break and at the end of each working day.
If the drill rig must be parked on a slope or incline, the tracks of the Power Pack
must be secured with wedges, in addition to the hydraulic brakes.
Drill rigs should be parked only where they do not impede public or site traffic.
If necessary they must be secured with warning triangle, signalling lines, or
warning lights.
During working breaks and at the end of each working day, the operator must
rest drill mast and drill string on the ground, and secure them against inadver-
tent or unauthorised movement.
The operator must:

- not leave the site if drill rig and tools are not secured
- set all operating levers in ”O” position prior to leaving the control panel
- stop the drill rig’s engine and secure it against inadvertent or unauthorised
start - up, prior to leaving the drill rig.
Inadvertent or unauthorised start- up is avoided, if the engine is stopped, the
starter key taken out of the ignition lock, and cover doors and lids are locked.
18. Always operate the basic rig from the operators platform when tramming.
19. Before tramming the drill rig, the drill mast must be placed on the drill mast
support in horizontal transport position.
20. All operations must be activated directly from the corresponding control
positions only.
21. The drill rig must only be driven within ranges, in which is no risk to cant over!
The drivers position of the drill rig is not equipped with a rollover protection sy-
stem (ROPS).
22. For the shifting the drill rig through darkness, a lighting with a minimum lumi-
nous intensity of 10 lux must be given in a distance of 7m from the drill rig to-
ward shifting direction.
23. The point of drill hole shall be illuminated, if necessary from the job site.
24. While working in a closed room a exhaust hose shall be used. Otherwise it can
cause intoxication.
25. If you must operate the rig underground or in a confined area, consult your
KLEMM Representative for assistance in safe operation.
26. The drill rig shall be used in areas, where no down- falling items cause danger.
27. Use only the purpose- made craneage lugs when lifting the rig. For loading the
drill rig with help of a crane please contact KLEMM comp.
04/2008 KR 702- 2 / Serial no. 19104 14

1.3.1 Special requirements and recommendations for combined
drill rigs with connected mobile power - packs
Tramming mode
The mobile power pack is connected to the drill rig with electrical control ca-
bles and the cluster of hydraulic hoses.
ATTENTION
Before tramming and before starting the diesel engine check all cable and
hose couplings mounted on the drill rig and the power pack; if loose, tighten
them correctly.
After starting the diesel engine and after pressurizing the total system,
check again couplings to be leakage - free !
Avoid tramming and unstable slopes and grounds. In the case of bad ground
conditions use wood or mats or special sheets to stabilize the drill rig posi-
tion.
The power pack is connected to the drill rig by a special traction bar with trai-
ler coupling end (eye). The trailor coupling is inserted in the counter part,
bolted with 4 steel bolts to the crawler frame.
The trailor coupling is linked with the crawler frame by inserting the appro-
ved lock bolt with handle and safety chain with splint.
CAUTION
Check always before tramming the trailor coupling system with mounted
and secured lock bolt!
Never replace the genuine block bolt by normal pin or other non - approved
materials.
For proper mounting and operation of the trailor coupling: (see picture).
genuine block bolt

with safety chain
and split pin
trailor coupling
04/2008 KR 702- 2 / Serial no. 19104 15

Drilling mode
- Stabilize the drill rig with the two rear propping cylinders.
- Block the two wheels of the mobile power pack with the steel wedges
included in the scope of supply and attached to the power pack
(see picture).
- Make the ground plane before drilling to keep the machine in horizontal
position!
- In special cases the mobile power pack will be disconnected from the drill
rig, the maximum distance can be appr. 25m by using long hoses.
This drilling mode requires special attention for the leakage - free
connection of the hose couplings to the power pack which will be out of
the visual control of the operator.
(operator inside the building, power pack outside)
Important
The diesel engine produces vibrations which may reposition the power
pack!
- Block the remote operated power pack to avoid collisious and accidents
by putting the wedges under the wheels.
- Before drilling check all safety devices like emergency stop switches and
the special drill feed safety cables with hydraulic switches, solenoid
valves (ESS).
Parking mode
- Keep the drill rig with power pack on a safe place, avoiding slopes and
soft grounds.
- Stabilize the rig with the rear hydr. propping cylinders and use wood bars
in muddy conditions under the bottom plates.
- Lock the wheels of the power pack with two steel wedges.
- Slew drill mast in horizontal position with drill unit between mast
carrier and mast support bracket.
- Remove starter key of the diesel engine.
04/2008 KR 702- 2 / Serial no. 19104 16

1.3.1.1 Disconnecting the Power Pack PP - 95 - DS from the drill rig
KR 702 - 2
It is important to work after the following points in the right order!
1. Block the tracks of the Power Pack with the steel wedges.
2. Lift down the propping wheel of the Power Pack. Ensure the weel is pushed
into the fully locked position before uncoupling the drill rig.
3. Take the split pin out of the bolt of the trailor coupling.
4. Take the bolt out of the trailor coupling.
5. Move the drill rig forward until the hitch of the Power Pack is not in contact
with the trailor coupling anymore.
6. Switch off the engine of the Power Pack and pull out the start key.
7. Screw off the connecting hoses and the connecting cable from the Power
Pack.
steel wedge rear and front (option)

hydr. propping cylinders
connecting hoses
and cable
trailor coupling with

lock bolt, safety
chain and split pin
propping wheel
04/2008 KR 702- 2 / Serial no. 19104 17

1.3.2 Safety recommendations for tramming operations of drill rig
KR 702 - 2
Tramming or any activation of the crawler tracks of KR 702- 2 drill rig inside buildings
or at the job site are only permitted with fully spreaded (telescoped) crawler chassis
to 1250 mm width.
Non - respect of these recommendations may be the reason for heavy accidents due
to reduced stability when tramming with retracted crawler chassis !!
The retracted mode for tramming is only permitted during passage of doors and
small entries.
ATTENTION:
Tram with fully telescoped crawler chassis (1250mm) just before you pass doors/
entries; then retract during passage manoevres and spread to full width immediately
after te passage.
Tramming operations of the KR 702- 2 rig are only permitted with drill mast in trans-
port position and laying on the special support frame. The rotary head must be posi-
tioned in the middle of the drill mast.
ATTENTION:
Prior to tramming on the job site prepare the ground and remove obstacles and on-
dulations like deep holes and small walls.
Permitted slope Permitted side inclination
Tramming and working 10 10

condition
Transport conditions 20 10

(mast down)
04/2008 KR 702- 2 / Serial no. 19104 18

Tramming and working condition
10
sketch of permitted slope
10
sketch of permitted side inclination
04/2008 KR 702- 2 / Serial no. 19104 19

Transport conditions
20
sketch of permitted slope
10
sketch of permitted side inclination
04/2008 KR 702- 2 / Serial no. 19104 20

1.4 Safety instructions for maintenance of the drill rig
1. Service and maintenance intervals must be adhered to as specified. Non -

compliance leads to immediate loss of all warranty entitlements.
2. The setting of pressure limiting valves and safety valves in the hydraulic
circuits of the drill rig must be changed only by KLEMM Bohrtechnik
approved personnel.
3. Welding of static and bearing components on the machine is to be carried out

only by the manufacturer or KLEMM Bohrtechnik approved personnel.
4. The rigs hydraulic plant must be checked regularly.
Replacement hoses or hydraulic components must be ORIGINAL spare parts

of KLEMM Bohrtechnik.
This requirement must be complied with for safety reasons and applies also
for all static and bearing components, such as
* Screws
* Bolts
* Springs and washers
* Boom components
* Drill mast components
* Undercarriage components
5. Replacement of wear parts
Repairs and replacement of wear parts can be carried out by qualified person-
nel in addition to standard maintenance and service intervals which must be
complied with.
If in doubt contact KLEMM for assistance.
6. Be sure to bleed accumulators before repair (see chapter 6.10 on page 90 in

this manual) and be sure to make them completely pressure - free before ope-
ning.
04/2008 KR 702- 2 / Serial no. 19104 21

7. Please, do not pressure wash the new drill rig within the first two weeks.
Do not use cleaning agents with solvent or degreasing substances.
Do not use aggressive chemical cleaning agents, e.g. concrete remover. This
can spoil the paint work and chromed parts.
Do not direct the pressure washer onto electric components and seals.
8. During the engine cleaning by water or steam jet, electrical / electronic con-
struction units, e.g. oil pressure switch (sensor), electronic controllers, electro-
nic control members etc., must not be exposed to a direct jet stream.
Otherwise penetrating humidity can lead to contact corrosion and to the loss
of measuring - / and control functions. E.g. oil pressure switches cannot be wa-
terproof cause of the necessary diaphragm ventilation; therefore caution
when hosing down.
If plugs are nevertheless inadvertent cleaned with a jet steam, the plug con-
nection is to be opened, to dry with compressed air and to spray with contact
spray.
04/2008 KR 702- 2 / Serial no. 19104 22

Safety reqirements for hydraulic lines
1. Markings :
a) Hydraulic hoses must carry continuous markings at intervals not greater

than 50 cm. These markings must be clearly readable and supply the
following data:
- Name of manufacturer
- Type
- Nominal diameter
- Date of manufacture
Example : ” 1 Q 08 ”
= 1st. Quarter 2008
b) Hose lines must carry the following data in durable markings:
- Name of the manufacturer

- Date of manufacture
- max. permissible
dynamic operat. pressure
2. Storage
Hydraulic hoses must be stored tension- free, in a dry and clean environment.
Direct sunlight and UV- irradiation must be avoided.

Storage time should not exceed four years.
3. Maintaining the hose conduits
a) Hose lines must be examined by an authorized person at least once a year.

Hose lines must be replaced if damages, embrittlements, deformations, lea-
kages, damage to the armatures etc. are determined by the examination.
Hose lines should be treated according to the “Safety rules for hydraulic ho-
ses ZH 1/74” of the professional association and the standard DIN 20066.
The storage and using should not exceed 6 years.
b) Hoses which have been operated as part of a hydraulic line must not under
any circumstances be reprocessed
4. Inspection
Hydraulic lines must be inspected by qualified personnel to assess their opera-

tional safety before the initial start- up, and subsequently at least once every
year.
Defective and faulty lines must be exchanged immediately.
04/2008 KR 702- 2 / Serial no. 19104 23

2 Preface
This manual describes the KR 702- 2 hydraulic power for all (tramming, align-
hydraulic crawler drill rig, manufactured ment and drilling) of the rig’s function.
by the Company KLEMM Bohrtechnik,
The rigs crawler tracks are non oscilla-
the assembly of technical components,
ting, which means that both tracks are
operational procedure as well as ser-
attached to a fixed axle. The drill rig
vice recommendations and preventive
KR 702- 2 has a telescopic crawler
maintenance requirements.
frame base, which can be extended
from 750 mm up to 1250 mm.
Hints and instructions for repairs and
trouble shooting are also included. Attention:
Tramming must be done with spreaded
The manual comes complete with a crawlers of 1250 mm (fully telescopic
parts catalogue, which depicts and des- mode). It is permitted to retract the
cribes modules and individual compo- crawlers to 750 mm if the rig passes
nents. Use the catalogue to identify part small openings under confined spaces.
number of the required component After passing doors and limited ope-
prior to ordering. nings the crawler base must be sprea-
ded to full telescopic range immedia-
Your KLEMM KR 702- 2 drill represents tely. Do not operate the tramming
”State of Art” in mobile drilling functions with retracted crawlers due to
equipment. Apart from flushing water or stability reasons.
air supply required for flushing purpo-
ses, the rig operates fully indepen- The drill mast is fitted in guiding strips
dently, ready to tackle the most extreme on the mast carrier and supports all dril-
ground conditions in almost any loca- ling accessories.
tion. A clamping device (accessory) ensures
rapid rod changes.
The rig’s boom is adjustable on two pla-
nes and - together with the special sle- All operating levers of the drill rig are
wing mechanism and mast carrier - al- conveniently positioned and clearly la-
lows vertical and horizontal drill mast beled with symbols indicating their
alignment, which is particularly advan- functions.
tageous when spotting in areas with li- The control console for mast alignment,
mited access, e.g. corners and reces- hydr. propping and spreading of the
ses. tracks is fixed on the left side of the base
frame.
The rig is powered by a seperate power
pack which is driven either by an elec- All drilling functions are activated from
tric motor or a diesel engine. An open a slewable control panel. The control
hydraulic system with max. operating elements for the tramming functions
pressure of 250 bar (3626 psi) supplies are mounted on the rear side of the rig.
04/2008 KR 702- 2 / Serial no. 19104 24

