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Drillmec SpADrilling Technologies
12, Via 1 MaggioI-29027 Gariga di Podenzano
PIACENZA (Italy)
Corporate web site: http://www.drillmec.comMailbox:
[email protected]
Ph +39.0523.354211Fx +39.0523.524418
TRAININGMR8000
CAREFULLY READ THIS MANUALBEFORE OPERATING THE MACHINE
!
Drilling rig semitrailer mounted
1
zilianiCasella di testo
zilianiCasella di testo
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DRILLING RIGMR 8000
2
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IDENTIFICATION
This equipment is identified through the serial number and/or
the identification numbers on main components.
EQUIPMENT IDENTIFICATION PLATE
The equipment identification plate shown in the picture re-ports
all identification data for the machine. The label islocated on the
lefthand side of the equipment, on the mastsupport. Always check
that the equipment part number(N. MATR.) stamped on the plate
matches with that re-ported on the front cover of this manual.
Piacenza - ITALY
Machine type
Serial Number
Year of manufacturing
Nominal Power
Weight
0953-3682E
[Kg]
[Kw]
3
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NOMENCLATURE OF THE MAIN COMPONENTS
CROWNBLOCK
MONKEYBOARD
TRAVELLINGBLOCK
POWERTONG
SERVICEWINCH
SUBSTRUCTURESEMITRAILER
DIESELENGINE
OILTANK
DRAWWORKS
COMPOUND
DRAWWORKS
STAIR
DIESELENGINE
WALKWAYS
TRANSMISSION
SUBSTRUCTURE
SERVICEWINCH
DRILL PIPE RAMPAND STAIR
ROTARYTABLE
DRILLFLOOR
POWER TONG
HYDRAULICBRAKE
TELESCOPICSECTION MAST
FIXEDSECTION
MAST
4
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TECHNICAL SPECIFICATION
Semitrailer mounted mobile rotary drilling rig DRILLMEC MR 8000
model, suitable for -20C to +40C range temperature.The rig is
manufactured in accordance with API standards.
MAST
Technical Data (Ratings to API 4F)
Static Hook load (w/10 lines) : 200 metric tons (440,000
lbs)Clear height : 35.97 m (118 ft) from ground levelClear height
to rotary beams : 4.17 m ( 15.11/16 ft) from ground levelRacking
Board Elevation : 16.76 m (55 ft) from drill floor levelCrown Block
Sheaves : four cluster sheaves OD 36 grooved for 1.1/8 cable;
one fast line sheaves OD 36 grooved for 1.1/8 cable; one deal
line sheaves OD 20 grooved for 1.1/8 cable;
Hydraulic Catheads Break-out : max pull 12,000 kilos (26,400
lbs)/ stroke 1.3 mHydraulic Catheads Spinning : max pull 6,000
kilos (13,200 lbs)/ stroke 4.6 m
Racking board capacity : 2850 m 5 OD - 6.5/8 TJ OD
DRAWWORKS
Main Drum:- Diam. x Lenght: 26 x 42.1/2- Spooling Capacity: 700
m (2,300 ft) of 1.1/8 OD wire line- 42 VC 650 Fawick air clutch-
Brake diameter x lenght 1168.4x203.2 mm (46 x 8)- Raising speeds: 5
forward, 1backward- Parmac hydraulic brake V80
Chains:- Main drum chain: 1 3/4 double ASA
The drawworks is complete with water cooling system and PARMAC
V80 hydromatic brake composed as follows:
DIESEL ENGINE AND TRANSMISSION
- 2 diesel engine CAT C15- Output power: 402kW (540 Hp) at 2,100
rpm- Pneumatic starter- Automatic Allison transmission S 5610 H
model- Compound: 2 chain transmissions ASA, oil lubrication.- Heavy
duty right angle gear box- 2 pumps for hydraulic system- 2 air
compressors with T30 IR ( max displacement 710 l/min)-
Pneumatically operated inertia brake
5
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SUBSTRUCTURE
- Max. Rotary Table Load (Casing Capacity) : 200 metric tons
(440,000 lbs)- Max. Setback Capacity : 113 metric ton (250,000
lbs)- Simultaneous Capacity : 313 metric tons (690,000 lbs)- Drill
Floor Height : 5,180 mt (17 ft)
Two steel skids are placed below the semi-trailer body levelling
jacks and are part of the substructure auxillary equip-ment.A
remarkable feature of the proposed substructure is the length of
the base skids that is 40 (12 m) approximately.The mast front
guylines together with those of the monkey board are fixed at the
end of each skid avoiding the need ofseveral external anchors
driven into the ground. Two anchors only placed at the rear of the
semi-trailer.Hydraulic winch mounted on drill floor with max pull
load 3000 kg ( 2943 daN)
SEMITRAILER
- Four hydraulic levelling jacks with an additional mechanical
safety locking device.- Lighting and road signs according to
international standards.- Folding walkways with handrails.-
Ladders.- N. 2 skids to be placed under the hydraulic levelling
jacks.- Single tyres.- 2 and 3.1/2 king pin- One spare tyre
ROTARY TABLE
- 27.1/2 opening- Complete with master bushing, adapter plate,
bit breaker and lifting slings- safety pads anti-slipping type- Max
speed: 300 rpm- Max static hook load on table: 770000 lbs (320
metric ton)- Rotary clutch: 20 CB 500
AUXILIARY HYDROMATIC BRAKE
- Parmac V80- Max pressure: 15psi- Max speed: 1550 rpm- Brake
capacity: 5000 Hp- Volume: 13-1/2 gal- Hydromatic brake air clutch:
26 CB 525
TRAVELLING BLOCK - HOOK
- Load capacity: 500,000 lbs (250 metric ton)- Sheave: five 30
(76.2 cm)- Grooved for drill line OD: 1.1/8
HYDRAULIC POWER TONGS
One (1) Hydraulic Power Tongs DRILLMEC, operated from a panel ,
to make-up and break-out drill pipes and drill collarsup 9.1/2,
consisting of:- Double hydraulics clamps. Top one rotating with max
torque: 101,000 lb-ft (14,000 kg-m).
6
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- Set of hydraulic cylinders for swinging the power tongs in/out
from well center to parking position.
LIGHTING SYSTEM
TOP OF THE MAST:
Q.ty 1Description EExd Obstruction Red Light with XenoFlash
230V-60HzType EVX4070
XF2J1FE110A3Supplyer Cortem Sirena
MONKEY BOARD:
Q.ty 1Description EExd Floodlight 230V-60Hz 400W with Metal
Jodure Lamp 400WType FLSA40Supplyer ITALSMEA
MAST:
Q.ty 6Description EExd Floodlightwhit Energy Saver Lamp 230V -
60Hz 23W (130Watt)Type EVGC 3070
Plet-23Supplyer Cortem
DRILLING FLOOR & SUBSTRUCTURE
Q.ty 5Description EExd Floodlight 230V-60Hz 400W with Metal
Jodure Lamp 400WType FLSA40Supplyer ITALSMEA
TRAILER:
Q.ty 2Description EExd Floodlight 230V-60Hz 400W with Metal
Jodure Lamp 400WType FLSA40Supplyer ITALSMEA
7
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MAIN DIMENSIONS
WORKING CONFIGURATION
TORNELLO MANOVRA
TORNELLO SERVIZIO
440
890
500
3030 1825
1033
20500 (67'-3")
30785 (101')
16764 (55')
35966 (118')
2020
2950 (9'-8")
7000 (23')
5182 (17')
1570 4170
12000 (40')
4616 (15')
5233 (17')
8
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KG 73000
KG 12000
KG 12000
KG 12000
KG 12000
KG 25000
3406
2500
7000
15
1375
4860
21075
5951
2374
1360
1360
1360
8670
TRANSPORT CONFIGURATION
9
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MAST GUYLINE LAYOUT
10
zilianiCalloutWIRE ROPE 22 mm
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A-3.4.4 HOIST WIRE ROPE REEVING DIAGRAM
11
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111
8
12
8
7
3
9
6
10
5
4
2
7 1
11
Item Code Q.ty Description
1 0190 6758 2 CHAIN 1.1/4" 100-3 ASA 78 LINKS
2 0190 6760 1 CHAIN 1.1/4" 100-4 ASA 86 LINKS
3 0190 6761 1 CHAIN 1.3/4" 140-2 ASA 158 LINKS
4 0190 6762 1 CHAIN 1.3/4" 140-2 ASA 86 LINKS
5 0190 6764 1 CHAIN 1.3/4" 140-2 ASA 108 LINKS
6 0190 6765 1 CHAIN 2" 160-1 ASA 114 LINKS
7 0190 6767 2 CHAIN 3/4" 60-2 ASA 84 LINKS
8 0190 6768 2 CHAIN 5/8" 50-1 ASA 68 LINKS
9 0190 6766 1 CHAIN 2" 160-1 ASA 120 LINKS
10 0190 7950 1 CHAIN 2" 160-1 ASA 122 LINKS
11 4059 0116 2 CARDAN JOINT
12 4059 0126 1 CARDAN JOINT
13
13 4100 1122 1 ROPE D.28.57 (1.1/8")
A-3.4.5 POWER FLOW DIAGRAM
12
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118
10
440 000
83
61
6,627
13
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440 000
250 000
690 000
14
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18500
15
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SAFETY DEVICES
Both the complete machine, and its individual parts, arefitted
with built-in safety devices.
- All cylinders are equipped with check valves. In case
ofbreaking of connecting pipes or pressure drop or fail-ure, the
cylinders will be locked thus preventing anyunwanted movements.
The machine is fitted with the following buttons for emer-gency
stop and mechanical locking devices:
WARNINGIn case of engine stop for a long time, it is mandatoryto
switch off the batteries Q1 and Q2.
- C20 emergency on the main control panel stops drill-ing rig
operation.
- Engine start up, and therefore machine operation, canonly be
performed by pressing start button on dieselengine control board
and battery breaker is on.
- Emergency control board near diesel engine stops onlydiesel
engine.
Q1
Q2
C20
Emergency
Emergency
16
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- C29 and C30 emergency is located on draw work andstops
drilling rig operation.
C29
C30
Safety mechanical block stabilizer (Fig. B-3.7).
- The drilling rig is equipped with a limit switch for
properoperation.
- The machine is also equipped with protective panelsand fixed
guards (fitted with the following plate: Safetydevice - Do not
remove) in order to avoid coming intocontact with drive gears in
motion or hot hydraulic com-ponents.
HAZARDBefore operating the machine, verify all safety devicesare
present and properly working.
