Operation and Maintenance Manual: Triplex Mud Pump - Skid Mounted

Operation and
Maintenance
Manual
Triplex mud pump - skid mounted
Machine type
7TS600
Manufacturing year
2011
Drillmec SpA
Drilling Technologies
12, Via 1° Maggio

I-29027 Gariga di Podenzano
PIACENZA (Italy)
Corporate web site: http://www.drillmec.com

Mailbox: info@drillmec.com
CAREFULLY READ THIS MANUAL Ph +39.0523.354211
BEFORE OPERATING THE MACHINE Fx +39.0523.524418
7TS600 - Operation and Maintenance Manual
Document code: UM191117/E - Revision 0 (03/2011)
This document cannot, in whole or in part, be reproduced, memorized as a software file, or handed over to third parties
under any form and by no means, without previous authorization by DRILLMEC S.p.A.
DRILLMEC S.p.A. reserves the right to introduce changes to its products at any time in view of a constant quality
improvement.
© Copyright 2011 DRILLMEC S.p.A. - All rights reserved
Printed in Italy
WARRANTY
All DRILLMEC machines and equipments are covered by warranty as far as any possible manufacturing defects
are concerned, either for a period of 12 (twelve) months, starting from the date of delivery to the final Customer, or
for 18 (eighteen) months, starting from the date of the B/L (Bill of Loading), unless otherwise specified in the supply
agreement.
That WARRANTY is held for applicable only provided that the DRILLMEC manufactured products are correctly used
by the final USER, by fully observing the contents of the Operation and Maintenance Manual. The WARRANTY isn’t
applied to machines or equipments which were in any way altered, which were subjected to misuse, negligence,
accidents or were affected in their performances or reliability, such as if repaired in any way not complying with the
DRILLMEC directives.
DRILLMEC obligations in matter of WARRANTY are limited to supplying parts and correcting bad workmanship, up
to an amount not exceeding the estimated costs of the repair itself. WARRANTY doesn’t cover any compensation for
revenue losses, transportation, hoisting and trucking expenses, such as direct and/or indirect damages caused to
the goods that aren’t imputable to DRILLMEC. Products and equipments which are furnished by DRILLMEC but not
manufactured by them, won’t carry else but MANUFACTURER WARRANTY alone.
All DRILLMEC responsibilities and obligations are clearly defined in this WARRANTY statement enclosed to the sale
agreement, and no further verbal or written agreement will be considered as being legal. In order to guarantee both
reliability and high performances of the equipments, we strongly recommend to attentively read the “SCHEDULED
MAINTENANCE” section. If, for any reason, those prescriptions are either ignored or realized by using non-OEM
(Original Equipment Manufacturer) spare parts, this WARRANTY declaration will instantly CEASE.
Customer Care
Drillmec S.p.A.
Drilling Technologies
7TS600 Operation and Maintenance Manual
UM191117/E - Rev.0 - 03/2011
Page IV
TECHNICAL SERVICE AND SPARE

PARTS
The requests for technical service and spare parts has to
be sent to the After Sale Service of DRILLMEC SpA. The
addresses, the telephone and fax numbers are reported in
page I of the subject manual before the main index.
The technical service can be executed by an Agent or by

a local Service Centre authorized by DRILLMEC Spa. In
such a case, the Customer has to record the identification
data concerning to such a Centre into the relevant space
provided on page I of the subject manual.
For the spare parts, the Customer has to refer to the Spare
Part Catalogue provided with the machine documentation.
If some not very important parts are not directly detectable
into the catalogue, the Customer has to refer to the After
Sale Service of DRILLMEC S.p.A.
HAZARD
Use only the DRILLMEC original spare parts.
The use of original spare parts is coupled not only
to the warranty applicability but also to the perfect
efficiency and safety of the machine all along its
life, according to the specifications provided by the
design and used during the machine manufacturing
procedure.
If the Customer does not use the original spare parts,
in extreme cases, the not acceptable conformity of the
replaced parts can causes serious hazards of injury
and of death. DRILLMEC Spa declines every type or
responsibility n the case of damages to plants or of
injuries to personnel connected to the use of not
original spare parts.
IMPORTANT
When a Customer contacts the DRILLMEC After Sale
Service or others Service Centres to allow a quicker
problem solving procedure, he has always to point
out the machine data signed on the memorandum
reported at page I. This procedure is extremely im-
portant also for the data validity and for the reference
Fig. 1
to possible technical updating concerning the spare
parts.
DRILLMEC Drilling Technologies - 12 Via 1° Maggio - Località Gariga I-29027 PODENZANO (PC) - ITALY
Phone +39 (0)523 354211 - Telefax +39 (0)523 524418
Web: http//: www. drillmec.it E-mail: info@drillmec.com
LOCAL AUTHORIZED DEALERSHIP AND SERVICE CENTRE

This area is reserved to take note of the identification data of Your Dealership and of the possible
Authorized Service Centre of Your Country.
MEMORANDUM OF THE MACHINE IDENTIFICATION DATA

This area is devoted to take note of the identification data relevant to Your own machine.
When You want to contact the DRILLMEC After Sale Service, it is necessary to point out always the
following identification data to ensure a quicker solving of the involved technical service problems:
Machine type
7TS600
Machine serial number
Manufacturing year
2011
Drilling rig type-approval
Power plant t ype-approval

White intentional page
Operation and Maintenance Manual 7TS600
GENERAL INFORMATION UM191117/E - Rev.0 - 03/2011
Page VII
FOREWORD 4 Mark and logotype of DRILLMEC SpA.

5 Section and page number.
Dear Customer, this Operating, Use and Maintenance
6 Section title.
Manual has been conceived to provide all information
necessary to allow the functioning, the use and the main-
tenance of the 7TS600 mud pump according to safety
and functioning efficiency criteria.

INSTRUCTION FOR THE MANUAL READ-
Operation and Maintenance Manual HH 102
ING INSTRUCTIONS UM189026/E - Rev.0 - 03/2008
Page C-3
C-1-1 DRILLING CONTROLS AND INSTRUMENTATIONS
This manual provides some different type information • Control panel of Power Control Room (for more

informations, see proper technical documentation).
From this control panel must be used to switch on
starting from the instruction for the manual reading up to the electric motor.
the machine technical performances, the safety rules, the

technical specifications of the maintenance products, the
operating rules, the transport rules, …etc. Fig. C-1.1
) )
"
" " "
As already pointed out into the Section B - SAFETY, "
) )
the operators will be required to carefully read and well 4

$
)
)
understand the contents of the manual before starting to $ $
use the machine. It is necessary the complete understand- $
ing especially of all the aspects relevant to the use, the 4

$
maintenance and the lubrication of the machine. 4

$ $
$
$
Then, the manual does not need only for a first sequential Fig. C-1.2
A8 Air pressure gauge

reading of all its information. It has to be used as a con- A25 Oil pilot pressure drilling rig
C51 Torque wrench suspension up-down
C52 Make-up Break-out Torque wrench
A26 Oil pilot pressure control panel H1 Command enabled lamp
tinuous reference to make clear every doubt concerning A27 Service oil pressure
A29 Mud pressure, standpipe manifold
H2
H3
Hydraulic oil filter obstruction lamp
High temperature hydraulic oil lamp
the machine. C4 Oil pump 3 lifting - top drive rotation control

C28 Oil pump 1 lifting - top drive rotation control
H4
H5
Low level hydraulic oil lamp
High temperature hydraulic oil pump lamp
C29 Oil pump 2 lifting - top drie rotation control H6 Emergency enabled lamp
C46 Tripping mode - drilling mode selector S3 Emergency
C47 Power slips in-out control S6 Command enabled
The manual has to be kept keep in easily accessible C48 Top drive rotation speed selector
C50 Inside BOP open-close selector
S11 Lamp check
areas. The operators must be able to use it through the

consultation of the Index that points out in a quick but
complete way the structure of the treated subjects allowing Fig. 2
in such a way a well defined searching procedure.
It is also advisable to know well the methods used to

realize the editing and the graphical technique used to
subdivide the subjects and to identify the several parts
of the manual (sections, chapters, figures ect.) in such
a way to be able to familiarize with a sort of “navigation”
inside the document.
The necessary information is reported here below.
TYPICAL STRUCTURE OF THE PAGES
The pages of the manual have always a typical structure

that is always characterized by the following elements:
1 Model of the treated machine or fixture.

2 Document identification code/language/edition.
Example: UM123456/I - Rev. 12/1996 = Operation
and Maintenance Manual written in Italian langua-
ge, edition issued on December 1996.
3 Document type (in this case Operation and Main-
tenance Manual).
UM191117/E - Rev.0 - 03/2011 GENERAL INFORMATION
Page VIII
Then, according to the subject treated into the pages, the This structure helps in realizing a linear and detailed tre-
following other elements can be present combined one atment of the different subjects, also making easier the
each other: possible references to other subjects.
7 Chapter title (first, second or third level). PAGE NUMBERING SYSTEM

8 Text
The page numbering system adopted into the subject
9 Figure
manual is not a continuous one: at the beginning of
10 Number of figure every section, the page number restarts from 1 (Section
11 Indentification of section cover).
Inside each section, the page numbering system is a
8 progressive one.
Example: Into section A, page A 2, page A 3, …. etc.
7
HH 102 Operation and Maintenance Manual
UM189026/E - Rev.0 - 03/2008
Page C-14
INSTRUCTIONS
TABLE NUMBERING SYSTEM
C-2 ASSEMBLY, INSTALLATION AND DISINSTALLATION INSTRUCTIONS
WARNING
The table numbering system adopted into the subject
Before consulting this section, attentively read para-
graph B-5 of Section B: SAFETY. P1 manual is not a continuous one: at the beginning of every
C-2-1 PRELIMINARY CHECKS first level chapter, the table number restart from 1.
1. Before starting to work, it is necessary to make
sure that all the checks and maintenance operations
required according with the machine performed working
hours were carried out.
Fig. C-2.1 Inside each fist level chapter, the table numbering system
IMPORTANT
Worked hour of total rig, you must be refered to hour-
is a progressive one and it is marked by the graphical
counter P1
2. Another mainly important check is that relevant

symbol Tab. X-0.0.
to the machine planarity (P2, A34, A35): when starting
again to work (for example, after the night stop), it is Example: Into chapter A-1, Tab.A-1.1, Tab.A-1.2, …. etc.
necessary to check that no ground settlings took place
in correspondence of the bearing feet and of the bearing
slab placed under the stabilizers. P2
restarts from 1.
3. It is also advisable to bleed off the hydraulic oil
tank. Anyway, that procedure requires the realization of Fig. C-2.2
some operations at work completion.
A34 A35
FIGURE NUMBERING SYSTEM
WARNING
A machine inclination, especially when the drilling
rods are already driven, compromises the well verti-
cality, and, even worse, can damage the drilling rods’
string and the top drive.
10 The figure numbering system adopted into the subject
manual is not a continuous one: at the beginning of every
first level chapter, the figure number restarts from 1.
11
Fig. C-2.3
9 Inside each fist level chapter, the figure numbering system

is a progressive one and it is marked by the graphical
symbol Fig. X-0.0.
Example: Into chapter A-1, Fig.A-1.1, Fig.A-1.2, …. etc.
RECALLING CONNECTION TO OTHER

Fig. 3 SUBJECTS
SUBDIVISION IN SECTION AND CHAPTERS To make easier the consultation of related subjects, the
recalling connections inside the manual are executed
This manual is subdivided into six Sections respectively pointing out the alphanumeric reference code of the invol-
marked through the letters A, B, C, D, E, F, G, H and I. ved chapter, figure or table. In such a way, it is possible
to avoid the pointing out of too long titles or of the page
Section A-GENERAL INFORMATION numbers.
Section B-SAFETY Example:
Section C-OPERATING INSTRUCTIONS • Recalling connection to a chapter: (refer to A) or (refer
Section D-MAINTENANCE to B-3.1.1);
Section E-OTHER HAZARDS • Recalling connection to a table: (refer to Tab.A-1);
Section F-TROUBLE SHOOTING • Recalling connection to a figure: (refer to Fig.A-1.);
Section G-OTHER RISKS • Recalling connection to a chapter and to a figure:
Section H-REMOVAL AND DEMOLITION (refer to A-1 and Fig.D-3);
On their turn, the sections are subdivided in Chapters.

There are chapters of first, second and third level.
Page IX
UPDATING
The information pointed out into the subject manual are based upon the technical document available at the moment
of the manual writing procedure.
According to the machine equipping kit and to the provided accessories, some differences can be found between
the real machine and the texts and figures into the manual. This situation can not be used by the Customer to create
some arguing procedure.
DRILLMEC can introduce in every moment some modifications to a particular version of the machine also if the base
information remains unchanged and then does not loose its validity.
Then, before starting up every operation on the machine, it is necessary to check to have at disposal all the necessary
information. Pay particular attention to the updating code of the available technical documentation.
For more detailed information, refer to the DRILLMEC After Sale Service.
SYMBOLS
In this manual different universal symbols were adopted.They are illustrated, with the indication of their meaning:
HAZARD
It represents extreme hazard; if you fail taking the necessary measures you (or others) are very likely to get
killed or severely injured.
WARNING
It represents a serious hazard. If you fail taking the necessary measures, there is a risk that you (or others)
get killed or severely injured. It also indicates the possibility to create serious damages to the machine that
can consequently become unsafe.
IMPORTANT
It introduce a recall to the safety procedures, some technical information or some practical advises with
the aim to make possible a more efficient and economic use of the machine respecting at the same time the
safety and the environment. The respect of the rules pointed out under this symbol usually helps the work-
ing execution.
Safety helmet
Safety gloves
Safety shoes
Breathers or anti dust masks

Page X
Ear plugs or noise or noise protective

headsets
Safety goggles or eyes’ protective masks
Hoses burst hazard
Hot parts hazard
Accumulator burst hazard
TYPE OF SIGNAL COLOUR

Prohibition signals Red, white
Warning signals Black, yellow
Information, instructions, Light blue
prescription signals
Fire signals Red
Safety and rescue signals Green
Hazard signals Black, yellow
INDEX UM191117/E - Rev.0 - 03/2011
Page XI
INDEX
TECHNICAL SERVICE AND SPARE PARTS .........................................................................................................IV
FOREWORD .................................................................................................................................................................... VII
INSTRUCTION FOR THE MANUAL READING .............................................................................................................. VII
TYPICAL STRUCTURE OF THE PAGES ........................................................................................................................ VII
SUBDIVISION IN SECTION AND CHAPTERS .............................................................................................................. VIII
PAGE NUMBERING SYSTEM........................................................................................................................................ VIII
TABLE NUMBERING SYSTEM ...................................................................................................................................... VIII
FIGURE NUMBERING SYSTEM .................................................................................................................................... VIII
RECALLING CONNECTION TO OTHER SUBJECTS ................................................................................................... VIII
UPDATING ........................................................................................................................................................................ IX
SYMBOLS ......................................................................................................................................................................... IX
SECTION A - GENERAL INFORMATION ............................................................................A-1

A-1 CONVENTIONAL REFERENCE ................................................................................................................... A-2
A-1.1 ORIENTATION ......................................................................................................................................................A-3
A-2 MACHINE IDENTIFICATION......................................................................................................................... A-4
A-2.1 MANUFACTURER ................................................................................................................................................A-4
A-2.2 MODEL ..................................................................................................................................................................A-4
A-2.3 IDENTIFICATION PLATES....................................................................................................................................A-4
A-2.4 OTHER PLATES ...................................................................................................................................................A-4
A-3 GENERAL DESCRIPTION ............................................................................................................................ A-5
A-3.1 MAIN COMPONENT DESIGNATIONS .................................................................................................................A-5
A-4 TECHNICAL SPECIFICATION ...................................................................................................................... A-9
A-4.1 MAIN DIMENSIONS ..............................................................................................................................................A-9
A-4.2 WEIGHTS ..............................................................................................................................................................A-9
A-5 POWER PUMP PERFORMANCE ............................................................................................................... A-10
A-6 TECHNICAL DATA .......................................................................................................................................A-11
A-6.1 DIESEL ENGINE ................................................................................................................................................. A-11
A-6.2 TRIPLEX PUMP .................................................................................................................................................. A-11
A-6.3 TRANSMISSION ................................................................................................................................................. A-11
A-6.4 ELECTRICAL SYSTEM....................................................................................................................................... A-11
A-7 MACHINE USE DESTINATION................................................................................................................... A-12
A-7.1 PROPER USE .....................................................................................................................................................A-12
A-7.2 IMPROPER USE .................................................................................................................................................A-12
A-7.3 MACHINE LIFETIME LIMITS ..............................................................................................................................A-12
A-7.4 FORESEEABLE OPERATORS’ TRAINING, EXPERIENCE OR ABILITY LEVELS ...........................................A-12
SECTION B - SAFETY .........................................................................................................B-1