The 2 EMERGENCY switches are ATTENTION:
mounted on the slewable control panel You must check daily the correct func-
and at the rear side of the rig. Activation tion of the EMERGENCY switches. Do
of these switches stops all of the rig’s not operate the machine if the EMER-
functions immediately. GENCY switches fails and shows no
function.
The EMERGENCY switch is composed The KLEMM Company reserves the
of a red buttom with electrical shut- off right to modify the drill rig and technical
of the diesel engine; this reaction is im- documentation without prior notice, in
mediate !! the interest of development.
KR 702- 2 with Power Pack PP- 95 - DS
04/2008 KR 702- 2 / Serial no. 19104 25

3 Technical description
3.1 Base frame with crawler tracks and boom
The base frame with fixed crawler tracks carries control and monitoring elements.
The uppercarriage carries a boom, consisting of slewing mechanism and mast car-
rier. The mast carrier guides and supports the drill mast.
Two telescoping propping jacks are attached to the back of the drill rig. Be sure to
always extend these prior to any attempt at drilling, to ensure adequate lateral stabi-
lity. Never drill without those stabilizing propping cylinders !!
Useful options are hydr. front stabilizers and the installation of a rope winch.
Attention:
Before starting tramming operations the spreaded crawlers of the drill rig
KR 702- 2 must be fully extended to 1250 mm.
04/2008 KR 702- 2 / Serial no. 19104 26

3.1.1 Crawler undercarriage
Each crawler consists of base frame, track chain, sprocket drive wheel, guide wheel
and four idlers, as well as a track tensioning device and the transmission.
The transmission consists of a planetary gear box with hydraulic motor. The gear
box is equipped with a multi- disc brake on the motor. This multi- disc brake is activa-
ted by constant spring pressure, and acts as parking brake only.
The brake is opened by oil pressure, e.g. oil flow of approx. 12- 15 bar or greater,
releases the brake.
Special axial seal rings protect the transmission from dirt and contamination.
3.1.2 Boom assembly

The boom assembly features allow a perfect setting- up and alignment of the drill
mast, and consist basically of swivel head and mast carrier, completed by hydraulic
cylinders.
The mast carrier in combination with the swivel head arrangement allows the entire
drill mast to be slewed from vertical to horizontal.
The swivel head (6x90°) is constructed to slew the drill mast in anchor drilling posi-
tions by using both slewing cylinders.
Swivel head movement is such that for tramming and transport purposes the
mast complete with drill head is ”shouldered” parallel to the boom, reducing the
height to only 2250 mm.
All hydraulic cylinders are equipped with load- bearing valves, which maintain
the cylinder in a fixed position in the event of a sudden loss of hydraulic pressure
(pump failure or hose damage).
Additional all hydraulic cylinders are equipped with special load holding valves
(parachute valves) which permit a controlled and low speed movement of the
boom and drill feed in case of a hose/pipe rupture.
04/2008 KR 702- 2 / Serial no. 19104 27

3.1.2.1 Special swivel head (6 x 90)
The design of the special swivel head allowes 6 different sidewise slewing ranges
(45_) of the drill mast to the left and to the right.
The sidewise slewing range can be changed by different positioning of the rod heads
of the two slewing cylinders which are mounted between the mast carrier and the
swivel head.
mast carrier
swivel head
bolt connection
stopcock
slewing cylinder
The conversion of the rod head position of the two hydr. cylinders must be done one
by one. Cause of the stopcocks which are installed in the hydr. lines to retract the
cylinder rods of the two slewing cylinders, it is possible to extract only one cylinder
rod by shutting of the retraction line of the second cylinder.
Do only demount the bolt of one rod head connection and extract the cylinder rod
into desired slewing range position of the swivel head. After correct installation of
the bolt connection, the second slewing cylinder can be converted.
ATTENTION!
Cause of safety reasons, the conversion of the cyl. rod heads is only allowed
with drill mast in horizontal (transport) position and rotary drill head in middle
position of the drill mast carrier.
04/2008 KR 702- 2 / Serial no. 19104 28

3.2 Drill mast 164 and attachments
The drill mast consists of square sectio-
Rotary drill Cat head with
ned steel profiles.
head KH 16 rope winch
The bottom end is fitted with a centrali-
ser, a clamping device and a toothed
support plate. The drill mast is attached
to the mast carrier.
The drill unit is mounted on a glide slide
which is guided on the drill mast. Axial
movement is assured by a feed chain
driven by a hydraulic cylinder.
Caution: Ensure that no one is within

the danger zone of the drill mast during
drilling operation. Operating the drill rig
when drilling personnel is within the
danger zone is forbidden, because per-
sons are endangered by slewing parts
of the drill mast.
When drilling mast has to be pressed
and fixed to ground or to the wall in or-
der to prevent mast from damages.
Safety Instructions for preparing to install

or remove the feed chain.
1. Mast in horizontal position and in working
height.
2. Block slide carriage.
3. Shutt off the diesel engine and the starter
key is taken out of the ignition lock .
4. Place both feed control levers to 0- posi-
Telesc. drill
tion (neutral). mast type 164
5. Installing or Removing of feed chain has
to be made only by trained technical per-
sonel.
6. Before operating the feed chain, you
must ensure that the feed chain is slacke-
ned by the chain-tension-device.
PLEASE NOTE:
Mast with feed chain mechanism:
Clamping device
The tension of the chain is controlled by a
special cylinder at the front of the drill
mast. This is a high pressure cylinder. Do
never disassemble it yourself.
04/2008 KR 702- 2 / Serial no. 19104 29

3.2.1 Safety instuctions for roller chains for drill feed system
(only drill mast with feed chain)
(only for drill masts with feed chain)
CAUTION
”The 3,5- time security factor versus rupture of the roller feed chain, according to
DIN EN 791 (drill rigs- safety), is only ensured when the feed chain will be regularly
controlled.
Please notice, that the allowed tensile strain of the chain on pitch length as a result
of wear shall be checked according to the manufacturers guide line and to keep the
records of the check.”
General rules:
Roller chains have to be checked daily for cracks and fissures. Pins and links with
wear marks and grooves or mechanical deformations must be replaced.Roller
chains have to be checked weekly for elongation.
The permitted elongation should not exeed 2%.
The elongation test is realised on a grease- free and clean chain.
If the permitted elongation is exceeded, the chain is not useable any more and must
be replaced.
Elongation test procedure:
The gauge distance must consider at least 17 double- links in the working range of
the chain and should be done as follows:
a) Fix the total length of 17 double- links of a new chain within the pitch distance
(roller to roller / link to link)
b) The test procedure compares the total length of the new chain and the used
chain and if the used chain shows increased lengths of 16 1/2 double- link gauge,
the chain must be replaced.
Nominal length values:
Drill feed type 164 1 double link 19,05 mm
17 double links 323,85 mm
04/2008 KR 702- 2 / Serial no. 19104 30

3.3 Engine and central hydraulics (Power Pack PP-95-DS)
The main power source is an air- coo- In order to hold the hydraulic fluid in
led four- stroke diesel engine with an a optimal working temperature
output of 95 kW (4- Cylinders). range, a temperature sensor is in-
stalled in the cooling circuit. If the hy-
For details see engine manual. All ope- draulic fluid reaches a temperatur of
rating functions (tramming, alignment 40_C the fan motor of the oil cooler
and drilling), are powered by a four- cir- is switched on by a hydr. valve. The
cuit hydraulic system with a max. sy- fan motor will be switched off auto-
stem pressure of 250 bar (3626 psi). matically after reaching a hydraulic
fluid temperature of 40_C.
The open centre hydraulic system is
supplied from a hydraulic oil tank with a Cooling of the hydraulic fluid is required
capacity of approx. 400 litres. to maintain the right operational tempe-
rature and retain optimum viscosity.
The entire system is sealed- off to fore- This is assured by a hydraulic oil coo-
stall contamination. ling device, consisting of the cooler with
hydraulically driven fan motor.
04/2008 KR 702- 2 / Serial no. 19104 31

4 Operation
4.1 Operating Instructions
Controls for setting- up and alignment

CAUTION of the boom are placed on the left side
of the rig.
IN CASE OF DANGER ALL OF THE All controls for drilling functions are
RIG FUNCTIONS CAN BE STOPPED mounted on the slewable control panel
BY ACTIVATING ONE OF THE - during transport placed parallel to
EMERGENCY- OFF SWITCHES. boom and tracks- which can be slewed
out to the left in several steps.
All controls for the differing operational
functions of the rig are located in clearly Before starting to operate the drill rig,
isolated sections. hydr. hoses and electr. cable must be
Start and monitoring elements for the connected between the drill rig and the
main drive (diesel engine) are located Power Pack (see description of con-
at the left front side of the Power Pack nection plates KR 702- 2 and Power
and at the slewable control panel of the Pack on following pages).
drill rig. To ensure a correct function, check all
cable and hose couplings which are
Control elements for tramming func- connected between the drill rig and the
tions are placed on left side at the back Power Pack. If loose, tighten them cor-
of the rig. rectly.
slewable tramming console engine control box

control panel
04/2008 KR 702- 2 / Serial no. 19104 32

4.1.1 Hydr. rapid couplings on connection plate KR 702 - 2
1 2 3 4
5 6 7 8 9
1. Tank 1 (35L / DN32)

Connecting hose 2m (part no. 44135), 25m 2x (part no. 49476)
2. Pump 2 (30S / DN25)
3. Electr. connection plug
4. Flushing connection
5. Pump 1 (30S / DN25)
6. Tank 2 (35L / DN32)
7. Pump 3 (16S / DN12)
8. Leak oil (15L / DN12)
9. Pilot control (10L / DN8)
ATTENTION!
The maximally permissible hose lengths of the hydraulic connection hoses
between the drill rig KR 702 - 2 and the Power Pack PP- 95 - DS are 40 meters.
The extension of the hydr. hoses or a connection of the hydr. hoses by using
quick - couplers is absolutely forbidden.
By using of longer hydraulic connection hoses or decreasing of the hose cross
section by installation of quick- couplers, an increase of the dynamic
pressures results, which can lead to damages in the hydraulic system.
04/2008 KR 702- 2 / Serial no. 19104 33

4.1.2 Hydr. rapid couplings on connection plate Power Pack
PP - 95 - DS
Electr. connection plug

(For checking or tramming the Power Pack without any
connected hydr. devices, a dummy plug must be con-
nected to the free electr. plug.)
Leak oil
Tank T2
Tank T1
Pump P2
(Q = 90 l/min)
Pump P1
(Q = 115 l/min)
Pump P3
(Q = 20 l/min)
Pilot control P4
(Q = 15 l/min)
CAUTION !
For connection other hydr. devices to the Power Pack the corresponding
hydr. circuits must be considered!
04/2008 KR 702- 2 / Serial no. 19104 34

4.2 Control elements on Power Pack PP-95-DS
All controls of Power Pack are located in clearly isolated sections. The control
elements for diesel engine (engine control box, rpm control potentiometer,
emergency off ...) are mounted at the left front side on the Power Pack. The positio-
ning of ball valves for “warm- up”, drilling and tramming operations are described on
the following pages.
engine control box
rpm control potentiometer
EMERGENCY OFF
pic. 1 left front side of the Power Pack
cooler of diesel engine
battery disconnecting
switch
electronic engine
regulator (EMR 3)
pic. 2 rear side of the Power Pack
The battery disconnecting switch must be turned to the left side

(anticlockwise) to interrupt the electric circuit before you start with service or
repair works or in case of danger.
At the end of operation, the disconnecting switch must be turned to the right
side (clockwise). The electric circuit is closed.
04/2008 KR 702- 2 / Serial no. 19104 35

4.2.1 Engine control box PP - 95 - DS
Counter for
working hours
2
Display
3
Ignition lock
1
It is forbidden to clean the start and control element with strong water
pressure or with a high pressure cleaner
Indications and diagnostic oppotunities on the display of the engine
control box
Normal Indication:
- first line: diesel engine rpm

- second line: coolant temperature (if overheated a warning is indicated
behind the temperature value
- third line: 1. Indication of hydr. oil temperature
2. Condition of the ESS- ropes mounted on the drill mast
(if ropes are to hight or to loose = ”fault”- message)
This line is only shown if ESS- system is installed.

