UM190159 E Rev1

Operation and
Maintenance Manual
Mechanical fast workover rig - carrier mounted
Machine type MR5000FW
Manufacturing year 2015
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
MR5000FW - Operation and Maintenance Manual
Document code: UM190159/E - Revision 1 (06/2015)
This document cannot, in whole or in part, be reproduced, memorized as a software file, or handed over to third par-
ties 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 2015 DRILLMEC S.p.A. - All rights reserved
Printed in Italy
REVISION HYSTORY
1 11/2016 Update assembly/disassembly - driller cabin fixing VeM ArM FeS

0 06/2015 First release VeM ArM FeS
Rev. Date (mm/yyyy) Reason for issue Prepared Checked Approved
White intentional page
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 MR5000FW
Machine serial number _____
Manufacturing year 2015
Drilling rig type-approval /
Power plant type-approval /

Operation and Maintenance Manual MR5000FW 7
UM190159/E - Rev.1 - 06/2015
WARRANTY TERMS AND CONDITIONS

Drillmec represents and warrants that the Equipment delivered in accordance with the Contract shall be in
compliance with the agreed Technical Specification and shall be free from defect in design, workmanship and
materials and that it shall give proper performance under the operating conditions foreseen in the Technical
Specifications for a period of twelve months from the date of start-up or fifteen months from the date of deliv-
ery, whichever occurs first.
The warranty shall not cover the effects of normal wear and tear (i.e: warranty does not cover seals, gaskets,
liners, filters or any other consumable item) and those occurring due to disregard by the Buyer of the Drillmec
operating and maintenance instructions, overloading of the Equipment or operating conditions different from
those contemplated in the Technical Specifications.
Warranty does not cover any defect caused by an accident, misuse, abuse, improper installation or operation,
lack of reasonable care, unauthorized modifications, loss of parts, use of not previously authorized non-original
Drillmec parts, tampering or attempted repair by a person not authorized by Drillmec.
In the case of supplying to Buyer’s design, Drillmec guarantees exclusively the compliance of the Equipment
with the specifications that have been indicated to it or, in the absence of precise indications, to the usual
prevailing quality allowances, with the exclusion of any guarantee with regard to the specific use to which the
Buyer intends to put the Equipment.
When the Equipment is assembled on machinery belonging to the Buyer or third parties, Drillmec solely guar-
antees that the Equipment supplied is compatible with the machine model indicated by the Buyer (type, size,
power rating etc...) as far as technical specifications and productivity requested are concerned.
Should the Equipment be assembled by the Buyer’s technicians, Drillmec will not be liable for any changes
to the Equipment characteristics, with reference to their safety.
Should the Equipment be assembled by Drillmec, the machines are always assumed to be new unless other-
wise stated by the Buyer. Should the Equipment be assembled on used machines, they are assumed to be in
perfect working order, as checking the state and condition of this machinery (wear, maintenance, etc..) does
not lie within the competence of Drillmec. Should the Buyer provide incorrect information about the machine
model and should such model be insuitable, or should the Buyer withhold information about the poor condition
of the machinery, and should the disrepair be obvious without any detailed examination of the machine and
obviously dangerous, Drillmec’s technicians will not proceede with the assembly of the Equipment. Should
this occur, the Buyer will still be under obligation to pay Drillmec the amount agreed in the Contract.
Drillmec will not be liable in any case for damages to people or property directly or indirectly caused by the
assembly of Equipment on Buyer’s machinery.
In any event of defects detected by the Buyer, the latter shall issue an official written claim to be addressed
to Drillmec After Sales Department within 15 days of the detection of the defect. The claim shall contain all
the necessary data (Equipment serial number, report of the damage, possible causes, complete description
of the items involved, pictures etc.); incomplete or not comprehensible claims will not be taken into account
and the Buyer shall lose its rights under the guarantee.
With reference to the above mentioned claim, Drillmec reserves the right to inspect the Equipment at its prem-
ises or on Buyer’s site (at its option) in order to determine the validity of the warranty claim, and if determined
to be valid, Drillmec, will, at its option:
•• Replace the defective Equipment or parts thereof, or

•• Authorize the Equipment or part to be returned to its authorized repair facility for repair, or
•• Authorize the Equipment or part to be repaired at Buyer’s plant at previously agreed costs.
In case a material shipment to Drillmec (or any other repair facility authorized by Drillmec) is required, the
Buyer is responsible for the cost of transportation to and from Drillmec; whilst in transit the Equipment/part
are at Buyer’s risk.
8 MR5000FW Operation and Maintenance Manual
UM190159/E - Rev.1 - 06/2015
The Buyer shall ensure that Equipment/part is properly packaged so as to ensure that no other damage oc-
curs during transit.
In the event that no identical Equipment/part is available for service repair, Drillmec has the right to replace it
with a device of equal capacity, or offer the Buyer the choice of an Equipment/part upgrade which may incur
an extra cost.
Repair or replacement (material/workmanship for repair) will be without charge, but any other expenses (i.e
removal and installation of other parts, including additional parts furnished), will be made at Buyer’s charge.
No charges will be accepted for returns, repairs or modifications done by the Buyer unless previously autho-
rized in writing by Drillmec
Should Drillmec provide the Buyer with replacement parts for Equipment alleged to be faulty prior to the ex-
amination of said parts by Drillmec, said action must not, in any case, be considered as acknowledgement
of fault. In such a case Drillmec shall invoice the Buyer the related costs of parts and, after examination and
making sure of its fault, Drillmec shall credit to the Buyer these costs.
As to any Equipment or part of it manufactured by third parties (whether sold separately hereunder or incorpo-
rated into another product sold hereunder), Drillmec agrees only to present the Buyer’s claim with respect to
defects to the manufacturer for adjustment, and the Buyer agrees that the liability of Drillmec shall not exceed
any adjustments with respect to which such manufacturer accepts responsibility. The warranty shall comply
with terms and conditions of the relevant manufacturer (copy of said warranty available upon request)
The Buyer acknowledges that the Equipment is of a size, design and type as described in details in the Techni-
cal Specifications and agrees that, except as stated herein, there are no other warranties, express or implied,
including those or merchantability or fitness for particular use, which Drillmec hereby disclaims.
Any eventual delay of payment gives Drillmec the right to exclude the warranty for the whole period that the
delay may persist.
This warranty supersedes all legal warranty for defects and compliance; in no event shall Drillmec be liable
to the Buyer for any direct, indirect, consequential, incidental or other damages, including without limitation
any claim for damages based on lost revenues or profit, however caused by the Equipment and arising from
any breach of contract.
Customer Care
Drillmec S.p.A.
Drilling Technologies
UM190159/E - Rev.1 - 06/2015
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 5 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 5 of the subject
manual.
For the spare parts, the Customer has to refer to the

Spare Part Catalogue provided with the machine docu-
mentation. 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 ma-
chine all along its life, according to the speci-
fications 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 con-
formity 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.
Fig. 1
IMPORTANT
When a Customer contacts the DRILLMEC After
Sale Service or others Service Centres to allow
a quicker problem solving procedure, he has al-
ways to point out the machine data signed on the
memorandum reported at page 5. This procedure
is extremely important also for the data validity
and for the reference to possible technical updat-
ing concerning the spare parts.
UM190159/E - Rev.1 - 06/2015

UM190159/E - Rev.1 - 06/2015
TABLE OF CONTENTS
Section A - INTRODUCTION
A-1 FOREWORD......................................................................................................................................2
Section B - GENERALINFORMATION
B-1 CONVENTIONAL REFERENCES..................................................................................................... 2
B-2 MACHINE IDENTIFICATION............................................................................................................. 3
B-3 GENERAL DESCRIPTION AND TECHNICAL CHARACTERISTICS................................................4
B-4 MACHINE USE DESTINATION....................................................................................................... 27
Section C - SAFETY
C-1 PERSONNEL QUALIFICATIONS...................................................................................................... 2
C-2 MACHINE PLATES............................................................................................................................3
C-3 SAFETY DEVICES.............................................................................................................................8
C-4 DIAGRAM OF SAFETY DEVICE FOR EMERGENCY STOP.......................................................... 11
C-5 GENERAL SAFETY DURING THE MACHINE TRANSPORT PHASE............................................12
C-6 GENERAL SAFETY DURING THE MACHINE ASSEMBLY, INSTALLATION AND
DISINSTALLATION PHASES...........................................................................................................12
C-7 GENERAL SAFETY DURING THE MACHINE OPERATION PHASE.............................................14
C-8 GENERAL SAFETY DURING THE ROUTINE AND THE EXTRAORDINARY
MAINTENANCE PHASES............................................................................................................... 15
C-9 SAFETY RULES REGARDING SCHEDULED MAINTENANCE.....................................................19
C-10 GENERAL SAFETY DURING THE OUT OF SERVICE SETTING AND ELIMINATION PHASE..... 20
Section D - INSTRUCTION
D-1 CONTROLS AND INSTRUMENTS . ................................................................................................. 2
D-2 DIESEL ENGINE STARTING AND STOPPING...............................................................................21
D-3 MAIN CONTROL PANEL................................................................................................................. 29
D-4 AIR SYSTEM (DRW. 50015235)...................................................................................................... 36
Section E - ASSEMBLY
E-1 ASSEMBLY INSTRUCTIONS............................................................................................................ 2
Section F - DISASSEMBLY
F-1 DISASSEMBLY INSTRUCTIONS...................................................................................................... 2
Section G - MAINTENANCE
G-1 LUBRICATING SYSTEM.................................................................................................................... 3
G-2 AIR CLUTCHES.................................................................................................................................9
G-3 OIL AND WATER PRESSURE........................................................................................................... 9
G-4 DISC BRAKES.................................................................................................................................10
G-5 DRIVE ROLLER CHAINS................................................................................................................ 11
G-6 ROUTINE MAINTENANCE.............................................................................................................. 13
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G-7 TANK WATER COOLING BRAKE.................................................................................................... 23

G-8 ROPES - WEAR CHECK................................................................................................................. 24
G-9 COMPLETE MACHINE - GENERAL INSPECTION.........................................................................25
G-10 BOLT TIGHTENING SPECIFICATIONS..........................................................................................26
G-11 HOSE FITTING SPECIFICATIONS................................................................................................. 27
Section H - TROUBLESHOOTING
H-1 TROUBLESHOOTING....................................................................................................................... 2
Section I - RESIDUAL RISK

I-1 RESIDUAL RISKS..............................................................................................................................2
Section L - DISMANTLING
L-1 DISMANTLING AND DEMOLITION................................................................................................... 2
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Section A - INTRODUCTION
SECTION INDEX
A-1 FOREWORD.............................................. 2
A
A-1.1 INSTRUCTION FOR THE MANUAL
READING................................................... 2
A-1.2 TYPICAL STRUCTURE OF THE
A-1.3
PAGES....................................................... 2
SUBDIVISION IN SECTION AND
B
CHAPTERS................................................ 3
A-1.4 PAGE NUMBERING SYSTEM................... 3
A-1.5 TABLE NUMBERING SYSTEM................. 3
A-1.6
A-1.7
FIGURE NUMBERING SYSTEM............... 3
RECALLING CONNECTION TO
C
OTHER SUBJECTS................................... 3
A-1.8 UPDATING................................................. 4
A-1.9 SYMBOLS.................................................. 4
D
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A A-1 FOREWORD A-1.2 TYPICAL STRUCTURE OF THE

PAGES
Dear Customer, this Operating, Use and Maintenance
Manual has been conceived to provide all information The pages of the manual have always a typical
necessary to allow the functioning, the use and the structure that is always characterized by the follow-
maintenance of the MR5000FW drlling rig according ing elements:
B to safety and functioning efficiency criteria.
1 Model of the treated machine or fixture.
A-1.1 INSTRUCTION FOR THE MANUAL 2 Document identification code/language/edi-
READING tion.
Example: UM123456/I - Rev. 12/1996 = Opera-
C This manual provides some different type information
starting from the instruction for the manual reading
tion and Maintenance Manual written in Italian
language, edition issued on December 1996.
up to the machine technical performances, the safety
3 Document type (in this case Operation and
rules, the technical specifications of the maintenance
Maintenance Manual).
products, the operating rules, the transport rules, …
etc. 4 Mark and logotype of DRILLMEC SpA.
D As already pointed out into the Section C - SAFETY,
5 Section page number.
6 Identification letter of section.
the operators will be required to carefully read and well
understand the contents of the manual before start-
ing to use the machine. It is necessary the complete
understanding especially of all the aspects relevant
E
5
to the use, the maintenance and the lubrication of
the machine. 4 3 1 2
Then, the manual does not need only for a first se-
quential reading of all its information. It has to be used
as a continuous reference to make clear every doubt
F concerning the machine.
6
The manual has to be kept keep in easily accessible
areas. The operators must be able to use it through
the consultation of the Index that points out in a quick
G but complete way the structure of the treated subjects

allowing in such a way a well defined searching pro-
cedure.
It is also advisable to know well the methods used to

realize the editing and the graphical technique used
H 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.
I Fig. A-1
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UM190159/E - Rev.1 - 06/2015
Then, according to the subject treated into the pages,

the following other elements can be present combined
On their turn, the sections are subdivided in Chap-
ters. A
one each other: There are chapters of first, second and third level.
This structure helps in realizing a linear and detailed
7 Chapter title (first, second or third level). treatment of the different subjects, also making easier
8 Text. the possible references to other subjects.
9 Figure.
A-1.4 PAGE NUMBERING SYSTEM B
10 Number of figure.
11 Special safety warnings. The page numbering system adopted into the subject
manual is not a continuous one: at the beginning of
every section, the page number restarts from 1 (Sec-
tion cover).
Inside each section, the page numbering system is a C
7
progressive one.
Example: Into section A, page 2, page 3, …. etc.
9
A-1.5 TABLE NUMBERING SYSTEM
The table numbering system adopted into the subject D
manual is not a continuous one: at the beginning of
every section, the table number restart from 1.
Inside each section, the table numbering system is

a progressive one and it is marked by the graphical
11 symbol Tab. X-0. E
Example: Into section A, Tab.A-1, Tab.A-2, …. etc.
A-1.6 FIGURE NUMBERING SYSTEM

The figure numbering system adopted into the subject
manual is not a continuous one: at the beginning of F
every section, the figure number restarts from 1.
Inside each section, the figure numbering system is

8 10 a progressive one and it is marked by the graphical
symbol Fig. X-0.
Example: Into section A, Fig.A-1, Fig.A-2, …. etc. G
Fig. A-2
A-1.7 RECALLING CONNECTION TO
OTHER SUBJECTS
A-1.3 SUBDIVISION IN SECTION AND
CHAPTERS To make easier the consultation of related subjects,
the recalling connections inside the manual are ex- H
This manual is subdivided into 9 Sections respec- ecuted pointing out the alphanumeric reference code
tively marked through the letters A, B, C, D, E, F, G, of the involved chapter, figure or table. In such a way,
H, and I. it is possible to avoid the pointing out of too long titles
Section A - INTRODUCTION or of the page numbers.
Section B - GENERAL INFORMATION
Section C - SAFETY
Example:
•• Recalling connection to a chapter: (refer to A) or I
Section D - INSTRUCTION (refer to B-3.1.1);
Section E - ASSEMBLY •• Recalling connection to a table: (refer to
Section F - DISASSEMBLY Tab.A-1);
Section G - MAINTENANCE •• Recalling connection to a figure: (refer to
Section H - TROUBLESHOOTING
Section I - RESIDUAL RISKS
Fig.A-1);
•• Recalling connection to a chapter and to a figure: L
Section L - DISMANTLING AND DEMOLITION (refer to A-1 and Fig. A-3).
UM190159/E - Rev.1 - 06/2015
A A-1.8 UPDATING
IMPORTANT
The information pointed out into the subject manual
are based upon the technical document available at It introduce a recall to the safety procedures, some
the moment of the manual writing procedure. technical information or some practical advises
with the aim to make possible a more efficient and
B According to the machine equipping kit and to the
provided accessories, some differences can be found
economic use of the machine respecting at the
same time the safety and the environment. The
between the real machine and the texts and figures respect of the rules pointed out under this symbol
into the manual. This situation can not be used by the usually helps the working execution.
Customer to create some arguing procedure.
C 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. Safety helmet
Then, before starting up every operation on the

D machine, it is necessary to check to have at disposal
all the necessary information. Pay particular attention Safety gloves
to the updating code of the available technical
documentation.
E For more detailed information, refer to the DRILLMEC

After Sale Service.
Safety shoes
A-1.9 SYMBOLS
Breathers or anti dust masks
In this manual different universal symbols were
F adopted. They are illustrated, with the indication of
their meaning:
Ear plugs for noise or noise protective
headsets
HAZARD
G It represents extreme hazard; if you fail taking the Safety goggles or eyes’ protective
necessary measures you (or others) are very likely masks
to get killed or severely injured.
Hoses burst hazard

H WARNING
It represents a serious hazard. If you fail taking the
necessary measures, there is a risk that you (or oth-
ers) get killed or severely injured. It also indicates Hot parts hazard
the possibility to create serious damages to the
I machine that can consequently become unsafe.
Accumulator burst hazard
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TYPE OF SIGNAL COLOUR

A
Prohibition signals Red, white
Warning signals Black, yellow
Information, instructions,
Light blue
prescription signals
Fire signals Red B
Safety and rescue signals Green
Hazard signals Black, white
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E
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Section B - GENERAL
SECTION INDEX INFORMATION A
B-1 CONVENTIONAL REFERENCES............ 2
B-1.1 MACHINE ORIENTATION......................... 2
B-2 MACHINE IDENTIFICATION.................... 3
B-2.1 MANUFACTURER.................................... 3 B-3.6.1 HOIST WIRE ROPE REEVING
B-2.2 MODEL...................................................... 3 DIAGRAM............................................... 19 B
B-2.3 IDENTIFICATION PLATES....................... 3 B-3.7 POWER FLOW DIAGRAM..................... 20
B-3 GENERAL DESCRIPTION AND B-3.8 A.P.I. PLATE............................................ 22
TECHNICAL CHARACTERISTICS.......... 4 B-3.9 STATIC HOOK LOAD VS WIND
B-3.1 NOMENCLATURE OF THE MAIN VELOCITY PLATE.................................. 24
COMPONENTS........................................ 4 B-3.10 RECOMMENDED MAXIMUM HOOK
LOAD 6 LINES........................................ 25
C
B-3.2 TECHNICAL SPECIFICATION.................. 5
B-3.2.1 GENERAL DESCRIPTION....................... 5 B-3.11 HAZARDOUS AREAS............................. 26
B-3.2.2 MAST........................................................ 5 B-3.12 FOOTPRINT ON WORKING
CONFIGURATION.................................. 27
B-3.2.3 CROWN BLOCK....................................... 6
B-3.2.4 MONKEY BOARD..................................... 6
B-4 MACHINE USE DESTINATION.............. 27 D
B-4.1 FORESEEN USE.................................... 27
B-3.2.5 STAND PIPE............................................. 6
B-4.2 IMPROPER USE..................................... 28
B-3.2.6 WORKING PLATFORM............................ 6
B-4.3 MACHINE LIFETIME LIMITS.................. 28
B-3.2.7 DRAWWORKS.......................................... 6
B-4.4 FORESEEABLE OPERATORS’
B-3.2.8 DIESEL ENGINE AND TRANSMISSION.. 7
B-3.2.9 AUTOMATIC GEAR BOX.......................... 8
TRAINING, EXPERIENCE OR ABILITY
LEVELS................................................... 28
E
B-3.2.10 AIR SYSTEM FOR RIG OPERATION...... 8 B-4.4.1 OPERATORS.......................................... 28
B-3.2.11 HYDRAULIC SYSTEM.............................. 8 B-4.4.2 PUPILS/APPRENTICES......................... 29
B-3.2.12 CARRIER.................................................. 8 B-4.4.3 GENERIC PERSONNEL......................... 29
B-3.2.13 EXTERNAL OUTRIGGERS...................... 9 F
B-3.2.14 TRANSFER............................................... 9
B-3.2.15 DRIVE CAB............................................... 9
B-3.2.16 LEVELLING OUTRIGGERS / RAISING
MAST CONTROL PANEL......................... 9
B-3.2.17 DRILLER CABIN..................................... 10 G
B-3.2.18 DRILL LINE............................................. 10
B-3.2.19 HYDRAULIC WINCH ON CARRIER....... 10
B-3.2.20 MAN RIDER WINCH............................... 10
B-3.2.21 TRAVELLING BLOCK - HOOK............... 10
B-3.2.22 POWER SWIVEL.................................... 10 H
B-3.2.23 DEAD LINE ANCHOR............................. 10
B-3.2.24 PUMP/KILL MANIFOLD.......................... 10
B-3.2.25 LIGHTING SYSTEM............................... 11
B-3.3 MAIN DIMENSIONS............................... 12
B-3.3.1 WORKING CONFIGURATION................ 12
I
B-3.3.2 TRANSPORT CONFIGURATION........... 13
B-3.4 MACHINE LIFTING WITH VERTICAL
ROPES.................................................... 14
B-3.5 MAST LIFTING AND TRANSPORT........ 15
B-3.6 MAST GUY LINE LAYOUT..................... 17
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UM190159/E - Rev.1 - 06/2015
B-1 CONVENTIONAL REFERENCES

A
B-1.1 MACHINE ORIENTATION
The machine must be considered conventionally oriented as represented in figure B-1.

Purpose of this convention is to make clear and unequivocal any reference made later on in this manual (for
B example, front side, rear side, etc.).
The possible exceptions to that convention will be time by time specified.
TOP
C SIDE
G FRONT
SIDE
REAR
SIDE
BOTTOM
SIDE
H
LEFT
SIDE
I FRONT REAR
SIDE SIDE
RIGHT
SIDE
L
Fig. B-1
UM190159/E - Rev.1 - 06/2015
B-2 MACHINE IDENTIFICATION

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

B
I-29027 PODENZANO (PC) - ITALIA
Phone +39 (0)523 354211
Telefax +39 (0)523 524418
Web: http//:www.drillmec.it C
E-mail: info@drillmec.com
B-2.2 MODEL
Mechanical fast workover rig model MR5000FW.