B-1 PERSONNEL QUALIFICATIONS ................................................................................................................ B-2
B-1.1 QUALIFICATION ...................................................................................................................................................B-2
B-1.2 WORKING GARMENTS .......................................................................................................................................B-2
B-2 MACHINE PLATES ...................................................................................................................................... B-3
B-3 SAFETY DEVICES ........................................................................................................................................ B-7
B-4 GENERAL SAFETY DURING THE ROUTINE AND THE EXTRAORDINARY MAINTENANCE PHASES B-7
B-4.1 MECHANICAL PART ............................................................................................................................................B-7
B-4.2 ELECTRIC PART ..................................................................................................................................................B-9
B-4.3 HYDRAULIC PART ...............................................................................................................................................B-9
B-5 SAFETY RULES REGARDING SCHEDULED MAINTENANCE............................................................... B-10
B-6 GENERAL SAFETY DURING THE OUT OF SERVICE SETTING AND ELIMINATION PHASE ................B-11
B-7 GENERAL INFORMATION FOR THE SAFETY USE OF THE MACHINE ................................................. B-12
B-7.1 TERMS OF USE EXPECTED .............................................................................................................................B-12
B-7.2 TERMS OF USE NOT ALLOWED.......................................................................................................................B-12
B-7.3 PERSONNEL TRAINING ...................................................................................................................................B-13
B-7.4 GENERAL EMERGENCY INDICATION ..............................................................................................................B-15
UM191117/E - Rev.0 - 03/2011 INDEX
Page XII
B-7.5 INFORMATION ON RESIDUAL RISK .................................................................................................................B-16
B-8 PROTECTION SYSTEM.............................................................................................................................. B-18
B-8.1 EMERGENCY BUTTONS ...................................................................................................................................B-18
SECTION C - OPERATING INSTRUCTIONS ......................................................................C-1

C-1 CONTROLS AND INSTRUMENTS ............................................................................................................... C-2
C-1.1 CONTROL PANEL ................................................................................................................................................C-3
C-1.2 REMOTE CONTROL ............................................................................................................................................C-4
C-1.3 COOLER PUMP CONTROL PANEL .....................................................................................................................C-4
C-1.4 DEVICES INSTALLED ON OTHER PARTS OF THE MACHINE ..........................................................................C-4
C-2 COMMISSIONING ......................................................................................................................................... C-8
C-2.1 PUMP ....................................................................................................................................................................C-9
C-2.2 SUCTION SYSTEM ..............................................................................................................................................C-9
C-2.3 DISCHARGE SYSTEM .......................................................................................................................................C-10
C-2.4 INITIAL OPERATION ..........................................................................................................................................C-10
C-3 OPERATING INSTRUCTIONS .................................................................................................................... C-13
C-3.1 SELECTION OF OPERATING PARAMETERS ..................................................................................................C-13
C-3.2 DIESEL ENGINE START ....................................................................................................................................C-15
C-3.3 POWER PUMP OPERATION .............................................................................................................................C-16
C-3.4 MANUAL EMERGENCY STOP...........................................................................................................................C-17
C-3.5 NORMAL POWER PUMP STOP ........................................................................................................................C-17
C-3.6 BREAKING-IN PERIOD ......................................................................................................................................C-18
C-4 PARKING AND OFF-DUTY INSTRUCTIONS ............................................................................................. C-18
C-4.1 PARKING ............................................................................................................................................................C-18
C-4.2 OFF-DUTY ..........................................................................................................................................................C-19
C-5 TRANSPORT INSTRUCTIONS................................................................................................................... C-20
C-5.1 LIFTING THE POWER PUMP ............................................................................................................................C-20
SECTION D - MAINTENANCE .............................................................................................D-1

D-1 PREFACE ...................................................................................................................................................... D-2
D-1.1 MAINTENANCE LAYOUT .....................................................................................................................................D-2
D-1.2 LUBRICATION AND GREASING POINTS............................................................................................................D-4
D-1.3 BOLT TIGHTENING POINTS ................................................................................................................................D-4
D-2 TABLES AND SPECIFICATIONS ................................................................................................................. D-4
D-2.1 LUBRICATING OILS .............................................................................................................................................D-4
D-2.2 GREASES .............................................................................................................................................................D-5
D-2.3 ANTI-CORROSION PRODUCTS ..........................................................................................................................D-5
D-3 LUBRICATION INSTRUCTIONS .................................................................................................................. D-6
D-3.1 MOTOR PUMP......................................................................................................................................................D-6
D-3.2 OIL LUBRICATION OF PUMP ..............................................................................................................................D-6
D-3.3 LUBRICATION OF DRIVE CHAIN AND CHAIN GEAR COUNTERSHAFT MAIN BEARINGS ............................D-6
D-3.4 PISTON AND LINER COOLING SYSTEM............................................................................................................D-8
D-3.5 DRIVE ROLLER CHAINS .....................................................................................................................................D-9
D-3.6 PULSATION DAMPENER MAINTENANCE........................................................................................................D-10
D-3.7 AIR CLUTCH .......................................................................................................................................................D-12
D-4 BOLT TIGHTENING SPECIFICATIONS ..................................................................................................... D-13
D-5 HOSE FITTING SPECIFICATIONS ............................................................................................................. D-15
D-5.1 STORING OF FLEXIBLE HOSES.......................................................................................................................D-16
D-5.2 NORMS AND METHODS OF USE OF THE FLEXIBLE HOSES........................................................................D-17
D-5.3 MAINTENANCE OF THE FLEXIBLE HOSES.....................................................................................................D-17
SECTION E - FLUID END MAINTENANCE ......................................................................... E-1

E-1 EXPENDABLES .............................................................................................................................................E-2
E-2 GASKET REPLACEMENT .............................................................................................................................E-2
INDEX UM191117/E - Rev.0 - 03/2011
Page XIII
E-3 SUCTION VALVES .........................................................................................................................................E-3

E-3.1 REMOVAL .............................................................................................................................................................E-3
E-3.2 INSTALLATION .....................................................................................................................................................E-3
E-4 DISCHARGE VALVES....................................................................................................................................E-4
E-4.1 REMOVAL .............................................................................................................................................................E-4
E-4.2 INSTALLATION .....................................................................................................................................................E-4
E-5 VALVE SEATS ................................................................................................................................................E-5
E-5.1 REMOVAL .............................................................................................................................................................E-5
E-5.2 INSTALLATION .....................................................................................................................................................E-5
E-6 PISTONS AND PISTON RODS ......................................................................................................................E-6
E-6.1 REMOVAL .............................................................................................................................................................E-6
E-7 INSTALLATION ..............................................................................................................................................E-7
E-8 LINERS ...........................................................................................................................................................E-8
E-8.1 REMOVAL .............................................................................................................................................................E-8
E-8.2 INSTALLATION .....................................................................................................................................................E-8
E-9 FLUID-END ACCESSORIES ..........................................................................................................................E-9
E-9.1 SUCTION DESURGER .........................................................................................................................................E-9
E-10 STRAINER ASSEMBLY .............................................................................................................................E-10
E-11 PULSATION DAMPENER ON THE DISCHARGE MANIFOLD .................................................................E-11
E-11.1 PRE-CHARGING INSTRUCTIONS ................................................................................................................... E-11
E-12 PRELOAD STUDS .....................................................................................................................................E-12
E-12.1 STUDS THREAD PRELOAD AND SETTINGS .................................................................................................E-12
SECTION F - TROUBLESHOOTING ................................................................................... F-1

F-1 TROUBLESHOOTING ....................................................................................................................................F-2
SECTION G - OTHER RISK .................................................................................................G-1

G-1 OTHER RISKS .............................................................................................................................................. G-2
G-1.1 PRESSURIZED ACCUMULATORS ..................................................................................................................... G-2
SECTION H - DISMANTLING AND DEMOLITION ..............................................................H-1

H-1 DISMANTLING AND DEMOLITION .............................................................................................................. H-2
UM191117/E - Rev.0 - 03/2011 INDEX
Page XIV

Page A-1
Section A - GENERAL INFORMATION

Page A-2
A-1 CONVENTIONAL REFERENCE

In this manual, and on the equipment itself, you will find warning messages. Each message starts with the word
“signal”. The meaning attached to the word “signal” for these purposes is explained hereafter.
For immediate understanding of some important information, we shall also use the symbols listed here after.
The symbol represents the message explained beside it.
The requirements for the personnel in charge and more basic information on the subject are also reported here.
Section A includes basic general information for getting familiar with the most important parts of the equipment.
Identification data, technical characteristics, etc., are also included.
HAZARD
It represent extreme hazard; if you fail taking the necessary measures you (or others) are very likely to get
killed or severely injured.
WARNING
It represent a serious hazard. If you fail taking the necessary measures, there is a risk that you (or others)
get killed or severely injured. It also indicate a hazard to the environment. A hazard to the environment can
result from improper use of polluting materials (e.g. used oil) and/or their improper disposal.
IMPORTANT
It warns you to use caution as, failure of this, you might risk personal injuries or damage the equipment. It
also provides indications for an efficient and economical use of the equipment.
Page A-3
A-1.1 ORIENTATION
The machine is considered oriented as shown in the figure.
This convention serves to make all further references in the manual clear and unequivocal.
Any exceptions to this rule will be specified at the time.
TOP
SIDE
REAR FLUID END

SIDE SIDE
BOTTOM
SIDE
LEFT
SIDE
REAR FLUID END

SIDE SIDE
RIGHT
SIDE
Fig. A-1
Page A-4
A-2 MACHINE IDENTIFICATION

A-2.1 MANUFACTURER
DRILLMEC
Drilling Technologies Division
Via 1° Maggio, 12 - Località Gariga

I-29027 PODENZANO (PC) - ITALIA
Phone +39 (0)523 354211
Telefax +39 (0)523 524418
A-2.2 MODEL
Triplex mud pump model 7TS600, powered with Cater-

pillar C18.
A-2.3 IDENTIFICATION PLATES
The identification plate is located on the right-hand side

of the control board.
The identification plate carries the machine identification

details, including the machine type, the serial number,
the year of manufacture, the installed power and the total
weight.
IMPORTANT
Always specify the equipment technical code and part
number (N° MATR.) when you require information or
technical assistance.
A-2.4 OTHER PLATES
The plates of all the main mechanical, hydraulic and elec- Fig. A-2
tric components not manufactured by DRILLMEC (pumps,
motors, etc.) are located on the relevant components, in
the positions where the respective manufacturers decided
to place them.
MUD PUMP
Type
Serial Number
Month/Year of manufacturing
Nominal power [kW]
Weight power unit [Kg]
Total weight [Kg]
DRILLMEC S.p.A. Drilling Technologies

Via 1° Maggio 12
29027 Gariga di Podenzano (PC) - ITALY
Tel.+39.0523.354211 Telefax +39.0523.524418
Web: http//:www.drillmec.it E-mail: info@drillmec.it
0953-4339E
Fig. A-3
Page A-5
A-3 GENERAL DESCRIPTION

A-3.1 MAIN COMPONENT DESIGNATIONS
A-3.1.1 COMPLETE PUMP
16 9 10 7 14 18 13 2
12
6 3
4 1 11
15
8 5 17
Fig. A-4
1. Triplex pump 11. Liner cooling system

2. Delivery line 12. Control panel
3. Suction line 13. Hydril
4. Chain transmission 14. Safety valve
5. Cardan shaft 15. Mud pressure gauge
6. Skid 16. Engine housing
7. Air tank 17. Suction pulsation dampener
8. Battery box 18. Jib crane
9. Diesel engine
10. Gear box
Page A-6
A-3.1.2 TRIPLEX PUMP
Longitudinal section of pump
Fig. A-5
1 Fluid-End
2 Suction valves
3 Delivery valves
4 Power-End
5 Piston-liner assembly
6 Cross head
Page A-7
A-3.1.3 DETAIL OF CHAIN TRANSMISSION LUBRICATION SYSTEM
Fig. A-6
A-3.1.4 DETAIL OF POWER END (CROSSHEAD) LUBRICATION SYSTEM
Fig. A-7
A-3.1.5 DETAIL OF PISTON LINER COOLING SYSTEM
Fig. A-8
Page A-8
A-3.1.6 EXPLODED VIEW OF PISTON LINER ASSEMBLY
Fig. A-9
Page A-9
A-4 TECHNICAL SPECIFICATION

A-4.1 MAIN DIMENSIONS
3584
2875
2713
350
9500
2750
2911
Fig. A-10
A-4.2 WEIGHTS
Total weight in work configuration approx. 27500 kg

Weight of triplex pump alone 10500 kg
Page A-10
A-5 POWER PUMP PERFORMANCE
IMPORTANT
The data showed in the table have been calculated according to full volumetric efficiency ( =1) and to 90%
of the mechanical efficiency ( = 0,90).
IMPORTANT
The dataplate with these ratings is also located on the pump and remote control panels.
Fig. A-11
Page A-11
A-6 TECHNICAL DATA
IMPORTANT
Unless otherwise indicated, the ratings are calculated net of efficiency (η =1).
A-6.1 DIESEL ENGINE
Manufacturer: Caterpillar
Type: C18
Power: 447.5KW, 600HP, at 1800RPM
A-6.2 TRIPLEX PUMP
Piston stroke: 7”
Piston/jacket configuration from: 4”to 7”
Suction dia: 8”
Delivery dia: 4”
Max pressure: 5000 PSI (344 bar)
A-6.3 TRANSMISSION
Mechanical gearbox make: DRILLMEC

Type: 01913284
Rations:
Slow gear selection 5,73
Fast gear selection 2,81
Final drive with cardan shaft and forced lubrication chain transmission: 4,28
Roller chain: P=1.1/2” ASA 120-6
A-6.4 ELECTRICAL SYSTEM
Electrical system voltage: 24 V

Batteries: 2 (24 V, 180 Ah)
Fuse protection
Page A-12
A-7 MACHINE USE DESTINATION

The pump comes under the category of worksite machinery, with a range of application which is both various and at the
same time requires careful classification to avoid improper and hazardous use, having the following characteristics:
• temperature min. –20°C, max. 50°C.
• relative humidity, max. 100% RH
A-7.1 PROPER USE
The pump is designed for pumping: bentonite mud, concrete mixes and water.
HAZARD
Those works can be exclusively carried out by strictly observing the instructions and the limits reported in this
manual. It is absolutely forbidden to try performing any works for which the machine wasn’t conceived.
A-7.2 IMPROPER USE
By improper use, the use of the machine for performing any work not expressly foreseen, for different purposes with
respect to those the machine was designed for, or with modalities not foreseen in this manual, is meant.
- Use of the machine for pumping liquids other than those indicated in paragraph A-7.1.
- Forcing the performance of the machine by continuous use of the manual emergency mode, thus exceeding the
limits given in performance chart.
IMPORTANT
In case of inobservance of even only one of the above described conditions, DRILLMEC S.p.A. decline every
responsibility to the Customer, as this would be considered “IMPROPER USE”.
A-7.3 MACHINE LIFETIME LIMITS
As far as the safety matter is concerned, the machine operative lifetime is unlimited, provided that the prescriptions
both for the routine and for the extraordinary maintenance of the safety means and devices indicated in the Instruction
Manual are strictly observed.
A-7.4 FORESEEABLE OPERATORS’ TRAINING, EXPERIENCE OR ABILITY LEVELS
A-7.4.1 OPERATORS
The machine was designed for being used by operators having the following characteristics:
• to belong either to masculine or to feminine sex
• to be aged at least 14 years
• to operate with both their hands
• to have no limits in their physical abilities

Page A-13
• to have got a specific training
A-7.4.2 PUPILS/APPRENTICES
The machine was designed for being used by pupils/apprentices having the following characteristics:
• to belong either to masculine or to feminine sex
• to be aged at least 14 years
• to operate with both their hands
• to have no limits in their physical abilities
• to have got a specific training
A-7.4.3 GENERIC PERSONNEL
During the working operations, the access to the field must be forbidden to generic personnel.
Anyway, the machine was designed by considering that the generic personnel who could possibly be within the ma-
chine respect area have the following characteristics:
• are aged at least 14 years
• haven’t any limits in their physical abilities
• have got a specific training or are accompanied and assisted by qualified personnel having got a specific
training.
Page A-14

SAFETY UM191113/E - Rev.0 - 01/2011
Page B-1
Section B - SAFETY
UM191113/E - Rev.0 - 01/2011 SAFETY
Page B-2
FOREWORD
In this manual, for example, the “safety symbology” Safety shoes

(SYMBOLOGY) was adopted, in order to signal possibly
dangerous situations.
IMPORTANT
Don’t remove the plates present on the machine. In
case of loss or deterioration of them, it is obligatory
headsets
for the User to promptly provide to replace them.
B-1 PERSONNEL QUALIFICATIONS