- under the ESS- symbol = diesel fuel indicator (at 15% filling = warning)
04/2008 KR 702- 2 / Serial no. 19104 36

Diagnostic oppotunities:
By simultaneous operating of button no. 2 + 3 the diagnostic oppotunities can be
selected
All inputs and outputs of the display and different engine data can be interrogated.
The buttons no. 2 + 3 on the engine control box are cursor buttons. The butten
no. 1 is the enter button.
In the lower part of the display the software version is indicated for service purposes.
In addition the language of the display can be adjusted here.
Diagnostic (Inputs and outputs of the control unit, engine data and system):
a) Inputs
Input 1 = permanent/inching (ESS):

If the selector switch perm/inching is in “permanent“ position, “1” is indicated. In posi-
tion “inching” the input is “0”.
Input 2 = inching/reset (ESS):

If the button inching/reset is pressed, “1” is indicated. If this button is not activated,
the input is “0”.
Input 3 = ESS drill mast (limit switch ESS):

If the limit switch, the rope tension and the electr. cable to the drill mast are ok, “1”
is indicated. If one of these conditions is failed, the Input is “0”
Input 4 = Hydr. oil level:

If there is enough hydr. oil in the oil tank, “0” is indicated. If the hydr. oil level is to low,
the input is “1”.
04/2008 KR 702- 2 / Serial no. 19104 37

Input 5 = Air filter:
If the air filter is contaminated, the input setting is “1”. If the air filter is clean, the input
is “0”.
Input 6 = Start:
If the start button or the ignition lock to start the engine is activated, the input setting
is “0”. If non of these conditions is fulfilled, the input stays in “1” setting.
Input 7: Option
Input 8 = Alternator:
If the alternator charges, the input stays in “1” setting (V- belt is ok).
If the alternator don’t charge, the input stays in “0” setting.
Input 9 = Operator panel

This value refers to the potentiometer for the speed adjustment of the diesel engine
“RPM ”at the control panel. Value depending upon potentiometer position approx..
2... 23V.
Input 10 = Travel panel (Power Pack)

This value refers to the potentiometer for the speed adjustment of the diesel engine
“RPM ”at the drivers stand (Power Pack). Value depending upon potentiometer posi-
tion approx.. 2... 23V.
Input 11 = Fuel tank level:

The indicator for the fuel tank level has an output signal from 4....20mA.
If an output signal of 4mA is clearly exceeded, it can be expected that a cable break
has already happened.
If an output signal of 20mA is clearly exceeded, a short- circuit can be expected.
Input 12 = Oil temperature:

The sensor for the oil temperature has an output signal of 4....20mA. If the 4mA limit
is under- run clearly, a cable break must be the cause. If the 20mA limit is exceeded
clearly, a short- circuit must be the cause.
b) Engine data
Here the following engine data can be interrogated.
04/2008 KR 702- 2 / Serial no. 19104 38

c) Outputs
Output 1 = Solenoid valve ESS:

If the conditions of the ESS (limit switch, activating, ...) are fulfilled, the output for the
solenoid valve will be set (=1) and the hydr. pilot control is activated.
If one of these conditions is not fulfilled, the input stays in “0” setting.
In addition this output is used, to switch off the power necessity when problems with
the diesel engine occur.
Output 2 = Solenoid cooler:

If the hydr. oil temperature is < 40_C, the output stays in “1” setting (cooler fan is not
working). If the hydr. oil temperature is > 40_C, the output stays in “0” setting (cooler
fan is working).
Output 3 = Warning:
This output is used for acoustic warnings when error messages of the diesel engine
occur (1 = Warning signal).
Outputs 4, 5, 7, 8: Option
d) System
The access to the area System is only released after consultation with KLEMM
Bohrtechnik and input of a special code.
04/2008 KR 702- 2 / Serial no. 19104 39

Error messages:
In the left part of the display different error messages can be indicated.
This error messages can not be recieped. After error correction and a new start
of the diesel engine, the messages are distinguished.
The following errors can be indicated:
1. Missing engine oil pressure 7. V- belt torn resp. the alternator

(at running diesel engine) don’t charge with a motor speed
of >1000 rpm
2. Overheating of the coolant 8. Overheating of the hydraulic oil
3. Fuel tank level under 15% filling
4. Air filter contaminated
5. Hydr. oil level to low
6. Cooling fluid level to low
04/2008 KR 702- 2 / Serial no. 19104 40

4.2.2 Engine control system Power Pack PP - 95 - DS
Cause of errors Reaction of the engine control system

Lack of cooling fluid S Warning in the display (text),
S Switching - off hydr. pilot control
S Switching - off diesel engine
To high cooling fluid S When temperature is >= 111_C Warning in the
temperature display (text)
S If temperature of cooling fluid is higher than
111_C, the power of the diesel engine will be
reduced up to 50% by the ECM system
S When temperature is >= 119_C Switching- off
diesel engine
To low oil pressure S Warning in the display (text),
Air filter contaminated S Warning in the display (text),
Lack of hydr. oil S Warning in the display (text),
V- belt torn S Warning in the display (text),
resp. the alternator S Switching - off hydr. pilot control
don’t charge with a motor S Switching - off diesel engine
speed of >1000 rpm
Overheating of the S Warning in the display (symbol),
hydraulic oil S Switching - off hydr. pilot control
S Acoustic warning signal
04/2008 KR 702- 2 / Serial no. 19104 41

4.2.3 Electronic engine regulator (EMR)
The electronic engine regulator (EMR) (pic. 1) is located at the rear side of the
power pack and can be reached through the rear cover door. The engine control
distribution (pic. 2) can be reached through the engine cover door on the left side
of the power pack.
At the engine control distribution there is a control lamp (1), a battery charge lamp
(2), an emergency rpm- potentiometer for the Diesel engine (3) as well as an inter-
face for a diagnostic computer (4).
Electronic engine regulator (EMR)
(pic. 1)
Engine control distribution
1 2
(pic. 2)
04/2008 KR 702- 2 / Serial no. 19104 42

Self - diagnosis of dieel engine by control lamp EMR
The EMR possesses numerous protection functions for the engine - depending on
the available measuring points or sensors. Depending on the seriousness of the re-
cognized fault, the engine may run on in reduced mode (limp home), whereby the
fault indicator lamp is continuously lit, or the engine is switched off, whereby the fault
indicator lamp flashes.
A lit fault indicator lamp indicates an error in the wiring (short circuit, cable break)
or a defect in the displays of the corresponding sensors. A further source of faults
could be falling below or exceeding the measuring value limits.
Faults in the electronics are registered or stored in the control unit and shown by the
fault indicator lamp. The fault indicator lamp is extinguished as soon as the fault has
been removed. Only when the electronics
has been switched to emergency running (- speed), need the engine be switched
off briefly with the keyoperated switch in order to extinguish the fault indicator lamp.
Also corrected or non- current faults remain stored in the control unit and can be
read out or deleted by the customer service of Klemm Bohrtechnik.
Important notes for EMR-System
Electrical welding
In order to prevent damage when carrying out ELECTRIC welding of the installa-
tion, the plug connections of the EMR and ESX- calculator shall first be pulled out!
They are located at the left hand side of the Diesel engine inside the sound proof
cover.
The ignition must be switched off when working on the EMR.
Remove plug
Removing the 25- pole control apparatus plug when the control apparatus is on,
i.e. when the voltage supply is on is not permitted.
1. Voltage supply off
- only then -
2. pull out plug
Damage
The plug connections of the control units are only dust and watertight when plug-
ged into mating connection! Until the mating connector has been plugged in, the
control units must be protected against spray water!
04/2008 KR 702- 2 / Serial no. 19104 43

4.3 Prior to start-up
F Be sure that all operating levers are in neutral ”OFF” position
F Check that EMERGENCY OFF switches on the slewable control panel and on
the tramming console of the drill rig and on the front side of the Power Pack
are inactive.
F Check diesel tank filling, engine oil level, transmission oil level, hydraulic oil
tank filling level using indicators and devices, and refill if necessary.
F Be sure that all hydraulic fittings are securely tightened (leaks !), and that lines
show no kinks or are jammed.
F Absolutely ckeck before the START the Power Pack:
a) Ball- valve in hydr. pump suction line and diesel engine fuel line opened?
b) All control levers in neutral ”O” position?
c) Hydraulic fittings tight?
d) Oil level adequate? (Engine, tramming motors, gears and hydraulic oil tank)
F Let the hydraulic system cycle to ”warm- up” (see following page).
The optimum operating temperature for hydraulic oil depends on the viscosity
class of the used hydr. oil (see chapter 6.2).
By warming up the hydraulic system, the regular sensivity of the hydraulic sy-
stem is reached.
If the drill rig is operated at lower oil temperatures without accomplished war-
ming - up phase, the retarded responding of the hydraulic functions occur.
In order to hold the hydraulic fluid in a optimal working temperature range,

a temperature sensor is installed in the cooling circuit. If the hydraulic fluid
reaches a temperatur of 40_C the fan motor of the oil cooler is switched on
by a hydr. valve. The fan motor will be switched off automatically after re-
aching a hydraulic fluid temperature of 40_C.
F To “warm up” the hydraulic system at cold outside temperatures all three shut-
off valves at the Power Pack (see picture) must be shifted in the position, in
which the hydr. oil can flow back into the tank without pressure build- up.
This is ensured with opened shut- off valves (see sticker at the Power Pack and
the description on following page). The shut- off valves can be closed after a
warming - up phase of approx. 10- 15 minutes.
04/2008 KR 702- 2 / Serial no. 19104 44

Ball valves on Power Pack PP - 95 - DS
Three ball valves in the engine compartment

behind the engine cover door at the right side
of the Power Pack
Ball valve position in warm - up phase
CAUTION !
For drilling operations the ball valves must be closed after reaching
the working oil temperature!
F If a emergency stop switch was activated during operation of the correctly atta-
ched drill rig, the stopped Power Pack can be restarted by the following steps:
a) Neutral position of all control functions must be guaranteed

b) Emergency stop switch at the drill rig and at the Power Pack must be
unlocked
c) Press start button at the drill rig.
04/2008 KR 702- 2 / Serial no. 19104 45