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DIAGRAM OF SAFETY DEVICE FOR EMERGENCY STOP
C30
C29
Q1 Q2
C20
Emergency
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RPM
RSSTE
ES
CONTROL AND INSTRUMENTS FOR DIESEL ENGINE (LEFT HAND FROM
FLYWHEELSIDE)
RPM Diesel engine hour-counter and RPM indicator
ES Emergency push buttonTE Diesel engine hour counterRSS Start -
Stop switch
Q1 Battery breaker
DEE Diesel engine engage
DEE
Q1
19
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Fig. C-1.5
R2
Fig. C-1.6
R3
R2 Throttle knob on control panel
R3 Throttle pedal on drill floor
20
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CONTROL AND INSTRUMENTS FOR DIESEL ENGINE (RIGHT HAND FROM
FLYWHEELSIDE)
TE Diesel engine hour-counterES Emergency push buttonRPM RPM
IndicatorRSS Start - Stop switch TE
R2
DEE Diesel engine engage
Q2 Battery breaker
RSSRPM
ES
DEE
Q2
R2 Throttle knob on control panel
21
zilianiCasella di testo
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POSITIONING CONTROLS
A10 Stabilizers oil pressure gaugeC18 L.H. Rear stabilizer
remote controlC19 R.H. Rear stabilizer remote controlC20 L.H. Front
stabilizer remote controlC21 R.H. Front stabilizer remote
controlC22 Mast raising cylinder remote controlC23 Mast telescopic
remote controlC24 Telescopic locking remote controlC25 Stabilizers
distributor shut-off ball valve
C18
A10
C25
C19 C20 C21 C22 C23 C24
22
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DRILLING CONTROLS AND INSTRUMENTS
A4 Compressed air gaugeA6 Main drum compressed air gaugeA7 Drum
brake cooling water pressureA8 Drawworks lubricating oil pressureA9
Lubricating oil pressure gauge for transmission compoundA11 Cathead
spinning pressure gaugeC14 Main drum clutch controlC15 Crown - O -
matic controlC16 Speed selector engineC17 Pneumatic system
feedingC18 Rotary table clutchC20 Emergency stopC21 Hydromatic
brake controlC27 Auxiliary equipment remote controlC28 Spinning
cathead controlC29 Break-out cathead controlHW1 Engine warning
lampHW2 Engine warning lampR2 Throttle knobR6 Torque regulator
spinning cathead
C15
A4 A9 A8 A7 A11
C16
C20
A6
R6
C21HW1
HW2R2
C27 C17
C18 C28 C29 C14
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A17 Weight indicatorA18 RPM Rotary tableA19 SPM Mud pump 1A20
SPM Mud pump 2A21 Torque Rotary tableA22 Mud pressureA23 Digital
pump stroke counter and totalizerA24 Tong line pullC31 Main drum
brake lever on drill floorR3 Throttle pedal
C31
R3
A17
A18
A24
A21
A22
A20
A19
A23
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DEVICE INSTALLED IN OTHERLOCATIONS
A26 Draw works lubricating oil pressure manometer
A25 Transmision lubricating oil pressure manometer
C29 Emergency lever on L.S. draw works
Fig. C-1.16
Fig. C-1.17
Fig. C-1.19
A26
A25
A24
Fig. C-1.18
C29
A24 Visual level oil tank transmission
25
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C30 Emergency lever on R.S. draw works
Fig. C-1.20
C30
A12 Hydraulic oil temperature meterA13 Visual level on oil
tank
Fig. C-1.21
A13A12
Fig. C-1.22
A28
C31
Fig. C-1.23
A28 Visual level oil tankC31 Main drum brake lever
26
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C27 Ball-Valve hydraulic pump suctionC28 Ball-Valve hydraulic
pump suction
FUEL LEVELPILOT ALARM
C27
C28
C30
C30 Service winch control on drill floor
27
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Mud system instrumentation is mounted inside dog house, for
information of this system you can see commercialdocuments.
C26
SERVICE WINCH ONMONKEY BOARD
C26 Service winch control on monkey board.
28
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DIESEL ENGINE STARTING (POWERPACK)
C-2.1.1 COLD STARTING
1) Check, that valve C24, C47 and C48 is open.2) Switch on key
C17.3) With machine already in working configuration, bring
throttle control R2 (drill floor control panel) to
minimumrpm.
4) Rotate clockwise start key RSS. This way the motorstarts the
diesel engine as soon as this is started, re-lease the
push-button.
5) Few minutes of operation at minimum load are suffi-cient to
reach engine working temperature.
IMPORTANTThe first machine positioning does not require
press-ing the throttle.Movements are performed at minimum rpm.
IMPORTANTMax. engine rotation is set at 2100 rpm ( 50 rpm).When
giving full power, always remenber to check rpmcounter and make
sure that max. rpm are never ex-ceeded. (RPM)
RSS
RSS
C24
C47
C48
R2
C17
RPM
29
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DIESEL ENGINE STOPPING (POWERPACK)
The correct diesel engine turn-off procedure is as follows.
1. Bring engine rotation speed to minimum, with no load,for
approx. two minutes to stabilize the temperature.
2. Stop the engine by switch RSS key.
TE Diesel engine hour-counterRSS Starting button on diesel
engineRPM RPM indicatorQ1/Q2 Battery breaker
OPERATING INSTRUCTIONS
PRELIMINARY CHECKS
1. Before starting work, make sure you have performedall
necessary checks and servicing operations as re-quired by the hours
worked by the machine.
IMPORTANTFor the complete machine, refer to hour-counter TE
2. It is recommended that you always refuel the hydrau-lic power
pack diesel engine before starting theworkshift. This will prevent
the machine from forcedstopping during operation.
Fig. C-3.1
TE
Fig. C-2.5
Fig. C-2.7
RSS
RSS
TE
RPM
Fig. C-2.6
Q2
Q1
30
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PRELIMINARY OPERATIONS
1. Set the skids according to Fig.
2. Set skids 1-2 under the four hydraulic levelling jacks ofthe
semitrailer.
3. Start the hydraulic oil circuit: Start engine at Iow speed
Operate C25 ever on the hydraulic control panel in
the installation postion.
4. Lower the two front and rear jacks of semitrailer bymeans of
distribution valves levers on the hydrauliccontrol panel located in
the rear left side ofsemitrailer.
5. Apply the side walkways to the semitrailer.
NOTEBefore shipment, lubrication oil is drained from
oilreservoirs (except for the one of the auxiliaires trans-mission
oil circuit).
RSS
RSS
C25
C18 C19 C20 C21
1 2
31
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LEVELLING OF RIG
1. Make sure that handle of speed selector C19 on con-trol panel
is in neutral position.
2. Check that main air tank is full by means of the relatedgauge
(A- 4).If it is not, fill it by an engine compressor or a
hoseconnected to external compressor.
3. Start engine at low speed
4. Run engine at low speed until both the engine water,speed
selector and converter oil reach the work tem-perature
5. By operating distributors levers on the hydraulic con-trol
panel properly level rig.To avoid frame twisting, simultaneously
operate the twofront handles and then the two rear handles.
Semitrailerfloor must be 1.650 mm. high from ground floor.
6. When rig is properly levelled, lock levelling jacks bymeans
of safety ring nuts.
IMPORTANTHook may be loaded only after rig is mechanicallylocked
by means of safety ring nuts.
7. Anchor to plinths the two tighteners fixed to the frontsides
of semitrailer.
SUBSTRUCTURE SETUP
NOTE:
Substructure is made up of two main elements: the ro-tary part
(skids, bearers, floors, etc...) and the setbackpart (part (skids,
bearers, floors, etc...).Rotary skid , as well as setback rotary on
the oppositedrillers side, can be either transported indipendently
fromthe related elements, or connected to them.1. Place the skid
below the two rear jacks of the trailer.2. Place the skid of rotary
element driller side accord-
ing the related drawing. In case of separate transpor-tation,
connect the skid of drillers opposite side torotary part by
suitable supports.
3. Set the two side floors of rotary frame.4. Hook a crane to
the four ears of the rotary frame and
lift it up to the working position.
5. Settle the four telescopic bearers at working heightby means
of safety pins.
6. Place the setback element skid at drillers side nearthe
rotary skid. In case of separate transportation,connect the skid of
drillers opposite side to the set-back element by means of suitable
bearers.
7. Hook a crane to the four ears of setback frame andraise it up
to the working position
8. Settle the four telescopic bearers to the working heightby
means of safety pins.
9. Anchor the rotary working floor to setback floor.10. Pin the
two rotary skids with the two setback skids.11. Connect the
substructure rear skid with the two set-
back skids.12. Set the four braces of above drawing and pin them
to
substructure skids.13. To make substructure more stable set the
six
tighteners between working floor and front and rearskids of
substructure.Lock tighteners at correct height by means of
jamnuts.
14. Install the B.O.P. trolley guides and fix them with
pins.Install the B.O.P. trolley.
15. By means of truck crane install pipe ramp and
sideladders.
16. Install working floor safety handrails.
INSTALLATION OF DRIVE CHAINBETWEEN ROTARY TABLECOUNTERSHAFT AND
ROTARY TABLE
A) Fix the two swinging chain housing as per drwg SpareParts
Catalogue.
B) Mount chain and tension it through tighteners (SpareParts
Catalogue).
32
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11
74
1010
5
9 6
2-3
1
POS. CODE Q.ty DESCRIPTION
1 01902240 1 DRIVE BAR STORAGE HOLE FIXTURE2 01906175 1 PROBE
ANCHORS AND TRANSMISSION ASSY3 01906177 1 SIDE PLATFORMS ASSEMBLY4
01906178 1 B.O.P. SERVICE TROLLY5 01906180 1 SUBSTRUCTURE
STAIRWAYS6 01906181 1 DRILL PIPE RAMP7 01906182 1 SUBSTRUCTURE
FRAMES8 01906191 1 DOG HOUSE GROUP9 01906258 1 DRILLING PIPE
SUPPORT FOOTBOARDS10 01906312 1 MAIN SKID FRAME11 01908104 1 DRILL
FLOOR HANDRAILS ASSY
33
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Fig. C-3.6
RAISING OF MAST
1. Make sure that no air is contained in the three stage raising
jacks by:- unscrewing breather plugs located in the upper section
of each stage of the jack;- operating the valve lever on the
hydraulic control panel, gradually pour oil into the breathers
until they are com-
pletely full;- screw the plugs.
2. Run engine at approximately 1200 RPM
34
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3. By means of valve lever on the hydraulic control panel
gradually raise mast in working position and lock it by meansof
lower pins.
4. Anchor fixed section guylines to tighteners of semitrailer
and to the substructure skids.
TELESCOPING OF MAST UPPER SECTION
1. Make sure that no air is contained in the telescopic jack
(Drwg. 0190 7331 - Spare Parts Manual) as per theinstructions given
in the Raising of mast paragraph, point 2.
2. With engine at approximately 1200 R.P.M., operate valve lever
on the hydraulic control panel and gradually telescopemast.During
this operation, the oil pressure in the jack is about 180/200
bar.When telescoping of the mast upper section is completed,
pressure is 210 bar (3000 P.S.I.) which is the triggeringvalue for
the operation of the safety valve on the hydraulic circuit.
3. By means of valve lever on the hydraulic control panel, lock
the safety pins between the intermediate section and theupper
section of mast.
4. By means of valve lever on the hydraulic control panel,
slightly lower the telescopic section on the above safety
pins.After that, pins are actually locked (drwg. No. 0190 4192 -
Spare Parts Manual).
5. Monkey board takes position with auto system of
folding,during mast raising ( Fig. C-3.7). After monkey board
takesright position, pins of handrails must be inserted .
6. Anchor guylines lower ends to tighteners of trailer and
substructure skids. Slightly tension tighteners (Spare Parts
35
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Manual).See also the API recommended guying patterns table.