D
B-2.3 IDENTIFICATION PLATES
The machine and its main components are identified

by serial numbers, mainly used by the DRILLMEC
After-Sales Technical Service in order to facilitate E
the dispatch of the technical service dossiers.
1
2
IMPORTANT
Always specify the equipment technical code and
3 F
serial number when you require information or 4
technical assistance.
5
A - Machine identification plate
The identification plate shown in the Fig. A-2 reports G

all identification data for the machine.
The identification plate is located on the carrier.
Fig. B-2
The plate contains the following data:
1 - Type/Commercial name of the machine
2 - Serial number
H
3 - Year of manufacture
4 - Nominal power (expressed in kW)
5 - Weight (expressed in Kg)
B - Other plates
I
The plates of all the main mechanical, hydraulic and
electric components not manufactured by DRILLMEC
(pumps, motors, etc.) are located on the relevant
components, in the positions where the respective L
manufacturers decided to place them.
Fig. B-3
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B-3 GENERAL DESCRIPTION AND TECHNICAL CHARACTERISTICS

A
B-3.1 NOMENCLATURE OF THE MAIN COMPONENTS
21
B 1 Carrier
2 Diesel engine
20
3 Front outrigger
4 Fuel tank
C 5 Transfer
6 Brake carrier system
7 Right angle transmission
8 Drawworks
9 Rear outrigger
D 10 Skid base
11 External outrigger 18 19
12 Mast raising cylinder
13 Working floor
18
14 Driller cabin
E 15 Fixed mast section
16 Power swivel 17
17 Travelling block 16
18 Guy lines
15
F 19 Monkey board
20 Telescopic mast section 14
21 Crown block 13
22 Spare line spool
12
23 Air tank
G 24 Transmission
25 Hydraulic oil tank
26 Water tank 1 2 3 4 5 6 7 8 9 10 11
27 Stairway
28 Service winch 30 34
H 29 Main rider winch 22 23 33 24 25 27 31 27
30 Positioning panel control
31 Right angle transmission for
35
power swivel
32 Oil tank for power swivel 32
I 33 Walkways
34 Pump/kill manifold
35 Stand pipe
27
L 33 26 29 28 27
Fig. B-4
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B-3.2 TECHNICAL SPECIFICATION

A
B-3.2.1 GENERAL DESCRIPTION
Carrier mounted high mobility workover rig Drillmec MR-5000 FW Fast Workover, drawworks single drum
with disc brake system, hydraulic operated telescopic mast.
The rig is manufactured in accordance with API 4F (4th edition), PSL-1. Suitable for 8°C ÷ +55°C range tem-
perature.
B
All Equipment will be certified to be used in accordance with safety zones defined in Institute of Petroleum
(IP) Code of Practice 15 (3rd Edition July 2005) and PDO specification SP-2037.
Rig with internally guyed mast utilizing outriggers: in order to save time in rig-up rig-down, the rig is equipped
with special outriggers installed in the rig’s rear side and hydraulically pulled out/in, where mast guy lines are
connected. C
-- Rig type MR5000FW
-- Drill pipe stands handling Range 2 (double)
-- Drawworks rated input 450 hp (335 kW)
-- Static hook load / number of lines 225,000 lbs (102 metric ton) – 6
-- Mast clear height from ground level 101 ft (30,760 m) D
B-3.2.2 MAST
The mast is composed by two independent sections, a fixed part and a telescopic part. The telescopic section
is complete with crown block and it scoped by means of one hydraulic jack.
The mast will be raised and lowered by means of hydraulic jack. E
-- Mast clear height from drilling floor 101 ft (30,760 m)
-- Mast static hook load / number of lines 225,000 lbs (102 metric ton) – 6
-- Rated wind capacity (as per API 4F):
F
With bare monkey board: 75 knots
With full monkey board: 60 knots
During erection and operating 25 knots
-- Hydraulic Cathead Break-out Q.ty 1

Stroke (approximate) 4¼ ft (1,3m)

Max pull (approximate)
Max line speed
26,400 lbs (12.000 kg)
26 m/min (85 ft/min) G
-- Hydraulic Cathead Spinning Q.ty 1
Stroke (approximate) 4¼ ft (1,3m)
Max pull (approximate) 26,400 lbs (12.000 kg)
Max line speed 26 m/min (85 ft/min)
H
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A
B-3.2.3 CROWN BLOCK
-- Fastline sheave 36” (762 mm) - Q.ty 1

-- Deadline sheave 24” (610 mm) - Q.ty 1
-- Working sheave 24” (610 mm) - Q.ty 2
-- Groove 1” (25.4 mm)
B -- Sand line sheave 24” (611 mm ) – grooved 9/16” (14.28 mm) - Q.ty 1
B-3.2.4 MONKEY BOARD
-- Monkey board height 55 ft (16905 m)
C -- Monkey board capacity:

1500 m of 4.1/2” tubing and 13.5 ppf – weight of 3.1/2”
drill pipe
6 doubles stands of 4.3/4” drill collar
B-3.2.5 STAND PIPE
D -- Stand pipe with gooseneck

Pipe diameter 2” (50.8 mm) Working pressure 3000 psi (207
bar)
Gate valve 2” – 5000 psi W.P. - Q.ty 2
Union assy 2” FIG. 1502 - Q.ty 8
Pressure visual gauge 0-3000 psi - Q.ty1
E
-- Rotary hose complete with hammer unions 2” Fig 1502.
ID 2”
Working pressure 3000 psi (207 bar)
Length 60 ft (18,3 m)
F B-3.2.6 WORKING PLATFORM
Working platform with adjustable height, supported by two struts, complete with:
-- One (1) pipe ramp
-- Two (2) stairs from working platform to ground level
G -- Working platform adjustable height:

Low position 1.5 m
High position 3.5 m
-- Approx working area: 7.5 m²

H B-3.2.7 DRAWWORKS
Single drum drawworks installed on carrier, complete with:

-- Disc brake
-- Auxiliary brake: pneumatic disc assist brake
I -- Hoisting speeds the same of diesel engine
-- Reverse speed
-- Crown block safety device (emergency stop device to prevent hoisting the travelling block against the crown
block, e.g. ‘crown-o-matic’). Bypass air valve to operate crown block safety device.
-- To be fitted with a ‘floor-o-matic’ to prevent travelling block system hitting the crown or work floor acciden-
tally.
L -- Spiral bevel gear in oil bath gear case, mounted on frame in front of drawwork.Coupling shaft to drawwork
input shaft
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-- Drawworks rated input horsepower 335 kW (450 hp)

-- Lebus / grooved 25.4 mm (1”) A
-- Main drum
Diameter x lenght 457.2 mm (18”) x 965 mm (28”)
Auxiliary brake Eaton Brake 136 WCB,
BRAKE COOLING / WATER CIRCUIT B

Brake of main drum is cooled by a water pressure system. The cooling circuit is composed of water tank, filter,
piping, centrifugal pump, heat exchanger.
LUBRICATING SYSTEM
C
All chains and gears of drawworks are oil-forced lubricated by means of hydraulic pumps complete with filters,
gauges, safety valves and standard accessories. Oil tank mounted on carrier with capacity of 240 l.
B-3.2.8 DIESEL ENGINE AND TRANSMISSION
The rig is powered by one Diesel engine Caterpillar model C15 with 540 hp output power at 2100 RPM com-
D
plete with muffler with spark arrestor, emergency shut off, air inlet shutoff, desert radiators (suitable to operate
at 55 deg Celsius ambient temperature).
Diesel engine will be fitted with sound attenuation enclosure.
Diesel engine suitable to be installed in zone 2 (as per PDO specification SP-2037), and will be equipped E
with:
-- Flame proof electrical equipment (oil pressure switches, temperature switches to be of certified flameproof
construction)
-- Flameproof electrical or non-electrical (hydraulic/pneumatic) starter system
-- An Cyclonic ATEX/EN1834 Spark Arrestor, certified for Zone 1 and gas or hydrocarbon refining and drilling
industries, on the exhaust system F
-- A quick closing valve in the air intake manifold tied-in to the ESD system, which can stop the engine
promptly in case of an emergency
-- A system for quick shut-off of fuel supply (mechanical and automatic)
-- There will be a three emergency shut-down (ESD) switches (one positioned at the driller’s console, one
positioned outside the powerhouse, and one positioned at the tool pusher’s office) to remotely shutdown
all engines in case of an emergency. The emergency shutdown is intended to create a total blackout on G
the rig and will be capable of shutting off fuel supply to all engines as well as closing the quick closing
valves in the air intake manifolds.
-- Anti-static and fire-resistant driving belts with non-metallic fan blades for cooling and auxiliary drive sys-
tems
-- Engine over speed protection by means of an automatic (“Rig Saver”) air intake shut off valve.
-- Low level alarm i.e. Murphy’s switch to enable checking of fluid level in the radiator without opening radia-
H
tor cap
-- Exhaust ducts that discharge to a safe area i.e. outside Zone 2 as defined by IP Model code of safe prac-
tice – Part 15
-- Water cooling on the exhaust manifold and other particularly hot parts like turbocharger so that the surface
temperature does not exceed 200 deg C.
-- An effective flame arrestor in the air intake manifold (in case of backfire in the air inlet)
I
-- Low oil pressure shut-down device
-- Sealed crankcase and a flame trap fitted to the crankcase breather.
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B-3.2.9 AUTOMATIC GEAR BOX

A
Automatic gear box installed on diesel engine with torque converter.
Hydraulic brake (retarder) is installed to avoid an overheat of carrier brake, during road travelling.
-- Gear box M5610AR

B -- Torque converter
-- Hoisting speed
TC680
5 + 1 reverse
B-3.2.10 AIR SYSTEM FOR RIG OPERATION
-- Air compressor couple with engine Ingersoll Rand T30 mod 2475
C

Max speed rotation
Max volumetric displacement
1250 rpm
187,5 GPM (710 l/min)
Max working pressure 159,5 PSI (11 bar)
Max HP with max WP pressure 7,1 HP (5,3 kW)
-- Air tank working operation

D

Tank capacity for rig operation 132 gals (500 l)
Capable to operate engine starter
Relief valve
Air dryer
B-3.2.11 HYDRAULIC SYSTEM

E
Hydraulic system powered by one plunger pump connected to automatic gear box, this system is used to:
-- Raising system
-- Levelling jacks
-- Hydraulic winch
-- Hydraulic cathead
F -- Hydraulic drive
-- Hydraulic suspension
-- Oil tank total capacity 184 gal (700 l)
G -- Oil level indicator, dipstick, filler, drain plug, thermometer
B-3.2.12 CARRIER
Carrier heavy duty type for off-road operation, with:

-- Welded frame made of high-grade steel
H -- Braking system consisting of a double circuit air operated brake plus one additional manually operated
brake.
-- Hydraulic operated front and rear suspension for perfect levelling
-- The carrier is supplied with standard bumper with road lighting.
-- Rear light, turn indicator and stopper light.
-- Lighting system 24 V
I -- Drive cab
-- Tool box
-- Walkways, access handrails remain connected during moves
-- Bumper
-- Stairs from ground to carrier
-- Radiator for cooling of oil lubrification of transmission
L -- Drill line spooler support
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-- Axles carrier 5
-- Tires singles 14.00 x R-24 10+2 spare A
-- Fuel tank capacity 600 lt
-- Hydraulic levelling jacks
with mechanical safety locking 4
B-3.2.13 EXTERNAL OUTRIGGERS

B
Rear external outriggers, suitable for internally guyed mast, complete with:
-- Mechanical leveling jacks
-- Pad eyes for guy lines connections
In transport condition the external outriggers are folded at carrier sides manually.
B-3.2.14 TRANSFER
C
Gear box utilized to select if move drawworks transmission or carrier axles
-- Air quick connection transfer to axles of carrier

--
--
Manual connection transfer to drawworks
Inertia hydraulic gear pump for emergency (drive) Gear pump Qty:1
D
-- Hydraulic gear pump for lubrication transfer Screw pump Qty:1
B-3.2.15 DRIVE CAB
Drive cab for one man, complete with: E

-- Adjustable bucket seat with safety-belt and shock absorber
-- Safety glass on all windows
-- Backwindow
-- Windshield wiper
-- Dual outside rear-view mirror
-- Air conditioning F
-- Hydraulic power assist steering controls
-- Transmission shift control
-- Carrier brakes
-- Engine throttle
-- Engine start-up and shut down switch
-- Tachometer G
-- Engine water temperature gauge
-- Engine oil pressure
-- Lighting and accessory circuit
B-3.2.16 LEVELLING OUTRIGGERS / RAISING MAST CONTROL PANEL

H
Control panel for levelling carrier and raising mast is mounted near mast lower section, complete with:
-- Levers commutation (drilling/ installation)
-- Levers for levelling outriggers (stabilizers)
-- Levers for raising mast
-- Levers for telescopic mast
-- Levers for telescopic locking
I
-- Oil pressure gauge
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B-3.2.17 DRILLER CABIN

A
Driller’s control cabin with seat for driller, suitable to install all controls of hoist unit, complete with A/C unit.
B-3.2.18 DRILL LINE
B -- Drill line
-- Lenght
1” (25.4 mm) 6x25 IWRC
600 m (1,950 ft)
B-3.2.19 HYDRAULIC WINCH ON CARRIER
-- Model LS2000H30-L-GR Ingersoll Rand

C -- Max load pull
-- Rope diameter
4,400 lb (2.000 kg)
13 mm
B-3.2.20 MAN RIDER WINCH
-- Model LS2-150RLP Ingersoll Rand

D --
--
Rated working load
Rope diameter
150 Kg
10 mm
-- Lifting speed (with rated load) 0 to 30 m/min at 6.3 bar/90 psi
-- Free air consumption 0 to 2.5 Nm3/min
-- Working pressure range 5 to 7 bar
E B-3.2.21 TRAVELLING BLOCK - HOOK
-- Working load capacity 300,000 lbs (136 metric ton)

-- Sheave diameter 30” (762 mm)
-- Sheave number 3
-- Nominal rope 1” (25.4 mm)
F
B-3.2.22 POWER SWIVEL
15PS KING OIL TOOLS power swivel unit hydraulically operated to work inside both 7” and 9 5/8” casing with
3 ½” IF connection on main shaft c/w saver sub.
G -- Static Load Rating 150 Tons

-- 100 RPM Load Rating 97 Tons
-- STD: fishing and work over 0-7000ft-lbs torque at 0-120rpm.
-- Drilling 0-10000 ft-lbs torque at 0-80rpm
-- Max WP 5000 psi
H B-3.2.23 DEAD LINE ANCHOR
-- Load sensor E542 Compression

-- Drill line diameter 1” (25.4 mm)
-- Single pull capacity 45,000 lbs (20.4 metric ton)
I B-3.2.24 PUMP/KILL MANIFOLD
High pressure pump manifold (H2S service), mounted on skid, complete with:
-- Gate valve 2” – 3000 psi with hammer union connection - Q.ty 2
-- Gate valve 2” – 3000 psi with hammer union connection - Q.ty 2
L -- One outlet c/w 2” Fig 1502 hammer union for ground high pressure line connection
-- Three off-take points for sensors on downstream side of the manifold.
-- One Pressure visual gauge, 0- 24,000 kPa, flanged
UM190159/E - Rev.1 - 06/2015
-- One Kill line outlet (2” Fig 1502 hammer lug union) for hook-up to wellhead/BOPs.
-- One Fill-up/bleed-off line outlet c/w 2” choke for bleed-off, with 1” Fig 1502 connection. A
-- Two inlets c/w 2” Fig. 1502 hammer lug wing unions for pumps (one for mud pump 7T450.3 supplied by
Drillmec, one for second pump supplied by customer).
-- Hoist floor outlet (2” Fig 1502 hammer lug union) for hook-up to drill/tubing string or to standpipe.
B-3.2.25 LIGHTING SYSTEM

B
•• Lighting for Mast
-- Led lights 19W Qty 11
-- Led lights normal/emergency 2x26 W Qty 1
-- Obstruction light
•• Lighting for Working platform
Qty 1
C
-- Led lights normal/emergency 2x26 W Qty 2
•• Lighting for Carrier
-- Led lights 2x26W Qty 3
-- Led lights normal/emergency 2x26 W
•• Lighting for Driller cabin
Qty 6 D
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B-3.3 MAIN DIMENSIONS

A
B-3.3.1 WORKING CONFIGURATION
30760 [101’]
E
16905 [55’]
F
(STEP)
460
4220
G 1670 9800 1930

1000
137 16501500 5850 15001500 2620 315

15075
H
670
3420
4090
2750
L 16688
Fig. B-5
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B-3.3.2 TRANSPORT CONFIGURATION

A
In transport configuration, the maximum allowed speed is 40 Km/h.
4515
D
17439
19598
TRANSPORT CONFIGURATION F
Total weight: 72000 Kg
L
Fig. B-6
UM190159/E - Rev.1 - 06/2015
B-3.4 MACHINE LIFTING WITH VERTICAL ROPES

A
Set the rig ready for handling, see next figure, it shows the handling phase:
-- the rig has to be handled without the mast;
-- connect the raising cables to the lifting frame (not supplied), make sure that cables are fixed correctly and
the size of cables are available for the load of rig.
B
HAZARD
During machine handling, the operators don’t have to be under the load, deadly danger.
C
HAZARD
Don’t use the connection point different from those showed, use improper lifting point, it’s danger
for operator and rig.
F
Total weight: 55000 Kg
with footboards and handrails
15830 kg 11670 kg
+ +
LIFTING WITH STAND ROPES
G
15830 kg 11670 kg
1650
12436
H
3650
3380
3000 15700
L
Fig. B-7
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B-3.5 MAST LIFTING AND TRANSPORT

A
To lift the mast positioned on the rig, use the appropriate padeyes.
IMPORTANT
The mast lifting must be performed only as shown in the figure, using the four lifting points indica-
B
ted.
HAZARD
During mast handling, the operators don’t have to be under the load, deadly danger.
C
E
3150
F
2500
2170
17050
G
Approx. mast weight: 24000 Kg
H
Fig. B-8
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A For assembling of transport beams, follow procedure:

-- position the beams 1 under mast, with distance to allow a correct lifting, without loss of balance during
moving.
-- fix the beams to the mast.
When the beams 1 are installed, it is possible lift the mast, also with padeyes A. Four links, two for each
B beam.
C
A
A
1 1
E
4 2 3 5
G Approx. mast weight: 24000 Kg
Fig. B-9
H Items Qty. Code Description

1 2 01905642 TRAVE SOLLEVAMENTO MAST
2 4 019010753 PIASTRA FISSAGGIO TRAVE MAST
3 16 70612429 DADO AUTOBLOCC. M24 UNI 7473 ZINCATO
4 8 70570124 BARRA FILETTATA M24 LU 1mt.
I
5 16 70902445 RONDELLA PIANA PER M24
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B-3.6 MAST GUY LINE LAYOUT

A
E B
C
200 kgf MAX 600 kgf
6
200 kgf MAX
6 3
B C D
4
E
7
7 5
200 kgf MAX
F
200 kgf MAX
600 kgf
G
D
L
Fig. B-10
UM190159/E - Rev.1 - 06/2015
A
C
E
12
B 12
7 12
3
C
B
D 11
4
E 10 1
9 2
8
D A
F
Fig. B-11
Pos Q.ty Code Description
G 1 10 71030100
DADO ESAGONALE PER TENDITORE CROSBY DA 1.1/2"
SINISTRO
DADO ESAGONALE PER TENDITORE CROSBY DA 1.1/2"
2 10 71030101
DESTRO
3 2 41030862 TIRANTE DI FUNE D.1" L=29200
H
4 2 41031125 TIRANTE DI FUNE D.3/4" Lu=17750
8 4 40630126 SPILLA DI SICUREZZA D.5
9 4 64021883 SPINA D.35 L.115 CON TESTA E FORO
I 10 4 01907804 STAFFA DI PROLUNGA
11 10 4099048 TENDITORE ZINCATO 1.1/2" G228 CORSA UTILE 24"
12 10 40950006 GRILLO ZINCATO G2130 9.5 T
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B-3.6.1 HOIST WIRE ROPE REEVING DIAGRAM

A
CROWN BLOCK
B
FAST LINE
DEAD LINE
F
MAIN DRUM
G
TRAVELLING BLOCK
H
REEL
DEAD LINE
L
ANCHOR
Fig. B-12
UM190159/E - Rev.1 - 06/2015
A B-3.7 POWER FLOW DIAGRAM
Air clutch Air clutch

33VC650S 20CB500
1-3/4” Chain 2” Chain
B Lubrication
Air clutch
16CB500
4 5
pump
C15 Diesel M5610AR Allison
Transmission Transfer
Engine
C
1 2
Compressor Cardan shaft Cardan shaft Bell
crank
D Service pump
3
Rope 1”
Fig. B-13
E
Hook load Hook speed
Speed Max. eff. (Kg)* At stall (Kg)* Speed RPM Main Drum Speed (m/sec)
HL Low 62490 102000 n Low 97 0.35
HL2 41468 80000 n2 145 0.43
F HL3 31765 60000 n3 194 0.64

HL4 22942 40000 n4 266 0.85
HL5 15827 30000 n5 390 1.27
HL6 - - n6 - -
G
* Based on torque converter max. eff. (μ=0.85)
Speed M Max Eff.* M at Stall # RPM

Ratio
gear (Nm) (Nm) (Max. Eff.)
H 1
2
4.0000
2.6842
6183
4103
13623
9101
439
655
3 2.0132 3143 6888 873
4 1.3510 2270 4608 1199
5 1.0000 1566 3454 1758
I R
6 0.6711
-5.15
1129 2308 2414
315
* Based on torque converter max. eff. (μ=0.85)

#
With torque converter at stall
wire rope eff. (6 lines) μ=0.842
mechanical eff. μ=0.9
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UM190159/E - Rev.1 - 06/2015
Pos Qty
Cardan joint features
Description Cod
A
- GEWES 43-77 TRANSM.
1 1 - FL. SAE1800 BR73/KV 70°-180 BR72 40590099
- Lz. 600 La. 110
- TRANSM. 2065
2 1 - FL. SAE203-12x12/KW 70° - 180 BR72
- Lz. 1570 La. 110
40590199
B
Rope features
Pos. Qty Description Code
3 1 Rope D.25,4 (1”) lenght 600 m. 41001347
C
Chain features
Min. breaking
Pos. Qty Pitch Chain n° Type Pitchs N° Code
load (N)
4 1 1 3/4” 140-2 ASA 101 340540 01905691
5 1 2” 160-1 ASA 110 222400 019018461
L
UM190159/E - Rev.1 - 06/2015
A B-3.8 A.P.I. PLATE
MAST
1
C
1
2
D
101
6
E 112.5
60
F
75
25
G
6’ - 4”
/
H
I Fig. B-14
1 - Serial number
2 - Date of manufacture
L
UM190159/E - Rev.1 - 06/2015
Mast plate position

A
E
Fig. B-15
L
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B-3.9 STATIC HOOK LOAD VS WIND VELOCITY PLATE

A
Fig. B-16
F Wind velocity plate position
H
Fig. B-17
L
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B-3.10 RECOMMENDED MAXIMUM HOOK LOAD 6 LINES

A
Fig. B-18
F
Maximum hook load plate position
H
Fig. B-19
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B-3.11 HAZARDOUS AREAS

A
R3000
3000
7100
R15000
C
17500
D R7500
BRINE PIPING & SYSTEM
E BRINE DESERT RESERVE

TRAILER MUD PUMP SKID DESERT
TRAILER
15000
KILL LINE FLEXIBLE
F
STEEL HOSE R3000
5550
BOP DESERT TRAILER

HYDRAULIC
HOSE
CARRIER
CHOKE LINE FLEXIBLE
STEEL HOSE
G 000
25000
R30
R15000
BOP CONTROL PANEL
H
SUPERVISORS
OFFICES
I ZONE 1 HAZARDOUS AREA
ZONE 2 HAZARDOUS AREA
ZONE EN 1834
L
Fig. B-20
UM190159/E - Rev.1 - 06/2015
B-3.12 FOOTPRINT ON WORKING CONFIGURATION

A
894
700
2725
11894
3090
D
3.4 Kg/cm² 7.4 Kg/cm² 950
700 8900
E
1.7 Kg/cm²
Fig. B-21 F
B-4 MACHINE USE DESTINATION

The machine was designed and realized in order to be used in an outside handicraft/industrial environment, G
having the following characteristics:
•• temperature min. 8°C, max. 55°C.
•• Maximum 3 second gust wind-speed: 35 m/s
The machine was designed in order to be used in a fire/explosion risk exposed environment.
H
B-4.1 FORESEEN USE
MR5000FW is a workover rig, designed for service operations in wells.
I
HAZARD
The work 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
L
conceived.
UM190159/E - Rev.1 - 06/2015
B-4.2 IMPROPER USE

A
The permitted applications are described in this manual.
Any use of the machine not complying with these applications or with the applications and modes envisaged
by the machine design shall be considered improper.
B
HAZARD
Although equipped with service winches, MR5000FW is not a hoisting means or a hauling means.
Using the machine other than directed by this manual is forbidden.
C The improper uses and the related hazards are listed below:
•• Lifting the stabilizers with machine not set for transport.
D HAZARD
Any translating or maneuvering by means of the chassis is forbidden if the equipment has been
previously set for working purposes. This improper use can result in the machine unbalancing or
overturning, which can cause serious hazards for the personnel’s safety.
•• Working with mast not in its proper vertical working position.