4.4 Engine start-up
a) Set rpm control potentiome- If the engine does not fire,
ter to approx. quarter speed repeat starting procedure
(on the left front side of the after 1 minute.
Power Pack or on slewable
control panel of the drill rig). The ignition lock is fitted
The potentiometer with the with a repeat- starter preven-
higher setting controls the en- tion lock. This means that the
gine speed. key must be returned to ”O”,
before restarting attempts.
b) Insert starter key into ignition
lock and turn clockwise to d) Return accelerator potentio-
position 1. The display of the meter to idling speed as
engine monitoring light up. soon as the engine is
running smoothly.
c) Turn starter key in ignition
lock to position 2, and release
as soon as engine starts Trouble - shoot by referring
firing. Do not activate the star- to the engine manual.
ter for more than 10 seconds
at a time.
Attention: Always ensure that the engine and starter motor are stationary
before the starter motor is engaged again.
4.4.1 Starting procedure of an Power Pack in cold ambient

temperature conditions
Outside temperature below 5C (41F)
• Start the engine

• 2 minutes idle running
• encrease engine revolution onto 1500 rev/min
• Actuate (casing- ) rotation (slow gear) and let it run for 5- 10 minutes
(oil should be ”hand- warm” then)
Outside temperature above 5C (41F)
• Start the engine

• 1 minutes idle running
• encrease engine revolution onto 1500 rev/min
• Actuate (casing- ) rotation (slow gear) and let it run for 3- 5 minutes
(oil should be ”hand- warm” then)
Caution!
Upon non- compliance of the warm- up phase there is a danger
of cavitation inside the pumps as well as delayed responsivity
of the hydr. functions.
04/2008 KR 702- 2 / Serial no. 19104 46

4.5 Tramming the crawler drill rig
CAUTION
Be sure to check for adequate clearance prior to each start- up and before
tramming, setting- up and drilling operations.
Do not apply levers fully to begin with, but activate as if accelerating a car.
Lever position determines the degree of opening of the control valves
and therewith the quantity of oil supplied.
Never activate one track only dragging the other one behind when turning
or changing direction. always let both tracks turn
clockwise / anti - clockwise.
1. Activate control levers in corresponding direction.
2. The crawler drill rig is steered by counter- activation of the control levers.
3. Parking brakes are automatically applied on recentering the control levers.
4. While tramming the rig be sure to align the drill mast horizontally resting on the
mast support bracket.
5. Drill head unit must be positioned between mast carrier and mast support
bracket.
6. Never attempt to turn the drill rig on the spot in swampy muddy or any soft
ground conditions. Try to free the tracks by tramming and turning slowly at the
same time.
Control lever for Control lever for

tramming left tramming right
EMERGENCY-
OFF
04/2008 KR 702- 2 / Serial no. 19104 47

4.5.1 Tramming the drill rig on slopes
When tramming and working on slopes with a slope angle of more than 20_, the drill
rig must be equipped and secured with a rope winch (it is forbidden to use free
fall winches) to avoid sliding down or rollover of the machine on slopes. The winch
must be equipped with a safety brake system. The cable connector point must be
designed and tested for dynamical loading forces. Pull force f on third layer of
winch
f > 0,50 for a slope angle of< 40_

pull force
f = -------------------------
mass of machine
Example:
CAUTION
If the pull force f is lesser than shown in the upper sketch, the corresponding winch
must not be used for securing the drill rig. A winch with a adequate pull force f accor-
ding the upper calculation must be used.
4.5.2 Manoevrability
To ensure maximum manoevrability and steering of the crawler tracks, it is important
to keep the track chains clean and free from build ups. Dirt and mud build up in the
crawler tracks make the chain stiff and difficult to pass over the sprockets.
This impairs the steering capacity and may cause ruptures and breakages of the
crawler chains.
04/2008 KR 702- 2 / Serial no. 19104 48

4.6 Setting up and alignment
The control console for boom alignment is located on the left side of the drill rig,
and consists of three adjacent operating levers. The fourth lever is optionally used
for sidewise shifting of drill head unit. These can be activated forward or backward
from the centre setting. Push or pull the levers to activate the corresponding hydrau-
lic cylinders.
All cylinders are fitted with load bearing valves, locking the cylinder in position even
when the control lever is released and centres automatically.
The levers - from left to right as you stand in front of the control console the following
functions :
1 2 3
symbols
1 3
Push : Push:
Drill mast Swivel head
displacement to the front tilting forwards
Pull : Pull :
Drill mast Swivel head
displacement to the back tilting backwards
2
Pull :
Swivel head to the
left around its axle
Push:
Swivel head to the
right around its axle
04/2008 KR 702- 2 / Serial no. 19104 49

4 5 6 7 8 9
symbols
4 7
Push/Pull: Push/Pull:
Telescope Right rear
left track section propping cylinder
up/down
5 8
Telescope Left front
right track section propping cylinder
up/down
6 9
Left rear Right front
propping cylinder propping cylinder
up/down up/down
04/2008 KR 702- 2 / Serial no. 19104 50

4.6.1 Safety instructions for operation with telesc. drill mast
type 164 and lateral slidable glide slide
The drill rig KR 702- 2 is equipped with two cylinder limitations ("15_) for the drill
mast. During drilling with telesc. drill mast and sidewise slidable glide slide, the two
cylinder limitations (see picture) must be fixed between the hydr. cylinders and the
slewing head.
Due to stability reasons it is strictly forbidden to dismount the limitations during

drilling process with mounted telesc. drill mast and sidewise slidable glide side.
cylinder cylinder
limitation limitation
04/2008 KR 702- 2 / Serial no. 19104 51

4.7 Drilling controls
4.7.1 Drilling controls on base drill rig
Pressure maintaining valve

for hold- back device 10 11 12
ATTENTION !
After every adjustment of the drill mast, you must regulate the
pressure maintaining valve! A to low regulation of the pressure
maintaining valve can result damages and danger for persons.
symbols
10 12
Manually adjustable Manually adjustable
pressure regulator drifter percussions
for drill string rotation frequency
(only for hydr. drifter)

Press
Frequency
11
Manually adjustable
pressure regulator
for drifter percussions
Press
04/2008 KR 702- 2 / Serial no. 19104 52

4.7.2 Drilling controls on slewable control panel
13 14 15 16 17 18 19 20
ESS- box
see page 56
symbols
13 15
Push/Pull: Push:
Drill string Rapid feed
rotation downward
Pull:
Rapid feed
upward
14 16
Push: Push:
Drifter percussion Feed downward
Pull:
Additional rotation Pull:
Feed upward
04/2008 KR 702- 2 / Serial no. 19104 53

symbols
17 19
Push: Push:
Winch hook down Close
clamping device
Pull:
Winch hook up
Pull:
Open
clamping device
18 20 *
P Manual regulation Push:
of feed pressure Side moving of
drill head unit
Pull:
Side moving of
drill head unit
Please note!
By different tight seals in the clamping cylinders, differences in mobility etc.,
the synchronisation can be affected unfavorably. In order to reach a
synchronisation of the clamping cylinders it is advisable to open and close the
clamping devices completely occasionally.
* CAUTION!
Do not touch the lever while drilling with rotary head!
Slidewise sliding of the drill head unit while drilling operations will damage the
drill rig and is danger for person!
04/2008 KR 702- 2 / Serial no. 19104 54

4.7.2.1 Safety Instructions for rope winches mounted on drill masts
The max. load admission area of the winch with drill mast in vertical position is limi-
ted to operations at maximum 2,0m distance from the drilling axis line of drill mast
(drill hole) in tramming direction. The sidewise load admission area is limited to the
tipping edges of the crawler tracks (see sketch below).
Cause of safety reasons this limitations of the rope winches load admission area
must striktly been observed, otherwise accidents and heavy damages on the drill
rig can result. In that case Klemm Bohrtechnik can not take over responsibility!
While operation the rope winch at least three rope windings has to be left on the rope
drum. The max. load capacity of the winch has to be taken out of the spare part cata-
logue.
CAUTION:
Never misuse the winch cable to trail / traction heavy weights (i.e. bars, barrels,
heavy pipes, reinforcement cages) to the drill rig.
The purpose of the winch is to mount accesories for drilling only within the max. load
admission area and only with drill mast in vertical position. The drill mast with
mounted rope winch is defenitely not a crane.
Sketch for Safety Instructions for rope winches mounted on drill masts
(Limitations of load admission area!)
Tipping edges max. 2,0m

of crawler tracks
Max. operating area rope winch
04/2008 KR 702- 2 / Serial no. 19104 55

4.8 ESS control box on slewable control panel
Functions on the electr. ESS -Box

1 EMERGENCY- switch off
2 Start - button
3 Gear switching for rotary drill head
- Switch in upper position: two speed motors (slow gear)
- Switch in lower position: two speed motors (fast gear)
4 Horn
5 RPM regulation for diesel engine
04/2008 KR 702- 2 / Serial no. 19104 56

4.9 Telescopic function of the drill mast
Drill mast type 164 is equipped with a hand operated valve to block telescopic mode
(see picture below)
Open position of the valve
The open position allows to use the telescopic function of the drill mast. While
drilling the telescopic mode will be activated first. Then the displacement of
the glide slide on the drill mast is activated.
If the valve block is closed the range of operation is limited to the displace-
ment of the glide slide on the drill mast.
Valve block with lever for switching

the telescopic function
04/2008 KR 702- 2 / Serial no. 19104 57

4.10 Operation
1. Use boom control levers to align the drill mast in the required position.
Mast has to be pressed against object to drill. Check mast inclination with angle
indicator.
2. Adjust the feed pressure setting using the adjustment valve on the control
panel.
3. The pressure setting can be monitored with the pressure gauge installed on
the power pack.
4. The right feed pressure setting depends on ground conditions, drilling diame-
ter and bore hole length, and is reflected by an optimum penetration rate.
CAUTION
System pressures are set at the primary pressure limiting valves.

Do not attampt to adjust these pressure settings.
This would be result in hose - seal - and valve damages.
It also reduces the life of this equipment.
5. While tramming the rig, be sure to align the drill mast horizontally, resting on
the mast support bracket. The drill head unit must be positioned between mast
carrier and mast support bracket.
6. Never attempt to turn the drill rig on the spot in swampy or boggy ground
conditions.Try to free the tracks by tramming and turning slowly at the same
time in case the machine gets trapped.
7. Working without a rod centralizer is normally not permitted.
Take care to ensure that the amount of play between the drill string and rod
centralizer does not exceed the amount specified.
Approximate max. clearance with respect to rod centralizer:
rod diameter + 4mm
If this approximate distance is reached, the jaws in the rod centralizer must be
replaced with new ones that are compatible with the rod diameter.
Note that the manufacturer can accept no warranty liability whatsoever
for loss or damage resulting from a failure to observe these setup guide-
lines.
Equipment of the KR 702 - 2 with the serial no. 19104
Drill head unit consists out of:

Rotary drill head KH 16
04/2008 KR 702- 2 / Serial no. 19104 58

Regardless of which system or method you are using make sure that you have also
the following tools and equipment on- site:
A) Coupling Grease with an applicator brush

B) A Wire Brush to clean casing and threads
C) Wrenches of the proper size for the inner drill string
( with a Safety Rope on the handle )
D) 2 No. 36” Pipe Wrenches (these are handy on any drill)
E) A set of Saw Horses of sufficient strength
to hold your drill rods and casing and to keep them off the ground
F) A Shovel to remove cuttings from the work area
G) An In - line Oiler (If you are using a DHD)
H) An extra Water Line with nozzle, to wash mud and grout from
tools and drill rig
I) A Grease Gun
J) A Level or Angle Indicator to align the mast on the hole
K) Whip Checks for all hoses
Before you start to operate the crawler chassis of the KR 702-2

the following indications must be strictly observed:
1) Support cylinders must be retracted.
2) Check ground conditions; if necessary level the groung with bars or plates.
3) Lift drill mast and slew it upwards.
4) Before the beginning of drilling operations, the support cylinders must be

extended for stability reasons.
Both operating levers must always be released and actuated to operate one or
both crawler chains.
04/2008 KR 702- 2 / Serial no. 19104 59