NOTEMake sure that mast inclination angle is correct, by
checking that the distance between well center and mast pinis 2020
mm. )
BREAKING - IN PERIOD
A correct breaking-in period ensures a long working life to your
rig. It is suggestable therefore not to require to the new rigto
operate at the maximum power.
a) ENGINEFollow the manufacturer s instructions.
36
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TORNELLO MANOVRA
TORNELLO SERVIZIO
440
890
500
3030 1825
1033
20500 (67'-3")
30785 (101')
16764 (55')
35966 (118')
2020
2950 (9'-8")
7000 (23')
5182 (17')
1570 4170
12000 (40')
4616 (15')
5233 (17')
b) RIGAfter 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 adjust-
ment to remove slacks caused by initial elongations.
RECOMMENDATIONIn order to prevent personal injury during the
perform-ance of any maintenance procedure, make sure thatcomponent
to be overhauled is not working.
37
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MAIN CONTROL PANEL
OPERATING INSTRUCTIONS
All air gauges, oil gauges and controls are mounted onmain
control panel, positioned on the drillfloor.Before starting
drilling operations and at frequent intervals,while rig is in
operation, check gauges and controls toensure that the correct air
and oil pressures are suppliedto each point (see the related tables
in the following pages).Operating instructions are indicated here
below and arealso illustrated on panel.
WARNINGNever stop the engine abruptly when operating at fullload
(unless required for emergency conditions).
1. Crown-o-matic push-button C15
ENGAGINGThe crown-o-matic is a safety device, wich
automaticallycontrols the tripping of the drilling travelling
block, preventigit from clashing against the crown block.This
system senses when the travelling block is within apreset distance
of the crown block. It disengages the clutch,then simultaneously
applies the brakes to the drawworks.
DISENGAGINGPush C15 button and simultaneously release the
brake:the drilling travelling block comes down due to its
ownweight. In the meanwhile, the driller assistant must go nearthe
drawworks and put the crown-o-matic toggle valve inits rest
position.
Item DescriptionStandard Crown Block Safety System
1 Track
2, 3 Short Toggle Valve Assembly
(P/N 50640652)
4, 5, 7 Clutch Assembly
6 Air Cylinder Assembly
BRAKELEVER
31
2
5
47
6
TOCONTROLPANEL
C15
38
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2. Speed selector engine control valve C16
3. Engine emergency shut-down-control valve C20For drilling rig
emergency stop, push the lever upward.This emergency lever stops
also the mud pumps.To restart, pull the lever C20 downward.
4. Diesel engine throttle-control valve R2Turning clockwise the
control knob increases RPM of die-sel engine.Turning ccw the
control knob decreases RPM of dieselengine.
5. Spinning cathead torque regulator-control valveR6
6. Auxiliary winch-remote control C30 (hydraulicwinch mounted on
drill floor)
7. Auxiliary winch-remote control C26 (on monkeyboard)
8. Hydraulic brake clutch-control valve C21The upward movement
of this valve handle engages thehydraulic brake clutchThe downward
movement disengages the hydraulic brakeclutch.
9. Rotary table fender sliding control valve C18The upward
movement of this valve handle the rotary tableopening fenderThe
downward movement the rotary table closing fender.
10. Hydraulic catheads-control valves C28 and C29The upward
movement of control valve C28 actuates thespinning cathead.The
upward movement of control valve C29 actuates thebreak-out
cathead.This handles automatically return to neutral position
whenreleased.Also the cylinders of catheads return automatically to
fullextended position.Turning clockwise the control knob increases
torque ofmake-up cathead.Turning ccw the control knob decreases
torque of make-up cathead.
C16
C 20
C21
R6R2
C18C29
39
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11. Main drum clutch-control valve C14The upward movement of
this valve handle engages themain drum clutch.The downward movement
disengages the main drum clutch.
12. Auxiliary equipment remote control valve C27Auxiliary
equipment (tongs or hydraulic motor, etc) areactuated by means of
handle C27.
C27
C14
40
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13. Main air pressure-gauge A4This gauge indicates the air
pressure in the control panel(7.7 bar steady-scale 0-16 bar)
14. Drawworks oil pressure-gauge A8It indicates lubricating oil
pressure of drawworks. In work-ing condition it shall be 0.7
bar-(scale 0-6 bar)
15. Brake rim cooling water pressure-gauge A7It indicates
cooling water pressure of internal circuit. Thewater flow must be
costant and its value is 189 lit/min(gauge scale 0-6 bar)
WARNINGBe sure that no water leakage is falling on brake band.In
case of failure, repair immediately.
16. Main drum clutch air pressure-gauge A6 low speedIt indicates
air pressure inside drum low speed clutch.
17. Spinning cathead oil pressure-gauge A11It indicates the
pressure inside spinning cathead cylinder.Pressure: 0-250 bar
(scale 0-400 bar)Pulling force. Up to 6 Ton
18. Lubricating oil pressure gauge for transmissioncompound
A9This gauge indicates lubricating oil pressure insidetransmission
compound
A4 A9 A8 A7 A6A11
41
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POWER TONG CONTROLS
Remote control panel
A15 Power tong clamping forceA16 Torque power tongC36 Lifting
up-downC37 Tilt open-closeC38 Torque make up-returnC39 Torque break
out-returnC40 Lower clamp open-close
Fig. C-4.7
A15A16 R10
R11
C36C39
C38 C40 C37
POWER TONG
ROTARY TABLE
POWER TONG
DRILL FLOOR
DRILLFLOOR
Fig. C-4.8
42
-
LUBRICATION SYSTEM
Proper Iubrication is essential for the correct functioning and
Iong working Iife af your rig.
- GREASING POINTS- FREQUENCY- TYPE OF GREASE
Greasing points are either Iocated on two centralized grease
panels or on the single elements.
Use- SHELL SUPER GREASE EP2 or equivalent
OIL LUBRICATION
For oil Iubrication, refer to D - 1.4 and follow the
instructions on the respective table regarding:
- Components te be Iubricated- Frequency- Quantity and type of
oil.- SAE regulations
Chains and bearings of transmission, are oil pressure lubricated
from two pump.Lubrication compound : pump Bosch cod.50700292
delivery= 45 l/min.Lubrication drawworks: pump Bosch cod.50700253
delivery= 63 l/min.Oil pressure is checked by gauge located on
control panel.Oil pressure 0.4-1.75 bar.A filter unit is located on
the discharge line of the pump Bosch.Clean carefully the filter
cartidge before the complete congestion.
CHECK AND MAINTAIN LUBRICATING SYSTEM AS FOLLOWS:
1) DAILY CHECK THE OIL LEVEL AS INDICATE IN THE TABLE2) CHECK
CONDITION OF DRIVE CHAINS, HOSES, DISCHARGE LINES, ETC. AND REPLACE
WHEN NECESSARY.3) KEEP OIL PRESSURE BETWEEN 0.4-1.75 BAR4) DRAIN,
FLUSH THE TANK AND CHANGE OIL AT THE END OF THE BREAKING - IN
PERIOD.
AFTERWARDS, CHANGE OIL EVERY 4000 WORKING HOURS OR MORE OFTEN,
IF OIL BECOMES CONTAMI-NATED WITH ABRASIVE PARTICLES OR CORROSIVE
COMPOUNDS.
43
-
CENTRALIZED GREASE PLATE ON DRAWWORKS (DRWG 01908094)
44
-
LINE No. DESCRIPTION
1 PLATE
10 GREASE FITTING
11 SLEEVE COUPLING
12 ELL
13 SLEEVE
14 FLEXIBLE PIPE
15 NUT
45
-
D-1.3 GREASE LUBRICATION TABLE6
7
3
1113
114
2
15
8
16 10 9 12
18
1745
18
46
-
FREQUENCY N IN DESCRIPTION TYPE OF GREASEFig. D-1.2
EVERY 1 DRAWWORKS:DAY STUFFING BOX OF WATER SWIVEL SHELL SUPER
GREASE EP2
JOINTEVERY 2 MAST:
DAY WIRELINE GUIDE ROLLERS OF SHELL SUPER GREASE EP2HYDRAULIC
CATHEADS
EVERY 3 WIRELINE LAZY FULLEYS FOR SHELL SUPER GREASE EP2DAY
HYDRAULIC CATHEADS
EVERY DAY 18 POWER TONG SHELL SUPER GREASE EP2
EVERY 7 DAYS 4 DRAWWORKS:MAIN GREASING PLATE SHELL SUPER GREASE
EP2
EVERY 7 DAYS 5 BRAKE LEVER PINS SHELL SUPER GREASE EP2
EVERY 7 DAYS 6 CROWN AND TRAVELLING BOX:BEARINGS AND JOINTS
SHELL SUPER GREASE EP2
EVERY 7 DAYS 7 HOOK:UPPER SEALS AND JOINTS SHELL SUPER GREASE
EP2
EVERY 7 8 MAST:DAYS ROPE ROLLERS SHELL SUPER GREASE EP2
ON THE INTERMEDIATE SECTIONEVERY 30 DAYS 9 DRAWWORKS: SHELL
SUPER GREASE EP2
IDLE GEARSEVERY 30 DAYS 10 TRANSMISSION:
UNIVERSAL SHAFT CROSS SHELL SUPER GREASE EP2IDLE GEARS
EVERY 30 DAYS 11 ROTARY TABLE TRANSMISSION:UNIVERSAL SHAFT CROSS
SHELL SUPER GREASE EP2
AT EVERY RAISING 12 DRAWWORKS:OR LOWERING OF WIRELINE GUIDE
ROLLER OF SHELL SUPER GREASE EP2
MAST DRAWWORKSAT EVERY RAISING 13 MAST:OR LOWERING OF PINS;
SHELL SUPER GREASE EP2
MASTAT EVERY RAISING 14 RAISING JACK PINS;OR LOWERING OF SHELL
SUPER GREASE EP2
MASTAT EVERY RAISING 15 TELESCOPING SECTION LOCKOR LOWERING OF
SHELL SUPER GREASE EP2
MASTSEE 16 ENGINE CATERPILLAR SEE MANUFACTURERS
MANUFACTURERS INSTRUCTIONS INSTRUCTIONS
SEE 17 PARMAC HYDRAULIC BRAKE SEE MANUFACTURERSMANUFACTURERS
INSTRUCTICNS INSTRUCTIONS
47
-
OIL LUBRICATION
4
611
8 9 11 2 1
310597
48
-
YCNEUQERF NIN.giF3.1-D
NOITPIRCSED YT.Q.TIL
.DIEAS EPYTLIO
YADYREVE 1 :SKROWWARDLEVELLIOKNAT-
RETLIFLIO-
052 03EAS 001ALAMOLLEHS
EESS'RERUTCAFUNAM
SNOITCURTSNI
2 ELGNATHGIRXOBRAEG
081 001ALAMOLLEHS
YADYREVE 3 LIO:ELBATYRATORLEVEL
5 022ALAMOLLEHS
EESS'RERUTCAFUNAM
SNOITCURTSNI
4 KOOHXELPIRT 5 LIOSULLETLLEHS64TS
EESS'RERUTCAFUNAM
SNOITCURTSNI
5 SROSSERPMOCRIA 5.2+5.2 NPCNOSAES30973298
DNARLLOSREGNI
YADYREVE 6 :TIUCRICCILUARDYHLEVELLIOKNAT-
RETLIFLIO-
LIOSULLETLLEHS64TS
EESS'RERUTCAFUNAM
SNOITCURTSNI
7 ENIGNELESEID 05+05 ALUMIRLLEHS04W51X
EESS'RERUTCAFUNAM
SNOITCURTSNI
8 ROTAIDARENIGNE 59+59 EZEERFITNALLEHS
EESS'RERUTCAFUNAM
SNOITCURTSNI
9 XOBRAEGNOSILLAEUQROTHTIW
RETREVNOC
08+08 IIINORXEDFTALLEHS
EESS'RERUTCAFUNAM
SNOITCURTSNI
01 GNIKARBMURDNIAMMETSYS
57 DIULFADISSACLLEHS23FH
)425CHSLIBOM(
EESS'RERUTCAFUNAM
SNOITCURTSNI
11 DNUOPMOC 081 001ALAMOLLEHS
49
-
AIR CLUTCHES
The clutches, highly reliable in any working conditions
(illustrated in section other manufacturers equipment of
thismanual).