E
HAZARD
The machine has been designed to operate with mast in vertical position: other configurations can
F cause serious hazards for the personnel’s safety.
B-4.3 MACHINE LIFETIME LIMITS
As far as the safety matter is concerned, the machine operative lifetime is unlimited, provided that the prescrip-
tions both for the routine and for the extraordinary maintenance of the safety means and devices indicated in
G the Instruction Manual are strictly observed.
B-4.4 FORESEEABLE OPERATORS’ TRAINING, EXPERIENCE OR ABILITY LEVELS
B-4.4.1 OPERATORS
H 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 16 years
•• to operate with both their hands
•• to have no limits in their physical abilities
I •• to have got a specific training
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B-4.4.2 PUPILS/APPRENTICES
A
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 16 years
•• to operate with both their hands
•• to have no limits in their physical abilities
•• to have got a specific training  B
B-4.4.3 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 machine respect area have the following characteristics:
C
•• are aged at least 16 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.
D
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E
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Section C - SAFETY
SECTION INDEX
C-1 PERSONNEL QUALIFICATIONS.............. 2
A
C-1.1 QUALIFICATION........................................ 2
C-1.2 WORKING GARMENTS............................ 2
C-2 MACHINE PLATES.................................... 3
C-3 SAFETY DEVICES.................................... 8 B
C-4 DIAGRAM OF SAFETY DEVICE FOR
EMERGENCY STOP............................... 11
C-5 GENERAL SAFETY DURING THE
MACHINE TRANSPORT PHASE............ 12
MACHINE ASSEMBLY, INSTALLATION
C
AND DISINSTALLATION PHASES......... 12
MACHINE OPERATION PHASE............. 14
ROUTINE AND THE EXTRAORDINARY D
MAINTENANCE PHASES....................... 15
C-8.1 MECHANICAL PART................................ 15
C-8.2 ELECTRIC PART..................................... 17
C-8.3 HYDRAULIC PART.................................. 18
C-9 SAFETY RULES REGARDING
E
SCHEDULED MAINTENANCE............... 19
OUT OF SERVICE SETTING AND
ELIMINATION PHASE............................. 20
F
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FOREWORD C-1.2 WORKING GARMENTS

A
In this manual, for example, the “safety symbology” The operators must be equipped with the following
(SYMBOLOGY) was adopted, in order to signal pos- individual safety means:
sibly dangerous situations.
B Safety helmet
IMPORTANT
Don’t remove the plates present on the machine.
In case of loss or deterioration of them, it is obliga-
tory for the User to promptly provide to replace Safety gloves
C them.
C-1 PERSONNEL
QUALIFICATIONS Thermal switch protection gloves
D C-1.1 QUALIFICATION
The personnel using the machine or operating on it
must be competent, and obligatorily have the follow- Safety goggles or glasses
ing characteristics:
E Physical: Good sight, hearing, coordination, and the

ability to safely carry out all the functions required for Face protective shield
the machine use.
Mental: Ability to understand and to apply the es-

tablished rules, the specifications and the safety
F precautions. The personnel must be attentive, use
good sense for their own safety and for that of other
Safety shoes
people; they must be willing to carry out the work in

a correct and responsible way.
Ear plugs or noise-protective headset
Emotional: The personnel must be calm and able to
G stand the stress and to use good sense, as far as their
physical and mental conditions are concerned.
Safety sling
Training: The personnel must have read and learned
this manual, the possibly annexed graphics and
H
diagrams, the indication and hazard warning plates.
They must be skilled and qualified in all the aspects
of machine use and maintenance. Long sleeved safety overalls.
Have got the licence: If requested by law.
I
IMPORTANT
Exclusively use type-approved and well preserved
safety material.
L
UM190159/E - Rev.1 - 06/2015
A
IMPORTANT
Avoid wearing rings, swatches etc, and approach-
ing to the moving parts with undressed long hair,
which could get caught into those parts and cause
serious damages. Also avoid using greasy clothes
because they are easily inflammable.
B
C-2 MACHINE PLATES C

Meaning:
It is forbidden the entrance of not authorized person-
nel.
Part code number: D

09531098
E
Fig. C-1
Meaning:
LWA = Average acoustic power level.
LpA = Acoustic pressure level on the operator’s control
F
place.
Fig. C-2
H
Meaning:
Accumulator burst hazard.
Part code number:

09531095
I
L
Fig. C-3
UM190159/E - Rev.1 - 06/2015
Meaning:
A Hoses burst hazard.
Part code number:

09531097
C Fig. C-4
Meaning:
Extremely hot parts: scorching hazard
Part code number:

D 09531096
E
Fig. C-5
Meaning:
F Danger of suspended loads.
Part code number:

n/a
Position:
G Service crane.
H
Fig. C-6
Meaning:
Danger of fire.
Part code number:
I 09531110
Position:
- Oil tank
- Batteries
L
Fig. C-7
UM190159/E - Rev.1 - 06/2015
Meaning:
Danger due to corrosive liquids. A
Part code number
09531111
Position:
- Batteries B
Fig. C-8 C
Meaning:
Danger. Explosive gas.
Part code number:

n/a D
Position:
- Batteries
E
Fig. C-9
Meaning:
Danger of hand crushing.
F
Part code number:
09531112
Position:
- Working base zone G
H
Fig. C-10
Meaning:
Generic danger.
Part code number:

n/a
I
L
Fig. C-11
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Meaning:
A Danger. High voltage.
Part code number:

09531107
B Position:
- Alternator
- Electric panels
C Fig. C-12
Meaning:
It is forbidden to remove the guards and the safety
devices.
D Part code number:

09531116
Position:
- Safety ropes
- Cardans
E
Fig. C-13
Meaning:
F It is forbidden to repair, to lubricate and to clean mov-
ing parts.
Part code number:

09531113
G Position:
- Power swivel shifting chains
- Transmission
H Meaning:
Warning, danger for moving parts.
Fig. C-14
WARNING
Before maintaining remove the engine starting key
from the control panel.
I Before operating the engine remount the protection
cover.
BEFORE MAINTAINING REMOVE
THE ENGINE STARTING KEY
FROM THE CONTROL PANEL
Part code number: BEFORE OPERATING THE ENGINE

09532167E REMOUNT THE PROTECTION COVER
L Position:
- Cardans
- Power swivel shifting chains Fig. C-15
UM190159/E - Rev.1 - 06/2015
Meaning:
It is mandatory to use proper ear plugs or acoustic A
protection headsets.
Part code number:

09531099
B
Fig. C-16 C
Meaning:
Grounding instructions.
WARNING
Before welding on the rig switch off all the batteries. D
Running casing in the well by welding connect the
negative pole to proper signaled point.
Part code number:

09532639E
E
Fig. C-17
Meaning:
Welding instructions.
F
Welding machine proper negative pole.
Part code number:

09532640E
G
Fig. C-18
H
Meaning:
Warning plate.
WARNING
Prior to operate the machine controls make sure that
the control levers are in neutral position. I
L
Fig. C-19
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A C-3 SAFETY DEVICES

Both the machine (in its wholeness) and the single
parts composing it are equipped with integrated safety
devices.
B -- All the cylinders are equipped with locking valves.

Should either the connection pipes get broken
or a sudden pressure drop (or total lack of pres-
sure) take place, the cylinders will keep locked,
so preventing any possible risk of generating any
uncontrolled movements.
C
The machine is equipped with the following emergency
stop pushbuttons and mechanical locks:
-- SE1 emergency, is located on the right side, before

SE1
the water tank and stops drilling rig operation.
D
E
Fig. C-20
-- SE2 emergency, is located in the driller cabin on

F the control panel and stops drilling rig operation.
-- SED emergency, is located in the driller cabin on
the chair (right hand) and stops drawworks opera-
tion. SE2
-- SER emergency, is located in the driller cabin on
the control panel and stops mud pump operation. SER
G
H Fig. C-21
I
SED
L
Fig. C-22
UM190159/E - Rev.1 - 06/2015
-- SE3 emergency, is located on control levelling

panel and stops levelling operations. SE3 A
Fig. C-23 C
-- SE9 emergency, is located on water tank and stops
services winch operation. SE9
E
Fig. C-24
-- JB.SD2 emergency is located in the driller cabin

and stops drilling rig operation, mud pump opera-
tion, generator and electric plants.
F
The same Shut-down function has been performed JB.SD2
by the emergency buttons JB.SD1 and JB.SD2
located respectively in the supervisor’s office and
on the desert trailer BOP.
G
Fig. C-25
H
-- Q1 selector for battery break-off.
Q1
I
L
Fig. C-26
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-- SE, emergency, is located on control panel near

A diesel engine and stops only diesel engine.
SE
C Fig. C-27
-- SE4, emergency Stop Switch is located on the

man rider remote control pendant. When activated,
winch drum rotation will immediately cease.
E SE4
H Fig. C-28
-- Safety mechanical block stabilizer
L
Fig. C-29
UM190159/E - Rev.1 - 06/2015
-- As prescribed by the relevant rules in force, on

the machine two fire extinguishers, identified by A
the symbol.
Fig. C-30 C
-- The drilling equipment is equipped with stroke limit stops, in order to assure a correct operation.
-- There are guards, covers and fixed protections identified by means of the writing “safety element – don’t
remove”, in order to prevent any possible contact with either moving transmission mechanisms or hot
hydraulic components.
D
HAZARD
Before operating with the machine, make sure that all safety devices are both present and efficient.
C-4 DIAGRAM OF SAFETY DEVICE FOR EMERGENCY STOP E
SE4
F
Q1 SE3
SE SE1 SE9 SE2 SED
SER P.SD1
L
Fig. C-31
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C-5 GENERAL SAFETY DURING THE MACHINE TRANSPORT PHASE

A
The rig is transported like:
-- trailer with mast at lower position.

-- wooden boxes.
B On every wooden case, the weight and the indication of the usable handling means are reported.
WARNING
C The task of keeping the packages for future handlings and transfers is charged to the User.
WARNING
The self-propelled unit is type-approved for transfers on roads of the Italian territory.
D It is charged to the carrier to check that the dimensions and weights of the self-propelled unit are
compatible with the limits fixed by the road traffic code in force in the country in which the transport
must be carried out.
C-6 GENERAL SAFETY DURING THE MACHINE ASSEMBLY,

E INSTALLATION AND DISINSTALLATION PHASES
The operators must wear the here following enlisted individual safety devices (PPE):
F Safety helmet
Safety gloves
G
Safety shoes
H
Long sleeved safety overalls.
I Safety goggles or eyes’ protective masks
-- Check the compatibility of the self-propelled unit weight with the carrying capacity of the drilling area.
-- Check the machine planarity by using the purposed water levels.
L -- Make sure that the ring nuts locking the stabilizers and the stiffening braces were correctly positioned.
-- The personnel not strictly busy in realizing the operation must not stay within the area surrounding the mast
base.
UM190159/E - Rev.1 - 06/2015
-- In proximity of aerial electric lines, the mast must be hoisted by observing the minimum safety distances
prescribed by the appointed authorities and foreseen by the relevant rules in force. A
-- Never go to work on a condition site or work on, around or near a piece of machinery when under the influ-
ence of drugs or alcohol. Beware of “over the counter” drug, many of which have specific warnings about
operating machinery after taking the medication.
B
WARNING
The minimum safety distances from the aerial electric ducts can vary for every country, according
with the particular climate and with the presence of humidity in the air.
As a mere information, the following informative table is here reported
C
HARD HAT
Line voltage Indicative minimum SAFETY
GOGGLES HEARING
distance from the PROTECTION
line BREATHING
MASK
D
SNUG
1,0 kV (distribution line) 5m FITTING
CLOTHES
6,6 kV (2-3 insulators) 5,2 m
33 kV (min. 3 insulators) 5,5 m
66 kV (min.6 insulators) 6m GLOVES
154 kV (min. 10 insulators) 8m

275 kV (min. 19 insulators) 10 m STEEL TOED
SHOES
E
Fig. C-32
WARNING
It is recommended to get informed about the pos-
sible presence of any underground long-distance F
lines and about their characteristics.
-- Make sure that the electric current generator

exhaust gases don’t invest the personnel opera-
tive stationary area. It is charged to the User, to
provide making available the means required for This is a Knot and cut off G
hazard! excess string
discharging the fumes in a safe area.
-- Check that there aren’t any leaks or leakages of
hydraulic fluids.
Fig. C-33
H
WARNING
Provide to the elimination, by means of a safe
treatment, of the drilling muds.
I
WARNING
Never go to work on a construction site or work
on, around or near a piece of machinery when
under the influence of drugs or alcohol. Beware
of “over the counter” drugs, many of which have L
specific warnings about operating machinery after
taking the medication. Fig. C-34
UM190159/E - Rev.1 - 06/2015
C-7 GENERAL SAFETY DURING THE MACHINE OPERATION PHASE

A
The operators must be equipped with the following individual safety means (PPE):
B Safety helmet
Safety gloves
C
Safety shoes
D
E Safety goggles or eyes’ protective masks
Ear plugs or noise or noise protective

headsets
F
-- Make sure that the electric current generator exhaust gases don’t invest the personnel operative stationary
area. It is charged to the User, to provide making available the means required for discharging the fumes
in a safe area.
G -- It is forbidden to use the hands for carrying out operations for which specific tools are foreseen.
-- Absolutely avoid using any badly preserved tools or using them in an improper way, as, for example: pliers
instead of wrenches, etc….
L
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C-8 GENERAL SAFETY DURING THE ROUTINE AND THE

EXTRAORDINARY MAINTENANCE PHASES
A
C-8.1 MECHANICAL PART
B
Safety helmet
C
Safety gloves
Safety shoes D

E
Breathers or anti dust masks
F
Ear plugs or noise or noise protective
headsets
Safety goggles or eyes’ protective masks

G
Safety sling
H
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 connections, from any oil, fuel or detergents’ residuals. Don’t use any aggressive detergents. I
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 detergents 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 L
hoisting capacity.
UM190159/E - Rev.1 - 06/2015
-- Before starting any maintenance operation, insert

A 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
B 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 ma-
C chine.
-- In order to protect the machine against the pos-
sibility of being accidentally started-up:
•• Close the main control devices and take off
the key.
•• Apply on the cut-out switch a hazard warning
D plate.
-- Exclusively use the tools of the machine outfit and,
anyway, high-quality ones.
-- In order to intervene on mast and crown block, get
protected against the risk of falls by using the pur-
posed safety sling, complying with the instructions
E supplied in the relevant specific instructions.
-- After having completed any maintenance or repair
intervention, before starting again the machine,
Fig. C-35
make sure that no tools, wiping clothes or other
materials are left near the moving mechanisms.
F
WARNING
Provide to the safe and possibly biodegradable
elimination of the consumption and auxiliary ma-
G terials and of the replaced parts.
L
UM190159/E - Rev.1 - 06/2015
C-8.2 ELECTRIC PART

A
Safety helmet
B
Safety gloves
C
Safety shoes
D
Safety goggles or eyes’ protective masks
-- 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.
E
-- Parts of the machinery subject to inspection, maintenance and repair interventions must be stress-relieving
connected, if prescribed. First check if such pars 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 emer-
gency, can actuate the cut out switch . Protect the working place with a white/red chain and mount a hazard F
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
G
The electrolytic accumulators contain sulfuric 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
flames. H
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.
I
L
UM190159/E - Rev.1 - 06/2015
C-8.3 HYDRAULIC PART

A
B Safety helmet
Safety gloves
C
Safety shoes
D
E Safety goggles or eyes’ protective masks
Face protective shield
F
-- The interventions on hydraulic plants shall be exclusively executed by personnel both trained and, quali-
fied in the hydraulic field.
-- When opening any delivery systems and pipes (hydraulic system, compressed air), it is necessary to dis-
G
charge 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 manufac-
turer.
H
WARNING
Provide to the safe and possibly biodegradable elimination of the hydraulic fluids and of the replaced
parts.
L
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C-9 SAFETY RULES REGARDING SCHEDULED MAINTENANCE

A
WARNING
Do not change the maximum relief valve setting on any hydraulic circuit without permission from the
manufacturer. Never change an accumulator circuit pressure setting without specific instructions from
the manufacturer. B
WARNING
Never make unauthorized modifications to structural members or pressure circuits.
C
WARNING
You must replace, not repair damaged hydraulic or concrete hoses or pipes.
D
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. E
WARNING
Never activate the system hydraulics without checking if another workman is in a hidden position.
Always yell “clear” before starting the engine or electric motor, and allow time for response. F
WARNING
Never work on a pressurized hydraulic system. Stop the engine or electric motor and relieve the ac-
cumulator circuit (if so equipped) before you open the hydraulic system. G
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
H
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. I
WARNING
Never open a pressurized pipeline. The pump op-
erator must release the pressure before you open
the line. If the line is pressurized with compressed L
air, let the operator release the pressure and verify Fig. C-36
that the air has escaped before you proceed.
UM190159/E - Rev.1 - 06/2015
C-10 GENERAL SAFETY DURING THE OUT OF SERVICE SETTING AND

A ELIMINATION PHASE
WARNING
B Provide to the safe and possibly biodegradable elimination of the demolition resulting materials.
WARNING
C Provide to the elimination of the electric/electronic materials (RAAE), in full compliance with the rel-
evant laws in force in the country in which the elimination must be performed.
WARNING
D Provide to the safe and possibly biodegradable elimination of the lubricating oils, the greases and
the hydraulic fluids.
L
UM190159/E - Rev.1 - 06/2015
Section D - INSTRUCTION
SECTION INDEX
D-1 CONTROLS AND INSTRUMENTS .......... 2
A
D-1.1 CONTROLS AND INSTRUMENTS FOR
DIESEL ENGINE CARRIER....................... 3
D-1.2 HYDRAULIC SUSPENSIONS PRESSURE
IN TRANSPORT CONFIGURATION.......... 5
D-1.3 TRANSFER CONTROLS........................... 6
B
D-1.4 POSITIONING CONTROLS....................... 7
D-1.5 MAST POSITIONING REMOTE RADIO
CONTROL.................................................. 8
D-1.6 DRILLER CABIN CONTROLS AND
INSTRUMENTS......................................... 9
C
D-1.7 CONTROLS OF OTHER LOCATIONS.... 16
D-1.8 MANIFOLD............................................... 20
D-1.9 MAN RIDER WINCH................................ 21
D-1.10 PUMP/KILL MANIFOLD........................... 21 D
D-2 DIESEL ENGINE STARTING AND
STOPPING............................................... 22
D-2.1 PRELIMINARY CHECKS......................... 22
D-2.2 DIESEL ENGINE STARTING IN CARRIER
CONFIGURATION................................... 23
D-2.3 DIESEL ENGINE STOPPING IN CARRIER
E
CONFIGURATION................................... 25
D-2.4 DIESEL ENGINE STARTING IN DRILLING
CONFIGURATION................................... 26
D-2.5 DIESEL ENGINE STOPPING IN DRILLING
CONFIGURATION................................... 29
F
D-3 MAIN CONTROL PANEL........................ 30
D-3.1 OPERATING INSTRUCTIONS................ 30
D-4 AIR SYSTEM (DRW. 50015235)............. 37
G
L
UM190159/E - Rev.1 - 06/2015
D-1 CONTROLS AND INSTRUMENTS

A
In the following chapters, the controls and instruments of the machine, starting from the devices present on
the main control panel, are represented.
In order to allow an univocal identification of the devices in all the chapters of this manual, and to identify the
different types of devices (for example: regulator, selector switch, etc.), it was decided to progressively number
B them and to let them precede by a letter, as here following explained.
C-1
C
DEVICE IDENTIFICATION PROGRESSIVE

LETTER NUMBER
D
Legend :
C = Hydraulic/pneumatic controls
R = Hydraulic/pneumatic regulators
E S = Electric controls
A = Hydraulic/pneumatic instrumentation
P = Electric instrumentation
H = Visual and acoustic electric signals
PB = Push bottom joystick
RK = Thumbwheel control joystick
F
G HAZARD
It is forbidden to carry out any machine use trials, without having previously read and learned the
contents of this manual and fully got familiar with the relevant controls.
Besides, it is necessary to learn the correct methods for using and operating the machine, in order
to prevent serious damages to persons and things.
H
L
UM190159/E - Rev.1 - 06/2015
D-1.1 CONTROLS AND INSTRUMENTS FOR DIESEL ENGINE CARRIER