4.10.1 Drilling
The choice for the right drilling method
` single rotary head
as well as the decision which drilling accesories and flushing medium (air and / or
water, only water, water and ground support medium like BAROID) is the best one,
can only be made after a careful consideration of all site conditions and the main
contract specifications.
After having chosen the accessories (of which Klemm offers a wide range off all diffe-
rent kinds) the operator has to determine the right feed pressure and R.P.M.
settings, in order to get the best performance.
Park the drill rig on levelled and bearing ground. Use boom and mast control levers
to spot the drill mast with the inclination required.
When drilling, mast has to be pressed and fixed to ground or to object to drill !!
Always check the mast inclination during set - up and drilling.
04/2008 KR 702- 2 / Serial no. 19104 60

5 Crawler tracks
The drill rig KR 702- 2 is equipped with two crawler tracks. In order to ensure a per-
fect function of the tracks, special attention to the correct track chain tension and
maintenance of the tramming gear must be paid.
Rotating component wear parts such as lower rollers, carrier rollers and Idlers
are sealed with lifetime friction seal groups and oil lubricated. Oil changes or refilling
are not necessary.
All srews have to be fastened after 50- 100 hours of operation with the required
torque. We recommend to check the torque of screws once a week.
5.1 Adjusting Track Tension
For operation of the drill rig it is important that the the chains are correctly tensioned.
A chain should be tensioned that it has approx. 2 cm slack span on 1 m.
If the distance from the supporting roller to the idler amounts to e.g. 1.5 m, then the
chain has to sag approx. 3 cm in the center.
Sketch catenary
If the sagging of the chain exhibits a higher value than 3 cm, grease has to be filled
in the lubrication fitting (2) of the tensioning cylinder (3) by a grease gun (4) until the
correct tensioning value is reached.
If the track chain tension is to high, the adapter nipple (1) of the tension cylinder (3)
is to be loosened and grease must be discharged, until the correct value is reached.
Afterwards the adapter nipple is to be tightened again.
Sketch track chain tension
04/2008 KR 702- 2 / Serial no. 19104 61

5.2 Repairs on crawler chains
ATTENTION
The Chains are under tension!
The Chains are tensioned by a high pressure grease cylinder!
ATTENTION
Before removing or repairing crawler chains, the drill rig must be switched off and
firmly stabilised.
Chain repairs must only be done only by qualified personnel. Worn bolts must al-
ways be renewed.
Do not weld on crawler plates. Broken crawler plates must be replaced by new.
Before repairs and replacement operations are executed, it is absolutely necessary
to reduce the chain tension. The tension of the chain is controlled by a special high
pressure cylinder filled with grease (see page 61 item no.1).
After repairs are finished, the track must be tensioned as described on page 61.
5.3 Controls on tramming gear box

To check the oil level of the tramming gear box, be sure that the filling plug for the
oil filling (1) and the drain plug (2) are positioned as shown below.
Tramming gear box

(spare part nr. 402269)
To check the oil level, the filling plug (1) must be unscrewed. The oil level must reach
up to the edge of the filling hole. If necessary oil must be refilled (total amount of filling
of approx. 1,2 litres).
Before screwing in the filling plug, the sealing must be controlled and replaced if ne-
cessary.
Important controls at the tramming gear box
Check leak tightness : daily

Check oil level : all 200 - 250 operating hours
Change oil : first change after aprox.. 200 operating hours.
Each further oil change all 2000- 4000 operation hours,
at latest however after 12 months.
04/2008 KR 702- 2 / Serial no. 19104 62

6 Care and maintenance of the KLEMM crawler drill
rig type KR 702 - 2
The use of machine and automatic drill rigs is very important in the modern day buil-
ding trade because it saves a considerable amount of labour and rationalizes the
drilling and blasting work.
The efficiency of the machine application must be as high as possible and particular
attention must be paid to a high availability of the machines.
Please bear in mind that machine failures on the building site can cause high conse-
quential costs and delays.
The availability of the machines and the avoidance of unforeseeable failures as-
sume a well organized maintenance system which ranges from the manufacturer
to the utilising company and building site operation.
The aim of scheduled care, maintenance and service is to achieve optimum availa-
bility of the implemented drill equipment and accessories.
A. Basic principles
Maintenance measures are:
` Maintenance
Measures for maintaining the nominal condition, e.g. cleaning, lubrica-

ting, oil change, simple adjustments.
` Inspection
Measures for defining and evaluating the actual condition.

` Preventive maintenance
Replacement of still operable parts or modules with the aim of preventi-

vely eliminating signs of wear before damage occurs.
` Repair
Measures for reinstating the nominal condition.
04/2008 KR 702- 2 / Serial no. 19104 63

B. Safety regulations
Care, maintenance and servicing of building machines considerably influences the

operating safety. It should be pointed out that every fifth industrial accident happens
in connection with maintenance. The two main causes of accident are:
a) Improper maintenance
b) Deficient operating safety due to absence of or insufficient

maintenance
The official safety rules consisting of the rules for the prevention of accidents, regula-
tions and safety rules must always be observed.
Individual regulations require inspection, in particular:
` as required or
` at fixed intervals
by:
` a specialist or
` expert
Specialists are persons who due to their professional training and experience have
sufficient knowledge in the field of the technical equipment to be tested and are able
to assess the safe condition of the technical equipment.
Experts are persons who due to their professional training and experience have spe-
cial knowledge in the field of the technical equipment to be tested. They should be
able to test and provide an expertise of the technical equipment.
For the purpose of these care and maintenance instructions this means that:
Care, maintenance and service work can be performed by trained, specialist per-
sonnel of the owner.
PLEASE NOTE
Structural changes, additions, mountings, adjustment of pressure limiting valves

and safety valves etc., which modify the equipment’s behaviour (e.g. Stability),
are to be effected only after consultation and with the written permission of
KLEMM Bohrtechnik and under the supervision of a KLEMM Bohrtechnik
Specialist Expert. Changes without consultation of the manufacturer result in a
total loss of warranty.
04/2008 KR 702- 2 / Serial no. 19104 64

6.1 Maintenance intervals
Proper maintenance prevents premature wear and preserves the functionality of the
device.
Any damages can be detected at an early stage and save the owner expensive re-
pairs.
The maintenance intervals are specified as follows:
- Every 8 operating hours or daily
- Every 40 operating hours or weekly
- Every 100 operating hours or after two weeks
- Every 250 operating hours or monthly
- Every 500 operating hours or every three months
- Every 1000 operating hours or once a year
- Every 2000 operating hours or once a year
For normal operation the intervals are accumulative, i.e. when work for the 100 hour
maintenance is due, the work for the 8, 40, 100, 250 and 500 hour maintenance is
also due.
For assignments with a strong development of dust and extreme wet it may be ne-
cessary to perform the lubrication and maintenance work at shorter intervals than
those specified.
PLEASE NOTE
The maintenance work must be recorded and countersigned in the maintenance

and repair log by the machine operator responsible upon completion. The Klemm
Bohrtechnik company will be allowed access to this log in the event of claims under
the guarantee.
DISPOSAL
Old oil, filter elements, hydr. hoses, fuels, lubricants, cleaning agents, batteries,
emptied or partially emptied vessels of above mentioned materials and cleaning
cloths etc. are special waste and must be disposed of as such!!
04/2008 KR 702- 2 / Serial no. 19104 65

6.2 Recommended Oil- and grease-types for drill rig KR 702-2
with Power Pack PP-95-DS
Fields of use Oil- and grease-type Quantity (liters)

SAE 10 W- 40 / SAE 10 W - 30
Diesel engine Specification:
approx. 15*
TCD 2012 L04 2V -ACEA E3, E5, B3, B4, A3
-API CH-4, SJ
Mineral hydraulic oil:

Specification: Requirements of hydraulic oils
HLP (DIN 51524-2) must be fulfilled.
VG 32: for winter conditions in
Central Europe
( - 20_C bis +20_C)
VG 46: for summer conditions in
Central Europe or Indoors
( - 5_C bis +30_C)
VG 68: for tropical conditions or
in warm rooms
(+5_C bis +40_C)
Hydr. circuit 400
Bio hydraulic oil:
Specification: VDMA 24’568 HEES (water-in-
soluble, synthetic esters), ISO 15380
VG 46: field of use for
outer temperatures
from - 15_C up to +40_C
Original Klemm oil filling:

Hydr. oil HLP 68 (mineral oil)
(VG 68)
(VG = viscosity class)
BP ENERGOL GR- XP 150

Specification: The oil must correspond to the
Tramming gear 1,2
requirements ”lubricating oils CPL” according
to DIN 51’517 part of 3.
Shell Alvania RL 2 Grease cartridge

Grease for
0,4 kg
general greasing Specification: DIN 51825, K2N-20
(part - no. 402000)
* These values are the approx. capacities for the crankcase oil sump which
not include the standard installed oil filters. Engines with auxiliary oil filters
will require additional oil. See also operation manual of diesel engine.
04/2008 KR 702- 2 / Serial no. 19104 66

6.2.1 Characteristics of different hydraulic oils for Klemm drill rigs
The selection of the right hydraulic- oil and the ambient- outside - temperature -
ranges have important influence on hydraulic functions and speeds of the drill rig.
The max. permissible viscosity- range for the hydraulic components is 1600mm2/s
only for engine start- up (cold start). For short running times (warm- up phase of
diesel engine) the permissible viscosity- range is 1000mm2/s.
The permitted operating- viscosity - range for the hydraulic components should be
between 10mm2/s und 380mm2/s.
The optimum operating- viscosity - range for the hydraulic components should be
between 16mm2/s und 36mm2/s. Please refer to the following ”Viscosity - Tempera-
ture” - diagrams for mineral hydraulic oils and the bio hydraulic oil Panolin
HLP Synth 46.
Viscosity - temperature - diagram for mineral hydr. oils

Viscosity in mm2/s
Temperature in C
Surface temperature range of the hydr. pump
04/2008 KR 702- 2 / Serial no. 19104 67

Viscosity - temperature - diagram for bio hydr. oil
Panolin HPL Synth 46 and mineral hydr. oil HVLP 46 + HVLP 68
Viscosity in mm2/s
Temperature in C
Surface temperature range of

the hydr. pump
Caution!
When hydr. oils of different manufacturers respectively different types of oil
from the same manufacturer are mixed, it can lead to silting and
sedimentations. These facts can create malfunctions and damages
of the hydr.system.
Caution!
Mineral oils and synthetic oils can not be mixed. Therefore please refer
always to page 66 (original Klemm oil fill).
04/2008 KR 702- 2 / Serial no. 19104 68

6.3 Filters and filter inserts for KR 702-2 and PP-95-DS
6.3.1 Filter and filter inserts for KR 702 - 2

(only with mounted hydr. drifter)
Drifter pre line filter cpl. Part no. 40338
Filter insert for drifter pre line 3μm (1 pc.) Part no. 41665
Filter contamitation indicator for drifter filter Part no. 45267
First change of the filter insert must be done after 100 working hours, all further 500
working hours, or sooner in case the dirt indicator needle moves up. After the filter
change the dirt indicator moves back into neutral position.
Filter contamination indicator
Drifter pre- line filter
04/2008 KR 702- 2 / Serial no. 19104 69

6.3.2 Filter and filter inserts for Power Pack PP - 95 - DS
ATTENTION!
Always stop the diesel engine of the drill rig before maintenance or repair work
is being done !!
Hydr. filter and filter insert

Return line filter cpl. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Part no. 403815
Filter insert for return line filter 10μm (1 pc.) . . . . . . . Part no. 403816
Filter contamitation indicator for return line filter . . . . Part no. 403351
Open the maintenance flap on top of the power pack. The return- line filter is moun-
ted on the hydr. oil tank of the power pack. Remove cover plate of filter housing,
change insert and close housing.
Filter changes : The first filter change has to be done after 100 operating hours.
Later changes all 500 hours
Maintenance flap Return line filter
Contamination indicator
for return line filter
Hydr. oil cooler
Hydr. oil tank
Fuel tank
04/2008 KR 702- 2 / Serial no. 19104 70