B-1.1 QUALIFICATION
The personnel using the machine or operating on it must
be competent, and obligatorily have the following cha-
racteristics:
IMPORTANT
Exclusively use type-approved and well preserved
Physical: Good sight, hearing, coordination, and the
safety material.
ability to safely carry out all the functions required for the
machine use.
Mental: Ability to understand and to apply the established IMPORTANT

rules, the specifications and the safety precautions. The Avoid wearing rings, swatches etc…., and approa-
personnel must be attentive, use good sense for their own ching to the moving parts with undressed long hair,
safety and for that of other people; they must be willing to which could get caught into those parts and cause
carry out the work in a correct and responsible way. serious damages. Also avoid using greasy clothes
because they are easily inflammable.
Emotional: The personnel must be calm and able to stand
the stress and to use good sense, as far as their physical
and mental conditions are concerned.
Training: The personnel must have read and learned this

manual, the possibly annexed graphics and diagrams,
the indication and hazard warning plates. They must be
skilled and qualified in all the aspects of machine use and
maintenance.
Have got the licence: If requested by law.
B-1.2 WORKING GARMENTS
The operators must be equipped with the following indi-

vidual safety means:
Safety helmet
Safety gloves
SAFETY UM191113/E - Rev.0 - 01/2011
Page B-3
B-2 MACHINE PLATES

Meaning:
It is forbidden the entrance of not authorized personnel.
Fig. B-1
Part code number:

09531098
Meaning:
Accumulator burst hazard.
Fig. B-2
Part code number:

09531095
Meaning:
Hoses burst hazard.
Fig. B-3
Part code number:

09531097
Meaning:
Extremely hot parts: scorching hazard
Fig. B-4
UM191113/E - Rev.0 - 01/2011 SAFETY
Page B-4
Part code number:

09531096
Meaning:
Danger of suspended loads.
Part code number:

n/a
Position:
Service crane.
Fig. B-5
Meaning:
Danger of fire.
Part code number:

09531110
Position:
- Oil tank
- Batteries
Fig. B-6
Meaning:
Danger due to corrosive liquids.
Part code number

09531111
Position:
- Batteries
Fig. B-7
Meaning:
Danger. Explosive gas.
Part code number:

n/a
Position:
- Batteries
Fig. B-8
SAFETY UM191113/E - Rev.0 - 01/2011
Page B-5
Meaning:
Danger of hand crushing.
Part code number:

09531112
Position:
- Working base zone
Fig. B-9
Meaning:
Generic danger.
Part code number:

n/a
Fig. B-10
Meaning:
Danger. High voltage.
Part code number:

09531107
Position:
- Alternator
- Electric panels
Fig. B-11
Meaning:
It is forbidden to remove the guards and the safety de-
vices.
Part code number:

09531116
Position:
- Safety ropes
- Cardans
Fig. B-12
UM191113/E - Rev.0 - 01/2011 SAFETY
Page B-6
Meaning:
It is forbidden to repair, to lubricate and to clean moving
parts.
Part code number:

09531113
Position:
- Power swivel shifting chains
Fig. B-13
Meaning:
Warning, danger for moving parts.
Part code number:

09532167E
Position:
- Cardans
- Power swivel shifting chains
Fig. B-14
Meaning:
It is mandatory to use proper ear plugs or acoustic protec-
tion headsets.
Part code number:

09531099
Fig. B15
Meaning:
Warning plate
0953-2971E
Fig. B16
SAFETY UM191113/E - Rev.0 - 01/2011
Page B-7
B-3 SAFETY DEVICES

Both the complete machine, and its individual parts, are fitted with built-in safety devices.
• Guards, housing and fixed guards.
• They prevent accidental contact with the drive train (chains, universal coupling, etc.) or lubrications system
with hot fluid circulating inside them.
HAZARD
If it is necessary for maintenance or repair to remove the guards, housings or other safety equipment, only
do so with the machine stopped (motor stopped). Do not retsart the machine unless all the guards, housings
and safety devices have been refitted. Serious personal injury hazard.
• Manual emergency system

Enables the operator to stop the pump immediately and hence arrest the delivery of pressurised fluid.
• Maximum pressure valve

The pump’s maximum pressure valve purges into the mud tank whenever the operating pressure exceeds the
preset maximum.
WARNING
The maximum allowed pressure setting at which the safety valve trips must be decided before starting work,
as given in the instructions in paragraph of performance table.
HAZARD
Before operating with the power pump to verify that all the devices you of emergency are present and effi-
cient.
B-4 GENERAL SAFETY DURING THE ROUTINE AND THE EXTRAORDINARY

MAINTENANCE PHASES
B-4.1 MECHANICAL PART
The operators must be equipped with the following individual safety means (DPI):
Safety helmet
Safety gloves
Safety shoes
UM191113/E - Rev.0 - 01/2011 SAFETY
Page B-8

headsets
Safety sling
When You are working, carrying out maintenance interventions or repairs, always use the utmost prudence:
• Before carrying out the maintenance or the repairing operations, clean the machine, especially the joints and
the screw connectio ns, from any oil, fuel or detergents’ residuals. Don’t use any aggressive detergents. Exclusively
use filament-free wiping clothes.
• Clean all the handles, footboards, rails, platforms and ladders from any dirt, snow and ice.
• Before cleaning the machine with water or a steam jet (high pressure sprayers) or by using other cleaners,
close and seal all the openings into which, for either safety and/or operating reasons, neither water, steam or deter-
gents must get infiltrated. This is particularly important for electro-motors and electric panels.
• Exclusively use hoisting equipments suitable and technically fit, as well as hoist means having an adequate
hoisting capacity.
• Before starting any maintenance operation, insert the safety retainers both for the equipments and for the
control levers; the machine must be positioned on a flat ground and the equipments must lean on the ground.
• Before carrying out the maintenance, hang on the control levers and on the ignition key the relevant hazard
warning plates; if You hold it as being necessary, apply warning plates also around the machine.
• Exclusively carry out the maintenance by still standing, cooled-down and safe-positioned machine.
• In order to protect the machine against the possibility of being accidentally started-up:
• Close the main control devices and take off the key.
• Apply on the cut-out switch a hazard warning plate.
• Disconnect the electric motor.
• Only use original equipment and high quality tools.
• During of the operations to dangerous heights, always provide with the safety harness and proceed as re-
quired by the specific directions.
• On completion of servicing and repairs, before starting the machine, check that no tools, rags or other mate-
rials are left next to the moving parts.
WARNING
Safely treat, if possible, with biodegradable treatment, and dispose of consumable and auxiliary materials as
well as of the old parts that have been replaced.
SAFETY UM191113/E - Rev.0 - 01/2011
Page B-9
B-4.2 ELECTRIC PART
Safety helmet
Safety gloves
Safety shoes
• The works to be executed on either electric plants or operating means can be exclusively carried out either by
an electrician or by qualified personnel, under the supervision of an electrician and in a fully complying way with
respect to the electro-technical rules.
• Parts of the machinery subject to inspection, maintenance and repair interventions must be stress-relieving con-
nected, if prescribed. First check if such parts really are under stress-relieving, then connect them to ground, let
them undergo a short circuit and insulate the adjacent parts under voltage.
• If the works must be executed on parts under voltage, call for a second person who, in case of an emergency, can
actuate the cut out switch . Protect the working place with a white/red chain and mount a hazard warning signal.
Use only tools insulated against electric voltage.
• When working on high voltage components, connect the power supply cable to the ground, after having cut out
the voltage.
WARNING
The electrolytic accumulators contain sulphuric acid which can provoke scalds.
• When working on accumulators, always wear goggles.

• The accumulators produce hydrogen, which is highly explosive and easily inflammable by sparks or free fla-
mes.
WARNING
Provide to eliminate the electric/electronic wastes (RAAE) in full compliance with the relevant laws in force
in the country in which the wastes’ elimination must be performed.
B-4.3 HYDRAULIC PART
Safety helmet
Safety gloves
UM191113/E - Rev.0 - 01/2011 SAFETY
Page B-10
Safety shoes
• The interventions on hydraulic plants shall be exclusively executed by personnel both trained and, qualified in
the hydraulic field.
• When opening any delivery systems and pipes (hydraulic system, compressed air), it is necessary to discharge
them from the pressure, before carrying out the intervention.
• Carry out the maintenance interventions only when the temperature values are comprehended within the normal
parameters ( 45°C).
• For disassembling the hydraulic accumulators, strictly observe the instructions supplied by the manufacturer.
WARNING
Provide to the safe and possibly biodegradable elimination of the hydraulic fluids and of the replaced
parts.
B-5 SAFETY RULES REGARDING SCHEDULED MAINTENANCE
WARNING
Do not change the maximum relief valve setting on any hydraulic circuit without permission from the manu-
facturer. Never change an accumulator circuit pressure setting without specific instructions from the manu-
facturer.
WARNING
Never make unauthorized modifications to structural members or pressure circuits.
WARNING
You must replace, not repair damaged hydraulic or concrete hoses or pipes.
WARNING
Electronic components can be destroyed by welding current.
Before welding on the unit, unplug all radio remote control power wires. If you have a proportional boom
system, the proportional amplifiers must be removed from the mother board before welding.
If in doubt, contact the service department of the manufacturer for instructions before proceeding.
WARNING
Never activate the system hydraulics without checking ifanother workman is in a hidden position. Always yell
“clear” before starting the engine or electric motor, and allow time for response.
WARNING
Never work on a pressurized hydraulic system. Stop the engine or electric motor and relieve the accumulator
circuit (if so equipped) before you open the hydraulic system.
SAFETY UM191113/E - Rev.0 - 01/2011
Page B-11
WARNING
Explosion hazard! Never open a pipeline that is under pressure. The pump must be run in reverse for at least
two strokes and then stopped before opening a pipeline. If you don’t know how to reverse the pump, have the
operator do it. If the pipeline is pressurized with air, do not open it. The operator is responsible for knowing
how to safely release the air pressure.
WARNING
Never open a pressurized pipeline. The pump operator must release the pressure before you open the line.
If the line is pressurized with compressed air, let the operator release the pressure and verify that the air has
escaped before you proceed.
B-6 GENERAL SAFETY DURING THE OUT OF SERVICE SETTING AND ELIMI-
NATION PHASE
WARNING
Provide to the safe and possibly biodegradable elimination of the demolition resulting materials.
WARNING
Provide to the elimination of the electric/electronic materials (RAAE), in full compliance with the relevant laws
in force in the country in which the elimination must be performed.
WARNING
Provide to the safe and possibly biodegradable elimination of the lubricating oils, the greases and the hy-
draulic fluids.
UM191113/E - Rev.0 - 01/2011 SAFETY
Page B-12
B-7 GENERAL INFORMATION FOR THE SAFETY USE OF THE MACHINE

This chapter recalles security aspects about the machine, giving information and instructions about:
• Dangerous situations that can be verified during the use of maintenance;
• General and specific precaution are to be take to eliminate risk.
WARNING
For more information it is necessary to refer to the technical documentation attached to this manual.
B-7.1 TERMS OF USE EXPECTED
The machines project is to work in conditions of security that’s if it is used as planned and respecting tecnical limits
written in this manual.
WARNING
The machine was projected and built to be used in safe zones: it is prohibited the use in dangerous places
where there could be a chance of an explosion.
B-7.2 TERMS OF USE NOT ALLOWED
The partial or total unobservance of the instructions listed in this manual could cause damage to the machine or to
people.
Not to be done:
• The use of the machine by a person that has note been trained;
• The opposite use of the way rules;
• Partial or total unuse of the of the instructions;
• Maintenance deficiency;
• Material treatment with uncompatible characteristics with specific machine tecnologies;
• The use of the unspecific spare parts.
Follow these particular warnings:
• The machines protections and all other safety devices cannot be in any way illegaly opened;
• All the operations on the fluid systems and electrical on the border of the machine or inside of the electrical panel
shall be made only be authorized personnel and following the instructions outlined in this manual;
• Use for the filling or topping off the tanks of the hydraulic oil and of the lubricant, the material recommended by
the manifacturer.
WARNING
Using the machine differently from what it is created for to obtain production value out of what was planned
or not enough maintenance, is considered “UNPROPER USE”.
To be more clear, the following paragraphs give precise info.
B-7.2.1 OPERATION ON WRONG MATERIALS
The motopump has been built for liquid pumping, operational products of drilling. Technical characteristic are brought
back to the motopump.
Width 2911 mm
Length 9500 mm
Height 3584 mm
Weight 27500 kg
SAFETY UM191113/E - Rev.0 - 01/2011
Page B-13
B-7.2.2 USE OF NOT ORIGINAL SPARE PARTS
Just the original spare parts can guarantee the correct function: especially in some parts, like electric, pneumatic,
mechanical and the technical documentation attached on the present manual.
HAZARD
It is not allowed to use components wich has a particular importance for people’s security, differently of
what planned.
B-7.2.3 MAINTENANCE DEFICIENCY
It’s necessary to make sure the frequency of the machines maintenance.
HAZARD
Whomever is operating on the maintenance, can do so only after putting the machine in a maintenance position,
after having activated all security disposition active and non in order to operate in a complete safe way.
B-7.2.4 UNAUTHORIZED MODIFICATIONS
No changes are allowed wich count in particular for security disposition and for control and comand.
HAZARD
It is absolutely not allowed interfere with the command and control circuits to modify the hardware structure.
These operations could determine a damage to the machine equipments and above a great danger to the
operator.
B-7.2.5 WORKING AREA
It is recomended to keep area around the machine free from any objects and equipments not related to it’s operations.
Nothing can interfere to the freedom of movement for the operator or the maintainer inside or outside the machine
during variations of work.
In case of emergency the personnel must have free access to the machine.
HAZARD
It is not allowed the access inside the cabin of soundproof of the machine to the people not authorized
maintenance. It is the operators job to have the prescription to respect and to signal to whom may concern
eventual inobservations. This warning is highlighted with plates arranged on access doors.
B-7.3 PERSONNEL TRAINING
The security instructions and warnings are shown in this manual supposing that the utilizer applies the specific pre-
scription of use and maintenance and the general ones in the different norms of prevention and in particular in the
directive 89/391/CEE with the directive that’s connected.
The comprehension of this manual and of the documents attached are the results of risk reduction, for workers health
and security.
It’s supposing that the operative personnel and the maintainer have the following requirements:
• A general and specific education at a sufficient level, each for it’s own competence, in order to read and compre-
hend the manual;
• The ability to interpret correctly the symbols and present messages;
• A complessive knowledge of the machine and of the establishment of wich it’s inserted;
• Specific experience in the tecnology of use;
UM191113/E - Rev.0 - 01/2011 SAFETY
Page B-14
• Relative knowledge on the attitude to have in case of emergency on the availability of the means of individual
protection and it’s correct usage.
B-7.3.1 PERSONNEL INSTRUCTIONS
The employer has to train the employees on the security devices of the operators and on the residual risks.
In particular:
• When the employer gives a duty needs to realize it’s capability in order to protect their health and safety;
• Needs to furnish the relevant means of protection;
• Needs to request the observance from the operator, the business rules conserning security and use of means of
protection individual and collective given in their attention;
• Needs to make sure that the operations of ordinary and straordinary or in anyway it’s necessary that the machines
security is processed regularly.
The operator needs to take care of it’s own security and health and the people present at work, on wich his effects
can fall on his actions or omissions, according to the personal knowledge, at the instructions and means supplied by
employer.
The unauthorized manumission of one or more parts of the machine, the use of accessories different from the ones
raccomended by the constructors shall invalidate any responsabilty.
WARNING
The operator must be instructed in front of possible anomalies, disfunctions or dangerous conditions for self or others,
and in all cases must:
• Stop immediatly the machine acting on emergency devices (red mushroom button installed on pulpit control);
• Do not perform on interventions on wich are outside duties and inform immediatly the supervisor in order to avoid
personal initiatives.
B-7.3.2 OPERATOR
Employee able to do, after training, the following activity:

• Conduct and adjustment of the machine through the use of devices installed on the pulpit of the comand in the
operator cabin;
• Control the functionality of the instruments of the device indicator;
• Verify the absence of allarm messages on the regulator display of the machine parameters;
• Set up and control of the functioning cycle;
• Storage periodic verification of the plaques and signs of warning set on the machine and eventual replacement
in case of weare;
• Verification of security electrical components and of emergency lights;
• The routine cleaning of the machine.
If the operator notices a presence of an anomalie where the parts have been controlled an immediate examination
needs to be done by the person that is competent.
WARNING
Any interventions on the rig by means the operator have to be made with protections and in accordance with
this manual.
B-7.3.3 MAINTENANCE OPERATOR
Maintenance mechanic:
Qualified technician able to bring the machine in normal conditions; he’s responsible for maintenance, repairs and adju-
stements on mechanical machines. He’s not allowed to operate on electrical installations in presence of tension.
SAFETY UM191113/E - Rev.0 - 01/2011
Page B-15
Electrical maintenance:
Qualified technician able to bring the machine in normal conditions; he’s responsible for interventions electrical na-
ture of adjustment, maintenance and repair. He’s able to operate in presence of tension inside the electric panel, in
compliance with the rules of safety and with appropriate safety devices.
For the mainteners are also responsible for the following periodic operations:
• Replacement cleaning filter (air, oil, etc,...);
• Topping off the fluid tank;
• Topping of the tank of the lubrication;
• Verify the safety electrical components;
• Verify the function of the emergency devices and light signaling.
B-7.4 GENERAL EMERGENCY INDICATION
The non compliance with the rules of safety and/or behavioral situations can produce danger for the operators and
damage to the machine. The machine has to be used only if in perfect condition, from employes that know the emer-
gency measurements very clearly and the possible dangers, and osserving the instructions very carefully, for use
and indication given in this manual.
The personnel responsible for the machine, for the ordinary and extraordinary maintenance must have learned all the
indications, that this manual has, and in particular behavioural standards of safety. During the course of the task, it
is necessary to utilize appropriate personal protective equipment, both in relation to the risks of the machine than to
those deriving from the company, like protective gloves, shoes prevention, etc....
Machine extensions, modifications and transformations are not allowed without the contructors conset that can com-
promize the safety. The same for the dismantling, transformation, installation and for the regulation of the safety.
HAZARD
It is absolutely forbidden to remove or render ineffective the repairs provided for the safety of the people,
it’s also forbidden to modify even partially the safety devices installed. It’s not alllowed to operate near the
machine without appropriate personal protective equipment and in particular:
• shoes prevention
• DPI
It’s absolutely not allowed to use the machine on working condition without the fixed protection of mobile
parts of rig.
Do not modify for any reason parts of the machine to adapt other device.
HAZARD
The utilizer must guarantee that the environment conditions in with the machine works in are within the limits
specified in this manual and in attached documentation.
Cleaning operation must be performed with engine off and cutting the group accumulators present.
Attention with cleaning the uphostery of the car, the panels and controls, with soft, dry cloth or lightly dam-
pend with a mild detergent solution not flammable.
UM191113/E - Rev.0 - 01/2011 SAFETY
Page B-16
B-7.5 INFORMATION ON RESIDUAL RISK
B-7.5.1 DANGER
During operations and maintenance, the operators may be exposed to some residual risk that, by the very nature of
the operations cannot be totally eliminated.
B-7.5.2 HAZARDS OF THE MACHINE
It does not subsist for the operators, Danger due to the mechanical organs present because all protect by special
guards, residual danger, impossible to eliminate,
exist during maintenance with removed repair; in the maintenance section of the present manual it is reported the
correct procedure to bring about, in safety conditions, the maintenance operations.
At points of danger, special license plates are on display monitor showing the present risk.
B-7.5.3 HAZARD OF HEAT
Access to the inner cabin, soundproof should be made only by maintenance staff properly protected with appropriate
personal DPI, to prevent burns and injures due to the high temperatures generated by the engine found on all cabin,
they are installed in a very clearly way appropriate monitored plates the highlight the dangers.
SAFETY UM191113/E - Rev.0 - 01/2011
Page B-17
B-7.5.4 HAZARDS GENERATED BY NOISE
It is an obbligation to the utilizer and to the responsible to respect the rules of national law in term of protection against
the personal daily exposure of the operators of the noise with eventual use prescription of individual protection device
in function of the level of noise pressure in the single working area and the level of the daily exposure of the employers.
In the areas where the complessive noise level take valves there is the excessive prescription of the use of personnal
protective equipment. During the maintenance with the soundproof cabin opened and with the endothermic engine it
is obligated for the employers to use DPI autoprotectors.
Apposite monitored plates are installed in a very visible way to highlight residual risks.
LOCATION SOUND PRESSURE LEVEL AVERAGE RATING POND A
B-7.5.5 HAZARDS GENERATED BY LUBRICATION OIL
Liquids used for the planting of lubrication and cooling, must be set such as to prevent danger to the health of people
during the handling and use. Products for such equipment containing polychlorinated byphenyls and polychlorinated
terphenyls are not to be used. The liquid utilizer for fluid system must inquire it’s supplier for the possible danger
do to the manipulation and usage of it’s own and so he must take the appropriate action. In handling the product it
must be avoided as much as possible contact with the skin and inhalation of mists of these substances. If so cannot
be escluded, personal equipment protection must be used. These precautions must be taken particularly during the
operations of maintenance and repair of fluid system; also substance for protection and care must be given to the
employees. Particularly dangerous is the penetration of liquids for hydraulic system in the epidermal, when they
emerge from systems under strong pressure do to leekings. In case of such injury, that initially can appear of minor
entity it is necessary the immediate medical help.
For more detailed information see emergency details of the oils an lubricants used, attached to this manual.
B-7.5.6 ELECTRICAL DANGER
There are no residual risks present of electrical nature.
B-7.5.7 FIRE HAZARDS
The engine needs fuel for the operation and that even in a cluttered tank installed in a position not easly raging in
case of impact or accident, has a residual risk of fire. Apposite monitored plaques are installed near the tanks of
highlight such danger.
Apposite monitor plates installed near the danger zone.

UM191113/E - Rev.0 - 01/2011 SAFETY
Page B-18
B-7.5.8 PLATES AND SIGNAL INSTRUCTION
Listed below are the main warnings and symbols of notice to indicate the existence of such risks.
These report are posted near dangerous points it would be requires to restore the monitor plates that with time have
been deteriorated.
In the area of machine in wich there are dangers, are purposely put in safety signs in which an employee can be
submited and the necessary of using the individual protection device.
B-8 PROTECTION SYSTEM

The machine is equipped with special protection / emergency systems to guarantee compliance with safety require-
ments necessary.
B-8.1 EMERGENCY BUTTONS
The pulpit of command is installed on a dedicated emergency button with a rotating red on a yellow background. The
pressure of the emergency generating the immediate arrest of the endothermic engine present and on the pump on
it connected.
OPERATING INSTRUCTIONS UM191117/E - Rev.0 - 03/2011
Page C-1
Section C - OPERATING INSTRUCTIONS

UM191117/E - Rev.0 - 03/2011 OPERATING INSTRUCTIONS
Page C-2
C-1 CONTROLS AND INSTRUMENTS

The following chapters explain the controls and instruments with which the machine is equipped, starting with the
main control panel.
The controls (regulator, switch, etc.) are numbered in sequence, preceded by a letter as explained below, to facilitate
their unequivocal identification.
C-1
DEVICE IDENTIFICATION LETTER SEQUENTIAL NUMBER
Legend:
C = Control
R = Regulator
S =Selector or switch
A or H = Alarm, led or monitoring equipment
X = Available for installation of other device
HAZARD
Do not attempt to operate the machine before having read and understood the contents of this manual and
having familiarised yourself with the controls.
Study the correct procedures of use and forbidden manoeuvres to be sure of avoiding serious personal injury
and damage to property.
Page C-3
C-1.1 CONTROL PANEL

1 5
1. DIAGNOSTIC LAMP: the diagnostic lamp is used to 2 4
indicate the existence of a fault by flashing a fault code.
6 7
2. ENGINE OIL PRESSURE: the oil pressure should be
greatest after a cold engine is started. 8
9
3. TACHOMETER: this gauge indicates engine speed
(rpm). 11 3
4. COOLANT TEMPERATURE: when the coolant tempe- 12 10 13

rature is above the normal operating value, the coolant
temperature gauge will be in the red zone. Fig. C-1
5. WARNING LAMP: there is a general fault in the en-

gine.
6. FUEL PRESSURE: this gauge indicates fuel pressure

to the fuel injection pump from the fuel filter.
7. SYSTEM VOLTAGE: this gauge indicates the voltage

of the electrical system.
8. CIRCUIT BREAKER: reset the circuit breaker if a circuit

breaker trips.
9. START SWITCH: the start has three position: OFF,

RUN and START.
10. IDLE SPEED SWITCH: not qualified.
11. MAINTENANCE LAMP: the EMC will activate the

maintenance indicator lamp when scheduled maintenance
is due.
12. MAINTENANCE CLEAR SWITCH: the maintenance

clear switch is required to reset maintenance lamp.
13. SHUTDOWN SWITCH: use the engine shutdown

switch.
For more informations on engine instrumentation see

Caterpillar’s manuals.
A1
S4
A1 Air system pressure gauge
SFC1A Clutch
SA0 Control selector local - remote
SA1 Throttle
S4 Gear selector HFL1
SH0 Emergency reset SA0 SFC1A
HFL1 Lubrication pump alarm
SA1 SH0
Fig. C-2
Page C-4
C-1.2 REMOTE CONTROL

HL
S2A Throttle
SE2 Emergency
SE2 SFC1B S2A
SFC1B Clutch remote control HL3
HL Cooling pump alarm
HL3 Lubrication pump alarm
HW Engine warning
HW
Remote control panel must be connected to main control
panel with cable. To control mud pump fromremote control
panel switch SA0 on remote.
Fig. C-3
C-1.3 COOLER PUMP CONTROL PANEL
HA Acoustic alarm
HL1 Start cooling pump lamp S0
HL2 Thermal overload lamp
S0 Cooling pump automatic - manual selector
HA
HL1 HL2
Fig. C-4
C-1.4 DEVICES INSTALLED ON OTHER
PARTS OF THE MACHINE
Q1 Battery breaker Q1
Fig. C-5
A27 Power end lubricating oil flow indicator
A27
Fig. C-6
Page C-5
A28 Chain transmission lubrication system pressure

gauge
A28
Fig. C-7
A26 Gearbox lubricating oil flow indicator
A26
Fig. C-8
A20 Clogged crossehead lubricating oil filter indica-

tor
A20
Fig. C-9
A21 Clogged bearing lubricating oil filter indicator
A21
Fig. C-10
Page C-6
A29 Clogged chain transmission lubricating oil filter

indicator
A29
Fig. C-11
C38 Liner cooling shut-off valve (piston wear check

purpose only)
C38
Fig. C-12
C32 Safety valve adjusting screw
C32
Fig. C-13
C35 Suction desurger butterfly valve
C35
Fig. C-14
Page C-7
A33 Delivery line pressure gauge
A33
Fig. C-15
C31 Ball valve closing air line
C31
Fig. C-16
1 Water discharge
2 Fuel out 1
3 Oil motor discharge 2
4 Fuel in 3
5 Oil gear box discharge
4
Fig. C-17
Page C-8
C-2 COMMISSIONING
WARNING
Before beginning any operation or procedure described in this chapter you must be aware of the safety rules
and information contained in Section B.
lf in doubt, read this section again and only when you have fully assimilated its contents should you begin
operations.
This section contains the instructions for the installation and start-up of the pump at the drilling site. The instructions
presented in this section should be followed for the initial installation and startup of the pump, whenever the pump
has been moved to a new location, or whenever major repairs have been made.
POWER-END FLUID-END
UPPER CROSSHEAD
CROSSHEAD DISCHARGE
CRANKSHAFT GUIDE MANIFOLD
STRIPPER
BOX
LINER
PISTON
ROD
LOWER
CRANKCASE CROSSHEAD SUCTION
CROSSHEAD
DRAIN EXTENSION MANIFOLD
GUIDE
ROD
Fig. C-18
Page C-9
C-2.1 PUMP
NEVER PUMP AGAINST CLOSED VALVES (ALL DI-

SCHARGE VALVES CLOSED).
STOP PUMP OPERATION BEFORE ATTEMPTING
REPAIRS.
PROPERLY LOCK-OUT OR DISCONNECT MAIN PO-

WER SOURCE TO THE PUMP BEFORE CONDUCTING
INSPECTION, MAINTENANCE OR REPAIR.
COMPLETELY BLEED ALL PRESSURE FROM FLUID

END BEFORE ATTEMPTING MAINTENANCE OR RE-
PAIR.
1. Be sure that the pump foundation is level and able

to support the weight of the pump.
2. lnstall the pump as close as possible to the mud

tank or pit to reduce the pressure drop in the suc-
tion line.
C-2.2 SUCTION SYSTEM
1. The diameter of the suction line must be equal to

or exceed the diameter of the pump suction con-
nection.
2. Use as short a suction line as possible. Suction

Desurger
3. lnstall the suction line in as straight a line as pos-
sible. If turns are necessary, use long radius ells.
IN
4. Be sure there are no air traps or air leaks in the

suction line.
5. A suction desurger is installed to prevent mud

cavitation (Refer to FLUID END ACCESSORIES Suction
in Section E-8.1). Manifold
Fig. C-19
6. Fully open all valves in the suction line before op-
erating the pump.
Relief Hydril
Valve
Pressure
gauge
IN
Return mud tank

Strainer
(inside)
Fig. C-20
Page C-10
C-2.3 DISCHARGE SYSTEM
WARNING
The discharge system is subject to high pressures.
Do not modify without authorization.
Failure to follow approved welding procedures on any of the discharge pipe manifolding or, piping beyond
manifolding subjected to internal pressures from pump operation could result in piping failure causing equi-
pment damage or personal injury.
WARNING
The pressure setting of the relief valve must not exceed the pressure rating of the liner size installed in the
pump.
NOTE:
The pressure ratings for the liners are listed in the specification charts of this Guide. They are also indicated on the
pump plate.
1. A pulsation dampener is installed in the discharge system to reduce vibration and increase component service
life. (Refer to FLUID END ACCESSORIES in Section E of this Guide).
NOTE:
The standard DRILLMEC strainer assembly has an API 4 1/16” - 5000 psi WP RTJ flange for dampener instal-
lation.
C-2.4 INITIAL OPERATION
Take special care when operating the pump for the first time or after major repairs have been made. Refer to caution
remarks under STARTUP C-2.4.2.
CAUTION
Be sure pump is properly lubricated before operating.
C-2.4.1 PREPARATION
1. If pump was not completely assembled at the factory, complete the assembly as required.
2. Check to be sure the suction and discharge systems have been properly installed. (See INSTALLATION).
3. Remove the cover plates from the power end.
4. lnspect the power end for contamination. Clean as required.
5. Drain all condensation from the power frame.
NOTE
Do not attempt to drain condensation from power frame if unit has been filled with lubricant.
6. lnstall cover plates.
7. Check that crankcase drain plug is installed and tight.
8. Fill the power end with the correct lubricant.