Regarding clutch maintenance, it is recommended to:
a) provide the proper air pressure to each ctutch - see the air
pressure tableb) see table
- models of clutches- minimum allowable lining thickness
When inspecting clutches check:
1) Condition of linings.Lining wear Is automatically balanced to
a certain extent by a rubber diaphragm. Check Iining wear at least
once amonth.
2) Condition of clutch drum.The clutch drum surface should
always be smooth. If it is badly warped or grooved, it should be
remachined.
3) Operation of quick release valves.Check all quick release
valve at Ieast once a month.The most common cause of quick release
valve failure is dirt, rustor machine cuttings stuck under the
seat.Due to improper valve operations, the clutch may disengage
incompletely and therefore cause overheating anddamage to the
diaphragm. Overheating may also be due to clutch dragging.
50
-
NOITPIRCSED ERUSSERPLANIMON
ISP rab
HCTULCSKROWWARD 721 8,8
ERUSSERPGNIDEEFLARENEGLENAPLORTNOC01AEGUAG
011 95,7
YCNEGREME 521 26,8
HCTULCELBATYRATOR 111 7,7
HCTULCEKARBCILUARDYH 111 7,7
AIR PRESSURE
51
-
ERUSSERPLIO
TNENOPMOC .LYTICAPAC LEVELROTACIDNI
FOECALPLORTNOC
)mc/gK(ERUSSERP
XAM .MON .NIM
KROWWARDDNA
NOISSIMSNART052 KCITSPID LORTNOC
LENAP52
)67,1(01
)07,0(5
)53,0(
ERUSSERPRETAW
TNEMELE NOITISOP FOECALPLORTNOC
YTICAPACnim/l
ERUSSERP)rab(ISP
TELNI TELTUO
MURDNIAMEKARB
S'RELLIRDEDIS
LORTNOCLENAP
981 57-05)2,5-5,3(
sag"4/1.1 sag"4/1.1
LEERDNASEKARB
S'RELLIRDEDIS
LORTNOCLENAP
021 57-05)2,5-5,3(
sag"2/1 sag"2/1
CILUARDYHEKARB
S'RELLIRDEDIS
LORTNOCLENAP
002 57-05)2,5-5,3(
TPN"3 TPN"2
METSYSEKARBNIRETAWDLOCESU:GNINRAW
OIL AND WATER PRESSURE
DRILLING DRUM BRAKES
SHOULD A REDUCTION IN THE BRAKING CAPACITY OCCUR, CHECK FOR:
1. Improper band brake adjustment.2. Water, oil or other rig
wash solutions sprayed on and around the brake rims, reducing the
coefficient of friction of the
linings.
IN CASE OF KICKING BRAKES, CHECK FOR:1. Improper release of
brake bands.2. Kinked or out-of-round brake bands.3. Brake system
adjustment.
GENERAL RECOMMENDATIONS
The following precautions should be taken in connection with
proper brake maintenance.a. Do not paint brake blocks or inside of
brake bands (paint retards heat transfer between blocks and
band).b. Do not pull brake blocks bolts too tight or allow them to
Ioosen.c. Do not Ieave brake blocks or relined bands out in
weather.d. Do not install new brake blocks without cleaning brake
bands of rust, etc.e. Check the brake rims at regular interval of
time. The maximum allowed wear on the rims is equal to 12 mm.f. In
case of maximum wear of rims, it must change the nms.g. The main
brake drum is water cooled by means of an internal circuit.
Water circulation flow is equal to 189 Lit/min.Check every six
month the good state of fittings and piping of water circuit.Always
use original spare parts.
h. Check the brake system at Ieast once a month.i. Check the
main handles once a year with Magnaflux (N.D.T.)
52
-
BRAKE WEAR
WATER COOLING CIRCULATION
53
-
DRIVE ROLLER CHAINS (DRWG. N 0190 7387)
Make sure that roller chains are always well Iubricated. As oil
cleanliness is an essential factor in chain Iubrication,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.Check clearance al Ieast once a
month.When possible use a chain length with an even number of
pitches to eliminate the need for an offset Iink.To obtain maximum
chain life, maintain proper chain tension.
Make an adjustment after approximately the first 200 hours of
operation to remove slack caused by initiai elongation.Thereafter,
the frequency of periodic adjustment Is governed by operating
conditions.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 thesuggested
maximum for average applications.Normally, horizontal and inclined
drives should be installed with an initial sag equal to
approximateiy 2% of sprocketcenter distance.
Check gear tooth wearing once every six months (especiaily the
pinion teeth).Clearance between tooth space and roller should not
exceed 0,3 mm.
BREAKING-IN PERIOD
A correct breaking-in period ensures a Iong working Iife to your
rig.a) Engine
follow the manufacturers instructions.b) Rig
After approximately the first 200 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.
ROUTINE MAINTENANCE
Routine inspection of components is the most important form of
preventive maintenance and with result in considerablesaving by
detecting any major trouble that might be developing and allowing
the necessary repairs to be made on aplanned or normal rig
downtime.
The following is a guide to some of the key points which should
be observed during routine inspection. The prevailingoperating
conditions surrounding each individual rig wiIl dictate the
frequency at which the inspections should be made;however, the
intervals listed below are recommended for optimum performance from
the equipment.
MECHANICAL PARTS - GREASING
IMPORTANTIf clogged or damaged, replace grease nipples with new
ones. (for fubricant specifications, see paragraph D -1.3).
54
-
111
8
12
8
7
3
9
6
10
5
4
2
7 1
11
Item Code Q.ty Description
1 0190 6758 2 CHAIN 1.1/4" 100-3 ASA 78 LINKS
2 0190 6760 1 CHAIN 1.1/4" 100-4 ASA 86 LINKS
3 0190 6761 1 CHAIN 1.3/4" 140-2 ASA 158 LINKS
4 0190 6762 1 CHAIN 1.3/4" 140-2 ASA 86 LINKS
5 0190 6764 1 CHAIN 1.3/4" 140-2 ASA 108 LINKS
6 0190 6765 1 CHAIN 2" 160-1 ASA 114 LINKS
7 0190 6767 2 CHAIN 3/4" 60-2 ASA 84 LINKS
8 0190 6768 2 CHAIN 5/8" 50-1 ASA 68 LINKS
9 0190 6766 1 CHAIN 2" 160-1 ASA 120 LINKS
10 0190 7950 1 CHAIN 2" 160-1 ASA 122 LINKS
11 4059 0116 2 CARDAN JOINT
12 4059 0126 1 CARDAN JOINT
13
13 4100 1122 1 ROPE D.28.57 (1.1/8")
55
-
TRAP YCNEUQERF NINGWD
NOITPIRCSED FOEPYTTNACIRBUL
TSAM
DNANWORCGNILLEVART
KCOLB
SYAD03YREVE *8 SECIVEDNRUTER,STROPPUSESAERGSNIAHCDNA
LLEHSSAERGREPUS
2PE
GNISIARYREVETAGNIREWOLDNA
TSAMFO
SYAD7YREVE
*31 SNIPESAERG LLEHSSAERGREPUS
2PE
*41
*7
SNIPKCAJGNISIARESAERG
SGNIRAEBLLAESAERG
LLEHSSAERGREPUS
2PELLEHS
SAERGREPUS2PE
*6 SGNIRAEBLLAESAERG LLEHSSAERGREPUS
2PE
GIREHTNISEVAEHSGNILLEVARTDNANWORCEHTFOGNINOITISOPEHT:ETONSUOIVERPEHTTAHTOSNOITAREPOPU-GNIGGIRHCAEHTIWDESREVEREBDLUOHSNORAEWSETUBIRTSIDSIHT.EVAEHSENILTSAFEHTSEMOCEBEVAEHSENIL-DAED
YEHTNEHWDECALPEREBDLUOHSHCIWFOHTOB,SEVAEHSDNASGNIRAEBEHTNROWEMOCEB
YRATORELBAT
YADYREVE **3 .LEVELLIOEHTKCEHCLEVELLIONIEGNAHCLACIDARYNA
EBDLUOHS,EMITTROHSAREVOEHTEBYAMSIHT.DETAGITSEVNI
RORETAW,LAESGNIKAELFOTLUSERELBATYRATOREHTOTNIYRTNEDUMTI,ESACRETTALEHTNI.CTE,GNISUOHGNISUOHNIARDOTDEDNEMMOCERSILIONAELC,HSERFHTIWTILLIFERDNA
ALAMOLLEHS022
SYAD7YREVE *11 TEKSAGREWOLDNAREPPUESAERG LLEHSSAERGREPUS
2PE
D-6.2 ROUTINE MAINTENANCE
56
-
TRAP YCNEUQERF NINGWD
NOITPIRCSED FOEPYTTNACIRBUL
NOISSIMSNART SYAD03YREVE *01 STNIOJLASREVINUESAERG
LLEHS2PESAERGREPUS
SKROWWARD YADYREVE **1 LEVELLIORIOVRESERKCEHC LLEHS001ALAMO
SYAD7YREVE *4 GNIRAEBNIAMESAERGETALP
LLEHS2PESAERGREPUS
SYAD03YREVE *9 SRAEGELDIESAERG LLEHS2PESAERGREPUS
SHTNOM3YREVE
,SEPIP,KNAT(METSYSNOITACIRBULEHTKCEHC.1TCATNISITIERUSSAOT).CTE,SLAESROTOR,SEGUAG
.SNOITCURTSBOROEGAMADMORFEERFDNA,STNIOJ,SEPIP,SEVLAV(METSYSRIAEHTKCEHC.2
).CTE,KNAT,SNEERCS,SEGUA).CTE,RAEWGNINIL(METSYSGNIKARBEHTKCEHC.3
'SRERUTCAFUNAMREHTO"EHTEES(SEHCTULCKCEHC.4)LAUNAMETARAPESFONOITCES"TNEMPIUQE
NEKORB,SNIPRETTOCGNISSIM(SEVIRDNIAHCKCEHC.5.CTE,SRELLORFONOITACIRBULETAUQEDANIROSKNIL.SSENTHGITREPORPROFSTUNDNASTLOBLLAKCEHC.6
.SLAESDNASREBBUR,STEKSAGLLAKCEHC.7
0001YREVESRUOH
**1 RETLIFDNALIOTNEMECALPER
LLEHS001ALAMO
DNUOPMOC YADYREVE
0001YREVESRUOH
**11
**11
LEVELLIORIOVRESERKCEHC
RETLIFDNALIOTNEMECALPER
LLEHS001ALAMO
ELGNATHGIRXOBRAEG
YADYREVE
0001YREVESRUOH
**2
**2
LEVELLIORIOVRESERKCEHC
RETLIFDNALIOTNEMECALPER
LLEHS001ALAMO
* Grease lubrication** Oil lubrication
IMPORTANTThe first lubricating oil replacement must be carried
out after the first 400 working hours, then observe theindications
supplied in the routine maintenance table.