Diesel engine filter for Deutz TCD 2012 L04 2V
Engine oil filter (Deutz)
Part no. oil filter (1 piece) . . . . . . . . . . . . . . . . . 47265

The engine oil filter (see photo) must be changed every 500 hours or once a year.
Fuel filter (Deutz)
Part no. fuel filter (2 pieces) . . . . . . . . . . . . . . . 403802

The fuel filter is mounted on the right - back side of the engine.
The fuel - filter must be changed every 500 hours.
Fuel filter Air filter
Fuel prefilter Engine oil filter
04/2008 KR 702- 2 / Serial no. 19104 71

Fuel prefilter with water separator
The diesel prefilter is mounted at the left side of the innerside of the sound proof
cover. The insert of the diesel prefilter and the seal kit must be changed at least
all 1000 hours (see also in the operation manual of the diesel engine).
The diesel prefilter must be controlled of water mass once a day.
Please note!
Inadequate maintenance of the fuel prefilter results heavy damages of the engine
fuel injection system!! In particular this valids for countries which use low quality
fuels.
Fuel prefilter
Part no. filter insert (1 piece) . . . . . . . . . . . . . . 403801
1 Fuel supply to pump

2 Fuel return from control block FCU (Fuel Control Unit)
3 Fuel hand pump with bayonet plug for locking and unlocking
4 Thermostat valve with shut down lever
5 Filter cartridge
6 Connection facility for electrical water level sensor
7 Drain cock
8 Water collection vessel (bowl)
9 Fuel inlet from fuel tank
10 Fuel return to fuel tank
A Connection for electr. warning / horn
04/2008 KR 702- 2 / Serial no. 19104 72

Fuel prefilter, changing / bleeding filter insert
Filter change:
D Close fuel stopcock (for high tanks)

D Position fuel collecting vessel beneath fuel prefilter.
D Loosen drain cock (7) and drain water + fuel completely.
D Unscrew filter cartridge (5) together with water collecting vessel (8) in
anti - clockwise direction and remove.
D Loosen water collecting vessel (8) from old filter cartridge (5) in anticlockwise
direction and remove.
D Empty remaining fuel into the fuel collecting vessel and clean water collecting
vessel (8).
D Screw water collecting vessel (8) onto the new filter cartridge (5) in clockwise
direction.
D Clean any dirt from the sealing surface of the new filter cartridge (5) and the
reverse side of the filter head
D Wet the sealing surfaces of the filter cartridge (5) slightly with fuel and screw
back onto the filter head in clockwise direction (17- 18 Nm).
D Open the fuel stopcock and bleed the system
(see ”Bleeding fuel system”).
D Dispose of collected fuel and old filter cartridge (5) properly.
Bleeding fuel system:
D Unlock the bayonet plug of the fuel hand pump (3) by pressing and turning
anti - clockwise at the same time. The pump plunger is now pushed out through
the spring.
Turn the shutdown lever of the thermostat valve (4) by approx. 45 in
clockwise direction until it is felt to engage.
D Pump until a very strong resistance is felt and pumping becomes very slow.
D Now carry on pumping a few more times (the return pipe must be filled).
D Start the engine and run for about 5 minutes in idle or low load.
Check the prefilter for leaks.
D Perform some more pumping movements. (The return line must be filled).
D Turn the shutdown lever of the thermostat valve (4) by approx. 45_ in
anti - clockwise direction until it is felt to engage.
D Lock the bayonet plug of the fuel hand pump (3) by pressing and turning
clockwise at the same time.
04/2008 KR 702- 2 / Serial no. 19104 73

Air filter
The air filter is mounted in the engine compartment and can be reached by the
swiveling door at the left side of the sound- proof cover (see picture). In the filter hou-
sing, a main filter element and a safety filter element are installed. Both filter ele-
ments must be changed all 500 operating hours. For changing the filter elements
the housing cover must be dismantled.
ATTENTION:
Never run the diesel engine without properly mounted air filter because the motor
will be damaged by abrasive airborne particles.
Part no. air filter cpl. (1 piece) . . . . . . . . . . . . . . . . . . . . . . . . . . . 403908

Part no. main element for air filter (1 piece) . . . . . . . . . . . . . . 403910
Part no. safety element for air filter (1 piece) . . . . . . . . . . . . . 403911
Air intake from the

environment Housing cover
Clean air to Filterchange

the engine
air intake
Air filter housing
Main element
Safety element
04/2008 KR 702- 2 / Serial no. 19104 74

6.4 Scope of the 100 hour inspection
100 hour inspection
The first inspection must be made after 100 operating hours.

The following points must be dealt with:
- Change engine oil and filter
- Change hydraulic filter
- Check gear oil levels
- Check screw connections for tight fit, tighten if necessary
- Checking welded structures
- Checking system pressures
- Eliminating possible leakages
- as well as performing all the work that

is listed in the 8 hour table (see lubrication, maintenance
and inspection schedule).
The 100 hour inspection must be made by KLEMM Bohrtechnik Customer Ser-
vice or an authorised dealer. Failure to do this work will lead to voiding of the gua-
rantee.
04/2008 KR 702- 2 / Serial no. 19104 75

Service Intervals in Operting Hours
6.5 Lubrication Chart
Maintenance and
Service Intervals 8 16 40 100 250 500 1000 2000
1. Diesel Engine Deutz TCD 2012 L04 2V

Check oil level in engine F
Change engine oil F
(by authorized technical personnel)
Clean cooling fins F
Check level of coolant F
Exchange engine oil filter cartridges F
Exchange fuel filter cartridges F
Check air filter contamination and clean if F
necessary
Check V-belt tension F
For maintenance detailed data of the engine manufacturer must be absolutely observed (see
engine manual)!
All 500 operation hours an engine inspection is to be accomplished by authorized technical
personnel.
2. Hydraulic oil tank

Check oil level F
Check for leaks F
Check oil temperature - see also Instructions F
Change oil (1st. after 500 h ) min. once a year F
Change filters F
3. Valves, fittings, hoses

Check for leaks - eliminate F
Check fittings for tightness F
4. Hydraulic oil cooler / Diesel engine cooler

Clean cooler block and air intake fans F
Check cooling fluid level F
5. Hydraulic pumps and motors

Check for leaks and noise characteristics F
6. Battery
Check acid and charge level F
04/2008 KR 702- 2 / Serial no. 19104 76

Service Intervals in Operting Hours
Lubrication Chart Maintenance
and Service Intervals
8 16 40 100 250 500 1000 2000
7. Crawler tracks
Check track chain tension F
Check oil level of tramming gear box F
(also see chapterl 5.3)
8. Drill mast
Check filling level of greasing points (regrease) F
Check oil level of fed gear
Check Feed Chain tension and clean the links F
Check Bearings and Bushings F
Check wear of rod centralizer F
(approximate max. clearance with respect to
rod centralizer: rod diameter + 4mm)
Drill head unit (rotary drill head / Hydr. drifter) Please refer to the technical manual of the
corresponding rotary drill head or Hydr. drifter
9. Glide slide
Check wear of guiding strips F
(max. lateral clearance = 5mm, max.
clearance in reference to the drilling center
higth = 10mm)*
Check Bearings and Bushings F
10. Boom
Check and lubrication point and regrease if F
necessary
Clean piston rods of the hydr. cylinders F
Check and grease guide strips F
Check bolts F
* Wear limits of the guiding strips mounted on max.5mm
glide slides
Guiding strip
max.10mm
04/2008 KR 702- 2 / Serial no. 19104 77

6.5.1 Maintenance of piston rods of hydraulic cylinders
It is recommended to lubricate piston rods that are not retracted in resting position,
regularly once or twice a week with hydraulic oil (or something similar).
Please conserve the piston rods with acid- free fat, if longer downtimes are
expected.
Please note:
Cleaning of chromed piston rods with a high pressure cleaner or alkaline
cleaning agents damages the chromium layer and destroys the corrosion
protection!
6.6 Special instructions for Deutz Diesel engine

TCD 2012 L04 2V
6.6.1 Permitted fuels for DEUTZ diesel engine

For Deutz diesel engines which are used for our drill rigs, the in technical circular
”TR 0199- 3005” listed fuel types are permitted.
The use of low quality fuel (inclusion of dirt, high water content) shall be avoided
in any case!
The consumption of such fuels can lead to severe damages of the injection system
and to engine breakdowns.
The requirements nowadays in view of environmantal laws assume high quality

injectors with narrow manufacturing tolerances, which don’t allow low quality fuels.
Injector damages occurred by low quality fuels, which don’t correspond with above
mentioned technical memo, do not fall under our warranty policy.
6.6.2 Dark coloration of diesel fuel due to oil ingress

Pay absolutely attention that the dark coloration of diesel fuel does not exceeds the
permissible limit value by oil ingress. This limit value is to be taken from the technical
circular TR 0199- 99 - 1133 of the company Deutz. In order to keep the dark colora-
tion of the diesel fuel small, the diesel tank must be driven as empty as possible be-
fore refilling.
04/2008 KR 702- 2 / Serial no. 19104 78

6.6.3 Cooling liquid
To ensure long life running conditions and to avoid damage of the Deutz Diesel en-
gine, the instructions of the manufacturer for the cooling liquid must be strictly ob-
served.
The instructions for the right maintenance of the cooling system protective liquid are
indicated in the manual of the manufacture (Chapter 4.3 - 4.3.3).
The following concentrations of the cooling liquid may not fall below / may not
exceed the following limits!!
Cooling system protective liquid: percentage of water:

max: 45 Vol % 55%
min: 35 Vol % 65%
The tank volume of the protective cooling system of the Deutz engine
TCD 2012 L04 2V is approx. 5,6 liters (only engine volume without extern cooling
system)
When it is necessary to fill up the cooling fluid because of exaporation, leaka-

ges or repairs (e.g. hose exchange) it is mandatory to have the right mixture
of water and cooling fluid.
This cooling fluid protects important inner of the motor against corrosion and further
destruction.
CAUTION !
The cooling fluid, which is filled in in the Klemm factory, has a concentration
of 40% protective liquid. That concentration will give protection against frost
to a temperature of - 25C (- 13F).
CAUTION - Important !
1.) Check the cooling fluid level every 40 operating hours (once a week).
The engine is shut down automatically when the level of the cooling fluid falls
below the minimum and can not be restarted again.
2.) Do never fill up with pure water alone!