A
HT3
H13A H11 HT1 HT0 HL1

B
HL3
H13 H1 HL2 GEAR LEVER
P3 P2 P1
P4
C
- +
1 2
80
60
RPM
100 STEERING TRANSFER TRANSFER TRANSFER
4 6 °C LUBRICATION HIGH TEMP WARNING X1000
P5
1/2 2 bar 8
3/4 120
!
40
! !
1/4
1
0 10 P 0 3
0 30
PARK TRANS CHECK RETARDER DRILLING
AXLE 1-2 AXLE 3-4 AXLE 5 OIL FILTER TRANS MODE 20 40
Km/h
H5 H7 H9 10 50
0 60
P6
H10 HL4
HW1
D
MAIN ENGINE
90 110
70 °C 130
ENGINE WARNING
50 150
SC1
H15 H16 H14 S10 S40 S50
HA1
S20 S30 S60
E
S70
Fig. D-1
F
H1 Recharge alternator lamp P4 Fuel level
H5 Axle 1-2 low air brake pressure lamp P5 Speed meter
H7
H9
Axle 3-4 low air brakes pressure lamp
Axle 5 low air brakes pressure lamp
P6
S10
Gear box oil temperature
Emergency lights insertion selector G
H10 Park brake lamp S20 Blinkers insertion selector
H11 Emergency drive steering lamp S30 Wind wiper selector
H13 Differential lock insertion lamp S40 Wind washer selector
H13A Differential lock insertion lamp S50 Differential lock insertion
H14
H15
Direction indicators lamp
Position lights lamp
S60
S70
Air conditioning system insertion
Direction indicators and lights selector
H
H16 Upper beams lamp SC1 Engine start-stop key
HA1 Transmission alarm
HL1 Transmission fault lamp
HL2 Transmission manual mode lamp
HL3
HL4
Transmission retarder insertion lamp
Transmission clogged oil filter lamp
I
HT0 Transfer wearing lamp
HT1 Transfer lubricating lamp
HT3 Transfer oil high temperature lamp
HW1 Engine warming lamp
P1
P2
RPM meter
Coolant temperature indicator
L
P3 Engine oil pressure
UM190159/E - Rev.1 - 06/2015
A
Q1 Battery breaker
Q1
C Fig. D-2
Engine control and instrument:

9 10 11 12 13 14
1 TACHOMETER: this gauge indicates
engine speed (rpm).
D 2 FUEL PRESSURE: this gauge indicates

fuel pressure to the fuel injection pump 15 16 17 18 19
from the fuel filter.
3 ENGINE OIL PRESSURE: the oil pressure
should be greatest after a cold engine is
started.
E 4 COOLANT TEMPERATURE: when the

coolant temperature is above the normal
operating value, the coolant temperature 1
gauge will be in the red zone.
5 SYSTEM VOLTAGE: this gauge indicates
the voltage of the electrical system.
F 6 Throttle (up/down) - 2 pos. selector with
return to center.
3 4
7 MAINTENANCE CLEAR: the maintenance 2 5
clear switch is required to reset
maintenance lamp. 8 SE
8 CIRCUIT BREAKER: reset the circuit
G 9.
breaker if a circuit breaker trips.
High engine oil temperature alarm lamp
7 KEY.SW
6
10. High engine water temperature alarm lamp
11. High manifold temperature alarm lamp
12. High cooling water temperature alarm lamp SH0
13. High alternator temperature alarm lamp
H 14. Alarm lamp
Fig. D-3
15. Emergency reset lamp

16. Spare
17. Maintenance lamp
18. Diagnostic lamp
19. Warning lamp
I KEY.SW START KEY SWITCH: the start has three
position: OFF, ON and START
SH0 Reset emergency pushbutton
For more informations on engine instrumentation see

L Caterpillar’s manuals.
UM190159/E - Rev.1 - 06/2015
D-1.2 HYDRAULIC SUSPENSIONS

PRESSURE IN TRANSPORT
A42
A
CONFIGURATION
A42A Front suspension pressure gauge on driver

side
A42B Front suspension pressure gauge on driver
opposite side
B
A42C Rear suspension pressure gauge on driver C41
opposite side
A42D Rear suspension pressure gauge on driver
side
C41A Front suspension pressure regulator valve C
on driver side
C41B Front suspension pressure regulator valve
on driver opposite side
C41C Rear suspension pressure regulator valve S60
on driver opposite side
C41D Rear suspension pressure valve on driver D
side
S60 Suspension pressure adjustment activation
enabling button
(see hydraulic drawing 019016386).

E
The relief valve is set at 180 bar. The carrier hydraulic
suspensions in transport configuration have to be Fig. D-4
set from 60 to 80 bar. It’s possible to read the setting
pressure on manometers A42A ÷ A42D.
To increase the suspension pressure:

C38 F
-- the control lever C38 has to be positioning to central
position (NEUTRAL);
-- press the button S60;
-- open the valves C41A ÷ C41D;
-- once the proper pressure value is reached, close
the valves previously opened;
G
-- release the button S60.
To decrease the suspension pressure:

-- open the valves C41A ÷ C41D;
-- once the proper pressure value is reached, close
Fig. D-5
H
the valves previously opened.
L
UM190159/E - Rev.1 - 06/2015
D-1.3 TRANSFER CONTROLS

A
FROM
CARRIER DRILLING ENGINE
B
C38
C
SF1
S1
D DIRECTION
TO
DRAWWORKS
FROM TO
E ENGINE DRAWWORKS
G
TRANSFER TO AXLE
H Fig. D-6
The transfer is a gear box utilized to select if move drawworks transmission (DRILLING position) or carrier
axles (CARRIER position).
I C38

Carrier - drilling control lever
The lever has three positions carrier - neutral - drilling. Lock the lever in the position chosen by the
pin A.
S1 Limit switch for arrange rig in carrier or drilling mode
SF1 Limit switch transfer in neutral position
L
UM190159/E - Rev.1 - 06/2015
D-1.4 POSITIONING CONTROLS

A
HS1 HS2 HS3 SE3

C
A10
D
C25
C19 C20 C21 C22 C23 C24

E
C18
Fig. D-7
F
A10 Stabilizers oil pressure gauge
C18 Left rear stabilizer up-down control
WARNING
C19
C20
Right rear stabilizer up-down control
Left front stabilizer up-down control After the positioning of the machine on the stabi-
G
C21 Right front stabilizer up-down control lizers, close the panel with the relative cover, to
C22 Mast raising cylinder remote control avoid accidental controls.
C23 Mast telescopic up-down control
C24 Telescopic locking control
C25 Stabilizer on-off selector (service - stabilizer
selector) H
HS1 Mast lifted lamp
HS2 Mast unlocked lamp
HS3 Mast locked lamp
SE3 Emergency
I
IMPORTANT
The controls C22, C23 and C24 must be used only
on emergency case with failure of remote radio
control, when it isn’t possible to repair remote
radio control, before a urgent operation.
L
UM190159/E - Rev.1 - 06/2015
D-1.5 MAST POSITIONING REMOTE RADIO CONTROL

A
B
SALITA TORRE SFILO TELESCOPICOTORRE BLOCCAGGIO TELESCOPICO
MAST RAISING UP TELESCOPIC MAST UP TELESCOPIC MAST LOCKING ON
test std. Abstand/ test std. Abstand/ test std. Abstand/ 11
C
spacing 30mm spacing 30mm spacing 30mm
23x39mm 23x39mm
1
R=4,8mm 2
R=4,8mm
3
23x39mm
R=4,8mm
10
D DISCESA TORRE
MAST RAISING DOWN
RIENTRO TELESCOPICOTORRE
TELESCOPIC MAST DOWN
SBLOCCAGGIO TELESCOPICO
TELESCOPIC MAST LOCKING OFF
radiomatic iON
1
TELESCOPICO TELESCOPICO
®
TORRE SOLLEVATA TORRE SBLOCCATO TORRE BLOCCATO

8 9
Nr.1
4 6
Ø 22,5
7
Farbe fehlt!
5
Farbe fehlt! Farbe fehlt!
Ø 8 Ø 8 Ø 8
0
Ø 8
E
MAST LIFTED TELESCOPIC TELESCOPIC
MAST UNLOCKED MAST LOCKED
F Fig. D-8
1 Mast raising cylinder remote control

2 Mast telescopic up-down control
G 3
4
Telescopic locking control
Mast lifted lamp
5 Mast unlocked lamp
6 Mast locked lamp
7 Emergency
8 Battery charge indicator
H 9
10
Radio control key
Start
11 Clackson
NOTE: To switch on the radio control, switch in

position 1 the selector 9 and press 2 times in se-
I quence the start button.
IMPORTANT
Use the remote radio control during rig-up and
L rig-down for mast positioning.
UM190159/E - Rev.1 - 06/2015
D-1.6 DRILLER CABIN CONTROLS AND INSTRUMENTS

A
6
4
B
3 5
1 1
E
Fig. D-9
F
1 Left and right hand controls on driller’s chair
2 Control panel (left on driller)
3
4
Control panel (left corner on driller)
Control panel (frontal on driller)
G
5 Control panel (right corner on driller)
6 Drilling Data Acquisition System (DAS)
monitor
NOTE: For the monitor, refer to the operator inter-

H
face manual attached.
L
UM190159/E - Rev.1 - 06/2015
Left and right hand controls on driller’s chair

A
B
C1
C J1
C8
D SED
E R1
C5
F Fig. D-10
C1 Main drum clutch control and engine

throttle
G C5 Authorization control on-off - 2 position key
selector
C8 Inertial brake main drum control
J1 Drawworks disc brake joystick
R1 Engine throttle regulator
SED Drawworks emergency mushroom
H pushbutton
L
UM190159/E - Rev.1 - 06/2015
Control panel (left on driller)

A
HG11 HSPW1 HLS HSP4A HSP4B HSN7 HL0 HST1 HW2 HL1B HL2B HL4B HT5B HG12
B
HW HALM HSP56 HSP3A HSP3B HST7 HSPDW2 HLP
A61
C13
SFR SE2 C
A30 A29
C60
R61
R60
SA2 SER
D
MUD PUP
CONTROLS
Fig. D-11
F
A29 External pump power swivel HSP4A Drawworks service brake check (SP4A**
supercharging pressure gauge pressure check) lamp
A30 Internal pump power swivel
supercharging pressure gauge
HSP4B Drawworks service brake check (SP4B**
pressure check) lamp
G
A61 Power swivel torque pressure gauge HSP56 Drawworks hydraulic pressure lamp
C13 Power swivel on-off control HSPDW1 Drawworks lubrication “on” lamp
C60 Rotation forward/reverse power swivel HSPDW2 Drawworks lubrication alarm lamp
control HST1 High temperature of power swivel
HALM Mudpump engine atex alarm lamp
HG11 Spare - lamp HST7
hydraulic oil lamp
High temperature of services hydraulic oil
H
HG12 Exhaust high temperature alarm lamp lamp
HL0 Control enable lamp HT5B Transfer warning lamp
HL1B Transmission check lamp HW Mudpump engine warning lamp
HL2B Transmission manual mode lamp HW2 Engine machine (Caterpillar) warning
HL4B
HLS
Transmission clogged oil filter lamp
Drawworks service brake “on” lamp R60
lamp
Power swivel torque regulator
I
HLP Drawworks parking brake “on” lamp R61 Power swivel RPM regulator
HSN7 Delivery clogged filter of the brake system SA2 Throttle - 3 pos. selector
lamp SE2 Rig emergency mushroom button
HSP3A Drawworks service brake check (SP3A* SER Mudpump emergency mushroom button
pressure check) lamp SFR Clutch remote control - 2 pos. selector L
HSP3B Drawworks service brake check (SP3B*
pressure check) lamp
UM190159/E - Rev.1 - 06/2015
A * SP3A - SP3B: pressure switch of the upper positive calipers in contact

** SP4A - SP4B: pressure switch of the lower positive calipers in contact
Control panel (left corner on driller)
C C12
C28 C29
D
C27 C37
C30
E JR9 R10
R6
F A14
A13 A11
Fig. D-12
G
A11 Spinning cathead oil pressure gauge
A13 “Nov” spinning pressure gauge
A14 “Farr” tong pressure gauge
C12 Parking brake control
C27 “Farr” tong on-off control
H C28 Spinning cathead control
C29 Breakout cathead control
C30 “Nov” spinning on-off control
C37 Hydraulic winch control
R9 “Nov” spinning pressure regulator
I R10 “Farr” tong pressure regulator
L
UM190159/E - Rev.1 - 06/2015
Control panel (frontal on driller)

A
C3 A1
D
A13
A21 A22 A20 A2 A3 A4

E
Fig. D-13
F
A1 Air pressure gauge
A2 Main drum clutch air pressure gauge
A3
A4
Brake rim cooling water pressure gauge
Drawworks lubricating oil pressure gauge
G
A17 Weight indicator
A20 Parking brake clamps pressure gauge
A21 Upper service clamps pressure gauge
A22 Lower service clamps pressure gauge
C3 Crown-O-matic control H
L
UM190159/E - Rev.1 - 06/2015
Control panel (right corner on driller)

A
D
A18
F Fig. D-14
A18 Tong line pull
L
UM190159/E - Rev.1 - 06/2015
P7 Emergency shut-down button

JB.SD2 Emergency shut-down button A
B
JB.SD2
P7
D
E
Fig. D-15
B.O.P. control unit

F
H
Fig. D-16
L
UM190159/E - Rev.1 - 06/2015
D-1.7 CONTROLS OF OTHER

A LOCATIONS
SE1
SE1 Emergency button
C Fig. D-17
SE9 Emergency services winch button

SE9
E
Fig. D-18
A25 Drawworks lubricating oil pressure gauge

F
A25
H Fig. D-19
A27 Visual level of the drawworks lubricating oil

tank
I A27
L
Fig. D-20
UM190159/E - Rev.1 - 06/2015
A13
A14
Hydraulic oil thermometer
Visual level hydraulic oil tank A
A14
D
A13
E
Fig. D-21
C35 Gate valve electropump suction

C36 Ball valve hydraulic pump suction
F
C36 I
C35
L
Fig. D-22
UM190159/E - Rev.1 - 06/2015
A A26
C43
Visual levels water tanks
Ball valve water pump suction
A26
D C43
E
Fig. D-23
C44 Water tank discharge valve

F
C44
H Fig. D-24
C45 Valve of the main drum water swivel joint
I
C45
L
Fig. D-25
UM190159/E - Rev.1 - 06/2015
A26 Hydraulic oil thermometer (power swivel

tank) A
A27 Visual level hydraulic oil power swivel tank
A26
A27
B
Fig. D-26 C
A9 Air tank pressure
A9
D
Air
vessel
E
Fig. D-27
F
Inlet air
G
Air
vessel
Fig. D-28
H
C16 Air tank condensate drainage valve
C16
L
Fig. D-29
UM190159/E - Rev.1 - 06/2015
A Air treatment device

C9 Air line closed valve
B C9
C Fig. D-30
A7 Command panel supply pressure

A8 Main turnstile clutch pressure R4 A7 R5
A12 Main turnstile inertia brake pressure
R4 Command panel supply regulator
D R5 Main turnstile clutch supply regulator
R7 Inertia brake regulator
A8
R7
E A12
Fig. D-31
Air treatment device on air tank outlet

F
H Fig. D-32
D-1.8 MANIFOLD
A19 C51
A19 Mud pressure gauge
C51 Gate valve 3” 5000 psi F.P.
I
C51
L
Fig. D-33
UM190159/E - Rev.1 - 06/2015
D-1.9 MAN RIDER WINCH

A
REMOTE CONTROL PENDANT
C52 Man rider winch “ON” button
C55 Function lever - payout
C56 Function lever - haul-in
SE4 Emergency Stop Switch B
C52
For more informations on man rider winch see manu-
facturer’s manuals. SE4
C55
C56
D
E
Fig. D-34
D-1.10 PUMP/KILL MANIFOLD
A28 Mud pressure gauge

F
C54 Gate valve 2” 3000 psi F.P.
A28
H
C54
L
Fig. D-35
UM190159/E - Rev.1 - 06/2015
A D-2 DIESEL ENGINE STARTING

AND STOPPING
WARNING
B Before starting any operation or procedure de-
scribed in this chapter, you must be familiar with
safety regulations and with the information con-
tained in Section C.
In case of doubt, read again Section C - SAFETY -
C and proceed only when you are sure that you have
understood properly. Hours
counter
D-2.1 PRELIMINARY CHECKS
1. Before starting work, make sure that are performed

D all necessary checks and servicing operations as
required by the hours worked by the machine.
IMPORTANT
E For the complete machine, refer to hour-counter
on each diesel engines.
Fig. D-36
2. It is recommended that you always refuel the diesel

F engine tank before starting the work shift. This will
prevent the machine from forced stopping during
operation. Fuel
H Fig. D-37
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UM190159/E - Rev.1 - 06/2015
D-2.2 DIESEL ENGINE STARTING IN

CARRIER CONFIGURATION A9 A
Before to perform the procedures described, check,
by mean manometer A9, that the pressure inside to
the air tank is 7 bar, enough for diesel engine starting
phase; if the pressure is not at least 7 bar, proceed with
the air tank charging phase thereby the diesel com- Air B
pressor installed on carrier or the plant compressor. vessel
Fig. D-38 C
Diesel
compressor
E
Fig. D-39
Check also, that valve C9 is open.

F
C9
G
Fig. D-40
H
Here follow it’s possible to find the correct procedure
to start the diesel engine in CARRIER configuration:
C38
1. The control lever C38 has to be positioning to
CARRIER.
I
L
Fig. D-41
UM190159/E - Rev.1 - 06/2015
2. The selector Q1 have to be engage.

A
Q1
C Fig. D-42
3. Check that the regulator gear box lever is in neutral

(N) position
D
Gear lever
E
Fig. D-43
4. Rotate of a release the key SC1,wait for that you

F finish to the check lamps and start engine.
SC1
G
H Fig. D-44
5. Verify that lamps H5, H7, H9 (low air brakes pres-

sure) are light off.
I H7 H9
H5
L
Fig. D-45
UM190159/E - Rev.1 - 06/2015
6. Hand brake disconnect.

A
Hand brake
Fig. D-46 C
D-2.3 DIESEL ENGINE STOPPING IN
CARRIER CONFIGURATION

to stop the diesel engine in CARRIER configuration: D
1. To move the gear box lever in Neutral position
(N). Gear lever
E
Fig. D-47
2. Rotate the diesel engine start/stop key SC1 in

counter clockwise F
SC1
G
Fig. D-48
H
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UM190159/E - Rev.1 - 06/2015
D-2.4 DIESEL ENGINE STARTING IN

A DRILLING CONFIGURATION A9
Before to perform the procedures described, check, by

mean manometer A9, that the pressure inside to the air
tank is 7 bar, enough for diesel engine starting phase;
B if the pressure is not at least 7 bar, proceed with the
air tank charging phase thereby the diesel compressor Air
installed on carrier or the plant compressor. vessel
C Fig. D-49
Diesel
compressor
E
Fig. D-50
Check also, that valve C9 is open.

F
C9
G
H Fig. D-51
Here follow it’s possible to find the correct procedure to

start the diesel engine in DRILLING configuration:
C38
1. The control lever C38 has to be positioning to
I DRILLING.
L
Fig. D-52
UM190159/E - Rev.1 - 06/2015
2. The selector Q1 have to be engage.

A
Q1
Fig. D-53 C
3. Check that the speed selector P7 is in neutral (N)
position
F
P7
Fig. D-54
H
4. The control lever C60 has to be positioning to cen-
tral position (the power swivel must not rotate).
C60
I
L
Fig. D-55
UM190159/E - Rev.1 - 06/2015
A 5. Turn key KEY.SW clockwise (1st latch).

Press the SH0.
Turn key KEY.SW clockwise (2nd latch).
B
SH0 KEY.SW
C Fig. D-57
6. Insert key C5 (right hand controls on driller’s

chair).
E C5
Fig. D-56
7. In drilling configuration the diesel engine RPM is

F controlled by the R1 regulator (left hand controls
on driller’s chair).
C1
To increase the diesel engine RPM it is possible

utilize to the lever C1.
G
R1
H Fig. D-58
L
UM190159/E - Rev.1 - 06/2015
D-2.5 DIESEL ENGINE STOPPING IN

DRILLING CONFIGURATION
A
to stop the diesel engine in DRILLING configuration:
1. To move the diesel engine to the lowest RPM by

the regulator R1.
B
R1
Fig. D-59 C
2. Rotate in counterclockwise the start/stop key KEY.
SW positioned on the engine.
SE
KEY.SW E
Fig. D-60
3. The diesel engine emergency stop is made push-

ing the buttons: SE1, SE2 and SE. F
SE1
Fig. D-61
H
SE2 I
L
Fig. D-62
UM190159/E - Rev.1 - 06/2015
A D-3 MAIN CONTROL PANEL

D-3.1 OPERATING INSTRUCTIONS
All air gauges, oil gauges and controls are mounted in the driller cabin.
Before starting drilling operations and at frequent intervals, while rig is in operation, check gauges and con-
B trols to ensure that the correct air and oil pressures are supplied to each point (see the related tables in the
following pages).
Operating instructions are indicated here below and are also illustrated on panel.
C WARNING
Never stop the engine abruptly when operating at full load (unless required for emergency condi-
tions).
L
UM190159/E - Rev.1 - 06/2015
1. Main drum clutch-control valve C1

The upward movement of this valve handle engages the main drum clutch and at the same time speeds A
up the motor.
The downward movement speeds down the motor and disengages the main drum clutch.
2. Switch of air compressed line C5
3. Auxiliary brake main drum (Eaton brake)- control valve C8 B

The upward movement of this valve handle engages the auxiliary brake.
The downward movement disengages the auxiliary brake.
4. Main drum brake - joystick J1

The upward movement of this joystick engages the disc brake.
The downward movement release the brake. C
IMPORTANT
To avoid hard braking of the drawworks, the driller, during braking phase, must accompany the brake
lever up to the end of its stroke and don’t release the dead man button, causing an immediate closing D
of the calipers.
5. Diesel engine throttle-control valve R1

Turning clockwise the control knob increases RPM of diesel engine.
Turning ccw the control knob decreases RPM of diesel engine.
E
6. Engine emergency shut-down button SED
For drawworks emergency stop, push the button. To restart, rotate the push-button on clockwise.
F
C1
J1 G
C8
SED
H
I
R1
C5
L
Fig. D-63
UM190159/E - Rev.1 - 06/2015
7. Power swivel pump control valve C13

A The upward movement of this valve handle engages the pump for rotation power swivel.
The downward movement disengages the pump for rotation power swivel.
8. Power swivel rotation control valve C60

The upward movement of control valve the rotation forward power swivel.
B The downward movement of control valve the rotation reverse power swivel.
9. Power swivel torque regulator control valve R60

Turning counterclockwise the control knob decreases torque power swivel.
Turning clockwise the control knob increases torque power swivel.
C 10. Power swivel rpm regulator control valve R61

Turning clockwise the control knob increases RPM of power swivel.
Turning ccw the control knob decreases RPM of power swivel.
11. Pump power swivel supercharging pressure gauge A29

This gauge indicates the supercharging pressure of external pump power swivel (scale 0-60 bar).
D 12. Pump power swivel supercharging pressure gauge A30

This gauge indicates the supercharging pressure of internal pump power swivel (scale 0-60 bar).
13. Power swivel torque pressure-gauge A61