57
-
HYDRAULIC SYSTEM - OIL LEVEL CHECK
For hydraulic oil level check, set the machine to
haulageconfiguration. This way, all jack are cIosed and the oil
inthe tanks is at its maximum level. The machine shouldalso be
perfectly Ieveled.Oil level should be closed to the maximum.
lf occasionally (due to operating reasons) the machinecannot be
set to the haulage configuration, the oil levelmust be checked by
means of the oil level visual indicator.With machine in working
canfiguration, oil level should neverbe lower than the indicator on
the see-through glass. Topup if oil level is too low.
(for hydraulic oil specifications, see paragraph D-1.4)
WARNINGWhen topping up, do not exceed maximum oil level(with
machine in haulage configuration)
HYDRAULIC SYSTEM - REPLACE OILFILTER AND TANK AIR
BLEEDINGCARTRIDGES
IMPORTANTThese components should be replaced at the time
speci-fied even if not required by the clogging
checkingdevices.
Access to hydraulic oil filter (on return line) is from thetank
top through screws A.
WARNINGThese operations should be performed in clean areasto
avoid that any earth, dirty and impurities can enterin the tank and
in the system.
IMPORTANTOnce the component is replaced, check hydraulic
oillevel as described in item D-6.3.
A
58
-
HYDRAULIC SYSTEM - OIL CHANGE
For hydraulic oiI change (as for oil Ievel check), the ma-chine
should be set to haulage configuration. With thisconfiguration, all
jacks are closed and the oil in the tanksis at its maximum level.
The machine should also be per-fectly Ieveled.Oil Ievel should be
closed to the maximum.
To ease up drainage, oil should be warm. This with
preventresidual sludge inside the tank.
Then, proceed as follows:1. Prepare a system for collection of
the used oil to be
connected to draining plugs A.
IMPORTANTThis tank contains apprax. 800 Iiters of hydraulic
oil.
2. Close valves B cutting off the tank from the
hydraulicsystem.
3. Undo plugs A and open the two bali valve C. To easeup oil
outflow, also undo the bleeding cartridges on topof the tank. Let
the oil drain.
WARNINGDo not disperse old oil in the environment as this
causespollution.
4. Close valves C and retighten plugs A.5. FilI up through the
return filter.
WARNINGAIways remember that the hydraulic oil, even whennew and
delivered in drums, contains pollutants. WhenfilIing oil up, use
special pumps provided with fllteringsystem.
6. Check that max. oil level is reached through level indi-cator
D.
WARNINGWhen fiIling up with oil, do not exceed max. oil
levelshown by indicator D.
Fig. D-6.3
Fig. D-6.4
C
A
B
B
Fig. D-6.5
D
59
-
7. Refit and retighten two new air bleeding cartridges.
(for hydrauIic oil specifications, see chapter D - 1.4)
WARNINGThese operations should be performed in clean areasto
avoid that any earth, dirty and impurities can enterthe hydraulic
oil tank
ROPES - WEAR CHECK
VisuaIly check hoisting and drilling wire rope, sand reelrope,
wear conditions.
In particutar, check what follows:- 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.
Make sure that ropes do not show:- broken strands- dents-
twists- permanent bends- signs of wear or deterioration that could
impair safety.
If any of these conditions are found, consider the meas-ures to
be taken with reference to the information containedin the
standards ISO 4309.
Always refer to ISO 4309 standards for all what concernsthe
ropes, their maintenance and replacement.
COMPLETE MACHINE - GENERALINSPECTION
Inspect the whole machine to make sure that it is in goodworking
order.
In particular, check the drilling fluid circulation system
fit-tings, high pressure couplings and seals. Inspect the
wholemachine for Ieakage.
Check good operation conditions and correct assembly andclosing
of protection hoods and guards.
HAZARDIn case of malfunctioning and/or faults, promptly
eli-minate the problem and stop any works until the ma-chine is in
good order again
Fig. D-6.6
60
-
BOLT TIGHTENING SPECIFICATIONS
61
-
HOSE FITTING SPECIFICATIONS
For best operation of the hydraulic system, always keepin mind
some important rules for hose fitting.
Hose fitting nuts shall be tighten until no leakage
occursthrough the coupling. Exceeding that point, does not im-prove
tightness and damages the coupling!
A hose should never be subject to torsion! When fitting thehose,
consider that during operation, the hose is subjectto changes in
length with consequent torsional effects.Therefore, hoses should
not be too short and the propersettling should be checked with hose
in resting position(see Fig. D-8.1).
If hoses routing requires the hose to bend, make sure thatthe
bending radius are correct (see Fig. D-8.2 and D-8.3).A bending
radius too small can cause restrictions in thesection and therefore
load losses. Moreover, these bendscan cause torsional stress and
even breakage of the hose!
For correct fitting of hoses , elbow fitting can be used
forinstallation in restricted space without impairing hose
effi-ciency and life (see Fig. D-8.3 and D-8.4).
62
-
63
-
Functional group: Semitrailer group Table Number Revision
Hydraulic power unit 1 01170400 - 1 0 (12-2006)
Functional group: Semitrailer group Table Number Revision
Hydraulic power unit 1 01170400 - 1 0 (12-2006)
Position Part Number Quantity Description Notes
1 RI01170400-01 1 Electric pump -2 RI01170400-02 1 Pump by hand
-3 RI01170400-03 1 Distributor -4 RI01170400-04 1 Exclusion
manometer -5 RI01170400-05 1 Manometer -6 RI01170400-06 1 Filter -7
RI01170400-07 1 Tank -8 RI01170400-08 1 Retaining valve -9
RI01170400-09 1 Control panel -10 RI01170400-10 1 Frame -
64
-
Functional group: Semitrailer group Table Number Revision
Hydraulic oil reservoir 1 01906232 - 1 0 (06-2007)
Functional group: Semitrailer group Table Number Revision
Hydraulic oil reservoir 1 01906232 - 1 0 (06-2007)
Position Part Number Quantity Description Notes
1 01906235 2 Description not available -2 01908758 1 Tank -3
01908759 1 Tank -4 01908760 2 Gasket -5 40690045 2 Thermometer -6
50310022 2 Pn 10 1" 1/2 ball valve -7 50310195 4 Valve -8 50510019
2 Connector -9 50520046 2 Cap -10 50530025 2 Air breather -11
50540178 2 Level indicator -12 50540181 2 Level indicator -13
50590007 2 Nipple -14 50590009 2 Nipple -15 50630073 4 A.f.l.
connector -16 50630077 8 3" art.280 nipple -17 50630079 2 A.f.l.
connector -18 50630182 2 A.f.l. connector -19 50971117 2 Filter -20
52030045 2 Washer -21 70351004 40 Screw -22 70351610 8 Screw -23
70661613 8 Nut -24 70911017 40 Elastic washer -25 70911627 8
Elastic washer -
65
-
Functional group: Mast group Table Number Revision
Monkey board handrails 2 01907330 - 1 0 (06-2007)
Functional group: Mast group Table Number Revision
Monkey board handrails 2 01907330 - 1 0 (06-2007)
Position Part Number Quantity Description Notes
1 01907649 1 Description not available -2 01907915 1 Description
not available -3 01907916 1 Description not available -4 01907917 1
Description not available -5 40630123 6 Shear pin -6 71191616 15
Pin -7 71300018 9 Split pin -
66
-
Functional group: Mast group Table Number Revision
Cylinder for extracting mast 2 01907331 - 1 0 (06-2007)
Functional group: Mast group Table Number Revision
Cylinder for extracting mast 2 01907331 - 1 0 (06-2007)
Position Part Number Quantity Description Notes
1 01906950 1 Description not available -2 01906951 1 Description
not available -3 01907931 2 Description not available -4 01908883 1
Description not available -5 50470576 1 Plate -6 51040304 1
Hydraulic piston -7 52104075 1 O-ring -8 70351614 8 Screw -9
70311624 4 Screw -10 70351612 8 Screw -11 70370824 4 Screw -12
70611618 20 Self-locking nut -13 70901648 4 Washer -14 70910814 4
Elastic washer -15 71050812 2 Split pin -16 71204009 2 Pin -
67
-
Functional group: Substructure group Table Number Revision
Machine base frame 3 01906312 - 1 0 (06-2007)
Functional group: Substructure group Table Number Revision
Machine base frame 3 01906312 - 1 0 (06-2007)
Position Part Number Quantity Description Notes
1 01906896 1 Front skid -2 01907096 1 Skid -
68
-
Functional group: Draw works group Table Number Revision
Swivel joint for water 4 01902248 - 1 0 (06-2007)
Functional group: Draw works group Table Number Revision
Swivel joint for water 4 01902248 - 1 0 (06-2007)
Position Part Number Quantity Description Notes
1 01902619 1 Body -2 01902620 1 Manifold -3 01902621 1 Cover -4
01902622 1 Flange -5 01902623 1 Bushing -6 01902624 2 Ring -7
40630186 1 Spring -8 01902625 2 Spacer -12 52700471 2 Gasket -13
52700470 4 Gasket -14 52104081 2 O.ring packing -15 01902626 2
Gasket -16 70351010 8 Screw -17 70911017 8 Elastic washer -18
61000006 2 Lubricator -19 50520037 2 Cap -
69
-
:puorg lanoitcnuF puorg skrow warD noisiveR rebmuN elbaT
01 - 70370910 4tfahsretnuoc tupni rewoP )7002-60(
Functional group: Draw works group Table Number Revision
Power input countershaft 4 01907307 - 1 0 (06-2007)
Position Part Number Quantity Description Notes
1 01906521 1 Description not available -2 01906522 1 Description
not available -3 01906524 1 Description not available -4 01906526 1
Description not available -5 01906527 2 Description not available
-6 01906528 2 Description not available -7 01906529 1 Description
not available -8 01906530 2 Description not available -9 01906531 2
Description not available -10 01907427 1 Description not available
-11 01907428 1 Description not available -12 019011621 1 Spacer -13
61070142 2 Description not available -14 70351609 12 Screw -15
70351610 20 Screw -16 70351614 24 Screw -17 70611618 24
Self-locking nut -18 71073236 2 Tang -
70
-
Functional group: Draw works group Table Number Revision
Installation of the travelling block limit switch 4 01906106 - 1
0 (06-2007)
Functional group: Draw works group Table Number Revision
Installation of the travelling block limit switch 4 01906106 - 1
0 (06-2007)
Position Part Number Quantity Description Notes
1 01906517 1 Description not available -3 01906518 1 Description
not available -4 01906519 1 Description not available -8 50640721 1
Cylinder -10 50640546 1 Hinge -11 50640723 1 Description not
available -12 70390062 2 Screw -13 70351205 4 Screw -14 70911221 4
Elastic washer -15 50640722 1 Fork -16 50640652 1 Valve -
71
-
DRILLING RIGHTD 250 TOP DRIVE
72
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Operation and Maintenance ManualGENERAL INFORMATION
Section A page 5
TOP
BOTTOM
OFFDRILLERSIDE
DRILLERSIDE
DWWKS SIDE
OFF DWWKS SIDEFig. A1
A - 1 ORIENTATION
Front and rear sections of the equipment, as other parts of the
equipment on side, shall be conventionally placedas shown in the
following diagram (unless specified otherwise).