Only use mixtures of water and cooling fluid!
3.) If these instructions for the filling up with the cooling fluid are not observed,
no warranty claims will be accepted!
Deutz Order - No. for cooling fluid: 01011490
04/2008 KR 702- 2 / Serial no. 19104 79

6.6.4 First filling and refilling of cooling liquid on Deutz diesel
engine type TCD 2012 L04 2V
1. Remove cap from coolant filling entry pipe of compensation tank.
2. Fill coolant by filling entry pipe. The compensation tank must be filled up
completely to the upper surface of filling entry pipe.
3. Install cap on filling entry pipe and close system.
4. Start diesel engine and keep running about 5 minutes.
5. Control coolant level by removing cap.
Attention: if coolant level should be too low, additional coolant fluid must
be filled in the system by repeating the operation step 1- 3.
Pic. 1: coolant diagram
1 Coolant outlet at the cooler 9 Heating

2 Thermostat 10 Coolant to thermostat
3 Coolant feed line to pump 11 Heating connection
4 Coolant pump 12 Compensation line
5 Lube oil cooler 13 Ventilation line to compensation tank
6 Cylinder cooling 14 Coolant outlet to cooler
7 Cylinder head cooling 15 Compensation tank
8 Coolant inlet to heating 16 Compensation line to heat exchanger
04/2008 KR 702- 2 / Serial no. 19104 80

The following points must be observed and respected
1. Control of coolant level: the level must be checked by removing the filling
cap; level must reach upper position of filling entry pipe!
2. After first filling and refilling processes the level of coolant must be ckecked
the next day before starting the diesel engine.
3. If coolant system has a leakage and about 1.0 liter fluid is missing, the
automatic level switch of the diesel engine seds a signal to the engine
control system. The power of the diesel engine will be reduced by 50% and
the error is shown on the display of the engine monitoring box (see pic. 2).
The leakage volume of coolant must be refilled immediately up to the
upper level on filling entry pipe to guarantee good operation conditions
of drill rig.
4. If diesel engine is overheating in the range of 125_Celsius = equivalent

285_Fahrenheit the power of the diesel engine will be reduced by 50%
and the error is shown on the display of the engine monitoring box (see
pic. 3). To avoid this error, the engine should run for about 5 minutes
without any operations of the drill rig before switching off.
CAUTION:
The cooling fluid is very hot and dangerous! Never remove filling cap from hot
engine coolant system, because hot steam will burn head, eyes, hands etc.!
pic 2: pic 3:
Indication coolant Indication coolant

level too low overheated
04/2008 KR 702- 2 / Serial no. 19104 81

6.7 Hydraulics
6.7.1 Hydraulic oil

Optimum transmission can be only assured, if operating temperature, viscosity and
quality are right. For detales see ”Recommanded Oils and Lubricants” - page 66.
Old oil, or oils having been subjected to temperatures in excess of 70_ C lose
important operating characteristics and reduce the service life of seals, hoses,
pumps and cylinders.
6.7.2 Filtration
Check the filter contamination indicator daily, as soon as the fluid
has reached a temperature of approx. 20_ - 30_C.
Observe the visual indicator:
- Pressure gauge (red- greenfield) on return line filter
- Red button on supply line filter for hydraulic drifter (option)
If the red button of the contamination indicator jumps out during cold starts
(below 27_ C operating temperature), the indicator is faulty and must be
replaced.
If the button jumps out after normal operating temperature is reached
(approx. 50_ C), the filter element is contaminated and must be replaced.
Filter Cartridges
Be sure to use only tested and approved cartridges.
a) HP- Filter - 3 μm in the percussion mechanism supply line
b) LP- Filter - 10 μm for the return line
04/2008 KR 702- 2 / Serial no. 19104 82

6.7.3 Oil Changes
Drain oil only at operating temperature. Be sure to clean fittings before opening drai-
ning plugs.
If the waste oil contains metal abrasion, drain pumps separately and check for attri-
tion. Oil motors should also be inspected.
Metal abrasion is due to increased attrition, causing reduction in performance, irre-
versible damage and subsequent total loss of the component.
Urgent replacement of the damaged pump or motor is required.

Condensation
High humidity and extreme fluctuation in oil temperature cause condensation.
Water stimulates saponification of the oil, causing frothing, and therewith increases
the possibility of cavitation and damage to the pumps.
The formation of foam can be checked through the inspection glass.
PLEASE NOTE!
Park the drill rig on even ground and let the fluid settle and cool down.
Drain the oil/water mixture and dispose it in accordance
with anti- pollution stipulations.
Afterwards fill in hydraulic fluid. Do only use the hydr. fluid
according to original Klemm hydr. oil filling!
Cleaning the Oil Tank

z Be sure to clean the oil tank during every oil change
z Use only non- fibrous cleaning rags.
z Thoroughly inspect the tank for utmost cleanline
Fill the hydr. tank

For filling new hydraulic oil, the connection of the return line filter must be used.
The filter at the filling connection has to be a filter with max. mash size 10µm.
PLEASE NOTE
New oil is always contaminated by filling devices, drums and other containers.
ATTENTION:
Damages due to filling of contaminated oil which has not been filled through
the connection of the return line filter (see picture on page 70) are not
warrentable!
04/2008 KR 702- 2 / Serial no. 19104 83

6.7.4 Repairs and maintenance of the hydraulic system
6.7.4.1 Trouble shooting

a) No oil supply and unusual noise characteristics from pump
Cause Reason Remedy

Local restriction in Open ball- valve fully
Cavitation in pump suction line, e.g. partially
closed ball- valve
Fluid too cold Heat fluid to

recommended tempera-
ture
Damaged tube, or Repair or replace tubes

defective hose or hoses
Fluid level in tank too low Replenish to right level

Fluid freezing
Wrong hydraulic fluid Replace with correct fluid
Fittings in suction line Tighten or replace fittings

take air in
Porous suction line Replace hose or tube
Wrongly aligned or Realign or tighten screws

Mechanical Vibrations loose connection
Vibrations of tubes Re - tighten connections
Worn or damaged Repair or replace

Pump
Worn or damaged Repair or replace

Engine / Motor
Suction and P- Port of Change connections

Pump rotating in wrong pump wrongly connected
direction
04/2008 KR 702- 2 / Serial no. 19104 84

b) No Pressure build - up
Cause Reason Remedy

Air intake on suction line Tighten and seal connec-
Pump not working tions
correctly
Damaged pump Repair or replace

Pump running hot
Viscosity of fluid too low Replace with fluid of
the right viscosity
Coupling faulty, or Repair defect

Pump RPM too low or Engine damaged
insufficient
engine capacity
Wrong pressure settings Adjust pressure setting

Leakage from pressure
port to return line Safety valve does not Clean, assess damage,
close. Dirt or wear / repair or replace
particles in line
Shuttle valve or Find faulty component,

other valve open. adjust, clean, repair
Dirt or abrasion particles or replace
in line, or electrical fault
Cylinder bore, piston or

piston seals damaged Repair or replace
damaged components
04/2008 KR 702- 2 / Serial no. 19104 85

c) Pressure or flow fluctuations
Cause Reason Remedy

Valve seat damaged Repair or replace
Knocking of pressure
limiting or safety val-
ves
Fluid contaminated Drain fluid. Clean tank

Valves sticking and system. Refill with
new fluid.
System not properly Bleed system.

Air pockets in the sy- ventilated See also Start- up in-
stem, causing irregular structions
or jerky movements
d) Temperature of fluid too high
Cause Reason Remedy

System malfunction due Clean, repair and replace
Hydraulic fluid to contamination or da- as required
is pumped under pres- maged components
sure through pressure
limiting or safety valve Safety valve setting too Adjust setting
to the tank low
Cooler motor faulty Repair or replace

Inadequate Cooler fins closed (dirt) Clean
Cooling
Tank filling level too low Replenish to required

Fluid circulation too level
fast
04/2008 KR 702- 2 / Serial no. 19104 86

e) Control valve not working correctly
Cause Reason Remedy

Contamination Dismantle spool, clean
Spool jamming valve
Fluid too hot
Cool fluid to approx.
Magnet burned out 50_C (122_F)
No pilot voltage Replace magnet
No pilot pressure, Check pilot voltage

or pilot pressure
(with pilot operated Check pilot pressure
shuttle valves) too low
6.7.5 Reference to repairs at the hydraulic system
CAUTION
Be sure to close ball- valves on pump suction lines before replacing pumps.
Before restarting operation, open the shut- off flaps in suction line! Otherwise the
pumps will be destroyed!
Disconnect pump bearing flush line and secure immediately using a blind plug.
Contamination entering this line will damage pump bearings.
This bearing- flush is used on capacity controlled pumps, and for (some) HD- con-
trolled, constant- flow pumps. This line must never be disconnected.
Before disassembling cylinders and motors, lower and support boom.
Set all operating levers to ”O”.
Check system pressure (gauges) and relieve pressure if necessary
to prevent accumulator effect.
6.7.5.1 Special guarantee remarks
This drill rig in covered under manufactures warranty for a period of 6 months or
1000 hours, whichever is sooner. Repairs must be carried out by our authorised dis-
tributors.
Wear and tear items, oils and coolants used for daily refilling, damages, consequen-
tial damages and transportation for repair are not claimable under our terms of War-
ranty.
Full details of the manufactures warranty are available on request.
The system pressure of the drill rig is fix adjusted by valve blocks, which are secured
against inexpert regulation.
An adjustment of the system pressure during the guarantee is only allowed with
explicity permission of the KLEMM Bohrtechnik.
Non - compliance leads to immediate loss of all warranty entitlements!
04/2008 KR 702- 2 / Serial no. 19104 87

6.8 Special Remarks (Welding Instructions)
Main components of boom, mast support and kinematic joints are recently made
from high quality cast steel like GG 60, GG 50, GG 40.3.
Those cast steel constructions do not accept weldings, because the metallurgical
structure of steel will be disturbed, prudurcing stress areas with possible failure.
Please contact KLEMM Bohrtechnik Technical Services, if you should repair or fix
items on cast steel components!
ATTENTION!
Welding operations at the drill rig are forbidden!
Necessary welding operations may only be done by specially trained
personnel of Klemm Bohrtechnik!!
ATTENTION!
The battery disconnecting switch must be turned to the left side
(anticlockwise) to interrupt the electric circuit before you start with service or
repair works or in case of danger.
At the end of operation, the disconnecting switch must be turned to the right
side (clockwise). The electric circuit is closed.
ATTENTION!
In order to prevent damage when carrying out ELECTRIC welding of the
installation, the plug connection of the (EMR) shall first be pulled out! It is
located at the rear side of the Power Pack inside the sound proof cover.
04/2008 KR 702- 2 / Serial no. 19104 88

6.9 Maintenance of the starter battery
The battery’s operational readiness is subject to constant recharge from the

dynamo.
The installed batteries are of the maintenance- free type.
6.9.1 Cold start
PLEASE NOTE
Store the battery at room temperature during the winter months

The capacity of the battery will be greatly reduced at low ambient temperatures.
Should the charge level be too low to start your engine, warming- up indoors or in
a water filled container, to approx. 20_ C, may be helpful.
If the charge level is insufficient:
a) Use second unit and jump leads
b) Check battery and recharge
6.9.2 Installing the battery
ATTENTION: Please note the risk of short circuit!

A) Switch off all consumers.
B) Check polarity +/- of pole shoes.
C) Pole shoes / pole ends must be metal bright.
Non - compliance causes resistance and drop in performance.
D) Tighten pole shoes securely.
E) Do not rest tools on the battery.
CAUTION
Danger of short circuiting

F) Protect poles and shoes with battery grease to prevent corrosion and
reduce current creepage.
04/2008 KR 702- 2 / Serial no. 19104 89

6.10 Accumulators
Hydraulik - accumulators are mounted on our drill rigs:

- at impact mechanism of hydraulic drifters
- at the hydraulic damping device of hydraulic drifters
- as pilot oil control unit
CAUTION
The pilot control accumulator has no approval obligation.