It indicates the torque pressure of power swivel (scale 0-400 bar).
E 14. Engine emergency shut-down button SE2

For rig emergency stop, push the button.
To restart, rotate the push-button on clockwise.
G A61
C13
SE2
A29
H
A30
C60
R61
R60
SER
L
Fig. D-64
UM190159/E - Rev.1 - 06/2015
15.Main drum parking brake control valve C12

The upward movement of this valve handle open the clamps of the parking brake. A
The downward movement close the clamps of the parking brake.
16.“Farr” tong pump control valve C27

The upward movement of this valve handle makes available the hydraulic supply to the tong.
The downward movement stops the hydraulic supply to the tong.
B
17. Hydraulic catheads - control valves C28 and C29
The upward movement of control valve C28 actuates the spinning cathead.
The upward movement of control valve C29 actuates the break-out cathead.
This handles automatically return to neutral position when released.
Also the cylinders of catheads return automatically to full extended position.
Turning clockwise the control knob R6 increases torque of spinning cathead.
C
Turning ccw the control knob R6 decreases torque of spinning cathead.
18.“Nov” spinning pump control valve C30

The upward movement of this valve handle makes available the hydraulic supply to the spinning.
The downward movement stops the hydraulic supply to the spinning. D
19. Auxiliary winch - remote control C37 (hydraulic winch mounted on carrier)
The upward movement of control valve hydraulic winch lift.
The downward movement of control valve hydraulic winch lower.
C12
C28 C29
G
C27 C37
C30
H
R6
JR9 R10
I
L
Fig. D-65
UM190159/E - Rev.1 - 06/2015
20. Spinning cathead torque regulator-control valve R6

A Turning counterclockwise the control knob decreases torque spinning cathead.
Turning clockwise the control knob increases torque spinning cathead.
21. “Nov” spinning pressure regulator control valve R9

Turning counterclockwise the control knob decreases the hydraulic supply pressure of spinning.
B Turning clockwise the control knob increases hydraulic supply pressure of spinning.
22. “Farr” tong pressure regulator control valve R10

Turning counterclockwise the control knob decreases hydraulic supply pressure of tong.
Turning clockwise the control knob increases hydraulic supply pressure of tong.
C 23. Spinning cathead oil pressure-gauge A11

It indicates the pressure inside spinning cathead cylinder.
Pressure: 0-250 bar (scale 0-400 bar)
Pulling force. Up to 6 Ton
24. “Nov” spinning pressure gauge A13

D It indicates the hydraulic supply pressure of spinning (scale 0-400 bar).
25. “Farr” tong pressure gauge A14

It indicates the hydraulic supply pressure of tong (scale 0-400 bar).
R6
R10
I
A14
A13 A11
L
Fig. D-66
UM190159/E - Rev.1 - 06/2015
25. Crown-o-matic push-button C3 Standard Crown Block Safety System

Item Description
A
ENGAGING
1 Track
The crown-o-matic is a safety device, which auto- 2,3 Short Toggle Valve Assy (P/N 50640652)
matically controls the tripping of the drilling travel- 4,5,7 Clutch Assembly
ling block, preventing it from clashing against the 6 Air Cylinder Assembly
crown block.
This system senses when the travelling block is
B
1
within a preset distance of the crown block. It dis- 3
engages the clutch, then simultaneously applies 2
the brakes to the drawworks.
TO
DISENGAGING
Push C3 button and simultaneously release the
CONTROL
PANEL
C
5
brake: the drilling travelling block comes down
due to its own weight. In the meanwhile, the driller
assistant must go near the drawworks and put the
crown-o-matic toggle valve in its rest position.
D
4
7
6
Fig. D-67
E
C3
G
L
Fig. D-68
UM190159/E - Rev.1 - 06/2015
26. Main air pressure gauge A1

A This gauge indicates the air pressure in the control panel (7.6 bar steady-scale 0-16 bar)
27. Main drum clutch air pressure gauge A2 low speed

It indicates air pressure inside drum low speed clutch (scale 0-10 bar).
B 28. Brake rim cooling water pressure gauge A3

It indicates cooling water pressure of internal circuit. The water flow must be constant and its value is 333
lit/min (gauge scale 0-6 bar).
WARNING
C Be sure that no water leakage is falling on brake band. In case of failure, repair immediately.
29. Drawworks oil pressure gauge A4

It indicates lubricating oil pressure of drawworks. In working condition it shall be 0.7 bar (scale 0-6 bar).
D 30. Parking brake clamps pressure gauge A20*

This gauge indicates the status of parking brake (scale 0-250 bar).
31. Upper service clamps pressure gauge A21*

This gauge indicates the status of upper clamps (scale 0-160 bar).
E 32. Lower service clamps pressure gauge A22*

This gauge indicates the status of lower clamps (scale 0-160 bar).
* If the gauge does not indicate pressure, the clamps are closed, while if the gauge indicate pressure, the
clamps are open.
G A1
A13
I
A21 A22 A20 A2 A3 A4
L
Fig. D-69
UM190159/E - Rev.1 - 06/2015
D-4 AIR SYSTEM (DRW. 50015235)

A
Air is supplied by one INGERSOLL RAND T30 Mod. 2475 (cod. 40140042), operated by engine transmis-
sion.
Air system is also made up of tank, pipes and hoses, valves and accessories.
As the air system provides the necessary operating air pressure to the various control devices, it is very im-
portant that it is properly maintened.
At routine intervals, and especially after rig has been inoperative for a period of time, the air lines should be
B
disconnected at farthest terminal points and blown out with clean, dry air. Always cap or cover open ends
of the air connections when rig is stored. Frequently inspect condition of air line hoses and replace when
necessary.
Refer to table in Sec. E for proper air pressure.
C
L
UM190159/E - Rev.1 - 06/2015
E
L
UM190159/E - Rev.1 - 06/2015
Section E - ASSEMBLY
SECTION INDEX
E-1 ASSEMBLY INSTRUCTIONS.................... 2
A
E-1.1 LEVELLING OF RIG.................................. 2
E-1.2 REEVING................................................. 15
E-1.3 RAISING OF MAST.................................. 15
E-1.4 WORKING FLOOR INSTALLATION B
COMPLETION......................................... 18
E-1.5 MONKEY BOARD POSITIONING........... 25
E-1.6 TELESCOPING OF MAST UPPER
SECTION................................................. 26
E-1.7 POWER SWIVEL INSTALLATION........... 28 C
E-1.8 CROWN-O-MATIC AND FLOOR
SAVER TEST........................................... 29
E-1.9 BREAKING - IN PERIOD......................... 30
E-1.10 MOVEMENT WITHIN THE WORKING
AREA........................................................ 30 D
L
UM190159/E - Rev.1 - 06/2015
E-1 ASSEMBLY INSTRUCTIONS

A
WARNING
Before starting any operation or procedure described in this chapter, you must be familiar with safety
B regulations and with the information contained in Section C.
In case of doubt, read again Section C - SAFETY - and proceed only when you are sure that you have
understood properly.
E-1.1 LEVELLING OF RIG

C
WARNING
In order to carry out the here following described operations, exclusively use hoisting means (cranes,
fork lift, trucks, etc...) adequate for the mass and dimensions to be handled.
D -- Position the machine within the working area, by adequately manoeuvring the truck
-- Now carry out an inspection around the machine, verifying that no possible damages due to the transport
are visible. In particular, check all the levels of the oil and water.
L
UM190159/E - Rev.1 - 06/2015
Phase 1
A
-- Place the skid 01905514 for the rear stabilizers at 1930 mm from well center.
Well center
B
1930
C
Approx. weight 1112.5 Kg
01905514
2500
D
4000
Well center
E
1500
1930
Fig. E-1
F
Phase 2
-- Park the rig carrier so that the axis of the rear stabilizer will be perfectly aligned with the appropriate hous-
ing placed on base skid.
G
-- Turn off the truck’s engine.
Well
center
L
Fig. E-2
UM190159/E - Rev.1 - 06/2015
A
Phase 3
-- Open the lateral walkways and install the handrails.

-- Positioning the base 019015649 for the front stabilizer.
-- Move the lever C38 on central position (neutral).
-- Move the lever C25 upward on stabilizer position.
B -- Lift the rig until working position, it has to be levelled at height of 1500 mm, this operation control the move-
ment by means lever C18, C19, C20, and C21.
-- During this phase, it’s important to check the machine levelling. When rig has reached the working position,
the all stabilizers have to be locked with ring nuts.
-- Install the lateral stairs.
C38
D C25
C20 C21
E C18 C19
Positioning controls
G
1500 mm
(working
position)
Well
center
H Ring nut lock
019015649
L
Fig. E-3
UM190159/E - Rev.1 - 06/2015
Phase 4
A
-- Place in working position the external stabilizer arms. For each stabilizer arm:
•• remove the safety latch 40630143 and the pin 71203015;
•• manually rotating the stabilizer arm towards outside;
•• lock the stabilizer arm by means the pin 71203015 and the safety latch 40630143. Tighten the screws
70353026 and lock them by means the nuts 70683030.
B
Stabilizer closed Stabilizer opened
C
1189
1430
Ground
A D
71203015 E
40630143
70353026
71203015
40630143 70683030
F
Fig. E-4
-- Positioning the two (2) base 019015649 for external stabilizers.

-- Place the end of the stabilizer with the ball inside the seat on the foot, adjust the height by the screw jack G
019014966 then fasten by ring nut.
-- Lock the external stabilizers with ring nuts.
H
1607
Ground
I
019014966
019015649
L
Fig. E-5
UM190159/E - Rev.1 - 06/2015
The external stabilizers have two opening positions: conﬁguration 1 with an opening angle of 117° and the
A conﬁguration 2 with an opening angle of 103°. The opening position of the stabilizers is related to the working
type.
STABILIZER OPENED STABILIZER OPENED

B CONFIGURATION 1 CONFIGURATION 2
1930
930
1930
C
5756
5397
E 11
7 °
3°
10
CENTER WELL
CENTER WELL
F
11511
10794
G
10
3°
11
7 °
L
Fig. E-6
UM190159/E - Rev.1 - 06/2015
Phase 5
A
-- Unlock the driller cabin:
•• remove the tighteners 019017143 fixed by means the pins 64021969 and 64021524.
•• remove the fork 01905744 fixed by means the pins 64021962 and safety latches 40630032.
E
01905744
64021962
40630032
F
H
64021969
40630126
I
019017143
64021524
40630126
L
Fig. E-7
UM190159/E - Rev.1 - 06/2015
A •• remove the pins 64021708 and 64021182 with relative safety latches 40630126 and 40630125.
A B
F
DETAIL A
40630125 DETAIL B
H
64021182
I
64021708
40630126
L
Fig. E-8
UM190159/E - Rev.1 - 06/2015
-- Manually rotating the driller cabin in working position.

-- Lock the driller cabin in working position: A
•• position the pins 64021672 and safety latches 40630127.
Center well
B
Pre-working position
Center well Working position

G
64021672
40630127
L
Fig. E-9
UM190159/E - Rev.1 - 06/2015
•• position the pins 64021708 and 64021182 with relative safety latches 40630126 and 40630125.
A
B
DETAIL A
C A
E 64021708 40630126
DETAIL B
H B
I 64021182 40630125
L
Fig. E-10
UM190159/E - Rev.1 - 06/2015
-- Remove the tighteners that unlock the working floor in transport position.
-- Lowering the working floor by means the crane. A
-- Open the working floor and open the footboards of the driller cabin.
Tighteners
of fixing
B
L
Fig. E-11
UM190159/E - Rev.1 - 06/2015
E
L
UM190159/E - Rev.1 - 06/2015
-- Install the handrails and the stairs of driller cabin.

A
3 4 B
6
C
8
5 D
7
1
E
5
2
3
6 F
10
G
9
12
I
11
L
Fig. E-12
UM190159/E - Rev.1 - 06/2015
A Items Qty. Code Description

1 1 019018491 OVERTURNABLE FOOTBOARD
3 2 019018502 HANDRAIL
4 1 019018503 HANDRAIL
B 5
6
2
2
019018504
019018494
HANDRAIL
LADDER
7 4 40630031 SPLIT PIN
8 4 64021121 PIN
9 1 01905684 ROD
10 2 40630054 SPRING PIN
11 2 71202008 PIN
C 12 2 40630125 SAFETY LATCH
L
UM190159/E - Rev.1 - 06/2015
Phase 6
C38 A
-- Move the lever C38 on drilling position.
-- Start the diesel engine as described in the before

paragraph C-2.4.
Fig. E-13 C
E-1.2 REEVING
-- Put the travelling block inside mast with hook on

bottom section of mast.
-- To a easy procedure, make reeving with a normal D
rope.
-- Anchor rope to drill line.
-- Pull normal rope to allow the reeving of drill line
(by means a external system, example fork lift or
other).
-- Drill line must be anchored to main drum on cut E
side, the other side must be anchored to dead line
system.
E-1.3 RAISING OF MAST
1. Install the guy lines on mast and arrange them

F
in such a way as to avoid interference with mast
raising operation.
2. Check that monkey board is locked in its appropri-
ate way.
3. Make sure that no air is contained in raising cylin- G
ders; for this scope perform the following instruc-
tions:
•• Unscrewing breather plugs located in the upper
section of each stage of cylinders.
•• Operate the lever on hydraulic control panel,
gradually pour oil into the breathers until they
H
are completely full.
•• Screw the plug.
IMPORTANT
I
Raising cylinder purging is recommended for the
first mast raising and when the rig is not operative
from long time.
L
UM190159/E - Rev.1 - 06/2015
4. Run engine at approximately 1200 rpm.

A
5. Operate joystick 1 on radio control, to raise mast SALITA TORRE
MAST RAISING UP
SFILO TELESCOPICOTORRE
TELESCOPIC MAST UP
BLOCCAGGIO TELESCOPICO
TELESCOPIC MAST LOCKING ON
in working position. Lifting pressure on test std. Abstand/

spacing 30mm
test std. Abstand/
spacing 30mm
test std. Abstand/
spacing 30mm
•• First stage: 120 bar. 1

23x39mm
R=4,8mm
23x39mm
R=4,8mm
23x39mm
R=4,8mm
•• Second stage: 170 bar

B •• Third stage: 215 bar. DISCESA TORRE
MAST RAISING DOWN
radiomatic iON
Peaks @ 250 bar may occur.
1
®
Nr.1
Farbe fehlt!
Ø 8 Farbe fehlt!
Ø 8
Farbe fehlt!
Ø 8 Ø 22,5
0
Ø 8
Raising pressure can be seen on manometer A10.

Lever C25 has to be on stabilizers position.
C Fig. E-14
IMPORTANT
During raising phase, if the pressure indicated in
the three phases are exceeded, more than 5÷10% A10
D stop the operation and check the configuration of
the travelling block.
C25
6. When the mast is close to its mast stand, adjust the
pressure of raising cylinder there by of joystick 1,
check visually the point of support and later on do
E not operate on lever when the mast and the stand
are in contact, avoiding a pressure increasing in-
side the cylinder then to preserve the entireness
Fig. E-15
of the stand.
L
UM190159/E - Rev.1 - 06/2015
7. Lock the mast with the stand there by of appropriate pins.

8. Link the guy line. A
D
Guy line of mast
fixed section Guy line of mast
fixed section
G
Locking pin of
fixed section mast
71051020 64021670 H
I
Fig. E-16
L
UM190159/E - Rev.1 - 06/2015
E-1.4 WORKING FLOOR INSTALLATION COMPLETION

A
Pin the working floor to the mast base frame and install the support legs.
B
1 Padeye for lifting mast
2 Working floor support
3 Manifold footboard fixing padeyes
4 Upper padeyes for driller cabin
C rotating support
5 Lower padeyes for driller cabin
rotating support
6 Working floor support
2
D
6
3
E 1
F 5
G
Fig. E-17
H Set the right height of the stairs and install them to the working platform.
Install all the handrails around the working floor.
The height of the working floor is adjustable; for this operation it is possible to use a crane or the service winch
installed on carrier.
L
UM190159/E - Rev.1 - 06/2015
The working platform can be placed at 1500 mm or 3500 mm depending on the needs of working.
A
A
B
A-A C
L
Fig. E-18
UM190159/E - Rev.1 - 06/2015
E
L
UM190159/E - Rev.1 - 06/2015
A 32 30
20 30
B
20 30
B
11 C
D
1
E
9 10
F
12 7 8 2
14 G
25 13
B
28
5
15 H
17 3
C 26 4
23 19 22 24 D
6
18
16
A 35 34 33
21 29
I
27
31 29
C D
L
Fig. E-19
UM190159/E - Rev.1 - 06/2015
A Items Qty. Code Description

1 4 01901254 HINGE FOR DOOR
3 3 01905497 HANDRAIL H=1300 L=640
4 1 01905498 HANDRAIL L=1565 H=1300
5 2 01905499 HANDRAIL L=820 H=1300
B 6
7
3
1
01905500
01905501
HANDRAIL L=950 H=1300
OVERTURNABLE HANDRAIL L=400 H=1300
8 2 01905502 OVERTURNABLE HANDRAIL L=555 H=1300
9 1 01905503 RH PIPE RAMP GATE
10 1 01905504 LH PIPE RAMP GATE
11 1 01905505 FOOTBOARD
12 1 01905506 FOOTBOARD
C 13
14
1
1
01905509
01905510
HANDRAIL H=1300 L=880
SPECIAL HANDRAIL L=888 H=1300
15 1 019010957 MANIFOLD LADDER
16 2 019015084 GR. HINGE FOR FOOTBOARDS
17 1 019016454 PIPE RAMP CARPENTRY
18 1 019016815 DRILL FLOOR CLOSING FOOTBOARD
D 19
20
2
4
019017042
64021496
GR. HINGE FOR FOOTBOARDS
PIN D.30 L.U. 155 WITH HANDLE
21 2 64023639 PIN WITH HANDLE AND HOLE D.30 Lu=120
22 1 01905486 DRILL FLOOR CENTRAL FOOTBOARD
23 1 01905487 DRILL FLOOR RIGHT FOOTBOARD
24 1 01905488 DRILL FLOOR LEFT FOOTBOARD
25 2 01905492 WORKING COLUMN
E 26
27
1
2
01905495
01905496
REMOVABLE FOOTBOARD
SUPPORT PLATE
28 1 01905511 MANIFOLD FOOTBOARD
29 4 40630126 PIN 5SM MOLLIFICIO ADIGE D.5 ZINC-PLATED LEFT WINDING
30 8 40630127 SAFETY STOP
31 2 64020864 PIN WITH HEAD D.30X85
32 4 64021672 CABIN LOCK PIN
F 33
34
4
4
70351006
70900618
HH SCREW M10X30 8.8 P.G. UNI 5739
FLAT WASHER M6 WIDE BAND UNI 6593
35 4 70911017 SPRING WASHER M10 UNI1751
L
UM190159/E - Rev.1 - 06/2015
1
F
G
4
H
3
Items Qty. Code Description I

1 1 019018412 ROD
2 2 40630054 SPRING PIN
3 2 71202008 PIN
4 2 40630125 SAFETY LATCH
L
Fig. E-20
UM190159/E - Rev.1 - 06/2015
A -- Install all electric cable, air and hydraulic hoses,

all instrumentation hoses.
-- Install and fix the manifold on the left side of the

mast:
•• pin 64020852
B •• cotter pin 71050814.
64020852
D 71050814
G Fig. E-21
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UM190159/E - Rev.1 - 06/2015
E-1.5 MONKEY BOARD POSITIONING

A
The monkey board gets positioned during the extraction of the mast telescopic section.
Fix the handrails of the monkey board in vertical position.
IMPORTANT B
At completion of the extraction of the telescopic section and after having locked the position, make
sure the monkey board safety cables are correctly anchored.
Telescopic section
E
Fune cod.41030929
F
Safety rope
G
Fixed section
H
Catena cod.
41050020
L
Fig. E-22
UM190159/E - Rev.1 - 06/2015
E-1.6 TELESCOPING OF MAST UPPER

A SECTION
1. Make sure that no air is contained in raising cylin-

ders; as per instruction given in paragraph E-1.3
point 3.
B
IMPORTANT
Telescopic cylinder purging is recommended
C for the first mast raising and when the rig is not
operative from long time.
2. Unlock safety pins between fixed section and tel-

escopic section. These pins are used to prevent tel-
escopic of mast upper section during transport.
D 3. Arrange guy lines in such a way as to avoid inter-
ference with the mast telescopic section.
4. Put in tension the service winch wire rope that is
used to lower the monkey board; unlock the monkey
board and start the operation of lowering until its
weight is supported from guy lines. Install the mon-
E key board lower guy lines with the monkey board
itself. Install the handrail in working position.
F IMPORTANT
Before to start with the telescopic operation, SALITA TORRE SFILO TELESCOPICOTORRE BLOCCAGGIO TELESCOPICO
perform a test to check the cylinder functionality: MAST RAISING UP

test std. Abstand/
spacing 30mm
TELESCOPIC MAST UP
test std. Abstand/
spacing 30mm
TELESCOPIC MAST LOCKING ON
test std. Abstand/
spacing 30mm
raise telescopic section approximately 50 ... 60 cm,

then come down; if the operation is correct, start
23x39mm
R=4,8mm 2
23x39mm
R=4,8mm 3
23x39mm
R=4,8mm
with the raising of telescopic section.