73
-
Operation and Maintenance ManualGENERAL INFORMATION
Section A page 6
Fig. A2
Machine Type
Serial Number
Year of Manufacturing
Nominal Power [kw]
Weight [kg]
Piacenza - Italy
A - 2 IDENTIFICATION
This equipment is identified through serial number
and/oridentification numbers on main components.
A - 2.1 EQUIPMENT IDENTIFICATIONPLATE
The equipment identification plate shown in the pictureprovides
all identification data for the machine. Alwayscheck that the
equipment part number (N. MATR.)stamped on the plate, matches with
that reported on thefront cover of this manual.
IMPORTANT
Always specify the equipment technical code and partnumber (N
MATR.) when you require information ortechnical assistance.
A - 2.2 MANUFACTURER
DRILLMEC Drilling Equipment Div. - 12 Via 1 Maggio -
LocalitGariga I-29027 Podenzano (PC) - ITALY Tel. +39 0523 354211-
Telefax +39 0523 524418;
A - 2.3 MODEL AND VERSION
TOP DRIVE model: with hydraulic power pack.
A - 2.4 OTHER IDENTIFICATION PLATES
The plates for all major mechanical, hydraulic and
electricalcomponents which are not manufactured by DRILLMEC(pumps,
motors, etc.) are fitted on the componentsthemselves, in the
locations assigned by the manufacturers.
74
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Operation and Maintenance ManualGENERAL INFORMATION
Section A page 7
MAXIMUM WORKING PRESSUREMAXIMUM WORKING PRESSURE
MAXIMUM DYNAMIC LOADMAXIMUM DYNAMIC LOADCAPACITY AT 100
RPMCAPACITY AT 100 RPM
MAXIMUM STATICMAXIMUM STATICLOAD CAPACITYLOAD CAPACITY
CUSTOMERCUSTOMER
MANUFACTUREDMANUFACTURED
SERIAL NUMBERSERIAL NUMBER
POWER SWIVELPOWER SWIVEL
SPECIFICATION SPECIFICATION 8C L.E. (EDITION 4)8C L.E. (EDITION
4)AUTH. 8C-0041 PSL1AUTH. 8C-0041 PSL1
BARBAR
MTMT
MTMT
MODELMODEL
TOP DRIVETOP DRIVE
09533652E09533652E
2 SPEED2 SPEED
1 SPEED1 SPEED
200
RPM
200
RPM
146
RPM
146
RPM
109
RPM
109
RPM
80 R
PM80
RPM
10400 ftlb10400 ftlb
14235 ftlb14235 ftlb
19030 ftlb19030 ftlb
26000 ftlb26000 ftlb
ftlb
ftlb
TORQ
UE
TORQ
UE
RPMRPM
2212522125
1475014750
73757375
2002001501501001005050
Fig. A3
0953-3720E0953-3720E
75
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Operation and Maintenance ManualGENERAL INFORMATION
Section A page 8
Fig. A4
TORQUE WRENCHTORQUE WRENCH
ftlb TORQUEftlb TORQUE
BREAK-OUTBREAK-OUTMAKE-UPMAKE-UP
PRES
SURE
- PS
IPR
ESSU
RE -
PSI
35603560
21402140
49904990
42754275
28502850
14251425
81130811305180051800
4425044250
36880368802950029500
2213022130
1475014750
73757375
09533658E09533658E
76
-
Operation and Maintenance ManualGENERAL INFORMATION
Section A page 9
1
14
13
7
9
4
15
12
11
10
86
5
3
2
NOTE:
1 - LINKS 2 - GOOSNECK 3 - HYDRAULIC MOTOR 4 - DOLLY 5 - GEAR
BOX 6 - PIPEHANDLER ROTATION GEAR 7 - DUPLEX HOOK 8 - LINK TILT
CYLINDER 9 - I.B.O.P. ACTUATOR10 - ELEVATOR11 - ELEVATOR LINKS12 -
TORQUE WRENCH13 - WEIGHT COMPENSATOR SYSTEM14 - WASHPIPE15 -
GUIDE
Fig. A5
A - 3 MAJOR COMPONENT DESCRIPTION - TOP DRIVE
The following section describes the component parts, and defines
terms used throughout this service manual.
77
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Operation and Maintenance ManualGENERAL INFORMATION
Section A page 10
DRI
LLIN
G M
OD
E
TRIP
PIN
G M
OD
E
LOAD PATH
TRIPPING MODEDRILLING MODE TRIPPING MODEDRILLING MODE
ELEVATORLINKS
DOUBLE HOOKLOAD SHOULDER
DOUBLE HOOK
ROTARY DRILLINGHOOK
TOP DRIVESUSPENDING
LINKS
WASH PIPEPACKING ASS.Y
MAIN SHAFTLOAD SHOULDER
SWIVELTHRUST BEARING
TRANSMISSIONBODY
COUNTERBALANCESYSTEM
MAIN SHAFT(DRILL SYSTEM)
BONNET
GOOSE NECK
LINK PIN
Fig. A6
A - 3.1 HTD 200 LOAD PATH
78
-
Operation and Maintenance ManualGENERAL INFORMATION
Section A page 11
HYDRAULIC MOTORS
HYDRAULIC MOTORS
MAIN BODY
Fig. A7
A - 3.2 HYDRAULIC MOTORS
The uses four (4) HYDRAULIC MOTORS mounted vertically side by
side on top and on bottom of themain body to power the The ports of
the motors are connected each other with a rigid pipe and finally
connected to an interface block withquick couplings.
79
-
Operation and Maintenance ManualGENERAL INFORMATION
Section A page 12
HYDRAULICCALIPER
BRAKEDISC
Fig. A8
Two hydraulic caliper disc brakes, mounted between each top
hydraulic motor and the main body, hold torque inthe drill string
and assist in positioning during directional work.An electrical
solenoid valve remotely operates the hydraulic caliper disc
brakes.
80
-
Operation and Maintenance ManualGENERAL INFORMATION
Section A page 13
TRANSMISSION/MOTOR HOUSING
MAIN BODY
Transmission/motor housing (main body) and swivel assembly
Fig. A9
A - 3.3 TRANSMISSION, MOTOR HOUSING (MAIN BODY) AND SWIVEL
ASSEMBLY
The transmission, motor housing and swivel assembly transfers
the power produced by hydraulic motors to the drillstring. Inside
the transmission/motor housing main body is a single-speed
double-reduction sput gear system thatprovides a 13,54:1 ratio from
the motors to the main shaft.
The main thrust bearing located inside the motor housing
supports drilling loads, while the load stem, which bypassesthe
thrust bearing and provides support for the rotating link adapter
and pipehandler, carries the tripping loads.
The main body of the motor housing provides a sealed oil
lubrication reservoir for the transmission gears and
bearings.Bearings and gears are force fed by an oil pump that is
integral with the main body. The filtered lubrication oil
constantlycirculates through the main thrust bearing, take-up
bearing, lower radial and compound gear bearings.
An industry standard wash pipe packing box assembly is located
between the main shaft/swivel stem and the S-pipeweldment. The
bonnet supports the S-pipe weldment. Two upper links serve to
attaching to standard rotary drillinghooks.
81
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Operation and Maintenance ManualGENERAL INFORMATION
Section A page 14
FIXED PART
MOVING PARTS
SUPPORT BRACKETS
AIR SPRING
Counterbalance system
Fig. A10
A - 3.4 CARRIAGE AND GUIDE BEAM
The travels vertically along a guide beam on a carriage attached
to the main body. The guide beam hangsfrom the crown block and
extends within 26,88 meters of the drill floor. The guide beam
attaches to a torque reactionspreader beam mounted across the lower
section of the mast/derrick, approximately 2 meters above the drill
floor.
The guide beam counters the drilling torque produced as the
transmission turns the drill string. The guide beam comesin 24,64
meters sections and requires brackets for mounting to the crown.The
guide beam sections are pinned toghether in such a way that they
hinge and can be assembled one section at atime, at the ground
level, and raised to the crown attachment using the drilling
hook.
The carriage consists of four roller brackets that mantains
alignment of the mainshaft with the drill string while movingup and
down on the guide beam. There are four rollers that run inside the
guide beam flanges to counter the drillingtorque and four guide
rollers that run on the inside of the guide beam flanges. Both the
guide and bogie rollers arethrough-hardened and run on grease
lubricated bearings.
82
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Operation and Maintenance ManualGENERAL INFORMATION
Section A page 15
GUIDEBEAM
CONNECTINGLINK
GUIDEBEAM
CARRIAGEASSEMBLY
TORQUE WRENCH
ELEVATOR LINKS
DRILLINGHOOK
LINKS
MAINBODY
GUIDE BEAM (ASSEMBLED)
TORQUE REACTION SPREADER BEAM
FRONT
Carriage and guide beamFig. A11
83
-
Operation and Maintenance ManualGENERAL INFORMATION
Section A page 16
IBOP
FRONT
DOUBLE HOOKROTATION GEAR
TWO WAYLINK TILT CYLINDERS
CLAMP
ELEVATORLINKS
MOUSE HOLEPOSITION
DRILL DOWNPOSITION
WELL CENTER(FLOAT POSITION)
TORQUEWRENCH
ROTATINGDOUBLE HOOKLINK ADAPTER
PINIONREDUCER
HYDRAULICDRIVE MOTOR
Fig. A12
A - 3.5 PIPEHANDLER
The Pipehandler consists of the following components:
Powered rotating double hook link adapter Torque wrench Two way
link tilt Internal blowout prevention (IBOP) Elevator links and
drill pipe elevator
84
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Operation and Maintenance ManualGENERAL INFORMATION
Section A page 17
The Rotating Double Hook combined with ahydraulic motor for 270
clockwise/counterclockwiserotation in order to position the
elevator to pick uppipes and to assist the derrick man. The free
rotationmode also allow the pipehandler to rotate with the
mainshaft.The two-way link tilt cylinder assemblies consist ofthe
cylinder body pinned to the rotating link adapterand the cylinder
rods pinned to the links through a setof clamps.Pressurizing the
cylinder assemblies by operating theswitch on the drillers console
extends the drill pipeelevator to the mouse hole or the drill down
position. Afloat position allows the links to return to well
center.
The Elevator Links can be moved to mouse hole ordrill down
position by means of the tilt cylinders, re-mote controlled from
the operators panel.
The Torque Wrench for make up/break out of pipe,is connected to
the pipe handler by means of asuspension beam. The torque wrench
can be locatedin two different positions on the suspension
beam,depending on which connection to be broken. Thetorque wrench
includes torque cylinders, clamp jawsand a guide funnel.