The Nitrogen pre- tension pressure is p = 15 bar.
In case of malfunction the accumulater may be changed
without special approval.
6.10.1 Introduction and precaution instructions

Klemm accumulators are in accordance the european regulation 97/ 23/ EG (Pres-
sure Equipment Directive), article 3, chapter 3.
If an accumulater will be detached and repaired the accumulator has to be
checked by an authorised person, according to the operational dependability
regulations §10 before it’s sent back to site.
Caution:
Nitrogen pre- tension has to be released before air- freighted.
This is valid for separate spare part or monted accumulators!
Any works on hydraulic systems or repair works shall be realized in suitable work-
shops (warehouses) or under clean environmental conditions!
04/2008 KR 702- 2 / Serial no. 19104 90

6.10.2 Works at accumulators
S Use only original Klemm parts! If not, you’ll loose warranty claim.!
S For ordering spare parts there are adequate part- numbers available
in our part lists. This is also valid for repair works!
S Watch the indicated torques for tensioning the screws!
S During disassemble - assemble of units, unit parts, seals,
watch the installation direction and location!
S Do not weld at accumulators for repair purposes!
S Part - assembly drawing shall be used for repairs!
S During works at open systems (drifter, rotary head) works like
oxygen cutting, grinding, welding etc. shall be avoided!
S Any mechanical damages, welding, pretensioning etc. are not allowed!
S The mounting of precision parts has to be executed carefully,
light moving, without jamming and uncontrolled forces!
S Before disassembling the accumulator the nitrogen has to be released:
- take off the cap plug.
- unscrew inlet screw carefully for approx. 1 - 1,5 revolutions, until
nitrogen escapes (hiss effect). Don’t take off the inlet screw completely,
until the pressure has been released completely.
S Disassemble the accumulator and clean all parts carefully.
S Check the parts on damages and change them, eventually the
whole accumulator.
S After each disassembly of an accumulator a new diaphragm,
new screws and seals shall be installed!
S Before assembling the accumulator each part has to be cleaned with non
explosive and non aggressive cleaner and pressurized air (don’t use
water, it leads to corrosion)!
S Fit diaphragm and seals according to the drawing. Oil the seal
edges and watch the assembling position!
S Assemble the accumulator according to the drawings.
S Fill the accumulator with nitrogen (N2) only!
S Use therefore only the original Klemm accumulator filling device
( P/N: 40753)!
S Watch the specified filling pressure of the accumulator!
S Don’t inhale nitrogen (N2)! work only in safe environment!
04/2008 KR 702- 2 / Serial no. 19104 91

6.10.3 Assembly of cpl. Accumulator
S Watch specified screw torques!
S All threads at the accumulator have to be free of dust and grease!
S Accumulators with support threads have to be glued in with high tensile
glue liquid!
S Works have to be executed in clean environmental areas!
S Hydraulic fittings and hoses have to be tighten properly!
S Check the specified filling pressure of the accumulator!
S Seals and screws have only beused in accordance to the Klemm parts
lists and shall be bought from Klemm only!
6.10.4 Putting into operation

S All persons who doing repair- or maintenance works at the accumulator
shall have read the operations manual and shall have well understood the
instructions.
Not authorized or not special instructed persons are not allowed to do
repair - or maintenance works at accumulators!
S Watch the safety instructions according to any countries law!
6.10.5 Using of accumulators

S Use accumulators only in oil temperature range - 10_C to + 80_C!
S Accumulators have to be secured versus external forced ruptures!
04/2008 KR 702- 2 / Serial no. 19104 92

6.11 Conservation of hydraulic piston rods and machine
components
external conservation procedure
Important
Before parts are mounted and used which were treated with external conservation
additives on metal surfaces, these corrosion inhibitors must be removed with special
solvents, fuel , petroleum or wax- containing solvents.
Gear parts, spline shafts and driving shafts which were preserved with corrosion in-
hibitors must be washed/treated with the same solvents/chemicals mentioned
above.
Caution
6. Make sure that shaft seals never get into contact with aggressive solvent
chemicals!
7. Make sure when removing corrosion inhibitors with solvents to use eye protec-
tion and gloves
8. Make sure to work in good ventilated areas because solvents may be toxic.
9. Be sure to avoid open fire and smoking because emanations of solvents are
inflammable.
Valvoline 150 is especially recommended to preserve shaft seals because this pro-
duct does not interfere with the seals material.
PLEASE NOTE
Please, do not pressure wash the new drill rig within the first two weeks.
Do not use cleaning agents with solvent or degreasing substances.
Do not use aggressive chemical cleaning agents, e.g. concrete remover.
This can spoil the paint work and chromed parts.
Do not direct the pressure washer onto electric components and seals.
04/2008 KR 702- 2 / Serial no. 19104 93

7 Attachment points for truck transport
7.1 Attachment points for drill rig KR 702-2
1 - 4 : Attachment points to fasten the drill rig for truck transport

5 : Fix the slewable control panel with the locking bolt in transport position
parallel to the tracks
6 : Do not use the trailer coupling as a attachment point to fasten the drill
rig for truck transport
1+2 3+4
(r.h. side + l.h. side of the drill rig) (r.h. side + l.h. side of the drill rig)
CAUTION
Truck transport and loading the drill rig with a crane

is only allowed after the gauge of the telescopic tracks is shifted
to maximum width!
04/2008 KR 702- 2 / Serial no. 19104 94

7.2 Attachment points for Power Pack PP-95-DS
7 - 10 : Attachment points to fasten the power pack for truck transport
7 8
9 10
04/2008 KR 702- 2 / Serial no. 19104 95

8 Rope attachment points (1-4) on the drill rig type
KR 702-2 for loading with the help of a crane
ATTENTION: Loading the drill rig with a crane is only allowed after:
- consultation with company KLEMM Bohrtechnik!
- the gauge of the telescopic tracks is been shifted to maximum width!
1+2 3+4
(r.h. side + l.h. side of the drill rig) (r.h. side + l.h. side of the drill rig)
right
wrong
04/2008 KR 702- 2 / Serial no. 19104 96

9 Technical data
9.1 Technical data KR 702 - 2
Tramming motors
Traction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . approx. . . . . . . . . . . . . 20 KN
Tramming speed . . . . . . . . . . . . . . . . . . . . . maximum . . . . . . . . . . 1,8 km/h
Undercarriage
Specific ground pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8,12 N/cm2
Total width . . . . . . . . . . . . . . . . . . . . . . . . . . . . 750mm (spreadable to 1250 mm)
Length (axle to axle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1385 mm
Length of tracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1935 mm
Width of grousers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200 mm
Ground clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210 mm
Drill mast
1. type 164 / 2150 lg.
Length O/A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2150 mm- 3150 mm
Feed length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1200 mm- 2200 mm
2. type 164 / 2450 lg.

Length O/A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2450 mm- 3450 mm
Feed length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1500 mm- 2500 mm
Feed force (250 bar / 3626 psi) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . max. 38 kN

Retraction force (250 bar / 3626 psi) . . . . . . . . . . . . . . . . . . . . . . . . . max. 60 kN
Feed speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12,0 m/min
Rapid feed speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48,0 m/min
Retraction speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7,2 m/min
Rapid retraction speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28,8 m/min
Transport dimensions
Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2900 mm
Width (tracks shifted to max. gauge) . . . . . . . . . . . . . . . . . . . . . . . . 1250 mm
Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2200 mm
Weight
Weight total with drill mast 164 / 2450 and drill head unit
(without drill rods) . . . . . . . . . . . . . . . . . . . . approx. . . . . . . . . . . . . 4,5 to
04/2008 KR 702- 2 / Serial no. 19104 97

9.2 Technical data Power Pack PP-95-DS
Power source
Deutz diesel engine type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TCD 2012 L04 2V
Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 kW
RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2300 -1
certified by . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . COM 3/ EPA
Diesel tank capacity . . . . . . . . . . . . . . . . . . approx. . . . . . . . . . . . . 150 liters
Hydraulic system:
Hydraulic pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 x 115 l/min. constant
1 x 92 l/min. constant
System pressure . . . . . . . max. . . . . . . . . . . . . . . . . . 250 bar / 3626 psi
Hydr. tank capacity . . . . . approx . . . . . . . . . . . . . . . . . . . . . . . . . . . 400 l
Electrics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24V / 100Ah
Transport dimensions
1. Power Pack with tracks
Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4200 mm
Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1640 mm
Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2388 mm
2. Power Pack with crawler undercarriage
Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3540 mm
Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1050 mm
Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2453 mm
Weight of standard Power Pack

with tracks . . . . . . . . . . . . . . . . . . . . . . . . . . . approx. . . . . . . . . . . . . 2,4 t
Caution!
The standard - ambient temperature range of - 205C (- 45F) up to +405C
(+1045F) shall not be exceeded.
Otherwise we cannot guarantee a trouble- free operation!
04/2008 KR 702- 2 / Serial no. 19104 98

9.3 Technical data of sound level measurement
acc. to DIN EN 791 and 2000/14/EC (Outdoor- Noise - Directive)
A -registered sound power level (LWA) in different

operating modes
Measured sound power level LWA:

without loading (idle running of engine) . . . . . . . . . . . . . . . . . . . 91 dB
with loading (full throttle of engine) . . . . . . . . . . . . . . . . . . . . . . . 106 dB
with running drill head unit (rotating) . . . . . . . . . . . . . . . . . . . . . . 107 dB
with running drill head unit (rotating/percussion) . . . . . . . . . . 127 dB
Declared sound power level LWAd(declared):

A -registered sound pressure level (LPA) in

different operating modes
Sound pressure level at the control panel of the machine LPAS:

Sound pressure level in distance of 10m from the machine LPA10:

04/2008 KR 702- 2 / Serial no. 19104 99

10 Kinematic possible mast movements
KR 702 - 2 basic version
04/2008 KR 702- 2 / Serial no. 19104 100

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TECHNICAL MANUAL

Hydraulic crawler drill rig

KLEMM Bohrtechnik GmbH

Reproduction or use in any form

KLEMM Bohrtechnik GmbH

04/2008 KR 702- 2 / Serial no. 19104 2

Für elektrische Bauteile bitte zu- For electrical components please

Durch Weiterentwicklung bedingte We reserve the right to modify

Crawler drill rig type : KR 702- 2

Serial no. : 19104

Year of manufacture : 04/2008

04/2008 KR 702- 2 / Serial no. 19104 3

04/2008 KR 702- 2 / Serial no. 19104 4

04/2008 KR 702- 2 / Serial no. 19104 5

04/2008 KR 702- 2 / Serial no. 19104 6

The signs CAUTION and PLEASE NOTE

This word is used to point out that inadequate or

PLEASE NOTE is used to make people aware of installations

04/2008 KR 702- 2 / Serial no. 19104 7

1.1 Extreme displacement of the center of gravity

1.3 Overlay of the degrees of freedom

04/2008 KR 702- 2 / Serial no. 19104 8

- Extremely low or high temperatures and or humidity

3.1 Equipment from KLEMM Bohrtechnik

- permissible stabilities und strengths

3.2 Adaptation at or of equipment of other manufacturers

Fundamental the same points as being considered above are to be observed.

In principle the in the manual and further attached documentation

04/2008 KR 702- 2 / Serial no. 19104 9

F All personnel involved in operating and maintaining this equipment

Operating instructions for the KLEMM Bohrtechnik drill rig must be

F Personal Safety Equipment

Wear Personal Safety Equipment - Working gloves

Wear tight clothes (protection clothes according to DIN).

04/2008 KR 702- 2 / Serial no. 19104 10

1. Operation and maintenance of KLEMM drill rig

Independent and unassisted operation (operator) and maintenance

1.1 Are at least 18 years of age (Check for local stipulations)

1.2 Are physically and mentally suited

1.3 Have been instructed in operating and maintaining

1.4 Can be expected to perform responsibly

And are designated for the job by the contractor/user.

Be sure that no one is within the drill mast’s danger zone.

04/2008 KR 702- 2 / Serial no. 19104 11

Safety devices and protective equipment of moving machine components

The transport of persons on the drill rig is strictly forbidden!!

10. Alignment of the drill mast

04/2008 KR 702- 2 / Serial no. 19104 12

If the operators vision is impaired during tramming and working, someone

12. Working in the area of utility lines (gas, water, electricity,...)

13. Working near overhead electrical lines

or if rated voltage unknown . . . . . . . . . . . . . . . . . . . . . safety distance = 5 m

14. Safety precaution trailer coupling.

The trailer coupling P/No. 40333 is approved for max. 40 kN = 4 tons

04/2008 KR 702- 2 / Serial no. 19104 13

The operator must:

04/2008 KR 702- 2 / Serial no. 19104 14

genuine block bolt

04/2008 KR 702- 2 / Serial no. 19104 15