G DISCESA TORRE
MAST RAISING DOWN
radiomatic iON
5. With the engine set approximately @1200 rpm,

®

Nr.1
Farbe fehlt!
Ø 8 Farbe fehlt!
Ø 8
Farbe fehlt!
Ø 8 Ø 22,5
operate joystick 2 on radio control to extend the

0
Ø 8

upper section.
During this operation, the lifting pressure is ap-
H proximately 170 bar ±10%. Fig. E-23

When the upper section is completely extend the
peak pressure could reach 200 bar due to me-
chanical endstroke of hydraulic cylinder.
6. Thereby of joystick 3 on radio control, lock the
safety pins between telescopic section and fixed
I section mast.
Check visually that locking pins are gone out cor-
rectly.
7. Thereby of joystick on radio control, slightly lower
the telescopic section on the above safety pins; in
L this way that pins are automatically locked.
UM190159/E - Rev.1 - 06/2015
8. Anchor guy lines lower ends to trailer and substructure skids and then, tension it.
A
NOTE: If pins to lock telescopic section are not gone out in the correctly position, there is a safety in
the system that disable the operation of drawworks.
C
Guy line mast
telescopic
section
Guy line mast Guy line mast

telescopic telescopic
section section
D
Guy line
monkey
board E
Guy line Guy line
monkey monkey
board board
F
Fig. E-24
H
L
UM190159/E - Rev.1 - 06/2015
E-1.7 POWER SWIVEL INSTALLATION

A
1. Install the tighteners supports 01905491 to the mast by means the pins 64023639 and safety latch
40630126.
2. Install the tighteners 019017041 between the supports 01905491 and the anchoring plate 01905489. Fix
the tighteners by means the pins 64023633 and safety latch 40630126.
B 3. Install the ropes and the tighteners 40990048 between the anchoring plate 01905489 and the mast fixing
ears B.
Note: For drill floor at 3500 mm height, use the rope 41031091 (length 23195mm), while for drill floor
at 1500 mm height, use the rope 41031090 (length 25195mm).
C
View from Q
D Q
B B
E 1340
==
13
F
15
32400
1113
34°
Tighten the
ropes: 3 t
410
Detail X
G Detail X
64023633
Detail Y
A A P
40630126
019015267
019016725
5040
5225
4815
64023639
4630
40630126
H 019016719
40990048
I
15
1523
82
1805
= =
47°
Detail Y
L Section A-A
Fig. E-25
UM190159/E - Rev.1 - 06/2015
4. Move power swivel on working floor to coupling it

with travelling block. Engage travelling block with A
power swivel.
5. Connect the arm of power swivel with the rope.
6. Lift the power swivel.
When you use the power swivel make the connection
with the hydraulic pump driven and connect the rotary B
hose to the gooseneck.
Rotary hose is arranged with 2” Fig 1502 hammer Connet the rotary
union. hose to the
Install one end of rotary hose to the union assy of the
stand pipe and tighten.
goosneck
C
Temporarily tie the rotary hose to the mast.
Procede to connect the rotary hose to the goose-
neck.
By means lift the end with union assy of rotary hose
and connect it to the end of the gooseneck and
tighten.
D
Verify that the orientation of the rotary hose does not
cause interference in the rig.
Connect with the
hydraulic pump
driven E
Fig. E-26
IMPORTANT F
Once the machine positioning operation is ended,
gring the lever C25 to drilling position. Lock the
lever in the final position by means the padlock.
G
C25
Fig. E-27
H
E-1.8 CROWN-O-MATIC AND FLOOR
SAVER TEST
After that mast assembly have been completed, to

verify Crown-O-Matic system is need bring to upper
limit the travelling block, at the end of travel it’s need
I
reduce the speed and you must control that draw-
works brakes before that travelling block crashes the
crown block. For lower limit it’s need make the same
operation, but with lowering of travelling block, in this
case it’s need to verify that hook doesn’t collide to
the drill floor, the drawworks must brakes before than
L
collision.
UM190159/E - Rev.1 - 06/2015
E-1.9 BREAKING - IN PERIOD

A
A correct breaking-in period ensures a long working life to your rig. It is suggest therefore not to require to the
new rig to operate at the maximum power.
a) ENGINE
Follow the manufacturer’s instructions.
B b) RIG
After approximately the first 200 working hours at the maximum power:
-- drain flush and refill the oil circuits with new oil
-- with reference to chain tension, make an adjustment to remove slacks caused by initial elonga-
tions.
C
WARNING
In order to prevent personal injury during the performance of any maintenance procedure, make sure
that component to be overhauled is not working.
D
E-1.10 MOVEMENT WITHIN THE WORKING AREA
In order to perform any displacements within a working area, consequently not subjected to the rules of the
road traffic code, carry out in reverse order the procedures indicated for setting the machine into service.
E Besides, observe the following prescription:
IMPORTANT
For the carrier movement to start the diesel engine in CARRIER configuration.
F -- The mast must be lowered to horizontal position, properly resting on the stand.
HAZARD
G Never move the carrier with mast in different position than horizontal, as required for haulage.
However, the risk is to unbalance the machine and even cause overturning.
HAZARD
H Do not lift stabilizers before the mast is horizontal. The risk is that of unbalancing the machine and
even cause overturning.
L
UM190159/E - Rev.1 - 06/2015
Section F - DISASSEMBLY
SECTION INDEX
F-1 DISASSEMBLY INSTRUCTIONS.............. 2
A
F-1.1 POWER SWIVEL DISINSTALLATION....... 3
F-1.2 WORKING FLOOR DISINSTALLATION.... 4
F-1.3 RIG DOWN OF MAST................................ 5
F-1.4 RIG DOWN OF MACHINE......................... 6 B
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UM190159/E - Rev.1 - 06/2015
F-1 DISASSEMBLY
A INSTRUCTIONS
WARNING
B Before starting any operation or procedure de-
scribed in this chapter, you must be familiar with
safety regulations and with the information con-
tained in Section C.
In case of doubt, read again Section C - SAFETY
C - and proceed only when you are sure that you

have understood properly.
IMPORTANT C25
D Once the machine positioning operation is ended,

gring the lever C25 to stabilizer position.
E
Fig. F-1
L
UM190159/E - Rev.1 - 06/2015
F-1.1 POWER SWIVEL DISINSTALLATION

A
1. Disconnect the hydraulic pump driven and disconnect the rotary hose to the gooseneck.
2. Lower the power swivel.
3. Disconnect the arm of power swivel with the rope.
4.
5.
Move power swivel on working floor to uncoupling it with travelling block.
Disinstall the ropes and the tighteners 40990048 between the anchoring plate 01905489 and the mast
B
fixing ears B.
6. Disinstall the tighteners 019017041 between the supports 01905491 and the anchoring plate 01905489..
7. Disinstall the tighteners supports 01905491 to the mast.
C
B B
01905491 H
019017041
40990048
01905489 I
L
Fig. F-2
UM190159/E - Rev.1 - 06/2015
F-1.2 WORKING FLOOR DISINSTALLATION

A
1. Remove the v-door slide.
2. Disinstall all handrails around the working floor.
3. Remove the stairs of the working platform.
E STAIR
V-DOOR SLIDE
G
HANDRAILS
STAIR
L
Fig. F-3
UM190159/E - Rev.1 - 06/2015
F-1.3 RIG DOWN OF MAST

Manifold
A
Perform a correct mast lowering, it is necessary to
carry out following sequences:
1. Disconnect the hydraulic hoses and remove the

manifold on the left side of the mast.
2. Bring travelling block in the higher position of mast.
B
After that you lowered the mast, travelling block is
going to bottom side of fixed mast section.
3. Remove telescopic section and monkey board
(lower ones) guy lines and arrange them in such
a way as to avoid interference with the telescopic Fig. F-4 C
mast lowering operation.
4. Raise the telescopic section until end of stroke of
cylinder thereby joystick 2, operate the joystick 3
to go in with the locking pins. SALITA TORRE SFILO TELESCOPICOTORRE BLOCCAGGIO TELESCOPICO
D
MAST RAISING UP TELESCOPIC MAST UP TELESCOPIC MAST LOCKING ON
test std. Abstand/ test std. Abstand/ test std. Abstand/
5. Operate joystick 2 to lower the telescopic sec-

spacing 30mm spacing 30mm spacing 30mm
tion. When telescopic section has arrived at final 1

23x39mm
R=4,8mm 2
23x39mm
R=4,8mm 3
23x39mm
R=4,8mm
position, let the travelling block down to the lower

position of mast. DISCESA TORRE
MAST RAISING DOWN
radiomatic iON
1
6. Fold in the monkey board thereby of service winch

®
Nr.1
Farbe fehlt!
Ø 8 Farbe fehlt! Farbe fehlt! Ø 22,5
E
Ø 8 Ø 8
and lock it with its appropriate device.
0
Ø 8

7. Remove fixed mast section guy lines and take

out the locking pins between mast and its support
stand. Fig. F-5
8. Start the lowering of mast operating joystick 1.
When mast reaches the trailer front stand, hold
the lever in position a few seconds to allow the F
discharge of carrier stress created during the mast
lowering phase.
IMPORTANT G
Always make sure that there is no air contained
in the raising jacks.
L
UM190159/E - Rev.1 - 06/2015
F-1.4 RIG DOWN OF MACHINE

A C38
Phase 1
-- Move the lever C38 on central position (neutral).
C Fig. F-6
L
UM190159/E - Rev.1 - 06/2015
Phase 2
A
-- Remove the handrails and the stair of driller cabin.
-- Close the footboard of the driller cabin and the working floor.
-- Lifting the working floor by means the crane.
-- Positions the tighteners that unlock the working floor in transport position.
B
Tighteners
of fixing
L
Fig. F-7
UM190159/E - Rev.1 - 06/2015
A -- Unlock the driller cabin:

•• remove the pins 64021708 and 64021182 with relative safety latches 40630126 and 40630125.
B
DETAIL A
C A
E 64021708 40630126
DETAIL B
H B
I 64021182 40630125
L
Fig. F-8
UM190159/E - Rev.1 - 06/2015
•• remove the pins 64021672 and safety latches 40630127.

-- Manually rotating the driller cabin in transport position. A
D
Center well Working position
64021672
G
40630127
I
Center well Transport position
L
Fig. F-9
UM190159/E - Rev.1 - 06/2015
A -- Lock the driller cabin in transport position:

•• Position the tighteners 019017143 fixed by means the pins 64021969 and 64021524;
•• Position the fork 01905744 fixed by means the pins 64021962 and safety latches 40630032;
E
01905744
64021962
40630032
F
H
64021969
40630126
I 019017143
64021524
40630126
L
Fig. F-10
UM190159/E - Rev.1 - 06/2015
•• Position the pins 64021708 and 64021182 with relative safety latches 40630126 and 40630125.
A
A B
DETAIL A
F
40630125 DETAIL B
64021182
H
I
64021708
40630126
L
Fig. F-11
UM190159/E - Rev.1 - 06/2015
Phase 3
A
-- Place in transport position the external stabilizer arms. For each stabilizer arm:
•• unlock the external stabilizers with ring nuts;
•• remove the two (2) base 019015649 for external stabilizers. If necessary for remove the base, adjust
the height by the screw jack 019014966;
B
C
Ground
D 019014966
019015649
Fig. F-12
E •• loosen the nuts 70683030 and the screws 70353026. Remove the pin 71203015 and the safety latch
40630143;
•• manually rotating the stabilizer arm towards inside;
•• lock the arm to the carrier by means the safety latch 40630143 and the pin 71203015.
F
Stabilizer opened Stabilizer closed
Ground
H A
I 71203015
40630143
70353026
71203015
70683030 40630143
L
Fig. F-13
UM190159/E - Rev.1 - 06/2015
Phase 4
A
-- Remove the lateral stairs.
-- Unlock the external stabilizers with ring nuts.
-- Verify that the lever C25 is on stabilizer position.
-- Lower the rig, this operation control the movement by means lever C18, C19, C20, and C21.
--
--
Remove the handrails and close the lateral walkways.
Remove the base 019015649 for the front stabilizer.
B
C25
C
C20 C21
C18 C19 D
Positioning controls
F
1500 mm
(working
position)
Well
center
Ring nut lock G
019015649
H
I
Fig. F-14
L
UM190159/E - Rev.1 - 06/2015
Phase 5
A
-- Move the lever C38 on drilling position.
-- Start the diesel engine as described in the before paragraph C-2.4.
-- Move the rig carrier.
C C38
Well
center
G Fig. F-15
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UM190159/E - Rev.1 - 06/2015
Phase 6
A
-- Remove the skid 01905514 for the rear stabilizers.
Well center B
Approx. weight 1112.5 Kg C

01905514
D
Well center
Fig. F-16 F
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UM190159/E - Rev.1 - 06/2015
E
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UM191159/E - Rev.1 - 06/2015
Section G - MAINTENANCE
SECTION INDEX
G-1 LUBRICATING SYSTEM........................... 3
A
G-1.1 OIL LUBRICATION..................................... 3
G-1.2 GREASE LUBRICATION TABLE............... 4 G-11.4 RECOMMENDED TEST SCOPE
G-1.3 OIL LUBRICATION TABLE......................... 6 “VISUAL INSPECTION” (PRIOR TO
G-2 AIR CLUTCHES........................................ 9 INITIAL SETTING INTO OPERATION
OR PUTTING BACK INTO
B
G-3 OIL AND WATER PRESSURE.................. 9 OPERATION)........................................... 30
G-4 DISC BRAKES........................................ 10 G-11.5 RECOMMENDED TEST SCOPE
G-4.1 PERIODIC INSPECTIONS...................... 10 “FUNCTIONAL TESTING” (PRIOR TO
G-4.1.1 WATER COOLING CIRCULATION.......... 11 INITIAL SETTING INTO OPERATION
G-5 DRIVE ROLLER CHAINS........................ 11 OR PUTTING BACK INTO C
OPERATION)........................................... 31
G-6 ROUTINE MAINTENANCE..................... 13
G-11.6 RECOMMEND TEST SCOPE “FOR
G-6.1 MECHANICAL PARTS - GREASING....... 13
SAFE PROVISION AND USE”
G-6.2 ROUTINE MAINTENANCE...................... 13 (RECURRENT OR EXTRAORDINARY
G-6.3 HYDRAULIC SYSTEM - OIL LEVEL
CHECK..................................................... 15
TEST)....................................................... 31
G-11.7 RECOMMENDED TEST CRITERIA
D
G-6.4 HYDRAULIC SYSTEM - REPLACE FOR HYDRAULIC HOSE
OIL FILTER AND TANK AIR ASSEMBLIES.......................................... 32
BLEEDING CARTRIDGE......................... 15 G-11.8 FACTORS INFLUENCING THE TEST
G-6.5 HYDRAULIC SYSTEM - OIL CHANGE... 16 PERIODS................................................. 32
G-6.6 DRAWWORKS LUBRICATION, G-11.9 RECOMMENDED TEST PERIODS......... 33 E
CONTROL AND REPLACE...................... 17 G-11.10 INFLUENCING FACTORS WITH
G-6.7 DRAWWORKS LUBRICATION - REGARD TO THE REPLACEMENT
REPLACEMENT OF OIL’S FILTER......... 17 INTERVALS.............................................. 33
G-6.8 DRAWWORKS RIGHT ANGLE GEAR G-11.11 RECOMMENDED REPLACEMENT
BOX - OIL CHANGE................................ 18 INTERVALS.............................................. 34 F
G-6.9 TRANSFER - OIL LEVEL AND
CHANGE.................................................. 18
G-6.9.1 TRANSFER LUBRICATION DIAGRAM... 19
G-6.10 POWER SWIVEL RIGHT ANGLE
GEAR BOX - OIL CHANGE..................... 20 G
G-6.11 HYDRAULIC SYSTEM POWER
SWIVEL - OIL LEVEL AND CHANGE...... 20
SWIVEL - REPLACEMENT OF OIL’S
G-7
FILTERS AND TANK’S AIR VENT............ 22
TANK WATER COOLING BRAKE.......... 23
H
G-8 ROPES - WEAR CHECK......................... 24
G-9 COMPLETE MACHINE - GENERAL
INSPECTION........................................... 25
G-10 BOLT TIGHTENING SPECIFICATIONS.. 26
G-11 HOSE FITTING SPECIFICATIONS......... 27
I
G-11.1 STORING OF FLEXIBLE HOSES............ 28
G-11.2 NORMS AND METHODS OF USE OF
THE FLEXIBLE HOSES........................... 29
G-11.3 MAINTENANCE OF THE FLEXIBLE
HOSES..................................................... 30
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UM191159/E - Rev.1 - 06/2015
FOREWORD
A
Personnel safety, good operation and machine life, and the capacity to perform as designed, depend on a
scrupulous compliance with the information contained in this chapter.
Failure of complying with the maintenance program is a potential hazard as the machine may not be in the
conditions envisaged for the applications required.
B
IMPORTANT
If the maintenance program is not dutifully observed, the guarantee shall not applicable.
DRILLMEC declines all responsibilities for any consequent damage.
C LUBRICATION AND PERIODICAL CHECKS
General rules for lubrication:

-- buy good quality of lubrication only and store in a clean place;
-- keep the machine clean before greasing;
D -- before you connect the grease pump clean the grease nipples accurately. After having greased remove
excess grease from the nipples;
-- substitute damaged grease nipples;
-- always use recommended lubricants.
Beside the programmed maintenance it is advisable to check all groups periodically as follows:
E -- tightening screws, connectors, etc.
-- hydraulic tube seals, pipes, etc.
WARNING
F The intervention must be executed at the right moment when the first anomaly arise.
Concerning maintenance of the diesel engine refer to the proper catalogue.
The elimination of old from any unit of the drilling rig (hydraulic oil, gear box oil, etc.) must be effected while
the machine is warm in order that the higher fluidity allows to drain the eventual impurity.
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UM191159/E - Rev.1 - 06/2015
G-1 LUBRICATING SYSTEM

A
Proper lubrication is essential for the correct functioning and long working life of your rig.
-- GREASING POINTS
-- FREQUENCY
-- TYPE OF GREASE B
Greasing points are either located on one centralized grease panel or on the single elements.
Use SHELL SUPER GREASE EP2 or equivalent.
G-1.1 OIL LUBRICATION C

For oil lubrication, refer to D-1.4 and follow the instructions on the respective table regarding:
-- Components to be lubricated
-- Frequency
-- Quantity and type of oil
-- SAE regulations D
Chains and bearings of transmission, and of bevel gear box are oil pressure lubricated from one pump. Draw-
works chains are oil bath lubricated.
Delivery of the pump 80 l/min (with engine at 2100 RPM).
The transmission box itself plays the role of oil reservoirs. A filter unit is located on the discharge line of the
pump. E
All drive chains are lubricated by means of oil bath. Following the completion of the breaking-in period after
the first 200 working hours, oil has to be totally replaced and filters to be replaced.
CHECK AND MAINTAIN LUBRICATING SYSTEM AS FOLLOWS:

1. Check condition of drive chains, sprockets, discharge lines, hoses and etc.. replace when necessary
2. Drain, flush and refill transmission box with new oil every six months, or more often if oil becomes contami-
F
nated with abrasive particles or corrosive transfer.
EVERY 8 HOURS
1. Check oil level
2. Check oil system for broken or leaking oil lines
G
3. Check functioning of oil pump for broken drive joint
4. Check the filter screen element for possible clogging. Is indicated by visual indicator, located on filter, when
it is totally red, in this case replace the screen element
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UM191159/E - Rev.1 - 06/2015
G-1.2 GREASE LUBRICATION TABLE

A
5
C
8
14
D
E 6
7
17
3
F 13 2
G
16 15 11 4 12
H 10 9
L 18 1
Fig. G-1
UM191159/E - Rev.1 - 06/2015
FREQUENCY REF. DESCRIPTION TYPE OF GREASE

A
1 Drawworks: stuffing box of water swivel joint
Every day Mast: wireline guide rollers of hydraulic ca- Shell Gadus S2 V220 2
2
theads
3
4
Wireline lazy pulleys for hydraulic catheads
Drawworks: main drum greasing plate
B
5 Crown block: bearings and joints
6 Travelling block: bearings and joints
Every 7 days 7 Hook: upper seals and joints Shell Gadus S2 V220 2
8
Mast:
Anchor weight indicator
C
Wire rope roller on first section
9 Drawworks: idle gear
Every 30 days Transmission: Shell Gadus S2 V220 2

10 Universal shaft cross
Idle gears and transfer D
11 Drawworks: wireline guide roller of drawworks
At every raising or 12 Mast: pins
Shell Gadus S2 V220 2
lowering of mast 13 Rasing jack pins
14 Telescopic section lock
15 Diesel engine E
16 Carrier
See manufacturer’s
Swivel: See manufacturer’s instructions
instructions 17
Greasing stuffing box, pins and bearing
18 Man rider
F
IMPORTANT
For more information, please refer to the technical schedule grease, attached to the documentation.
G
WARNING
Do not mix different greases; do not use greases with lower specifications.
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G-1.3 OIL LUBRICATION TABLE

A
E 12
G
14
H 9 2 1 4 5 3
L 8 7 10 6 11 13
Fig. G-2
UM191159/E - Rev.1 - 06/2015
FREQUENCY REF. DESCRIPTION

Q.ty
(Kg)
OIL TYPE A
Drawworks:
1 Tank oil level 300 Mobil gear 600XP 100
Oil filter
Hydraulic circuit:
2 Tank oil level
Oil filter
800 DTE 10 Excel 46 Mobil B
Power swivel hydraulic circuit:
Every day 3 Tank oil level 280 DTE 10 Excel 46 Mobil
Oil filters
Drawworks right angle gear box:
4 Oil level
Oil filter
20 Shell Omala Oil 100 C
Power swivel right angle gear box:
5 Oil level 20 Shell Omala Oil 100
Oil filter
Every week
5000 working hours
6
6
Transfer - Oil level check
Transfer - Oil and filter change
54
54
Shell Spirax S5 ATE 75W/90
Shell Spirax S5 ATE 75W/90
D
Diesel engine
7 Oil level 40 Shell Rimula R3 X 15W40
Oil filter
8 Engine radiator 100 Shell Italia Antifreeze
Allison gear box: E
9 Oil level 115 Shell Spirax S3 ATF MD3
See manufacturer's Oil filter
instructions T30 Seasons CPN 89237903
10 Air compressor 1.5
Ingersoll-Rand
11
12
Service winch 2000 Kg
Travelling block
15
5
Shell Omala Oil 220
DTE 10 Excel 46 Mobil
F
13 Man rider - reduction gear 0.11 See manufacturer’s instructions
14 Axles reducer 2.5 Shell Spirax S2 A 80W/90
IMPORTANT
G
For more information, please refer to the technical schedules oils, attached to the documentation.
IMPORTANT H
ALWAYS use the correct fluids for the working environmental conditions.
Fluids must pour freely at minimum operating temperatures.
IMPORTANT I
Should you want to change the oil brand, it is advisable to drain and substitute all the old oil.
DRILLMEC S.p.A. advices avoiding the use of equivalent oils.
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UM191159/E - Rev.1 - 06/2015
A
IMPORTANT
Do not mix mineral oil with synthetic oil as hey don’t have same characteristics!
This could cause formation of FOAM which could negatively influence operation of the various hy-
draulic components units.
B
WARNING
Do not mix oils with different specifications!
This could cause problems or damages to mechanical groups touched.
C
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G-2 AIR CLUTCHES

A
The clutches, highly reliable in any working conditions.
Regarding clutch maintenance, it is recommended to provide the proper air pressure to each clutch - see the
air pressure table.
When inspecting clutches check:

B
1. Condition of linings.
Lining wear is automatically balanced to a certain extent by a rubber diaphragm. Check lining wear at least
once a month.
2. Condition of clutch drum. C
The clutch drum surface should always be smooth. If it is badly warped or grooved, it should be rema-
chined.
3. Operation of quick release valves.
D
Check all quick release valve at least once a month. The most common cause of quick release valve failure
is dirt, rust or machine cuttings stuck under the seat.
Due to improper valve operations, the clutch may disengage incompletely and therefore cause overheating
and damage to the diaphragm. Overheating may also be due to clutch dragging.
AIR PRESSURE
E
MAX. PRESSURE
DESCRIPTION
PSI bar
Drawworks clutch 125 8,7
Eaton disc brake
Control panel general feeding pressure gauge
150
110
10,3
7,6
F
Air compressor max. pressure 145 10
Right angle gear box air clutch pressure 110 7,6
Pressure line emergency 125 8,7
G
G-3 OIL AND WATER PRESSURE
OIL PRESSURE
LEVEL PLACE OF PRESSURE PSI (bar)
COMPONENT CAPACITY L.
INDICATOR CONTROL Max. Nom. Min. H
Drawworks and 25 10 5
300 Visual level Control Panel
Transmission (1,76) (0,70) (0,35)
WATER PRESSURE
PLACE OF CAPACITY PRESSURE
ELEMENT POSITION INLET OUTLET
Main Drum Brake Right side

CONTROL
Control panel
[l/min]
333
PSI (bar)
3 2” gas 1.1/2” gas
I
WARNING: USE COLD WATER IN BRAKE SYSTEM
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UM191159/E - Rev.1 - 06/2015
G-4 DISC BRAKES

A
G-4.1 PERIODIC INSPECTIONS
The following precautions should be taken in connection with proper brake maintenance.
The frequency of these checks depends on the frequency of brake use. Anyway we suggest to perform these
B checks at least every 3 month.
1. Check the wear of the linings periodically. The maximum wear limits is 8 mm (positive brake) and 9 mm
(negative brake) for each lining; going over this maximum wear limit can cause serious damages to the
brake. When the maximum wear limit has been reached, replace the linings.
C 2. Check, for negative brakes, that the gap between the disc and each lining pad is 1.5 mm. If the gap is
higher, restore the original gap.
3. Check, for negative brakes, that the flat springs are properly lubricated.
4. Check that no lubricant traces are found on the disc or pad surfaces.
5. Check that all the fixing screws are tightened properly.
D 6. Check out the integrity of flexible hoses.