Page C-11
NOTE:
Lubrication specifications and quantities for each type pump are listed in the LUBRICATION section of this Guide
and on the pump plate.
9. Lubricate grease fittings on piston wash system.
10. Make sure all covers are installed and all nuts and bolts are tightened to the torque specifications listed at the
back of this guide.
11. Fill piston wash system with coolant.
a. Remove four locking hooks from each end of piston wash system reservoir cover.
b. Slide reservoir cover open to filI reservoir.
c. Replace cover and install locking hooks.
NOTE:
Add anti-freeze to piston wash system if there is a possibility of freezing.
C-2.4.2 STARTUP
CAUTION
- IF THERE ARE UNUSUAL NOISES OR OTHER INDICATIONS THAT THE PUMP IS NOT OPERATING COR-
RECTLY, STOP THE PUMP IMMEDIATELY AND CORRECT THE PROBLEM BEFORE CONTINUING OPERA-
TION.
- IF OIL PRESSURE EXCEEDS 8 bar OR FALLS BELOW 1.5 bar (AT MAXIMUM RPM) STOP THE PUMP IM-
MEDIATELY AND CORRECT THE PROBLEM BEFORE CONTINUING.
1. Engage power pump clutch by putting the relative lever on the control panel in the upward position.
Operate pump slowly, 50 strokes per minute maximum, for 5 minutes with no fluid end pressure.
2. Be sure that the oil pressure gauge indicates between 1.5 and 8 bar (at maximum RPM).
3. Check each liner to ensure that the piston wash system is operating properly.
4. After 5 minutes of slow speed operation, stop the pump. Allow 10 minutes for oil to return to the crankcase and
check the lubricant level. lf required, add oil until the level reaches the FULL mark on the dipstick. (Refer to the
LUBRICATION section of this Guide).
5. Restart the pump. With no pressure on the fluid end, gradually increase the speed until the normal operating
speed is reached.
Page C-12
CAUTION
- IF THERE ARE UNUSUAL NOISES OR OTHER IN-
DICATIONS THAT THE PUMP IS NOT OPERATING
CORRECTLY, STOP THE PUMP IMMEDIATELY AND
CORRECT THE PROBLEM BEFORE CONTINU-
ING.
- IF OIL PRESSURE EXCEEDS 8 bar OR FALLS BE-

LOW 1.5 bar (AT MAXIMUM RPM) STOP THE PUMP
IMMEDIATELY AND CORRECT THE PROBLEM
BEFORE CONTINUING.
6. Be sure the oil pressure gauge indicates between Fig. C-21

1.5 and 8 bar (at maximum RPM).
7. Check each liner to ensure that the piston wash

system is operating properly.
8. Gradually increase fluid end pressure until the

required operating pressure is reached.
WARNING
DO NOT EXCEED THE MAXIMUM OPERATING PRES-
SURE INDICATED ON THE PUMP NAMEPLATE AND
LISTED IN THE SPECIFICATION CHARTS IN THIS
GUIDE.DO NOT ATTEMPT TO PUMP AGAINST CLO-
SED DISCHARGE VALVES.
9. Operate pump for 30 minutes at required operating

pressure. As pump operates inspect around the
nuts of the liners, the cylinders, and the valves for
leaks. lf leaks are found, stop the pump immedia-
tely, make the necessary repairs, and restart the
pump.
10. Stop the pump after 30 minutes of operation.
11. Inspect all studs, and capscrews. Tighten if neces-

sary. Torque specifications are listed at the back of
this Guide.
12. The pump is now ready for normal operation.
13. After breaking-in period (see breaking-in instruc-

tions) the power pump max. speed is 149 strokes
at:
- a pressure of 1638 psi (113 bar) with 7” liners.
- a pressure of 3219 psi (222 bar) with 5” liners.
Page C-13
C-3 OPERATING INSTRUCTIONS
WARNING
Before beginning any operation or procedure descri-
bed in this chapter you must be aware of the safety
rules and information contained in Section B.
lf in doubt, read this section again and only when
you have fully assimilated its contents should you
commence operations.
C-3.1 SELECTION OF OPERATING PARA-

METERS
Select the operating parameters that you intend to use

before starting a job.
First of all determine the delivery and pressure at which
you intend to pump the fluid.
Check that the required values are compatible with the po-
wer pump’s range by consulting the performance chart.
WARNING
Do not use the power pump incorrectly: if the delivery,
pressure values are not compatible with the utilisation
range do not use the power pump to do a given job.
Otherwise you risk damaging the power pump.
When you have selected the delivery, working pressure

and operating cycle, you must regulate the power pump
as follows to optimise efficiency:
- diameter of piston-liner assembly;

- diesel engine revs;
- gears.
C-3.1.1 RELIEF VALVE
The principal features of the valve are as follows:
1. Relief pressure setting can be adjusted easily by

turning a single nut, adjustment can be made with
pressure in the valve.
2. Accuracy of relief pressure setting is not affected

or changed by continual pressure surges or vibra-
tions.
3. Valve is easily reset by moving a single lever, no

replacement shear pins or special tools are required
and no time is lost in resetting the valve. Fig. C-22
4. Accuracy of original relief pressure setting is

maintained regardless of the number of valve op-
erations.
Page C-14
5. Completely safe in operation, there are no flying

pieces of shear pins or other unguarded moving
parts.
6. The valve can be manually discharged at any time,

regardless of line pressure, by means of a ‘release
button’ provided in the valve.
7. Open or set condition of valve is indicated by the

position of the “release button”.
8. Linkage is enclosed and protected from dirt and

corrosion.
C-3.1.2 ADJUSTMENT OF RELIEF VALVE
If great accuracy in the valve pressure setting is required, ADJUSTING NUT
RELEASE BUTTON
or the valve calibration has been lost, the valve pressure
setting can be adjusted to the indication of a pressure
gauge. PRESS TO RELEASE
An accurate pressure gauge should be connected to

read the line pressure. If a pressure gauge is used, with
e built-in dampening device the line pressure should be
RESET
built up slowly to allow for the lag in the gauge reading. If
possible, the line pressure should be built up with little or
no pressure pulsation.
First adjust valve to desired pressure setting as indicated Fig. C-23

by the calibration plate and indicator. Apply pressure until
the valve operates noting the gauge indication. If the
gauge indication was low, the valve adjusting nut should
be tightened; if the indication was high, the nut should be
loosened. One full turn of the adjusting nut will change
the pressure setting about 550 psi. Repeat operation
and adjustment until valve discharges at the desired relief
pressure shown by the gauge.
Page C-15
C-3.2 DIESEL ENGINE START
WARNING
Whenever you start up the power pump diesel engine
make sure that the gear lever is in the idle position
(neutral), i.e. with no gear engaged.
Also make sure that all the system connections (suc-
tion and delivery)have been properly made and that
the system is ready for use.
Make sure too that the charging pump has been
started up and is running properly. Q1
C-3.2.1 COLD START
To start the power pump diesel engine:
1. Check the batteries are connected: if necessary

connect them using the switch Q1.
2. Check the manometer A1: minimum 7 bar.
3. Check the selector SA0 must be in local position.

Fig. C-24
4. Turn key SC1 clockwise.
IMPORTANT A1
lf you have difficult starting the engine do not insist
with key for more than 10-15 seconds, otherwise you
risk putting undue strain on the starter motor and air
pressure.
Wait about a minute if you have to make several
attempts.
SA0
5. Adjust SA1 in order to maintain a speed of appro-
ximately 1300 rpm for at least 3 minutes. Do not
accelerate abruptly at this stage.
This will allow the engine to reach its proper ope- SA1
rating temperature of 70-95°C.
Fig. C-25
C-3.2.2 WARM START
For warm starts, i.e. after brief halts with the engine off,
proceed as described in the previous section C-3.2.1,
but skip point 5.
SC1
Fig. C-26
Page C-16
C-3.3 POWER PUMP OPERATION
C-3.3.1 DIESEL ENGINE REVS ADJUSTMENT
IMPORTANT
Generally speaking, the required revs should be rea-
ched slowly, accelerating gradually. This is especially
important in the case of cold starts or restarting.
C-3.3.2 GEAR CHANGE
WARNING
lt is forbidden to make random gear changes during
work: otherwise you risk changing the operating
parameters set.
Before changing gear during operation, consult the
performance chart.
The same table is also located on the control panel. S4
The correct gear change procedure is as follows:
1. Use SA1 to reduce the engine revs

SFC1A
2. Operate the clutch SFC1A and change gear with
S4, keeping the clutch lever pressed until the gear
is properly engaged.
SA1
3. Engage the clutch and set SA1 in the desired po-
sition
Fig. C-27
IMPORTANT
It is forbidden to change gear without using the clutch
and without reducing the engine revs below 1000 rpm
otherwise you risk damaging the mechanical parts.
Page C-17
C-3.4 MANUAL EMERGENCY STOP
In the event of emergencies, stop the power pump by

pressing the button SE1.
This manoeuvre immediately cuts the diesel engine,

causing:
SC1
- all the power pump’s moving parts to stop;
- the high pressure fluid delivery to stop.
SE1
You must then remove the electrical contact by turning
key SC1 anticlockwise.
Fig. C-28
C-3.4.1 MANUAL EMERGENCY RESET
S4
WARNING
Before reactivating the emergency system and re-
starting the power pump, you must first eliminate the
cause of the emergency stop.
SFC1A
Turn key SC1 in stop position and turn the button SE1
clockwise which resets the manual emergency electric
circuit.Start up the diesel engine by following the proce-
dure described in section C-4.2.
SA1
C-3.5 NORMAL POWER PUMP STOP Fig. C-29
WARNING
In normal operating conditions avoid stopping the
diesel engine abruptly so as not to create thermal
shocks that could eventually damage the engine.
1. Operate the clutch SFC1A and the lever S4 to set SC1

the gear lever in neutral.
2. Adjust SA1 to set the engine at approximately 1300 SE1

rpm for at least two minutes and let the engine cool
gradually and evenly.
Fig. C-30
3. Turn key SC1 anticlockwise to disconnect the elec-
trical contact.
IMPORTANT
In emergencies the engine must be cut quickly pres-
sing the button SE1 and ignoring the above instruc-
tions, as explained in section C-3.4.
Page C-18
C-3.6 BREAKING-IN PERIOD
A correct braking-in period ensures a long working life to your pump.
Pump
1. During the firts 200 working hours pump speed must not exceed 100 ÷110 strokes/min. and pump max. pressure
must be equal to 50% of values indicated in the performance table (see Fig. A-11).
2. After the first 1000 working hours, change lubricating oil.
3. After the first 1000 working hours, check screws and bolts are tightened properly.
Engine
See manufacturer’s instructions in the Section “Other manufacturer’s equipment” of this manual.
C-4 PARKING AND OFF-DUTY INSTRUCTIONS
WARNING
Before beginning any operation or procedure described in this chapter you must be aware of the safety rules
and information contained in Section B.
lf in doubt, read this section again and only when you have fully assimilated its contents should you com-
mence operations.
C-4.1 PARKING
Whenever the machine is stopped at the end of a workshift, for overnight halts or for holidays, it should be regarded
as parked.
Basic precautions must be taken when the machine is parked to eliminate the risk of injury to anyone approaching
the machine:
1. Disconnect the electrical system with Q1.
2. Remove the lockout key.
3. Disconnect the charging pump from the main power supply.
At the technical level, a number of important operations must be performed before to parking:
- pump clean water for several minutes to wash the pipes and the charging pump and prevent solids from depo-
siting.
- remove the front plugs (see Section E ) and check that the water pumping operation has been sufficient to clean
the fluid end. lf not, remove and clean it as described in section E.
HAZARD
Never leave the key in the control panel when the machine is parked or during halts or maintenance: accidental
machine start would be extremely dangerous!
Leaving the key in the panel creates a serious potential risk; anyone could start up the engine, carry out
dangerous manoeuvres or tamper with the machine.
Page C-19
IMPORTANT
These operations are very important since solid deposits in the pump manifolds when the machine is idle
(and particularly plugging substance and bentonite mud) will impair future efficiency and might cause serious
meccanical damage when the machine is started up.
C-4.2 OFF-DUTY
Whenever the machine is idle for maintenance work or long periods (storage) it should be regarded as off-duty.
Generally speaking, in addition to taking the precautions for parking, you should also place a notice on the control
board stating that the machine is out of service.
lf the period of storage exceeds 10 days you must also take the following special precautionary measures
1. Remove the fluid-end suction and delivery valves.
2. Thoroughly clean the fluid-end inside and cover the surfaces with protective and corrosion-inhibiting treat-
ment.
3. Parts temporarily removed from the pump must be thoroughly cleaned, coated with protective substances and
stored as if they were new.
4. Lubricate the liner inside surface and let the piston moving for some beats in such a way to put the grease over
all the surface.
IMPORTANT
Remember that the triplex pump is made with sophisticated materials and that the parts subject to the greatest
stress have a very high quality surface finish. Spare parts must also be stored carefully:
- Metal parts must be protected against corrosion and physical damage such as knocks.
- Rubber parts must be protected against deformation and ageing. They must not be suspended or stored
untidily and must not be exposed to light, heat or contact with oils or solvents.
IMPORTANT
During storage scheduled maintenance must be performed regularly; fluids must be changed and parts
subject to ageing replaced.
In all cases, all the parts of the machine must be checked prior to putting it back into service after a long
period off-duty.
Page C-20
C-5 TRANSPORT INSTRUCTIONS
WARNING
Before starting every operation or procedure described into this chapter, you must be aware of the safety
rules and information contained in Section B.
If in doubt, read this section again and only when you have fully assimilated its contents should you com-
mence operations.
C-5.1 LIFTING THE POWER PUMP
IMPORTANT
If the machine is not lifted in the correct manner the load may shift and cause damage or injury.
Strictly abide the following instructions:
1. Set the power pump in its parking configuration.
2. Make sure that all the compartments are closed and that no material (pipes, mechanical parts, etc.) is free to
move about on the skid.
IMPORTANT
If you intend to use the unoccupied parts of the skid to transport material, make sure that it will not damage
the power pump’s components and that it is firmly secured to the skid.
3. Fit the lifting kit to the lifting points, as shown in figure.
WARNING
The lifting kit shown below is for reference only and it is not supplied.
Fig. C-31
Page C-21
4. Fasten hempen ropes at the ends of the skid in order to steer the load, once it has been lifted, while remaining
at safe distance.
5. Hook the lifting device to the shackles A, making sure that the sling are appropriately sized for the load to be
lifted (see A-4.2) and the machine dimensions (see A-4.1).
HAZARD
Do not move below or near the load during lifting. Risk of fatal injury!
HAZARD
Do not use any load lifting or fastening points other than those specified above: otherwise serious damage
or injury may result.
Fig. C-32
Page C-22

MAINTENANCE UM191117/E - Rev.0 - 03/2011
Page D-1
Section D - MAINTENANCE
UM191117/E - Rev.0 - 03/2011 MAINTENANCE
Page D-2
D-1 PREFACE
The safety of the operators, the function and service of the machine in conformity with the declared specifications,
depend on scrupulous observation of the instructions given in this chapter.
Failure to observe the maintenance schedule is hazardous inasmuch as the machine may fail to be in the condition
required for its intended use.
IMPORTANT
Failure to observe the maintenance schedule voids the warranty. DRILLMEC declines all liability for and
resulting damage and injury.
D-1.1 MAINTENANCE LAYOUT
13
8 5 4 6 3
7 2 10
11
12
Fig. D-1
WARNING
Before starting any procedure described in this chapter, review the safety information given in Section B of
the manual.
Page D-3
D-1.1.1 SCHEDULED MAINTENANCE
* NOTE: Clean the interior of the casing thoroughly before filling with new oil.
Frequency (hours)
Maintenance Operation Ref.
10 50 100 250 500 1000 2000 3000 10000
Complete machine - General Inspection x 1
Fluid End - Inspection and cleaning during stops x 2
Liners cooling system - Check of fluid level x 3
Power end lubrication system - Check of oil level x 4
Chain transmission lubrication system - Check oil
x 5
level
Chain transmission - Check the chain tightness o x 5
Power end - Check of filter clogging x 3
Chain transmission - Check of filter clogging x 5
Bearing lubrication - Check of filter clogging x 6
Extension rod and pistons - Greasing of seal rings x 7
Universal joint - Greasing x 8
Gearbox - Check oil level x 9
Gate valve - Greasing x 10
Valve assembly - Check the wear x 2
Stripper box - Check the wear x 11
Pistons and liner - Check the wear x 12
Service crane - Greasing x 13
Power end lubrication system - Replace cartridge
x 4
filter
Chain transmission - Replace cartridge filter x 5
Power end lubrication system - Change oil o x 4
Chain transmission - Change oil o x 5
Piston and liner cooling system - Change cooling
o x 4
fluid
Gearbox - Change oil o x 9
o = Only first time

x = Normal frequency
IMPORTANT
For diesel engine maintenance intervals, refer to the attached manufacturer’s manual (Caterpillar).
Page D-4
D-1.2 LUBRICATION AND GREASING POINTS
Frequency (hours)
10 50 100 250 500 1000 2000 3000 10000
Extension rod and pistons greasing x 7
Universal joint greasing x 8
Gate valve greasing x 10
Service crane greasing x 13
o = Only first time
D-1.3 BOLT TIGHTENING POINTS
Frequency (hours)
10 50 100 250 500 1000 2000 3000 10000
Check of bolt tightening of fluid end x 2
Check of bolt tightening of main components x 1
o = Only first time

D-2 TABLES AND SPECIFICATIONS

D-2.1 LUBRICATING OILS
At delivery, the machine is supplied with lubricant as specified in the following table.
Capacity Type Oil - Ambient temperature

Component Ref.
(liters) -20°C to +55°C -1°C to +68°C
Power end lubrication system 320 Shell Omala 220 Shell Omala 320 4
Chain transmission lubrication system 170 Shell Tellus 46 5
Gearbox 47 Shell Spirax HD 80W/90 9
Liner and piston cooling system Emulsified water 3
IMPORTANT
Do not mix mineral oil with synthetic oil: they don’t have the same characteristics!
This could cause formation of FOAM which could negatively influence on good operation of the various units
hydraulic components.
Should you want to change the oil brand, it is advisable to drain and substitute all the old oil.
Page D-5
RECOMMENDED LUBRICANT OIL TABLE
Type AGIP SHELL ESSO MOBIL BP TEXACO

SAE 90 Blasia 220 Omala EP 220 Spartan EP 220 Mobil Gear 630 Energol GR-XP 220 Meropa 220
Gear Oil GX Mobil UBE HD
SAE80w/90 Rotra MP 80W/90 Spirax HD 80W/90 SAE 80W/90 SAE 80W/90
80W/90 80X/90
Rando Oil HD
Hydraulic Oil Arnica 46 Tellus 46 Nuto 46 DTE 25 Energol HLP 46
B46
Sigma turbo Delvac Super
HD-SAE10W Myrina 20W/40 Essolube XD-40 SAE 15W/40 SAE 15W/40
15W/40 15W/40
D-2.1.1 DIESEL ENGINE OIL
Use the oil recommended by the diesel engine manufacturer.