The Remote Operated I.B.O.P. (10.000 PSI) isoperated by two
hydraulic cylinders remote controlledfrom the operators panel.
85
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Operation and Maintenance ManualGENERAL INFORMATION
Section A page 18
A - 4 TOP DRIVE SPECIFICATIONS
A - 4.1 TOP DRIVE SPECIFICATIONS
MODEL:
LOAD CAPACITIES
MAXIMUM STATIC LOAD CAPACITY: 200.000 kgMAXIMUM DYNAMIC LOAD
CAPACITY AT 100 RPM: 115.000 kgMAXIMUM PASSAGE DIAMETER: 76
mmMAXIMUM WORKING PRESSURE: 350 barsLOWER THREAD: NC 50 API - 4
IFMAX TORQUE: 3525 daNmMAX SPEED: 200 RPM
PERFORMANCE DIAGRAM:
Fig. A13
TOP DRIVETOP DRIVE
09533652E09533652E
2 SPEED2 SPEED
1 SPEED1 SPEED
200
RPM
200
RPM
146
RPM
146
RPM
109
RPM
109
RPM
80 R
PM80
RPM
10400 ftlb10400 ftlb
14235 ftlb14235 ftlb
19030 ftlb19030 ftlb
26000 ftlb26000 ftlb
ftlb
ftlb
TORQ
UE
TORQ
UE
RPMRPM
2212522125
1475014750
73757375
2002001501501001005050
TOP DRIVE POWER OUTPUT: 295 kwDOUBLE HOOK CAPACITY: 200.000
kgELEVATOR LINK CAPACITY: 226800 kg (250 Short ton.)LENGHT: 108
(2743 mm)LINK SIZE: 2.x108
WEIGHT: 6500 kg approx.
* TOP DRIVE includes guide dolly and connection link to
travelling block
86
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Operation and Maintenance ManualGENERAL INFORMATION
Section A page 19
PIPE HANDLER - COUNTERBALANCE SYSTEMUTILITY REQUIREMENTS RIG AIR
SUPPLY: 8 bar
TORQUE WRENCH:The TORQUE WRENCH can handle pipe from 4 to 6.5/8
ODMAXIMUM MAKE-UP TORQUE: 4400 daNmMAXIMUM BREAK-OUT TORQUE: 5925
daNm
87
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Operation and Maintenance ManualGENERAL INFORMATION
Section A page 20
AIR
INTA
KE
FUEL
TA
NK
OIL
TA
NK
DRA
INA
GE
BALL
VA
LVESU
CTI
ON
BALL
VA
LVE
HYD
RAU
LIC
PU
MPS
MU
LTIP
LE P
UM
P D
RIVE
UN
ITBA
SE S
KID
TRA
NSM
ISSI
ON
SH
AFT
RAD
IATO
R
AIR
INTA
KE
INSU
LATI
ON
HO
OD
DIE
SEL
ENG
INE
AIR
FIL
TER
PUM
P D
RIVE
LU
BRIC
ATIO
NC
IRC
UIT
HEA
T EX
CH
AN
GER
AIR
DIS
CH
ARG
E
AIR
DIS
CH
ARG
E
QU
ICK
COU
PLIN
GCO
NN
ECTI
NG
BLO
CK
OIL
TA
NK
INSP
ECTI
ON
CO
VER
AIR
FIL
TER
FUEL
TA
NK
HYD
RAU
LIC
CIR
CU
ITH
EAT
EXC
HA
NG
ER
FILT
ERH
YDRA
ULI
C O
IL T
AN
K
EXA
UST
MU
FFLE
R
DIE
SEL
ENG
INE
RAD
IATO
R
Fig. A14
A - 5 MAJOR COMPONENT DESCRIPTION - HYDRAULIC POWER UNIT(HPU)
FOR
The following section describes the HPU component parts and
defines terms used throughout this service manual.
88
-
Operation and Maintenance ManualGENERAL INFORMATION
Section A page 21
A - 6 HYDRAULIC POWER UNIT (HPU) SPECIFICATIONS
Model: 1 x Caterpillar 3408 DITA EPA-CARB
Arrangement drawing: 0190 3398
Transmission circuit:Pressure range: 0 - 350 barFlow range: 0 -
800 l/min
Replenishment circuit:Pressure min: 16 barFlow: 90 l/min
Pipehandler circuit - Torque Wrench:Pressure: 350 barFlow: 0 -
113 l/min
Link Tilt:Pressure: 180 barFlow: 0 - 30 l/min
Diesel engine:Max power output: 376,5 bkw (505 bhp) @1800 RPMMax
fuel consumption: .....l/hour at ..... kw ..... (..... gph at .....
hp) (see engine manuals)Max rated RPM: 1800 RPM
Tank capacities:Hydraulic oil tank: 950 ltr.Diesel tank: 600
ltr.
Weights:Total weight HPU: 11830 kgs
Painting:All items painted, where relevant, with DRILLMEC
procedure.
Service loop hydraulic hoses:
PILOT PRESSUREFlex. SAE 100 R2AT 1/2 pilot pressure
CLOSED LOOP CIRCUITFlex. SAE 100 R13 2 motor deliveryFlex. SAE
100 R2AT 2 drainage
PIPEHANDLER - TORQUE WRENCHFlex. SAE 100 R13 1 1/4 services
deliveryFlex. SAE 100 R2AT 1 1/4 services return
COUNTERBALANCE SYSTEMFlex. SAE 100 R1AT 3/4 air pressure
89
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Operation and Maintenance ManualOPERATING INSTRUCTIONS
Section C page 3
Fig. C2
A1 P1 H1 H2 H3
SP1
H4
SC10
R7 R8 SC12 SC9 SC3 SC7 SC1
SC6
SC5
SC8SC4
SC11
C - 1.1 CONTROLS AND INSTRUMENTSON TOP DRIVE CONTROL PANEL
P1 Top Drive Rpm Analog MeterA1 Top Drive Torque Pressure
GaugeSC1 Hook Rotation ControlSC3 Link ControlSC4 Link-On Free
ControlSC5 Ibop Valve Open-Close ControlSC6 Top Drive Brake
ControlSC7 Torque Wrench Automatic Sequence ControlSC8
Make-Up/Break-Out ControlSC9 Top Drive Emergency StopSC10 Throttle
Min-Max For Top Drive HpuSC11 Top Drive Rotation Speed SelectorSC12
Top Drive Rotation Fwd/Rev ControlSP1 Controls AuthorizationH1
Return Filter Clogging Indicator LampH2 Discharge Filter Clogging
Indicator LampH3 Minimum Oil Level Indicator LampH4 Controls
Authorization LampR7 Top Drive Rotation Rpm RegulatorR8 Top Drive
Torque Regulator
90
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Operation and Maintenance ManualOPERATING INSTRUCTIONS
Section C page 4
C - 1.2 CONTROLS AND INSTRUMENTSIN THE HYDRAULIC POWER UNIT
Fig. C3
A58
A62
A61
A60
A59
Fig. C4
A54 A55 A53 A52 R52
Fig. C5
A63
C60 C61 C62
A58 RPM meterA59 Oil pressureA60 AmmeterA61 Water temperatureA62
Fuel pressure
A53 Piloting oil pressureA52 Compensator air pressureR52
Compensator pressure regulatorA54 Replenishing pressure (CLOSED
CIRCUIT)A55 Replenishing pressure (CLOSED CIRCUIT)
A63 Oil temperature thermometerC60 Ball valve on hydraulic
system suction lineC61 Ball valve on hydraulic system suction
lineC62 Ball valve on hydraulic system suction line
91
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Operation and Maintenance ManualOPERATING INSTRUCTIONS
Section C page 5
Fig. C6
C63
Fig. C7
A64
Fig. C8
A65
C63 Ball valve on reservoir oil drain
A64 Oil visual level
A-65 Fuel visual level
92
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Operation and Maintenance ManualOPERATING INSTRUCTIONS
Section C page 6
C - 2 HYDRAULIC POWER UNITSTARTING INSTRUCTIONS
C - 2.1 CHECKS BEFORE STARTING
The easiest checks have to be manually executed:
- Diesel engine oil level check.
- Visual check of the hydraulic oil level (however, a properlamp
signals the reaching of the minimum allowed pointof this
level).
- Water level check into the radiator.
- Fuel level check (A65).
- Oil level check into the pump driving unit.
- At the first start-up of the Power Pack, check that thebattery
cables are correctly connected. Such cablesare usually disconnected
during transport.
- Check that the suction valves of the pumps, placedon the
hydraulic oil reservoir, are properly opened.
93
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Operation and Maintenance ManualOPERATING INSTRUCTIONS
Section C page 7
C - 2.2 DIESEL ENGINE STARTING
C - 2.2.1 WARM-UP / STARTUP
1) Turn on the diesel engine.
2) Set diesel engine to minimum rpm for 15/20 min.
3) Increase the number of rpm up to 800/1000.
Fig. C9
94
-
Operation and Maintenance ManualOPERATING INSTRUCTIONS
Section C page 8
Fig. C10
A54 A55 A53 A52 R52
Fig. C11
A61
A59
Fig. C12
SC10
SP1
C - 2.3 CHECKS AFTER START-UP
- After having executed all the operations described atthe
preceding point, check that the pressure displayedon the
"supercharging" pressure gauges A54 and A55is stabilized on 16 18
bar.
- Check the piloting pressure displayed on the pressuregauge
A53. The pressure has to be 25 30 bar.
- Check the air pressure to supply the counter-balancesystem of
the top drive. Such a pressure can beadjusted through the pressure
regulator R52 readingthe value displayed on the pressure gauge
A52.
- Warm-up the engine (the warm-up time depends onthe climatic
conditions).
- Check on the engine instruments that the pressuresand the
temperatures are the correct ones accordingto the indications
provided by the manufacturer of theengine.
- Now it is possible to increase the speed of the dieselengine.
Access to the top drive control panel on thedrill floor.
- Press the push-button SP1 = Control authorization.
- Turn the selector SC10 from Min position to Maxone.
- With the top drive near the drill floor, exercise eachcontrol
on the driller's console following the operatinginstructions of
paragraph C-3 and the operatingprocedures of paragraph C-4.