7. The main brake drum is water cooled by means of an internal circuit.
Water circulation flow is equal to 200 Lit/min.
Check every six month the good state of fittings and piping of water circuit.
Always use original spare parts.
8. Switch on and off the oil supply several times, to check the seals integrity and the springs functionality.
E 9. Check the brake system at least one a month.
See manufacturer’s instructions
F Negative brake
H
Positive brake
L
Fig. G-3
UM191159/E - Rev.1 - 06/2015
G-4.1.1 WATER COOLING CIRCULATION

A
Fig. G-4
E
G-5 DRIVE ROLLER CHAINS
Make sure that roller chains are always well lubricated. As oil cleanliness is an essential factor in chain lubri-
cation, accurately clean every chain before mounting it, to reduce the amount of foreign contaminants in the
oil.
Clearance of chain links should never exceed 0,1 - 0,2 mm.
F
Check clearance at least once a month.
When possible use a chain length with an even number of pitches to eliminate the need for an offset link.
To obtain maximum chain life, maintain proper chain tension.
Make an adjustment after approximately the first 400 hours of operation to remove slack caused by initial
elongation. Thereafter, the frequency of periodic adjustment Is governed by operating conditions.
G
Sprocket center distance must be more than half the sum of the sprocket outside diameters to avoid tooth
interference.
A center distance equal lo the diameter of the large sprocket plus one-half the diameter of the small sprocket
is the suggested maximum for average applications. H
Normally, horizontal and inclined drives should be installed with an initial sag equal to approximately 2% of
sprocket center distance.
Check gear tooth wearing once every six months (especially the pinion teeth).
I
Clearance between tooth space and roller should not exceed 0,3 mm.
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UM191159/E - Rev.1 - 06/2015
A Air clutch Air clutch

33VC650S 20CB500
1-3/4” Chain 2” Chain
4 5
Air clutch
Lubrication
B
16CB500
pump
C15 Diesel M5610AR Allison
Transmission Transfer
Engine
C 1 2
Compressor Cardan shaft Cardan shaft Bell
crank
Service pump
3
Rope 1”
D
Cardan joint features
Pos Qty Description Cod
- GEWES 43-77 TRANSM.
E 1 1 - FL. SAE1800 BR73/KV 70°-180 BR72
- Lz. 600 La. 110
40590099
- TRANSM. 2065
2 1 - FL. SAE203-12x12/KW 70° - 180 BR72 40590199
- Lz. 1570 La. 110
F
Rope features
Pos. Qty Description Code
3 1 Rope D.25,4 (1”) lenght 600 m. 41001347
Chain features
Pitchs Min. breaking
Pos. Qty Pitch Chain n° Type Code
G
N° load (N)
4 1 1 3/4” 140-2 ASA 101 340540 01905691
5 1 2” 160-1 ASA 110 222400 019018461
H Fig. G-5
BREAKING-IN PERIOD
I A correct breaking-in period ensures a long working life to your rig.
a. Engine: follow the manufacturer’s instructions.

b. Rig: after approximately the first 2000 working hours:
-- drain, flush and refill the oil circuits with new oil;
-- with reference to chain tension, make an adjustment to remove slacks caused by initial elongation.
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UM191159/E - Rev.1 - 06/2015
G-6 ROUTINE MAINTENANCE

A
Routine inspection of components is the most important form of preventive maintenance and with result in
considerable saving by detecting any major trouble that might be developing and allowing the necessary
repairs to be made on a planned or normal rig downtime.
The following is a guide to some of the key points which should be observed during routine inspection. The
prevailing operating conditions surrounding each individual rig wiIl dictate the frequency at which the inspec-
tions should be made; however, the intervals listed below are recommended for optimum performance from B
the equipment.
G-6.1 MECHANICAL PARTS - GREASING
C
IMPORTANT
If clogged or damaged, replace grease nipples with new ones (for lubricant specifications, see chapter
G-1.3).
G-6.2 ROUTINE MAINTENANCE D

REF.
(see Fig.
PART FREQUENCY DESCRIPTION TYPE OF LUBRICANT
D-1, D-2,
D-3 and D-4
Grease supports, return devices
E
Every 30 days 8* Shell Gadus S2 V220 2
and chain
Mast
At every raising and 12* Grease pins Shell Gadus S2 V220 2
lowering of mast 13* Grease raising jack pins Shell Gadus S2 V220 2
Crown and
travelling Every 7 days 5* Grease all bearings Shell Gadus S2 V220 2 F
block
6* Grease all bearings Shell Gadus S2 V220 2
Note: the positioning of the crown and travelling sheaves in the rig should be reversed with each rigging-
up operation so that the previous dead-line sheave becomes the fast line sheave. This distributes wear
Swivel
on the bearings and sheaves, both of which should be replaced when they become worn.
Every day 17* Grease stuffing box Shell Gadus S2 V220 2
G
17* Grease swivel pins Shell Gadus S2 V220 2
Every 7 days
17* Grease upper and lower gasket Shell Gadus S2 V220 2
Every 30 days 17* Grease main bearing Shell Gadus S2 V220 2
Transmission Every 30 days 10* Grease universal joint Shell Gadus S2 V220 2 H
Drawworks Every day 1** Check reservoir oil level Mobil gear 600XP 100
Every 7 days 4* Grease main drum plate Shell Gadus S2 V220 2
Every 30 days 9* Grease idle gears Shell Gadus S2 V220 2
1. Check the lubrication system (tank, pipes, gauges, rotorseals, etc.) to
assure it is intact and free from damage or obstructions.
2. Check the air system (valves, pipes, joints, gauges, screens, tank, etc.)
I
3. Check the braking system (lining wear, etc.)
Every 3 months 4. Check clutches (see manufacturer’s instructions)
5. Check chain drives (missing cotter pins, broken links or inadequate
lubrication of rollers, etc.
6. Check all bolts and nuts for proper tightness.
7. Check all gaskets, rubbers and seals. L
Every 2000 Hours /
1** Oil and filter replacement Mobil gear 600XP 100
6 months
UM191159/E - Rev.1 - 06/2015
A PART FREQUENCY
REF.
(see Fig.
DESCRIPTION TYPE OF LUBRICANT
D-1, D-2,
D-3 and D-4
Every day 2** Check reservoir oil level DTE 10 Excel 46 Mobil
Hydraulic
circuit Every 2000 Hours /
B 6 months
2** Oil and filter replacement DTE 10 Excel 46 Mobil
Power swivel Every day 3** Check reservoir oil level DTE 10 Excel 46 Mobil
hydraulic Every 2000 Hours /
circuit 3** Oil and filter replacement DTE 10 Excel 46 Mobil
6 months
Drawworks Every day 4** Check reservoir oil level Shell Omala Oil 100
C right angle
gear Every 4000 hours 4** Oil and filter replacement Shell Omala Oil 100
Power swivel Every day 5** Check reservoir oil level Shell Omala Oil 100
right angle
gear Every 4000 hours 5** Oil and filter replacement Shell Omala Oil 100
D Diesel engine
instructions
7** See manufacturer’s instructions Shell Rimula R3 X 15W40
Allison gear See manufacturer’s

9** Check reservoir oil level Shell Spirax S3 ATF MD3
box instructions
Every 3000 Km 14** Oil level check Shell Spirax S2 A 80W/90
Carrier - axles
Every 20000 Km 14** Oil replacement Shell Spirax S2 A 80W/90
E Air
compressor
instructions
10** See manufacturer’s instructions
T30 Seasons CPN 9237903
Ingersoll-Rand
Service winch 11** See manufacturer’s instructions Shell Omala 220
instructions
Travelling See manufacturer’s
12** See manufacturer’s instructions DTE 10 Excel 46 Mobil
F
block instructions
See manufacturer’s See manufacturer’s
Man rider 13.** See manufacturer’s instructions
instructions instructions
* = Grease lubrication
** = Oil lubrication
G
IMPORTANT
The first lubricating oil replacement must carried out after the first 400 working hours, then observe
the indications supplied in the routine maintenance table.
H
IMPORTANT
For commercial components maintenance intervals refer to the attached manufacturer’s manual.
L
UM191159/E - Rev.1 - 06/2015
G-6.3 HYDRAULIC SYSTEM - OIL

LEVEL CHECK A
For hydraulic oil level check, set the machine to haul-
age configuration. This way, all jack are closed and the
oil in the tanks is at its maximum level. The machine
should also be perfectly levelled.
Oil level should be close to the maximum.
B
If occasionally (due to operating reasons) the machine
cannot be set to the haulage configuration, the oil
level must be checked by means of the oil level visual
indicator. With machine in working configuration, oil
level should never be lower than the indicator on the C
see-through glass. Top up if oil level is too low.
(For hydraulic oil specifications, see chapter D-1.4
“Oil lubrication table”).
WARNING
D
When topping up, do not exceed maximum oil level
(with machine in haulage configuration).
E
G-6.4 HYDRAULIC SYSTEM - REPLACE
Fig. G-6
OIL FILTER AND TANK AIR
BLEEDING CARTRIDGE
IMPORTANT
F
These components should be replaced at the time
specified even if not required by the clogging
B A
checking devices.
It is possible to approach main filter A of hydraulic oil G

from hydraulic tank’s top, unscrewing the screws.
To replace air vent’s cartridge B from hydraulic oil’s

tank it is enough to unscrew them from their threaded
H
Fig. G-7
support.
WARNING
These operations should be performed in clean
areas to avoid that any earth, dirty and impurities
can enter in the tank and in the system.
I
IMPORTANT
Once the component is replaced, check hydraulic L
oil level as described in item Hydraulic system -
oil level check.
UM191159/E - Rev.1 - 06/2015
G-6.5 HYDRAULIC SYSTEM - OIL

A CHANGE
For hydraulic oil change (as for oil level check), the
machine should be set to haulage configuration. With
this configuration, all jacks are closed and the oil in
B the tanks is at its maximum level. The machine should

also be perfectly levelled.
Oil level should be close to the maximum.
To ease up drainage, oil should be warm. This with

prevent residual sludge inside the tank.
C Then, proceed as follows:
1. Prepare a system for collection of the used oil to

be connected to draining plug A.
D IMPORTANT
A
This tank contains approx. 828 liters of hydraulic
B
oil.
2. Close valves B cutting off the tank from the hy-

E draulic system.
3. Undo plug A. To ease up oil outflow, also undo the

bleeding cartridges on top of the tank. Let the oil Fig. G-8
drain.
F WARNING
Do not disperse old oil in the environment as this
causes pollution.
G 4. Close and retighten plug A.
5. Fill up through the return filter.
C
WARNING
H Always remember that the hydraulic oil, even when
new and delivered in drums, contains pollutants.
When filling oil up, use special pumps provided
with filtering system.
I 6. Check that max. oil level is reached through level

indicator C.
WARNING
When filling up with oil, do not exceed max. oil
L level shown by indicator C.
Fig. G-9
UM191159/E - Rev.1 - 06/2015
7. Refit and retighten two new air bleeding cartridg-

es. A
(For hydraulic oil specifications, see chapter of
Lubrication).
WARNING B
can enter the hydraulic oil tank.
C
G-6.6 DRAWWORKS LUBRICATION,
CONTROL AND REPLACE
B
Drawworks lubrication oil replace follow these pro-
cedure: D
-- Connect waste tank of lubrication oil, it’s connected
to outlet A. A
-- Fill with new oil by inlet B.
-- Check oil level with indicator level C.
E
IMPORTANT Fig. G-10
At every oil replacement clean the filter inside to
the tank.
F
C
G
G-6.7 DRAWWORKS LUBRICATION -
REPLACEMENT OF OIL’S FILTER
H
Fig. G-11
IMPORTANT
Replacement of these components must be per-
formed when scheduled, even when obstruction’s
control devices do not show the need.
The replacement of the filter can be easily performed

once the container A has been unscrewed.
I
A
IMPORTANT
When once of the component is replaced, check L
the hydraulic oil level.
Fig. G-12
UM191159/E - Rev.1 - 06/2015
G-6.8 DRAWWORKS RIGHT ANGLE

A GEAR BOX - OIL CHANGE A
The oil substitution of the right angle has to be done

with hydraulic oil substitution.
B -- Positioned a vessel below of draining, with ad-

equate capacity to contain the oil gear box.
-- Unscrew the draining plug B, and wait the complete

leaking of oil from right angle gear box. B
C -- Close the draining plug. Fig. G-13
-- Restore the quantity of oil removed through the

gate A.
D IMPORTANT
If the last operation is not carried out, after the
hydraulic oil substitution, to the start of the ma-
chine control the level of the hydraulic oil tank, if
E it decrease, added oil until reach the max level.
G-6.9 TRANSFER - OIL LEVEL AND

F CHANGE
Oil level is visualized thereby the level visual indica-

tor A.
A
To change the oil follow this procedure:
G
1. Position a vessel, below of draining plug B, with
adequate capacity to contain the oil transfer.
B
2. Unscrew the draining plug B and wait the complete
H leaking of oil from transfer. Fig. G-14
3. Replace the magnetic filter.

C
4. Close the draining plug B.
I 5. Fill in, thereby charge plug C, until the maximum
oil level is reached; check the maximum oil level
thereby indicator level A.
L
Fig. G-15
UM191159/E - Rev.1 - 06/2015
G-6.9.1 TRANSFER LUBRICATION DIAGRAM

A
Charge plug
7A
8A
9A B
rks
wo
draw
To
g
llin
Dri
6A rrier
C
Ca
Pipe DN 10 (3/8”)
r Pipes DN 6
we 10A
t po ine
Inle eng
from 5A
Pipe DN 10 (3/8”)
11A
D
Breather
4A
Taken to survey
Hydraulic pump pressure
12A
8 3A
Breather
DN 19 (3/4”)
E
2 2 13A
4
2A ar
Re les
Ax
3 3/8” 1A
3/8” 6 5
3/4”
Level plug
nt
Fro les
Ax
F
(28 Lt) 9
(11 Lt) 1
M.I.
Hydraulic
motor
DN 19 (3/4”)
Pos Q.ty Code Description

1 1 50971210 Oil filter H
2 2 50641792 Pressure switch
3 1 50851214 Retaining valve (0.35 bar)
4 60l 09510137 Hydraulic oil
5 1 50851227 Retaining valve (2 bar)
6 1 40720309 Heat exchanger I
8 1 50851706 Valve
9 1 40690181 Transmitter
L
Fig. G-16
UM191159/E - Rev.1 - 06/2015
G-6.10 POWER SWIVEL RIGHT ANGLE

A GEAR BOX - OIL CHANGE
A
The oil substitution of the right angle has to be done

with hydraulic oil substitution.
B -- Positioned a vessel below of draining, with ad-

equate capacity to contain the oil gear box. B
-- Unscrew the draining plug B, and wait the complete

leaking of oil from right angle gear box.
C -- Close the draining plug. Fig. G-17
-- Restore the quantity of oil removed through the

gate A.
D IMPORTANT
If the last operation is not carried out, after the
hydraulic oil substitution, to the start of the ma-
chine control the level of the hydraulic oil tank, if
E it decrease, added oil until reach the max level.

F SWIVEL - OIL LEVEL AND
A
CHANGE
Oil level is visualized thereby the level visual indica-

tor A.
G To change the oil follow this procedure:
1. Prepare a system for collection of the used oil

B
to be connected to draining plugs B. To ease up
drainage, oil should be warm. This with prevent
H residual sludge inside the tank. Fig. G-18
2. Close valves C cutting off the tank from the power

swivel hydraulic system.
3. Unscrew the draining plugs B and wait the com-

I plete leaking of oil from tank.
4. Close the draining plugs B.

C
5. Clean the magnetic rod every time the oil is
changed. The magnetic rod is located under the
L tank.
Fig. G-19
UM191159/E - Rev.1 - 06/2015
6. Fill in, thereby charge plug D, until the maximum

oil level is reached. A
D
WARNING
Always remember that the hydraulic oil, even when
new and delivered in drums, contains pollutants.
B
When filling oil up, use special pumps provided
with filtering system.
7. Check that max. oil level is reached through level

indicator A. Fig. G-20 C
WARNING
When filling up with oil, do not exceed max. oil
level shown by indicator A. D
8. Refit and retighten new air bleeding cartridge.
(For hydraulic oil specifications, see chapter of
Lubrication).
E
WARNING
can enter the hydraulic oil tank. F
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UM191159/E - Rev.1 - 06/2015

A SWIVEL - REPLACEMENT OF
OIL’S FILTERS AND TANK’S AIR
VENT
C
B IMPORTANT A
Replacement of these components must be per- B

formed when scheduled, even when obstruction’s
control devices do not show the need. B
C It is possible to approach main filter A of hydraulic oil
from hydraulic tank’s top, unscrewing screws.
To replace the filters on the drainage elements, un-
screw the containers B. B
To replace air vent’s cartridge C from hydraulic oil’s
B
D tank it is enough to unscrew them from their threaded
support.
To replace the filters on the delivery line, open the
filter bodies D.
E IMPORTANT
When once of the component is replaced, check
the hydraulic oil level. Fig. G-21
F WARNING
Make attention to avoid any dirt and impurities
from entering the tank and the system.
G
D
H Fig. G-22
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UM191159/E - Rev.1 - 06/2015
G-7 TANK WATER COOLING

BRAKE
A
-- Control level water every day.
-- Clean up the filter and to replace water every

month. B
Visual level
Fig. G-23 C
D
Filter
E
Fig. G-24
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UM191159/E - Rev.1 - 06/2015
G-8 ROPES - WEAR CHECK

A
Visually check hoisting and drilling wire rope, sand
reel rope, wear conditions.
In particular, check what follows:

B -- rope end connections
-- rope stretches going through pulleys or blocks
during use
-- rope stretches that can be subject to friction or
rubbing against external parts.
C Make sure that ropes do not show:

-- broken strands
Fig. G-25
-- dents
-- twists
-- permanent bends
-- signs of wear or deterioration that could impair
D safety.
If any of these conditions are found, consider the

measures to be taken with reference to the information
contained in the standards ISO 4309.
Always refer to ISO 4309 standards for all what
E concerns the ropes, their maintenance and replace-
ment.
H Fig. G-26 Fig. G-28
L
Fig. G-27 Fig. G-29
UM191159/E - Rev.1 - 06/2015
Fig. G-30 Fig. G-31 C
WARNING
During the replacement of the rope, pay attention
to the guards covering the pulleys of the crown D
block.
CARTER
E
F
Fig. G-32
G-9 COMPLETE MACHINE - GENERAL INSPECTION

Inspect the whole machine to make sure that it is in good working order.
In particular, check the drilling fluid circulation system fittings, high pressure couplings and seals. Inspect the
H
whole machine for leakage.
Check good operation conditions and correct assembly and closing of protection hoods and guards.
HAZARD
I
In case of malfunctioning and/or faults, promptly eliminate the problem and stop any works until the
machine is in good order again.
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UM191159/E - Rev.1 - 06/2015
G-10 BOLT TIGHTENING SPECIFICATIONS

A
PRELOAD AND LOCKING TORQUE FOR SCREW THREADED ISO STANDARD PITCH
Preload have been calculated equal to 70% of minimum yield.
Torsion moment have been calculated with rule (39) of Junker & Blume manual, using a friction factor
of equal to 0,14.
B Maximum preload V [kg] Maximum Torque Ma [kgm]
Screw’s
nominal 6.6 8.8 10.9 12.9 6.6 8.8 10.9 12.9
diameter 6D 8G 10K 12K 6D 8G 10K 12K
M4x0,7 222 394 554 665 0,17 0,31 0,43 0,52
C M5x0,8 357 635 895
1270
1070
1520
0,33
0,58
0,6
1,03
0,84
1,46
1,01
1,75
M6x1 507 902
M7x1 728 1300 1820 2180 0,94 1,69 2,35 2,83
M8x1,25 920 1640 2310 2770 1,39 2,48 3,49 4,19
M9x1,25 1210 2160 3050 3630 2,05 3,67 5,18 6,17
D M10x1,5
M12x1,75
1480
2120
2600
3780
3660
5320
4380
6380
2,83
4,74
4,97
8,45
7
11,9
8,37
14,3
M14x2 2890 5160 7250 8700 7,54 13,46 18,92 22,7
M16x2 3950 7020 9900 11900 11,5 20,4 28,8 34,6
M18x2,5 4840 8600 12100 14500 16 28,4 40 48
M20x2,5 6160 11000 15450 18500 22,2 39,6 55,6 66,6
E M22x2,5 7630 13600 19100 22900 30 53 74,5 90
M24x3 8900 15900 22300 26700 39 70 98 117
M27x3 11500 20600 28900 34700 56 101 142 170
M30x3 14100 25200 35400 42400 77 138 193 232
F
PRELOAD AND LOCKING TORQUE FOR SCREW THREADED ISO FINE PITCH
Preload have been calculated equal to 70% of minimum yield.
Torsion moment have been calculated with rule (39) of Junker & Blume manual, using a friction factor
of equal to 0,14.
G
Screw’s Maximum preload V [kg] Maximum Torque Ma [kgm]
nominal 6.6 8.8 10.9 12.9 6.6 8.8 10.9 12.9
diameter 6D 8G 10K 12K 6D 8G 10K 12K
M8x1 995 1750 2470 2960 1,48 2,6 3,7 4,4
H M10x1,25 1540 2740 3860 4630 2,9 5,2 7,3 8,7
M12x1,25 2420 4140 5800 6980 5,3 9,1 12,5 15,4
M12x1,5 2220 3960 5570 6680 5 8,9 12,8 15
M14x1,5 3150 5600 7880 9450 8 14,3 20 24
M16x1,5 4200 7500 10500 12600 12 21,5 30 36
I M18x1,5
M20x1,5
5430
6900
9700
12100
13600
17150
16300
20600
17,4
24,4
31
43
43
61
52
73
M22x1,5 8400 15000 21000 25200 32 57,5 80,5 97
M24x2 9650 17200 24200 29000 41 73,5 103 124
M27x2 12500 22300 31300 37500 60 107 150 180
M30x2 15700 27800 39200 47000 83 147 208 250
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UM191159/E - Rev.1 - 06/2015
G-11 HOSE FITTING

SPECIFICATIONS
A
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 oc- B

curs through the coupling. Exceeding that point, does
not improve tightness and damages the coupling!
Fig. G-33 C
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 D
hose in resting position.
E
Fig. G-34
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
F
the section and therefore load losses. Moreover, these
bends can cause torsional stress and even breakage
of the hose!
H
Fig. G-35
For correct fitting of hoses, elbow fitting can be used

for installation in restricted space without impairing
hose efficiency and life.
L
Fig. G-36
UM191159/E - Rev.1 - 06/2015
G-11.1 STORING OF FLEXIBLE HOSES

A
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 com-
bination of factors. The reinforce materials are, in the same way, damaged by unproper storing conditions.
B 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 ac-
C curately 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
D sources nor in conditions of high or low humidity. A maximum level of humidity 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.
E 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.
F 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.
G 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
H 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.
I 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 hori-
L zontal position without bending them.
UM191159/E - Rev.1 - 06/2015
RODENTS AND INSECTS

The hoses must be protected against rodents and insects. When this risk is probable, proper precautions A
must be taken.
G-11.2 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
B
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 C
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
damage the rubber.
D
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 E
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
F
are not used.
ENVIRONMENTAL CONDITIONS
The hoses must be used only in the environmental conditions which they have been manufactured for.
TORSION
G
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.
H
VIBRATIONS
The vibrations subject the hoses to the stress and to the heat, above all near the joints and premature explo-
sions can occur. It is then suggested to check that the hoses have been manufactured to withstand these
stresses.
CUSPS I
Some users blocks the passage of the liquid thought the hose creating cusps in it. This method is not sug-
gested by the manufacturers, as the reinforcement is subjected to an excessive stress that could bring to
explosion.
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UM191159/E - Rev.1 - 06/2015
G-11.3 MAINTENANCE OF THE FLEXIBLE HOSES

A
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:
B -- 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.
These irregularities justify the replacement of the hose.