(Consult the instruction book enclosed with the machine documentation).
D-2.2 GREASES
Use the following products for grease lubrication:
SHELL SUPER GREASE EP2
SHELL RETINAX HD2 (piston rod extension)
AGIP SHELL ESSO MOBIL

GR MU/EP 1 SUPER GREASE EP1 NEBULA EP1 MOBYLEX 47
RETINAX HD2 NEBULA EP2
WARNING
Do not mix different greases; do not use greases with lower specifications.
D-2.3 ANTI-CORROSION PRODUCTS
For treating machined metal surfaces, which are subject to ageing and corrosion, we recommend the use of CHES-
TERTON RUST GUARD HEAVY DUTY, or other similar products, which form a thin, effective, long-lasting protective
film on the surface.
These products are required for storing spare parts or disassembled mechanical parts when the pump is being stored.
Also apply to the fluid-end for this purpose.
WARNING
When parts treated with these products are operated in contact with gaskets or other machined surfaces
(such as jackets/pistons) the protective film must be removed with the appropriate solvent before assembly.
Failure to do so risks damaging the parts in contact. Do not use these products on rubber parts.
Page D-6
D-3 LUBRICATION INSTRUCTIONS

D-3.1 MOTOR PUMP
Refer to fig. D-1.1 and follow the instructions of the table in par. D-1.2 for:
- greasing points (also marked on the motor pump itself)
- greasing intervals
For the type of grease to be used, see the table in par. D-2.3
D-3.2 OIL LUBRICATION OF PUMP
Refer to and follow the instructions of table D-1.1 for:
- points to be lubricated
- lubrication frequency
- type of oil
The triplex mud pump has a splash-gravity lubrication system for connecting rod bearings, which relies upon the rota-
tion of the crankshaft to pick up lubricant from the sump.
Lubrication tank, fixed inside pump frame, catch the oil drawn up by the circulating pump and distribute it to the bear-
ings and cross heads.
Oil then flows into the sump, constructed as an integral part of the power-end frame. The sump contain magnetic bar
to catch contaminant particles and a mesh suction filter. It can be easily inspected, for maintenance, by opening the
top cover with breather cap.
A Flow rate indicator and an oil dipstick are located on one side of the power-end.
The first oil change has to be made after completion of the braking-in period.
To obtain the best lubrication and to protect gaskets, oil temperature should not exceed 65°C.
It is possible, however, to work at higher temperatures (up to 80°C approximately) provided that the manufacturer’s
ratio between oil viscosity and temperature is maintained.
D-3.3 LUBRICATION OF DRIVE CHAIN AND CHAIN GEAR COUNTERSHAFT MAIN BEAR-
INGS
The drive chain and the main bearing of chain gear countershaft are pressure lubricated by gear pump.
A filter is located on the gear pump suction side. Pressure drops may indicate filter screen (25 micron) needs clean-
ing.
The oil tank is constructed as an integral part of the drive frame.
Pressure, and oil level are indicated respectively by a pressure gauge and a dipstick located on side of drive frame.
Pressure must range between 1.5 and 8 bar (at maximum RPM).
After completion of the breaking-in period the first oil change has to be made and the filter screen has to be re-
placed.
To obtain the best lubrication and to protect gaskets, oil temperature should not Exceed 65°C.
It is possible, however, to work at higher temperatures (up to 80° C approximately) provided that the manufacturer’s
ratio between oil viscosity and temperature is maintained.
Page D-7
Check and maintain lubrication system as follows:
1. Daily check oil level as indicated in table D-1.1.
2. Check condition of gears and drive chain. Replace them, when necessary.
3. Keep oil pressure between 1.5 and 8 bar (at maximum RPM) and oil temperature between 35° - 60°C.
4. Drain, flush and refill oil tank with new oil after breaking-in period (that is, after the first 500 working hours).
Afterwards, change oil every 3000 working hours or more often, if necessary.
Page D-8
D-3.4 PISTON AND LINER COOLING SYS-

TEM
Early liner failures are generally caused by piston failure. If at the starting the centrifugal pump doesn’t work, act
Piston life is greatly affected by heat, in particular by the on the impeller bleeding valve.
heat generated by sliding friction. A recirculating cooling
system is therefore supplied to cool the liner surface.
Stoppage of the cooling fluid will result in almost instant
failure of the piston rubbers and possibly extensive dam-
age to the liner bore.
1
3
The cooling fluid composition is the following:
- 10 liters of water
- 1 liter of emulsifiable oil (type roll or similar).
Special care must be exercised to see that fluid is kept
clean and relatively cool.
The cooling system is made up of a reservoir (item 1 in

the following figure) centrifugal electric pump (item 2 in 2
the following figure) and various hoses.
The above pump directs the fluid from reservoir and hoses
along the circular outer edge of the steel piston body from
Fig. D-2
there, the liquid flows into the bottom of the piston rod
chamber and then back into the reservoir.
Frequently check that reservoir is full by lifting its cap.
The cooling reservoir should be drained and all drilling

mud, sand, and trash flushed out as frequently as required
to maintain the coolant in an acceptable condition. it is,
however, recommended to change the coolant and clean
the reservoir anytime a piston fails.
PISTON WEAR CHECK

- To check the piston wear and to control the mud loss,
it is possible to stop the liner washing and cooling
flow acting on the C38 cock (see C-1.4 section of
this manual)
- At the end of the check open again completely the
C38 cock.
It is also recommended to accurately clean the bottom of

the liner piston rod chambers. Failure to clean them will
lead to contamination of the liner coolant in a recirculating
type system and permit a build-up of mud and debris. if this
build-up is left unchecked, drilling mud could eventually
enter the power end and contaminate the gear oil.
During replacement of liners and pistons, mud can enter

the above chambers.
In this case:
- Disconnect pipe (item 3 in the following figure) con-
necting the chambers to the reservoir
- Drain and accurately clean the piston rod cham-
bers
Page D-9
D-3.5 DRIVE ROLLER CHAINS
- Be sure that the roller transmission chains are always rect chain tension.
well lubricated. The oil pollution is a decisive factor
for the chain lubrication then it is necessary to clean Sag in inches based on 2% of sprocket centers
carefully each chain before installing it in such a way Shaft centers 20 30 40 50 60 70 80 90 100 125 150
to reduce the quantity of extraneous particles into inches
the oil. Sag. inches .50 .63 .88 1.00 1.25 1.50 1.63 1.88 2.00 2.50 3.00
Shaft centers 500 750 1000 1250 1500 1750 2000 2250
- Check the backlashes of the chain links at least one mm
time at a month. Sag. mm 10 15 20 25 30 35 40 45
- If it is possible, use a chain with a even number of

couplings in such a way to remove the needing for
an uncoupled link.
- To ensure a long life for the chain, keep the chain

itself properly stretched.
- Execute an adjustment of the chain after the first 200

working hours in such a way to remove the backlash
caused by the beginning stretching. Then, adjust it
periodically according to the operating conditions.
- Check the wear of the gear teeth at least every six

month (pay particular attention to the wear of the
Fig. D-3
pinion teeth).
HAZARD
If for maintenance and repair purpose you have to
remove housings, covers or guards, do so only when
the machine is stationary (engine off).
Do not start up the machine unless all the housings
covers and guards are properly fitted: otherwise seri-
ous personal injury could result.
Normally, horizontal and inclined drives should be installed

with an initial sag equal to approximately 2 per cent of
sprocket centers.
Vertical center drives, and those subject to shock load-

ing, reversal of rotation, or dynamic braking, should be
operated with both spans of chain almost taught. Peri-
odic inspection of such drives should be made to avoid
operation with excessive slack and to maintain proper
chain tension.
To determine the amount of sag, pull one side of the chain

taught allowing all the excess chain to accumulate in the
opposite span. As illustrated in fig. 3, place a straight
edge over the slack span and, pulling the chain down
at the center, measure the amount of sag. lf necessary,
adjust drive centers for proper sag that will result in cor-
Page D-10
D-3.6 PULSATION DAMPENER MAINTENANCE
The pulsation dampener will provide the maximum dampening efficiency when the nitrogen precharge is at the proper
value. There are two factors causing the precharge to change. These are: leaking off of the nitrogen gas and changes
in the ambient temperature of the unit. If all connections are tight the gas precharge will last for years. However,
over such long periods of time, a scarcely detectable leak can cause a large change in precharge pressure. If the
precharge pressure should appear to be below normal, the following should be checked with soapy water before
disturbing any connections.
1. The threaded connections for the pressure gauge and the charging valve.
2. Remove the valve cap from the charging valve and determine that the valve is fully closed.
3. Check the junction between the cover plate and the body and around the studs and nuts used to secure the
cover plate to the body.
If no leaks are discovered in the above locations, there may be a hole in the diaphragm.
If the leak appears to be large, the diaphragm should be changed immediately. If the leak appears to be small, the
precharge should be corrected by adding additional nitrogen gas and the unit checked again at a later date to deter-
mine if the leak is still present.
Follow the procedure described in the section “Replacement of pulsation dampener diaphragm” when changing the
diaphragm.
When large changes in the ambient temperature occur, as between summer and winter, it may be necessary to change
the precharge to adjust for these temperature changes. For example: if the unit is precharged to 100 psi at 20°C and
the temperature later changes to 10°C, the precharge pressure will drop to 95.5 psi.
If the precharge pressure is too low, the pulsation dampener will stand practically full of fluid at normal line pressure.
This will affect a loss in the working volume of the gas which will reduce the efficiency of the dampener.
If the precharge pressure is too high, the diaphragm insert will rest on the bottom, valving off the fluid inlet. Under this
condition no dampening can take place until the line pressure exceeds the precharge pressure. During the time the
line pressure is nearly equal to the precharge pressure, the diaphragm will pound against the inlet opening, causing
a reduced service life of the diaphragm.
Pulsation dampeners
- Make sure they are charged at the right pressure:
- Discharge: 350-1000 psi (24.6 - 70 kg/cm2)
NOTE
Precharge pressure may be 60% of system pressure but not to exceed 1000 psi (70 kg/cm2)
Page D-11
D-3.6.1 REPLACEMENT OF DISCHARGE PULSATION DAMPENER DIAPHRAGM
1. Make sure pressurized gas has been completely bled off from the pulsation dampener.
2. Remove the upper flange (item 2).
3. Remove damaged diaphragm.
4. Inspect inside surfaces of the pulsation dampener body (item 1) and completely remove any foreign matter,
rust or scale, that may be present.
5. Install new diaphragm (item 5) by laying it flat and folding it into a smaller shape, which should be inserted into
the body opening. Adjust the diaphragm perfectly to the inside contour of the pulsation dampener body. Fix neck
and ring of the diaphragm around the body opening, without distorting the diaphragm. To make this operation
easier, spread the diaphragm with talcum powder.
6. Insert the stabilizer plate (item 4) with its flange. Fix them to the diaphragm with the screw (item 3).
7. Grease inside of diaphragm neck.
8. Reset upper flange without damaging the diaphragm. Tighten nuts (item 6) to a torque value of 1200 N•m. The
pulsation dampener is now ready to be charged.
Fig. D-4
Page D-12
D-3.7 AIR CLUTCH Clearance mm Max air tube

Type displacement
BI-M VS mm
The clutch is a VS 330 Coremo model.
The clutch does not require any special maintenance op- 110 1 - 7
eration (see manufacturer’s data in the following notes). 210 2 - 7
115 1 - 8
Adjustement. 215-315 2 2 8
106 1 - 8
Correct clearance data are show on this table. Maximum
206 2 - 8
airtube displacement allows clearances three times larger
than those specified on table. Obviously the reaction time 108 - 1.5 10
encreases according. 208-308 - 2.5 10
Smaller clearances may cause drag torque and over 125 1.5 1.5 10
heating. 225-235 2.5 3 10
111 - 2 12
For correct use
211-311 - 3 12
Check that oil, grease or other lubríficant substance does 130 2 2 12

not leak on to the linings. 230 2.5 3 12
Check lining wear every six months. lf necessary clean 330 3.5 4 12
lining surface with glass paper or degreasing solution. If 114 - 2 14
temperature increases over 100°C check air-tube condi- 214 - 3.5 14
tion because over this temperature it may be subjected
314 - 5 14
to a rapid ageing or charring. When checking lining wear,
116 - 2.5 12
keep in mind that the unit must always have correct gap
(see table). 216 - 3.5 12
140 2 2.5 14
240 3.5 4 14
340 4.5 5.5 14
118 2.5 2.5 14
218 3 4 14
318 4 6 14
350 4 - 15
160 2.5 2.5 16
260-224 3 4 16
360 4 6 16
280 4 - 18
Fig. D-5
Page D-13
D-4 BOLT TIGHTENING SPECIFICATIONS

PRELOAD AND LOCKING TORQUE FOR SCREW THREADED ISO STANDARD PITCH
Preload have been calculated equal to 70% of minimum yeld.
Torsion moment have been calculated with rule (39) of Junker & Blume manual, using a friction factor of equal to
0,14.
STANDARD SCREW
Torque
Diameter UNC UNF
Lb-Ft Kgm Lb-Ft Kgm
1/4” 6 0,82 7 0,96
5/16” 13 1,79 14 1,93
3/8” 23 3,17 26 3,59
7/16” 37 5,10 41 5,65
1/2” 57 7,86 64 8,83
9/16” 82 11,30 91 12,5
5/8” 111 15,30 128 17,6
3/4” 200 27,60 223 30,7
7/8” 315 43,50 340 46,8
1” 400 55,20 460 63,5
1.1/8” 570 78,60 635 87,6
1.1/4” 645 89,00 710 98
1.3/8” 845 117,00 960 132
1.1/2” 1120 155,00 1500 207
SCREW WITH EXAGONAL HEAD WITH HEAT TREATMENT SAE1038 GRADE 5 (8G C45-C50)
Torque
Diameter UNC UNF
Lb-Ft Kgm Lb-Ft Kgm
1/4” 11 1,52 13 1,79
5/16” 21 2,9 23 3,18
3/8” 38 5,24 40 5,52
7/16” 55 7,58 60 8,28
1/2” 85 11,7 95 13,2
9/16” 125 17,2 140 19,6
5/8” 175 24,8 210 29
3/4” 300 41,4 330 45,5
7/8” 450 62,1 490 67,6
1” 680 93,8 715 98,6
1.1/8” 885 122,3 990 136,6
1.1/4” 1255 173 1380 191
1.3/8” 1635 226 1875 259
1.1/2” 2180 301 2430 335
SCREW WITH EXAGONAL HEAD WITH HIGH STRENGTH STEEL SAE1040 GRADE B (40CD4-ASTM)
Torque
Diameter UNC UNF
Lb-Ft Kgm Lb-Ft Kgm
1/4” 12 1,655 15 2,7
5/16” 25 3,45 30 4,14
3/8” 50 6,9 60 9,75
7/16” 85 11,7 95 13,1
1/2” 125 17,2 140 19,6
9/16” 175 24,1 195 26,9
5/8” 245 33,8 270 37,2
3/4” 425 58,6 460 63,5
7/8” 660 91 700 96,6
1” 990 135,6 1050 14
1.1/8” 1470 212 1655 22
1.1/4” 2100 290 2310 31
1.3/8” 2750 379 3110 42
1.1/2” 3640 503 4100 56
Page D-14
4.8 5.8 8.8