C 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.
D
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.
G-11.4 RECOMMENDED TEST SCOPE “VISUAL INSPECTION” (PRIOR TO INITIAL

E SETTING INTO OPERATION OR PUTTING BACK INTO OPERATION)
-- Is all information for use available which is required for the safe operation of the hydraulic plant (e.g. hy-
draulic plan, parts list, description of the plant, drawings, operating / maintenance instructions, hydrostore
documents, safety data sheets for the hydraulic fluid being used etc.)?
F -- Do the hydraulic hose assemblies correspond to the hydraulic plan and to the parts list and the description
of the plant (including the hydraulic fluid being used)?
-- Have safety measures been taken for the case of exceptionally high pressure impacts or pressure increases,
such as for example, pressure control valves?
-- Are the individual hoses of the hydraulic hose assembly marked with the name or a short designation of
G manufacturer, EN-number and type (pressure level), nominal diameter, quarter/year of manufacture? (s.
DIN EN 982, [12])
-- Are hydraulic hose assemblies individually marked on the fittings with the name or a short designation of
the manufacturer, the max. admissible operating pressure, month and year of manufacture?
-- Are hydraulic hose assemblies installed in such a way, that according to DIN 20066 [7]?
H -- The natural position does not obstruct the movement.

-- A torsion of the hose, a tensile load due to a line which is too short, or a bending radius which is too low
are all avoided.
-- The hose is led by buckling protection (if applicable at the connection element);
-- External mechanical influences or abrasion at the edges are avoided by sufficient distance;
I -- Damage by running over is avoided by means of hose bridges;

-- Loosely installed hose assemblies are protected by hose guiding devices (such as hose brackets and
fixtures;
-- A thermal protection (shielding) protects from high temperatures?
-- With regard to their installation location, are the hydraulic hose assemblies designed and arranged in such
L a way, that they:
-- Cannot be mixed-up and are unambiguously and durably marked;
UM191159/E - Rev.1 - 06/2015
-- Are protected against any foreseeable damage, e.g. mechanical or due to environmental influences such
as cooling lubricants; A
-- Do not impair maintenance of the work equipment?
-- Are hydraulic hose assemblies which are used in areas of high-level requirements, (e.g. holding up a load)
protected against hose break?
-- Are hydraulic hose assemblies which in case of failure may generate hazards due to whiplash or escape
of hydraulic fluid provided with suitable protective measures, such as fastening, capturing device or shield- B
ing?
-- Are the hydraulic hose assemblies installed in such a way that they cannot be used as a ladder or means
for access?
-- Do the hydraulic hose assemblies of the initially operated or reoperated machines already show damages?
If damages have been detected C
-- Have the installed hydraulic hose assemblies or hoses exceeded the period of storage or use, recom-
mended by the individual manufacturer
-- Are the hydraulic hose assemblies over-lacquered (over painted)?
-- Does the operating manual state testing intervals? If so, what?
D
Note: The hydraulic hose assemblies being installed shall not consist of hoses which have already
been used as part of a hose assembly before! (s. DIN EN 982, no. 5.3.4.3).
G-11.5 RECOMMENDED TEST SCOPE “FUNCTIONAL TESTING” (PRIOR TO

INITIAL SETTING INTO OPERATION OR PUTTING BACK INTO OPERATION)
E
-- Does the hydraulic control system fulfil the intended function and comply with the plant description?
-- Is there an indication by acoustic signals or similar indicating extremely high pressure impact or pressure
increase for the hydraulic hose assembly for all required machine functions during the intended machine
operation?
F
All parts of the hydraulic plant shall be tested with the intended maximum operating pressure which can be
reached in all intended applications:
Have measurable leakages been detected at the hydraulic hose assembly and connection elements?
Did all hydraulic hose assemblies withstand the pressure?
Are there spots of abrasion due to hydraulic hose assemblies moving under operation conditions?
G
G-11.6 RECOMMEND TEST SCOPE “FOR SAFE PROVISION AND USE”
(RECURRENT OR EXTRAORDINARY TEST)
-- Is the information for use (operating instructions, hydraulic plan, parts list etc.) from the manufacturer still
complete and available? H
-- Do the conditions of use and environmental conditions of the machine still comply with the initial intended
use of the machine?
(This requires consideration of for example: kind of product, cycle times, number of pieces produced, hydraulic
pressures and volume / flows temperatures, hydraulic fluid(s) used, speeds/ stopping times of hazardous move-
ments, moved/ upheld masses, loading and unloading method of workpieces, place of installation, external
I
influences (e.g. vibration, humidity, pollution by oil, UV-radiation, mechanical influences, ambient temperature
etc.), position of transport ways and kind of transport means being used (hazards of damage), location and
access for operation and maintenance, arrangement and assembly of additional equipment, interaction/ link
with other machinery).
L
UM191159/E - Rev.1 - 06/2015
-- Have the above mentioned preconditions changed, which previously formed the basis for specifying a
A defined duration of use of the hydraulic hose assembly? If so, have the testing periods and replacement
intervals been considered accordingly and if necessary, been changed?
-- Are the markings at the hydraulic hose assemblies still existent and legible?
-- Do the hydraulic hose assemblies show any deficiencies indicated ?
-- Are the safety measures against whiplash hazard and/or escape of hydraulic fluid at the relevant hydraulic
B hose assemblies still existent respectively installed?
-- Have the periods for recurrent tests at the hydraulic hose assemblies been specified and kept? If required, the
periods have to be specified by the user and the required tests have to be carried out or arranged for.
-- Have the intervals for replacement recommended by the manufacturer respectively the maximum duration
of use specified by the user for hydraulic hose assemblies been taken into account ?
C -- Have shortened test intervals been established, e.g. to biannually or quarterly (instead of yearly or bian-
nually) in case of intended prolonged duration of use of hydraulic hose assemblies?
-- In case of modifications at the machine and in the hydraulic plant (control and equipment) as well as after
extensive maintenance work, in particular if this involves the new installation of hydraulic hose assemblies,
a relevant test for „proper assembly and safe function”
D -- Have those modifications been recorded and have they been considered in the machine documenta-
tion?
G-11.7 RECOMMENDED TEST CRITERIA FOR HYDRAULIC HOSE ASSEMBLIES
E -- Damage at the outer layer to the reinforcement? (abrasion spots, cuts, cracks);
-- Embrittlement of outer layer (crack formation of the hose material);
-- Deformations, which do not correspond to the original shape of the hydraulic hose assembly, in the non-
pressure state or in the pressurized state or in case of bending e.g. separation of layers, formation of
bubbles, squeeze points, buckling points;
-- Leakages at the hose, hose assembly or fittings;
F -- Disentanglement of the hose out of the fittings;
-- Damaging or deformation of fittings which reduces the function and strength of the fittings or the connec-
tion of hose-fittings;
-- Corrosion of fittings, reducing the function and strength;
G -- Do hydraulic hose assemblies have freedom of movement, or has there been formation of squeeze, shear-
ing or abrasion points due to the assembly of new plant parts or aggregates?
-- Do hydraulic hose assemblies protrude into traffic routes, even if the aggregates being coupled with the
hydraulic hose assemblies are operated to the final position?
-- Have hydraulic hose assemblies been over-lacquered (over painted (explanation: no detection of marks
and cracks)?
H -- Have storage periods and durations of use been exceeded ?
-- Have all coverings been re-installed and are they active (after testing, relocation, rearrangement)?
-- Are there additional tear-off protections existent or required?
G-11.8 FACTORS INFLUENCING THE TEST PERIODS

I
-- Hazards which may occur when using the work equipment for all relevant operation procedures (basis:
hazard evaluation);
-- Increased requirements for safety (such as holding of loads in particular gravity-loaded axes) e.g. due to
the protection concept of the machinery manufacturer and provisions for shortened periods in the opera-
L tion manual;
-- Conditions of use of work equipment and hydraulic plant (e.g. particular loads, conditions with defined
overload, operating times, operation parameters, influence of the hydraulic fluid being used);
UM191159/E - Rev.1 - 06/2015
-- Environmental conditions (damaging external influences such as vibration, humidity, pollution, mechanical
influences, ozone generation by electric motors or welding transformers) and more, s. table 3); A
-- Comparison, whether the actual operating conditions / conditions of use comply with those conditions stated
by the manufacturer at acquisition;
-- General manufacturer’s information (of machinery manufacturer or the manufacturer of the hydraulic hose
assemblies) with regard to test intervals;
-- Age respectively rate of wear of the work equipment or of the hydraulic hose assembly; B
-- Prolongation of replacement intervals;
-- Kind and system by means of which the intended maintenance is carried out, in particular for safety relevant
components and wear parts;
-- Experience made by the users / set-up/ maintenance personnel with the work equipment and the hydraulic
plant (with regard to failure behaviour, occurrence of defects, interruptions, increase of such events); C
-- Evaluation of results from the visual and function inspection prior to the daily use of the machine;
-- Any known accidents at comparable machines or hydraulic plants;
-- Evaluation of test results of recurrent tests at those hydraulic hose assemblies or those being operated
under comparable conditions;
-- Test results prior to commissioning. D
G-11.9 RECOMMENDED TEST PERIODS
Requirements for hydraulic hose assembly Recommended test period

Normal requirements 12 months E
Increased requirements for safety, e.g. due to: 6 months
-- increased operating times (e.g. multiple-shift opera-
tion);
-- strong external influences;
-- intended prolonged duration of use ;
-- (replacement intervals, see. chapter 3.5) or
F
-- provisions stated by the machine manufacturer for
particular gravity-loaded axes.
G-11.10 INFLUENCING FACTORS WITH REGARD TO THE REPLACEMENT

INTERVALS
G
-- Statements or instructions given by the manufacturer of the hydraulic hose assemblies or the machinery
manufacturer, particularly provisions given by the manufacturer for gravity-loaded axes;
H
-- Conditions of use and environment;
-- Hazards due to hydraulic fluid, the pipe itself or a hazardous machine or load movement in case of dam-
age or break of the hose assembly;
-- Test and empirical values of the machinery manufacturer or the user;
-- Secondary protective measures against hazards in case of failure of the hose assembly, e. g. covering,
line break protection;
-- Proper execution of tests with regard to the safe operational state in adequately determined time intervals, I
(if necessary shortened) by a competent person.
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UM191159/E - Rev.1 - 06/2015
G-11.11 RECOMMENDED REPLACEMENT INTERVALS

A
Requirements for the hydraulic hose assembly Recommended replacement intervals
Normal requirements 6 years
Increased requirements for safety, e.g. by: 2 years
B -- increased operating times (e. g. multiple-shift opera-

tion);
-- strong external influences;
-- provisions stated by the machine manufacturer for
particular gravity-loaded axes.
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UM190159/E - Rev.1 - 06/2015
Section H -
SECTION INDEX TROUBLESHOOTING A
H-1 TROUBLESHOOTING............................... 2
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UM190159/E - Rev.1 - 06/2015
H-1 TROUBLESHOOTING
A
DRAWWORKS TROUBLESHOOTING
TROUBLE CAUSE REMEDY
B 1. Low lubricating oil a. Lack of oil a. Add oil to level
b. Broken or leaking oil lines b. Eliminate leaking or replace
c. Irregular operation of pump due c. Replace broken or worn
to broken drive chain or worn element
gears
C 2. High lubricating oil pressure

d. Clogging of filter screen
a. Stopped up oil lines
d. Replace filter screen
a. Remove obstruction
b. Inadequate viscosity of oil b. See table: recommended
lubricants
3. Reduction in breaking capacity a. Wear of the linings a. Clear and replace linings
D b. Lubricant traces are found on

the disc or pad surfaces
b. Clean the disc or pad surfaces
5. Irregular air pressure a. Irregular functioning of air a. Check the air compressor
compressor
b. Irregular functioning of control b. Dismount vavles and clean or
E valves
c. Stopped up air lines
replace worn elements
c. Bleed off lines
d. Loosening of joints with air d. Tighten joints
leaks
F MAST TROUBLESHOOTING
1. Do not raise the mast with: a. Hooked drum lines a. Free lines
- hydraulic oil gauge tending b. Insufficient oil in reservoir b. Add oil
G to maximum pressure
- oil gauge indicating low c. Broken drive joint to pump c. Replace
pressure or no pressure at d. Leaking pipes or valves in the d. Replace
all hydraulic circuit
2. Standpipe vibrations (with or a. Loosening of standpipe ties a. Tighten tie screws and remove
without noise) clearance
H b. Malfunctioning of mud pump
(frequently due to pulsation
b. Inspect pump, starting with
pulsation dampener
dampener)
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UM190159/E - Rev.1 - 06/2015
SWIVEL TROUBLESHOOTING
A
1. Premature failing of washpipe a. Lack of lubrication a. Grease (at leastonce a day)
packing b. Worn washpipe b. Replace along with a new
packing
c. Misalignment of washpipe c. Repair or replace housing cap B
due to distortion of housing and washpipe
cap through rough handling or
accident
d. Insufficient tightening of packing d. Tighten packing housing
housing, allowing packing to
rotate in “cartridge”
sufficiently to prevent rotation
C
e. Damaged spacer rings or e. Replace
excessive tightening of packing
housing
f. Improper bearing adjustment f. Properly adjust bearings
(vertical clearance >0 18 mm) D
g. Loosening of packing g. Add packing
2. Oil leaks at oil seals a. Worn or damaged oil seals a. Replace
b. Worn surfaces of oil seals b. Replace
c. Breather becoming plugged c. Clean breather
E
L
UM190159/E - Rev.1 - 06/2015
E
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UM190159/E - Rev.1 - 06/2015
Section I - RESIDUAL RISK

SECTION INDEX
I-1 RESIDUAL RISKS..................................... 2
A
I-1.1 CYLINDERS UNDER PRESSURE............ 2
I-1.2 DANGER OF HOSES EXPLOSION.......... 2
I-1.3 ACCUMULATORS UNDER PRESSURE... 3
B
L
UM190159/E - Rev.1 - 06/2015
FOREWORD
A
The Machine was designed in such a way to protect
the personnel safety and was equipped with all the
accessories, means and devices required for operat-
ing in full safety.
B In case of both routine and extraordinary maintenance,
as well as in every operating condition, the machine
can be therefore considered as being “safe”, obviously
by adopting every useful safety precaution or every
measure foreseen by the relevant laws in force, or
enlisted in Section C of this manual.
C Although, it is unavoidable that some residual risks,
here following enlisted, still exist.
I-1 RESIDUAL RISKS

An improper use of the Machine (See paragraph
D B-4.2) is the main cause of injuries’ risk, and is there-
fore expressly forbidden. The residual risks reported in
this paragraph refer to a correct use of the Machine.
I-1.1 CYLINDERS UNDER PRESSURE

E The stabilizers’ cylinders, the pull ones, the mast lifting
cylinders keep under pressure even after completion
of the working activities. Before operating on one of
them, in order to carry out some possible maintenance
activities, provide to discharge their residual pressure
F by slowly loosening the fittings between the valve
and the cylinder, after having consulted the hydraulic
diagram.
H Fig. I-37
I-1.2 DANGER OF HOSES EXPLOSION
Even if unlikely to happen, the occurrence of a pos-

sible explosion of the hoses must be taken into con-
sideration. That risk is signalled by purposed warning
I plates.
L
UM190159/E - Rev.1 - 06/2015
I-1.3 ACCUMULATORS UNDER

PRESSURE A
Danger of high pressure fluid getting out, due to the
residual pressure inside the hydraulic accumulators.
That risk gets reduced by following the prescription
reported in this manual. B
HAZARD
Before working on pressurized lines (hydraulic
oil, compressed air, water or drilling fluids) and/or Fig. I-38 C
disconnect components, make sure that the pres-
sure has been discharged and the fluid contained
is not longer hot.
E
Fig. I-39
Fig. I-40
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UM190159/E - Rev.1 - 06/2015
E
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UM190159/E - Rev.1 - 06/2015
Section L - DISMANTLING
SECTION INDEX AND DEMOLITION A
L-1 DISMANTLING AND DEMOLITION.......... 2
L
UM190159/E - Rev.1 - 06/2015
L-1 DISMANTLING AND DEMOLITION

A
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.
B 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 dismantling is carried out, can be considered as “special wastes”: fuel for endothermic motors, hydraulic
C 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.
D HAZARD
Before starting up the dismantling procedure, it is necessary to create around the machine a proper
space able to allow all the needed movements without additional hazards for the personnel.
E HAZARD
During the disassembly operations must be present only the personnel strictly necessary. Personnel
should be qualified and trained.
F HAZARD
Some parts with high dimensions and weight can be handled only by means of some proper lifting
devices. Use the chains or ropes of adequate rating for the load.
G HAZARD
Do not walk beneath or near to the raised load.
DANGER OF DEATH.
H HAZARD
Pay the maximum attention during the dismantling procedure because the possible falling of ma-
chine parts and components can create a serious danger for the Operators and can damage the near
plants.
I
HAZARD
Risk of environmental pollution.
Disconnect the electric and hydraulic power supply of the machine and before proceeding to disas-
semble/ demolish the mechanical parts, be sure to:
L - Discharge the accumulators of the mud pump, compressor and clamps’ plants.
- Empty the hydraulic tank and the lubrication tank of the mud pump reducer, etc., and verify the
discharge of all their circuits. Discharge all the remaining guards containing lubricant oils.

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Operation and

Mechanical fast workover rig - carrier mounted

Machine type MR5000FW

Manufacturing year 2015

12, Via 1° Maggio

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

© Copyright 2015 DRILLMEC S.p.A. - All rights reserved

1 11/2016 Update assembly/disassembly - driller cabin fixing VeM ArM FeS

LOCAL AUTHORIZED DEALERSHIP AND SERVICE CENTRE

MEMORANDUM OF THE MACHINE IDENTIFICATION DATA

Machine type MR5000FW

Machine serial number _____

Manufacturing year 2015

Drilling rig type-approval /

Power plant type-approval /

WARRANTY TERMS AND CONDITIONS

•• Replace the defective Equipment or parts thereof, or

TECHNICAL SERVICE AND SPARE

The technical service can be executed by an Agent or

For the spare parts, the Customer has to refer to the

White intentional page

G-7 TANK WATER COOLING BRAKE.................................................................................................... 23

Section I - RESIDUAL RISK

A A-1 FOREWORD A-1.2 TYPICAL STRUCTURE OF THE

G but complete way the structure of the treated subjects

It is also advisable to know well the methods used to

Then, according to the subject treated into the pages,

Inside each section, the table numbering system is

A-1.6 FIGURE NUMBERING SYSTEM

Inside each section, the figure numbering system is

C DRILLMEC can introduce in every moment some

Then, before starting up every operation on the

E For more detailed information, refer to the DRILLMEC

Hoses burst hazard

Accumulator burst hazard

TYPE OF SIGNAL COLOUR

B-1 CONVENTIONAL REFERENCES

The machine must be considered conventionally oriented as represented in figure B-1.

B-2 MACHINE IDENTIFICATION

Via 1° Maggio, 12 - Località Gariga

Mechanical fast workover rig model MR5000FW.

The machine and its main components are identified

The identification plate shown in the Fig. A-2 reports G

B-3 GENERAL DESCRIPTION AND TECHNICAL CHARACTERISTICS

B-3.2 TECHNICAL SPECIFICATION

-- Hydraulic Cathead Break-out Q.ty 1

-- Fastline sheave 36” (762 mm) - Q.ty 1

B-3.2.4 MONKEY BOARD

-- Monkey board height 55 ft (16905 m)

C -- Monkey board capacity:

B-3.2.5 STAND PIPE

D -- Stand pipe with gooseneck

F B-3.2.6 WORKING PLATFORM

G -- Working platform adjustable height:

-- Approx working area: 7.5 m²

Single drum drawworks installed on carrier, complete with:

-- Drawworks rated input horsepower 335 kW (450 hp)

BRAKE COOLING / WATER CIRCUIT B

B-3.2.8 DIESEL ENGINE AND TRANSMISSION

B-3.2.9 AUTOMATIC GEAR BOX

-- Gear box M5610AR

B-3.2.10 AIR SYSTEM FOR RIG OPERATION

-- Air tank working operation