Diameter x Pitch 0,7 Rs = 224 0,7 Rs = 280 0,7 Rs = 448
Clamping Load Torque Clamping Load Torque Clamping Load Torque
mm N Nm N Nm N Nm
3 x 0,5 1130 0,67 1400 0,84 2550 1,5
4x 0,7 1970 1,5 2500 1,9 3930 3,1
5 x 0,8 3180 3 4000 3,8 6360 6
6x1 4500 5,2 5600 6,5 9000 10,4
8 x 1,25 8200 12,3 10250 15,4 16400 24,6
8x1 8780 13 1100 16,3 17600 26
10 x 1,5 13000 25,1 16200 31,3 26000 50,1
10 x 1,25 13700 26,2 17100 32,7 27400 52,4
12 x 1,75 18900 42,4 23600 53 37800 84,4
12 x 1,25 20600 45,3 25800 56,6 41300 90,6
14 x 2 25800 67,4 32200 84,3 51500 135
14 x 1,5 28000 71,7 35000 89,6 56000 143
16 x 2 35200 102 44000 128 70300 205
16 x 1,5 27400 107 46800 134 74800 214
18 x 2,5 43000 142 53800 177 86000 283
18 x 1,5 48400 154 60500 193 96800 308
20 x 2,5 24900 200 68600 250 110000 400
20 x 1,5 60900 216 76200 270 122000 431
22 x 2,5 67900 266 84800 322 136000 532
22 x 1,5 74600 286 93200 357 149000 571
24 x 3 79100 345 98800 432 158000 691
24 x 2 86000 365 108000 457 172000 731
27 x 3 10300 505 129000 631 206000 1010
27 x 2 111000 534 139000 667 222000 1070
30 x 3,5 126000 686 157000 854 251000 1370
30 x 2 139000 738 174000 923 278000 1480
33 x 3,5 155344 933 194180 1166 310688 1866
33 x 2 170240 994 212800 1243 340480 1989
10.9 12.9
Diameter x Pitch 0,7 Rs = 630 0,7 Rs = 756
Clamping Load Torque Clamping Load Torque
mm N Nm N Nm
3 x 0,5 3170 1,9 3800 2,3
4x 0,7 5530 4,3 6640 5,2
5 x 0,8 8950 8,5 10700 10,1
6x1 12700 14,6 15200 17,5
8 x 1,25 23100 34,7 27700 41,6
8x1 24700 36,6 29600 43,9
10 x 1,5 36500 70,5 43900 84,6
10 x 1,25 38500 73,6 46300 88,4
12 x 1,75 53000 119 63700 143
12 x 1,25 58000 127 69600 153
14 x 2 72500 190 86900 228
14 x 1,5 78800 202 94500 242
16 x 2 98900 288 119000 346
16 x 1,5 105000 302 126000 362
18 x 2,5 121000 398 145000 478
18 x 1,5 136000 434 163000 520
20 x 2,5 154000 562 185000 674
20 x 1,5 171000 607 206000 728
22 x 2,5 191000 748 229000 897
22 x 1,5 210000 803 252000 964
24 x 3 222000 971 267000 1170
24 x 2 242000 1030 290000 1230
27 x 3 289000 1420 347000 1700
27 x 2 312000 1500 375000 1800
30 x 3,5 353000 1930 424000 2310
30 x 2 391000 2080 469000 2490
33 x 3,5 436905 2624 524286 3148
33 x 2 478800 2797 574560 3356
Page D-15
D-5 HOSE FITTING SPECIFICATIONS

For best operation of the hydraulic system, always keep
in mind some important rules for hose fitting.
Hose fitting nuts shall be tighten until no leakage occurs

through the coupling. Exceeding that point, does not im-
prove tightness and damages the coupling!
Fig. D-6
A hose should never be subject to torsion! When fitting the

hose, consider that during operation, the hose is subject
to changes in length with consequent torsional effects.
Therefore, hoses should not be too short and the proper
settling should be checked with hose in resting position.
Fig. D-7
If hoses routing requires the hose to bend, make sure that

the bending radius are correct.
A bending radius too small can cause restrictions in
the section and therefore load losses. Moreover, these
bends can cause torsional stress and even breakage of
the hose!
Fig. D-8
For correct fitting of hoses, elbow fitting can be used for

installation in restricted space without impairing hose ef-
ficiency and life.
Fig. D-9
Page D-16
D-5.1 STORING OF FLEXIBLE HOSES
RECOMMENDATIONS FOR A CORRECT STORING

The rubber is subjected, by its nature, to changes in its physical properties. These changes, which normally take place
in time, according to the used type of rubber, can be accelerated by a special factor or by a combination of factors. The
reinforce materials are, in the same way, damaged by unproper storing conditions. The following recommendations
contain some precautions to take in order to ensure the minimum wear of the stored goods.
STORING TIME
The storing time should be minimized by means of a scheduled rotation program. When it is not possible to avoid
long storing times and when the following recommendations are not respected, it is necessary to accurately check
the hose before using it.
TEMPERATURE AND HUMIDITY

The best temperature for the storing of the rubber hoses is between 10 to 25 degrees centigrade. The hoses should
not be hold stored with temperature higher than 40°C or lower than 0°C. When the temperature is under -15°C, it is
necessary to keep precautions when handling the hoses. The hoses must not be stored near to heat sources nor in
conditions of high or low humidity. A maximum level of umidity of 65% is recommended.
LIGHT
The hoses must be stored in obscured places, avoiding the direct exposition to the sunlight or to strong artificial lights.
If the store has some glass windows or doors, these must be obscured.
OXYGEN AND NITROGEN

The hoses must be protected against the air by a proper package or by storing them into airtight containers. As the
nitrogen has a particularly aggressive action over all the rubber products, the storehouse must not contain materials
that emit nitrogen, like equipment under high voltage, electrical motors or other materials which generate sparks or
magnetic fields.
CONTACTS WITH OTHER MATERIALS

The hoses must not be in contact with solvents, fuels, oils, greases, volatile chemical compounds, acids, disinfectants
and other organic liquids in general. Moreover, the direct contact with some metals (for example manganese, iron,
copper and its alloys) and relevant compounds causes harmful effects on some types of rubber. Contacts with PVC
and wood or fabrics soaked of creosote must be avoided.
HEAT SOURCES
When the temperature limits cannot be respected, it is necessary to use a thermal protection.
ELECTRIC OR MAGNETIC FIELDS

The variations of the electric or magnetic fields must be removed in the storehouses because that could cause currents
in the metallic connections, heating them. Similar fields could be caused by high-voltage wires or by high-frequency
generators.
STORING CONDITIONS
The hoses must be stored in easy conditions, free from stretches, compressions or other deformations and contacts
must be avoided with objects that could cut or drill them.
It is preferable to store the hoses on special shelvings or dry surfaces.
The packaged hoses must be stored in horizontal position avoiding to stack them. When this is not possible, the height
of the stacks must be such to avoid permanent deformations of the hoses placed at the bottom.
The inner diameter of the package must never be lower than the double of the curvature radius declared by the
manufacturer in compliance with the technical standards. It is suggested to avoid to store the packages of hoses
on rods or hooks. It is suggested, moreover, to store the hoses, which are delivered straight, in horizontal position
without bending them.
RODENTS AND INSECTS

The hoses must be protected against rodents and insects. When this risk is probable, proper precautions must be
taken.
Page D-17
D-5.2 NORMS AND METHODS OF USE OF THE FLEXIBLE HOSES
PRE-ASSEMBLY CHECKS
Before the installation after a replacement, it is necessary to accurately check the hose characteristics to verify that
type, diameter and length are in compliance with the required specifications. Moreover, a visual check must be executed
in order to ensure that there are not obstructions, cuts, damaged cover or any other evident imperfections.
HANDLING
The hoses must be handled with care avoiding shocks, draggings on abrasive surfaces and compressions. The hoses
must not be pulled with violence when are twisted or contorted. The heavy hoses, generally delivered in horizontal
straight position, must be placed over proper supports for the transport.
If wooden supports are used, these must not be treated with creasote or painted with substances which could dam-
age the rubber.
PRESSURE AND SEALING TEST

The operating pressure, generally marked on the hoses, must be respected. After the installation, when the air balls
have been removed, gradually increase the pressure up to the operating pressure to test the assembly and check
possible leaks.
TEMPERATURE
The hoses must be always used within the generally pointed out temperature ranges. In case of doubts, call the
manufacturer.
TRANSPORTED PRODUCTS
The hoses must be used for the transport of substances, which they have been manufactured for. In case of doubts,
call the manufacturer. As much as possible, the hoses must not be kept under pressure when they are not used.
ENVIRONMENTAL CONDITIONS
The hoses must be used only in the environmental conditions which they have been manufactured for.
TORSION
The hoses have not been manufactured to work in torsion, except for specific purpose.
STRETCH
The stretch must be within the limits specified by the manufacturer.
VIBRATIONS
The vibrations subject the hoses to the stress and to the heat, above all near the joints and premature explosions can
occur. It is then suggested to check that the hoses have been manufactured to withstand these stresses.
CUSPS
Some users blocks the passage of the liquid thought the hose creating cusps in it. This method is not suggested by
the manufacturers, as the reinforcement is subjected to an excessive stress that could bring to explosion.
D-5.3 MAINTENANCE OF THE FLEXIBLE HOSES
MAINTENANCE
The frequency of the hose maintenance is determinated depending on the use of the hose. In the normal checks,
special care must be taken on the connections and on the presence of the following irregularities that point out the
deterioration of the hose:
• fissures, cuts, scraps, ungluing, tearings of the cover that make the reinforcement visible;
• deformations, balls, local bulges in pressure;
• hardened or too tender parts;
• leaks.
Page D-18
These irregularities justify the replacement of the hose.

When the cover reports the expiry date, this must be respected even if the hose does not show evident signs of
deterioration.
REPAIRS
The repairs are not suggested. However, if the deterioration is placed at one edge of the hose, this can be cut.
CLEANING
Clean, if necessary, by soap and water avoiding the use of solvents (petroleum, paraffin, etc) or detergents. Never
use abrasive, sharpened or cutting tools (metallic brushes) for the cleaning.
FLUID END MAINTENANCE UM191117/E - Rev.0 - 03/2011
Page E-1
Section E - FLUID END MAINTENANCE

UM191117/E - Rev.0 - 03/2011 FLUID END MAINTENANCE
Page E-2
E-1 EXPENDABLES
Gaskets, valves, valve seats, valve springs, liners, and
piston are considered expendable components.
WARNING
NEVER REACH INSIDE OPERATING PUMP.
NEVER PUMP AGAINST CLOSED VALVES (ALL DI-
SCHARGE VALVES CLOSED).
STOP PUMP OPERATION BEFORE ATTEMPTING
REPAIRS.
PROPERLY LOCK-OUT OR DISCONNECT MAIN PO-
WER SOURCE TO THE PUMP BEFORE CONDUCTING
INSPECTION, MAINTENANCE, OR REPAIR.
COMPLETELY BLEED ALL PRESSURE FROM FLU-
ID END BEFORE ATTEMPTING MAINTENANCE OR
REPAIR.
NOTE:
Be sure to tighten fasteners to the proper torque
value. Torque specifications for important fluid end
fasteners are given at the back of this Guide. Refer
to a standard torque chart for any fasteners not listed
in this Guide.
E-2 GASKET REPLACEMENT

For liner gasket replacement see LINERS
1 5
1. Use a hammer and steel bar to remove threaded 3
discharge valve plug retainer (1)
2. Unscrew nuts (2) and remove cylinder head plug 2
(3).
3. Remove discharge gasket (3).
4. Remove front gasket (4).
5. lnspect gaskets. Discard if damaged or worn.
6. Clean gasket groove and lubricate with multipurpo-
se grease. 4
7. Install gaskets. Use new gasket if necessary.
8. Install discharge valve. Tighten with hammer and 1
steel bar.
NOTE:
Threaded retainers are buttress fit and must be tight-
ened completely.
9. Install cylinder head and nuts. Tighten with proper

wrench.
Fig. E-1
Page E-3
E-3 SUCTION VALVES

E-3.1 REMOVAL
1. Remove discharge valve plug retainer (1).
2. Inspect gasket (4). Remove and discard gasket if

damaged or worn.
3. Pull spring ends (3) from slot. 4
3 1
4. Rock valve guide slightly to loosen. Rotate guide 2
90° degrees and lift upward in vertical bore to re-
move (2).
5. Remove suction valve and valve spring.
E-3.2 INSTALLATION
1. Position valve on valve seat.
2. Place valve spring over valve.

Fig. E-2
3. Insert valve guide lengthwise (with one of the curved
surfaces facing the piston) until the center of the
guide is over the valve stem and spring.
4. Push the guide down over valve stem and spring.
5. Rotate the guide 90 degrees, mating the curved

surfaces of the guide with the curved surfaces of
the vertical bore.
CAUTION
VALVE GUIDE WILL BE DAMAGED DURING PUMP
OPERATION IF COCKED OR MISALIGNED DURING
INSTALLATION.
Fig. E-3
6. lnspect valve guide and retainer to be sure they are

installed correctly.
7. Install cylinder head gasket.
8. Install cylinder head plug and nuts. Tighten with

proper wrench.
Fig. E-4
Page E-4
E-4 DISCHARGE VALVES

2
E-4.1 REMOVAL
1. Unscrew the threaded plug (2) with hammer and

steel bar.
2. Remove the plug with integral valve guide (1). 1
NOTE:
The discharge valve guide for 7TS600.1 is bolted to
the cover plug.
3. Remove discharge valve and valve spring.
E-4.2 INSTALLATION
1. Position discharge valve on valve seat.
2. Place valve spring over valve.
3. Inspect cover plug gasket. Replace if damaged or

worn.
Fig. E-5
4. lnstall cover plug making sure that valve guide is

correctly positioned over valve.
5. Tighten cover plug with hammer and steel bar.
NOTE:
Threaded cover plug is buttress fit and must be tighte-
ned completely.
Fig. E-6
Page E-5
E-5 VALVE SEATS

E-5.1 REMOVAL
WARNING
Never use a torch to remove valve seats. Excessive
heat will distort forgings around valve seat.
NOTE:
Valve seat pullers are availabie from DRILLMEC.
Specify serial number of power mud pump when
ordering puller.
1. Remove valve guide and valve (see section on

appropriate valve).
2. Use a suitable puller to remove valve seat. (See

CAUTION and NOTE.)
E-5.2 INSTALLATION
NOTE:
Do not re-use valve seats. Always replace removed
valve seats with new ones. Fig. E-7
1. Remove all mud and scale from area that valve

seat contacts with wire brush.
2. Thoroughly clean the area that the valve- seat con-
tacts with rags and a suitable cleaning solution.
WARNING
Never use gasoline as a cleaning solution.
3. Wipe the contact area dry with a soft clean rag.

Area must be completely dry before installing valve
seat.
Fig. E-8
4. lnstall valve seat into the tapered seat area.
5. Drive the valve seat into place with a hammer and

wooden block.
NOTE:
Pump pressure will drive the seat into its final posi-
tion.
6. Install the valve, valve spring, and valve guide.

Page E-6
E-6 PISTONS AND PISTON RODS

Drillmec Triplex pumps have API SA-4 piston rod connec-
tions designed for single-acting pistons and 1-1/2 inch
diameter bores in the piston body. The threads on the
piston rods are 1-1/2” - 8UN.
E-6.1 REMOVAL
1. Remove cylinder head plug.
2. Remove and inspect gasket. Discard if damaged

or worn. Fig. E-9
3. Completely retract the extension rod and remove

the piston rod clamp A.
4. Push piston rod and piston out through cylinder

head.
5. Remove stop nuts and piston from piston rod.
Fig. E-10
Fig. E-11
Page E-7
E-7 INSTALLATION
NOTE:
Burrs and rough spots on the extension and piston
rod fianges will cause piston and liner misalignment.
Before reassembly and installation, inspect the ex-
tension and piston rod flanges. Remove any burrs
or rough spots by filing or grinding.
1. lnstall new piston with O-ring onto piston rod.
2. lnstall stop nut on piston rod. Torque stop nut to

870 ft.-Ibs. Fig. E-12
3. Lubricate liner bore and piston with multipurpose

grease.
4. lnsert the assembled piston and piston rod, flange

end first, into the fluid end and through the liner.
5. Position the piston rod flange against the extension

rod flange.
NOTES:
There should be no space between the piston rod and
extension rod flanges. Fig. E-13
If the piston rod clamp will not tighten completely, inspect

the clamping faces of the extension rod, piston rod, and 1
clamp for grooves or burrs. Carefully remove any grooves
or burrs on the clamping faces by filing or grinding.
6. lnstall the piston rod clamp (2).
7. Torque the M20 clamp bolts evenly to 388 N•m (286

Ft•lbs). The clamp should fit tightly around the rod
flanges and should not rotate.
2
8. lnstall gasket, cylinder head plug, and nuts. Tighten Fig. E-14
with proper wrench.
Page E-8
E-8 LINERS
WARNING
Use the liner davit when handling liners. Liners are
heavy and workspace is confined.
E-8.1 REMOVAL
1. Remove the cylinder head cover.
2. Completely retract the extension rod and remove

the piston rod clamp.
Fig. E-15
3. Remove the piston rod and piston.
4. Remove the liner retainer from the threaded ring

(1).
5. Pull the liner out of the frame bore.
NOTE:
If liner cannot be easily removed from the frame bore
contact your DRILLMEC service representative for
alternate method of removing liner.
E-8.2 INSTALLATION
1. Grease the liner boss and face with heavy grease.

This lubrication prevents corrosion and aids in
removal of the liner for later maintenance or repla-
cement.
2. Clean the liner bore and face of the fluid end.
3. Lubricate the gasket recess and install a gasket on

the face of the fluid-end.
4. Install the liner in the liner bore. Push liner into bore
Fig. E-16
until it stops against fluid end block.
5. Place the threaded liner retainer over the liner and

install into threaded ring.
6. Tighten threaded liner retainer against the liner and

tighten with hammer and steel bar.
NOTE:
Threaded liner retainer is buttress fit and must be
completely tight,
Page E-9
E-9 FLUID-END ACCESSORIES

1
Two pulsation dampeners are mounted on your power
pump to reduce pressure surges in the mud system so
that more uniform flow of fluid is obtained.
One dampener is located on the suction manifold an the
other on the discharge manifold.
E-9.1 SUCTION DESURGER
The suction desuger is located on the end of the suction

manifold . The suction desurger extends the service life of
the charging pump by smoothing the suction flow.
Before starting the pump for the first time, as well as pe-
riodically during pump operation, check the air pressure
in the desurger.
1. Open the plug (1).
2. Use a standard tire pressure gauge to check air

pressure. Pressure should be 20 psi. If low, use
standard air compressor to fill to 20 psi.
3. Close plug (1). Fig. E-17
4. lf pressure integrity is lost at any time, inspect the

rubber diaphragm inside the suction manifold for
damage.
WARNING
It is dangerous to charge suction desurger before
installation.
Use nitrogen or air only. Never use oxygen.
Page E-10
E-10 STRAINER ASSEMBLY
This standard accessory consists of a studded strainer

body, flange, and strainer screen. The strainer assembly
supports the pulsation dampener and strains the mud to
prevent trash from entering the high pressure mud system.
lnspect the strainer screen at regular intervals or if relief
valve discharges excessively.
WARNING
Completely bleed all pressure from fluid end before
attempting maintenance or repair. Fig. E-18
1. Remove the cap flange (1).
2. Clean or replace screen (2).
3. Install the cap flange . Refer to torque charts in the

back of this Guide.
NOTE:
Two outlets for 3” and 2”-5000 psi WP API are provided
for discharge and bleed off purpose.
Page E-11
E-11 PULSATION DAMPENER ON THE DI- 2. Make sure the needle valve (4) is perfectly
closed.
SCHARGE MANIFOLD
The following plate is fixed on the dampener: 3. Remove the needle valve cap (item 1). Connect
the needle valve to a nitrogen bottle by means of
Pulsation dampener a suitable high pressure charging hose (5).
type 5000 PSI
cap. 10 u.s.gal. ( 37.8 liters) 4. Open the needle valve (4).
IMPORTANT
- Do not weld - drill - or alter: this is a pressure ves- 5. Slowly open the bottle valve to let the gas flow from
sel the bottle into the pulsation dampener. This must
be done with the line pressure reduced to a value
- Discharge all pressure from gas chamber through
not higher than the pre-charge pressure.
valve beneath this cover before disassembling
- Pre-charge gas chamber with compressed nitrogen
before using. 6. When dampener gauge (3) shows desired charging
pressure, close bottle valve.
- Pre-charge range 350 - 1000 PSI.
WARNING 7. Close the needle valve (4).

Do not pre-charge with oxygen.
8. Remove the hose (5) from dampener valve.
- It is dangerous to pre-charge pulsation dampener
before installation.
9. Reset the needle valve cap (1).
- Use nitrogen or air only. Never use oxygen.
E-11.1 PRE-CHARGING INSTRUCTIONS 10. Reset the pulsation dampener cover (2).
1. Remove pulsation dampener cover (2).
Fig. E-19
Page E-12
E-12 PRELOAD STUDS

E-12.1 STUDS THREAD PRELOAD AND SETTINGS
Maximum preload (kN) Maximum torque (Nm)

Pos. Stud diameter Screw class Screw class
6.8 8.8 10.9 12.9 6.8 8.8 10.9 12.9
1 M.52x3 70563,0 94084,1 132305,8 158766,9 6333,9 8445,2 11876,1 14251,3
2 M.33x2 28209,3 37612,6 52892,8 63471,3 1602,3 2136,4 3004,4 3605,3
3 M.27x3 16428,3 21904,4 30803,1 36963,8 787,6 1050,1 1476,7 1772,1
2
1
Fig. E-20
TROUBLESHOOTING UM191117/E - Rev.0 - 03/2011
Page F-1
Section F - TROUBLESHOOTING
UM191117/E - Rev.0 - 03/2011 TROUBLESHOOTING
Page F-2
F-1 TROUBLESHOOTING
It is not possible to troubleshoot the causes of problems which occur during pumping itself.
To identify the problem, it is important to analyse the symptoms.
The troubleshooting table gives some of the most common problems, their causes and solutions.
IMPORTANT
If the troubleshooting table is not sufficient to resolve your problem, please contact DRILLMEC Customer
Care.
WARNING
Never reach into the pump while it is operating. Never run the pump with the delivery valve closed.
Stop pumping before making any repairs. Before inspecting, servicing or repairing the motor
pump, disconnect the pump from the power supply. Completely depressurise the fluid-end before doing any
service or repair work.
Page F-3
PROBLEM CAUSE SOLUTION

INSUFFICIENT DELIVERY PRES- VALVE OR VALVE SEAT WORN OR REPLACE VALVE/ VALVE SEAT
SURE LOW CUT BY FLUID
VALVE LOCKED OPEN REMOVE FOREIGN BODIES
MESH FILTER BLOCKED CLEAN/REPLACE DELIVERY MESH
FILTER
FLUID LEAKAGE FROM PISTON REPLACE PISTON / JACKET
INCORRECT PRESSURE GAUGE RECALIBRATE / REPLACE PRES-
READING SURE GAUGE
LOW SUCTION PRESSURE LOW FLUID HEAD INCREASE FLUID HEAD INCREASE
BOOST
BOOSTER PUMP WORN CHECK BOOSTER PUMP
FLOW OBSTRUCTED REMOVE OBSTRUCTIONS FROM
SUCTION LINE
INCORRECT PIPE LAYOUT CORRECT LAYOUT
INCORRECT PRESSURE GAUGE CONTACT PUMP MANUFACTU-
READING RER
RECALIBRATE/REPLACE PRESSU-
RE GAUGE
AIR IN THE SUCTION LINE REPAIR SUCTION LINE
AIR IN THE BOOSTER PUMP ADJUST/REPLACE STIFFING BOX
ON SHAFT OR GASKET
LACK OF PRESSURE IN THE SUC- CHECK/CHARGE
TION DESURGER
PASS MUD THROUGH DEGASSER
FLUID HAMMERING WITH SUCTION COMPRESSOR
ALLOW PIPES TO FILL COMPLE-
AIR/CAVITATION IN THE PUMPED TELY
FLUID
REDUCE PUMP SPEED
ADJUST DESURGER SUCTION
PRESSURE
LOW DELIVERY PRESSURE SEE “LOW DELIVERY PRESSURE”
DELIVERY DESURGER REPAIR / CHARGE / REPLACE
DELIVERY LINE NOT SECURED INSTALL SUPPORTS OR LOCKS
DELIVERY LINE VIBRATION LOW DELIVERY PRESSURE SEE”LOW DELIVERY PRESSURE “
LOW SUCTION PRESSURE SEE “LOW SUCTION PRESSURE”
FLUID HAMMERING SEE “FLUID HAMMERING”
VALVE CAP/FRONT PANEL LOO- TIGHTEN DOWN CAP/FRONT PA-
SE NEL
REPLACE GASKET REPLACE GASKET
SIGNIFICANT LEAKAGE
GASKET SURFACE / SEAT DAMA- REPLACE VALVE CAP/FRONT
GED PANEL
REPAIR FLUID-END
Page F-4

ABRASIVE PARTICLES IN THE CHECK DESILTER
FLUID
LARGE PARTICLES IN THE FLUID CHECK DESANDER
VALVE SEAL COMPROMISED VALVE SPRING BROKEN - REPLA-
CE
SHORT VALVE LIFE EXCESSIVE
VALVE GUIDE WORN - REPLACE
VALVE WEAR
VALVE OR VALVE SEAT WORN -
REPLACE
LOW FLUID SUPPLY TO THE SEE “LOW SUCTION PRESSURE”
PUMP
DEFECTIVE PULSATION DAMPER REPAIR/REPLACE
ABRASIVE PARTICLES IN THE PUMP FILTERED FLUID AND CLE-
FLUID END AN THE PISTON THOROUGHLY
DRY FRICTION REPAIR JACKET COOLING SY-
E X C E S S I V E P I S TO N / J A C K E T STEM
WEAR EXCESSIVE JACKET WEAR USE HIGH CHROME STEEL JA-
CKET
EXCESSIVE PISTON WEAR TIGHTEN DOWN THE ROD CLAM-
PS
PISTON ROD EXTENSION WORN/ REPLACE THE PISTON ROD EX-
DAMAGED TENSION
PISTON ROD EXTENSION SCO- CLEAN THE GASKETS AND PISTON
LEAKAGE FROM THE PISTON ROD RED ROD WHEN INSTALLING
EXTENSION GASKET SEAT WORN SEAL RINGS REPLACE
SCRAPERS NOT TIGHT CHECK ASSEMBLY ORIENTATION
PRESSURE IN THE POWER-END CLEAN/REPLACE AIR BLEED VAL-
CASING VE
LEAKAGE FROM THE LUBRICATON WORN SEALS REPLACE
SYSTEM OIL GASKETS DAMAGED SEALS REPLACE
EXTERNAL EDGE OF GASKET IN- CLEAN AND POLISH THE INTERIOR
CORRECTLY SEATED OF THE LUBRICATION OIL SEAL
SEAT
CLEAN AND POLISH THE RING ON
FOREIGN BODY IN THE SEAL WHICH THE SEAL RESTS
REPLACE THE RING
PRESSURE IN THE POWER-END CLEAN / REPLACE THE AIR BLEED
CASING VALVE
LOW OIL LEVEL CHECK AND TOP UP
LUBRICATION FAILURE IN THE
OIL TEMPERATURE TOO HIGH SEE “HIGH OIL TEMPERATURE”
POWER-END/CROSS-HEAD
DIRTY OIL CHANGE OIL AND FILTER
HIGH OIL TEMPERATURE >=80°C UNSUITABLE OIL TYPE CHECK OIL TYPE
SLACK PISTON / RODSLACK ROD CHECK AND TIGHTEN DOWN
EXTENSION
WORN BEARINGS REPLACE
NOISE IN THE POWER - END
PLAY IN CROSS-HEAD PIN CHECK AND TIGHTEN DOWN
WORN CAMSHAFTWORN CROSS- REPAIR/REPLACE
HEAD
Page F-5

DIRTY OIL CHANGE OIL AND FILTER
INCORRECTLY SET/BLOCKED SA- ADJUST / REPLACE SAFETY VAL-
FETY VALVE VE
OIL FILTER BLOCKED CHANGE OIL AND FILTER
HIGH OIL PRESSURE REDUCED OIL LINE CROSS-SEC- CLEAN OUT
TION
OIL LINE BENT / CRIMPED CHECK
INCORRET PRESSURE GAUGE REPLACE PRESSURE GAUGE
READING
SAFETY VALVE (WHERE FITTED ) CHECK SETTING NOT TOO LOW
INCORRECT OIL TYPE CHECK OIL TYPE
HIGH OIL TEMPERATURE OIL LINE CRIMPED CHECK LINES
HEAT EXCHANGER (WHERE FIT- CHECK WATER PUMP OPERA-
TED) TION
Page F-6

OTHER RISK UM191117/E - Rev.0 - 03/2011
Page G-1
Section G - OTHER RISK

UM191117/E - Rev.0 - 03/2011 OTHER RISK
Page G-2
G-1 OTHER RISKS
WARNING
In case of repairs after a fault has been detected or of preventive maintenance, and however for any envisaged
application, the machine can be considered almost free of any risk, provided that the all safety cautions are
taken, as required by the regulations currently in force and as mentioned in Section B of this manual.
G-1.1 PRESSURIZED ACCUMULATORS
On the rig are installed some accumulators under pressure.
It is necessary to consider their potential danger during maintenance/repairing of hydraulic and pneumatic systems.
The tank of compressed air is positioned on the carrier and one is used as an auxiliary tank for normal machine
operations.
The drilling fluid system (air / mud) has parts that remain pressurized also when the machine is not working
One hydraulic accumulator is located on mud pump as pulsation dampener.
HAZARD
Before working on pressurized lines (hydraulic oil, compressed air, water or drilling fluids) and/or disconnect
components, make sure that the pressure has been discharged and the fluid contained is not longer hot.
DISMANTLING AND DEMOLITION UM191117/E - Rev.0 - 03/2011
Page H-1
Section H - DISMANTLING AND DEMOLITION

UM191117/E - Rev.0 - 03/2011 DISMANTLING AND DEMOLITION
Page H-2
H-1 DISMANTLING AND DEMOLITION

The demolition of the machine must be exclusively entrusted to Qualified and Trained Personnel.
If the Customer doesn’t dispose of the adequate Personnel or instruments for carrying out the demolition procedures
in fully safe conditions and in such a way to grant the Operators’ safety, get addressed to the DRILLMEC Technical
Personnel.
The machine was realized by prevalently using ferrous materials, aluminium and other metal alloys which can be
re-cycled.
There are some components realized by using technical polymeric materials, glass.
There are also the following materials which, according with the relevant laws in force in the country in which the di-
smantling is carried out, can be considered as “special wastes”: fuel for endothermic motors, hydraulic oils, lubricating
oils, greases, drilling muds, electric accumulators and electric or electronic wastes.
It is charged to the demolition responsible to get carefully informed, according with the relevant laws in force, about
the modalities foreseen for the elimination of the special wastes and to act in full compliance with them.
HAZARD
Risk of environmental pollution.
Before proceeding to disassemble/demolish the mechanical parts, be sure to:
- Discharge the piping from drilling mud.
- Empty the cooling tank rod, verify the discharge of all the circuit.

Operation and Maintenance Manual: Triplex Mud Pump - Skid Mounted

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Operation and

Triplex mud pump - skid mounted

12, Via 1° Maggio

Corporate web site: http://www.drillmec.com

© Copyright 2011 DRILLMEC S.p.A. - All rights reserved

TECHNICAL SERVICE AND SPARE

The technical service can be executed by an Agent or by

LOCAL AUTHORIZED DEALERSHIP AND SERVICE CENTRE

MEMORANDUM OF THE MACHINE IDENTIFICATION DATA

Machine serial number

Drilling rig type-approval

Power plant t ype-approval

FOREWORD 4 Mark and logotype of DRILLMEC SpA.

C-1-1 DRILLING CONTROLS AND INSTRUMENTATIONS

the machine technical performances, the safety rules, the

the operators will be required to carefully read and well 4

understand the contents of the manual before starting to $ $

use the machine. It is necessary the complete understand- $

ing especially of all the aspects relevant to the use, the 4

maintenance and the lubrication of the machine. 4

A8 Air pressure gauge

the machine. C4 Oil pump 3 lifting - top drive rotation control

areas. The operators must be able to use it through the

It is also advisable to know well the methods used to

TYPICAL STRUCTURE OF THE PAGES

The pages of the manual have always a typical structure

1 Model of the treated machine or fixture.

7 Chapter title (first, second or third level). PAGE NUMBERING SYSTEM

2. Another mainly important check is that relevant

9 Inside each fist level chapter, the figure numbering system

RECALLING CONNECTION TO OTHER

On their turn, the sections are subdivided in Chapters.

Breathers or anti dust masks

Ear plugs or noise or noise protective

Safety goggles or eyes’ protective masks

Hoses burst hazard

Hot parts hazard

Accumulator burst hazard

TYPE OF SIGNAL COLOUR

SECTION A - GENERAL INFORMATION ............................................................................A-1

SECTION B - SAFETY .........................................................................................................B-1

SECTION C - OPERATING INSTRUCTIONS ......................................................................C-1

SECTION D - MAINTENANCE .............................................................................................D-1

SECTION E - FLUID END MAINTENANCE ......................................................................... E-1

E-3 SUCTION VALVES .........................................................................................................................................E-3

SECTION F - TROUBLESHOOTING ................................................................................... F-1

SECTION G - OTHER RISK .................................................................................................G-1

SECTION H - DISMANTLING AND DEMOLITION ..............................................................H-1

White intentional page

Section A - GENERAL INFORMATION

A-1 CONVENTIONAL REFERENCE

The machine is considered oriented as shown in the figure.

Any exceptions to this rule will be specified at the time.

REAR FLUID END

REAR FLUID END

A-2 MACHINE IDENTIFICATION

Via 1° Maggio, 12 - Località Gariga

Triplex mud pump model 7TS600, powered with Cater-

A-2.3 IDENTIFICATION PLATES

The identification plate is located on the right-hand side

The identification plate carries the machine identification

A-2.4 OTHER PLATES

Nominal power [kW]

the operators will be required to carefully read and well 4

understand the contents of the manual before starting to $ $

use the machine. It is necessary the complete understand- $

ing especially of all the aspects relevant to the use, the 4

maintenance and the lubrication of the machine. 4