95
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Operation and Maintenance ManualOPERATING INSTRUCTIONS
Section C page 9
Fig. C13
A1 P1 H1 H2 H3
SP1
H4
SC10
R7 R8 SC12 SC9 SC3 SC7 SC1
SC6
SC5
SC8SC4
SC11
C - 3 OPERATING INSTRUCTIONS
P1 Top Drive Rpm Analog MeterA1 Top Drive Torque Pressure
GaugeSC1 Hook Rotation ControlSC3 Link ControlSC4 Link-On Free
ControlSC5 Ibop Valve Open-Close ControlSC6 Top Drive Brake
ControlSC7 Torque Wrench Automatic Sequence ControlSC8
Make-Up/Break-Out ControlSC9 Top Drive Emergency StopSC10 Throttle
Min-Max For Top Drive HpuSC11 Top Drive Rotation Speed SelectorSC12
Top Drive Rotation Fwd/Rev ControlSP1 Controls AuthorizationH1
Return Filter Clogging Indicator LampH2 Discharge Filter Clogging
Indicator LampH3 Minimum Oil Level Indicator LampH4 Controls
Authorization LampR7 Top Drive Rotation Rpm RegulatorR8 Top Drive
Torque Regulator
96
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Operation and Maintenance ManualOPERATING INSTRUCTIONS
Section C page 10
C - 3.1 DRILLERS CONSOLE AND TOP DRIVE CONTROL PANEL
LOBMYS ROTACIDNI/LORTNOCEMAN
NOITCNUFDNANOITPIRCSED
1P golanaMPRevirdpoTretem
.epipllirdfoMPRehtsyalpsiD
1A erusserpeuqrotevirdpoTeguag
eguagehtdnuoraetalpehtnognidaereuqrotepipllirdehtsyalpsiDllirdotlanoitroporpyltceridsitiucricdesolcehtnierusserpciluardyh
euqrotepip
1CS noitatorkoohelbuoDlortnoc
.)wc(THGIRdna)wcc(TFEL,LARTUEN:noitisopreveleerhteraerehTehtevomotdrawpurevelehtevoM
KOOHELBUOD .tfelehtot.E.P.D+
ehtot.E.P.D+KOOHELBUODehtevomotdrawnwodrevelehtevoMthgir
2CS nwod/puhcnerweuqroTlortnoc
noisnepsusehtnosnoitisopowtnidetacolebnachcnerweuqrotehT.nekorbebotnoitcennochciwnognidneped,maeb
NOITISOPREPPU>---PUREVELEHTEVOMNOITISOPREWOL>---NWODREVELEHTEVOM
3CS lortnockniL
revelehtgnivom,ffosinoitisoplartuenehT.rednilyctlitknilehtsetavitcA.noitisop)elohesuom("pukcip"otsknilrotaveleehtsdnetxedrawpu
drawnwodrevelehtgnivomnehtdna09reldnahepipetatoR:GNINRAWnoitisop"nwodllird"otsknilrotaveleehttcarter
4CS lortnoceerf-nokniL)taolftlitkniL(
othctiwsehtgninrutnehwnoitisop)lartuen(retnecehtot"taolf"sknilehTnoitisop"eerf"eht
5CS esolc-nepoevlavPOBIlortnoc
ehtstcartertfelehtothctiwsehtgninruT.evlavPOBIreppuehtsetavitcAthgirehtothctiwsehtgninruT.evlavehtnepootrednilycrotavitcaPOBI
evlavehtesolcotsrednilycehtsdnetxe
6CS lortnocekarbevirdpoT
emasehtnidnaekarbylppa,noitisop"NO"ehtothctiwsehtgninruTpoToslA.delbasidsihcnerweuqrotfoecneuqescitamotuaehtemit
.erusserptolipehtgnittucdelbasidsinoitatorevirD.ekarbesaeler,noitisop"FFO"ehtothctiwsehtgninruT
7CS citamotuahcnerweuqroTlortnocecneuqes
REWOL:ecneuqescitamotuaehtetavitcadrawpurevelehtgnivoM.ETATORPMALCREPPU,ESOLCPMALCREPPU,ESOLCPMALC
POTdnaEERFSINOITATORKOOHELBUODemitemasehtnI*eht,noitisoplartuennisirevelehtnehW.EERFSINOITATOREVIRD
noitisop"EMOH"ehtotsetatoryllacitamotuahcnerweuqrot
97
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Operation and Maintenance ManualOPERATING INSTRUCTIONS
Section C page 11
LOBMYS ROTACIDNI/LORTNOC EMAN NOITCNUFDNANOITPIRCSED
8CS lortnoctuo-kaerb/pu-ekaM
naetavitcaottcelesuoy,noitisop"PU-EKAM"othctiwsehtgninruTpu-ekmaotsetatorhcnerweuqrot(ecneuqespu-ekamcitamotua
.)noitcennocnaetavitcaottcelesuoy,noitisop"TUO-KAERB"othctiwsehtgninruT
tuo-kaerbotsetatorhcnerweuqrot(ecneuqestuo-kaerbcitamotua.)noitcennoc
9CS potsycnegremeevirdpoT
potsehtgnisserP.snoitarepoevirDpoTllanwodstuhspotsycnegremEfonwodtuhsesuaclliwdnapotsotnoitatorevirDpoTesuaclliwnottub
.enigneleseidUPHLORTNOC"sserP.esaelerdnanottubetatoR:TESERYCNEGREME
.noebtsum4HthgilehT.)1PSnottub("NOITAZIROHTUA.enigneleseidehtnonruT.noitcurtsnignitratsUPHehtwolloF
01CS poTrofxaM-niMelttorhTUPHevirD
MPRmuminimenigneleseidehtesuaclliwtfelothctiwsehtgninruT.)MPR0001~(
detarmumixameigneleseidehtesuaclliwthgirothctiwsehtgninruT)MPR0081(MPR
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98
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Operation and Maintenance ManualOPERATING INSTRUCTIONS
Section C page 12
LOBMYS ROTACIDNI/LORTNOC EMAN NOITCNUFDNANOITPIRCSED
3H rotacidnilevelliomuminiMpmal
muminimehtnwoddeppordlevelliotahtmralalausivasevigtI
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C - 3.1.1 WARNING LAMP SWITCHING-ON
The measures to be taken when the warning lamp comeson depend on
the type of fault detected.
In principle, the engine should be immediately turned offwhen
the following warning lamps come on:
H1 Clogged hydraulic oil filter - RETURNH2 Clogged hydraulic oil
filter - DISCHARGEH3 Hydraulic oil - MINIMUM LEVEL
WARNING
Working with H3 warning lamp on is forbidden, as itcan cause
damage to other parts of the system.Also check OIL THERMOMETER A-63
on HPU oiltank.
WARNING
An hydraulic oil overtemperature is a sign ofmalfunctioning of
some part of the system, cloggedfilter or heat exchanger.
Once the machine is turned off, find the cause of malfunctionand
repair it. If you are unable to solve the problem, contacta service
center or DRILLMEC S.p.A. directly (full addressis printed on cover
and first page of this manual).
At regular intervals, also check instruments for DIESELENGINE in
sound proof hood.
The engine should be immediately turned off when thesesituations
occurr:
- Low engine oil pressure- Engine water over temperature- Low
battery charge
WARNING
When above warning lamps are turned on, stop theengine; leaving
the engine running can cause seriousdamage to the engine.
99
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Operation and Maintenance ManualOPERATING INSTRUCTIONS
Section C page 13
Fig. C14
P1A1
R7 R8 SC12
SC11
C - 4 OPERATING PROCEDURES
C - 4.1 TOOL ROTATION
The power swivel rotation (drilling tool) is controlled
withlever SC12: push the lever down for clockwise rotation,pull the
lever up for anticlockwise rotation.
IMPORTANT
Lever SC12 can be locked in full stroke positionallowing the
operator to control other drillingparameters such as pull/push
regulation, rpm or torque.
Rpm (speed) is controlled by R7; torque is controlled byR8. Rpm
and torque control can be turned clockwise fromleft (min.) to right
(max).
Read torque on A1 gauge, read rpm on P1 rpm meter.Another kind
of speed and torque control can be performedby means of selector
SC11 (2-position selector).
IMPORTANT
During the drilling, if the stops locking the rotation ofthe
power swivel, do not move the rotation command
lever setting it in neutral position, but turn the
torqueregulator in anticlockwise direction setting the pressureto
zero (see pressure gaugeof power swivel rotationtorque) them set
lever again to neutral position.
100
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Operation and Maintenance ManualOPERATING INSTRUCTIONS
Section C page 14
MAIN SHAFT
IBOP ACTIVATORSHELL
UPPER IBOPACTIVATOR CYLINDER
CRANK ASSEMBLY
OPEN
CLOSE
IBOP
Fig. C15
C - 4.2 IBOP SAFETY VALVES
Turning the IBOP switch on the drillers console to theCLOSE
position extends the hydraulic actuatorcylinders, moving the
actuator shell body downward (seefollowing figure). This downward
movement rotates thecrank assemblies 90, closing the IBOP ball
valve.
Turning the switch to the OPEN position retracts thecylinders
rod, pulling the IBOP actuator shell upward-opening the IBOP. Full
hydraulic pilot pressure isapplied to fully open or close the
valve, mantaining theshell position.
101
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Operation and Maintenance ManualOPERATING INSTRUCTIONS
Section C page 15
Fig. C16
A1 P1
SC12 SC7
SC6
C - 4.3 ACTIVATING TOP DRIVE BRAKE
Turning the switch SC6 to the ON position, apply brakeand in the
same time the automatic sequence of torquewrench is disabled.Also
Top Drive rotation is disabled (cutting the pilotpressure). Turning
the switch to the OFF position, releasethe brake.
SC7 Torque wrench automatic sequence
SC12 Top Drive rotation
When applying brake, two hydraulic caliper disc brakes,mounted
between each top hydraulic motor and the mainbody, hold torque in
the drill string and assist in positioningduring directional
work.
For safety reasons, Top Drive rotation and torque
wrenchautomatic sequence are disabled.
102
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Operation and Maintenance ManualOPERATING INSTRUCTIONS
Section C page 16
DOUBLE HOOK
LINKS
DRILL PIPEELEVATOR
CW
CCW
WELLCENTER
TORQUE WRENCH
HYDRAULICMOTOR
POSITIONINGGEAR
PINION
Fig. C17
C - 4.4 PIPE HANDLER OPERATION
C - 4.4.1 ROTATING DOUBLE HOOK AND LINKS
The rotating double hook supports the weight of thedrill string
through a set of links that hang from thehook.
The positioning gear is an integral part of the rotatingdouble
hook. The positioning gear, meshed with ahydraulic motor driven
pinion gear, rotates thepipehandler.
103
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Operation and Maintenance ManualOPERATING INSTRUCTIONS
Section C page 17
Fig. C18
SC4
SC3
SC1
C - 4.4.2 LINK TILT
The link tilt consists of two double-rod assemblies with
thecylinder body pinned to the rotating double hook and rodend of
the cylinder pinned to the elevator link. Moving thelink tilt lever
upward, SC3 on the drillers console, extendsthe drill pipe elevator
to the MOUSE HOLE position.
WARNING
Rotate pipe handler 90 with SC-1 before to move thelever
downward SC-3 to reach the DRILL-DOWNposition.Be sure not to
interfere with guide beam.
Moving the link tilt lever downward retracts the drill
pipeelevator to the drill down position. Turning the link tilt
floatswitch SC4 to free position allows the elevator to return
towell center.
Elevator travel is adjustable. If it is necessary to adjust
themousehole position, relocate the clamps on the links
asrequired.
104
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Operation and Maintenance ManualOPERATING INSTRUCTIONS
Section C page 18
FRONT
DOUBLE HOOKROTATION GEAR
HYDRAULICDRIVE MOTOR
REDUCER
PINION
ROTATINGDOUBLE HOOKLINK ADAPTER
GUIDE BEAM
TORQUEWRENCH
DRILL DOWNPOSITION
WELL CENTER(FLOAT POSITION)
ELEVATORASSEMBLY
MOUSE HOLEPOSITION
CLAMP(ADJUSTABLE)
ELEVATORLINKS
TWO WAYLINK TILT CYLINDER
WARNING!ROTATE PIPE HANDLER 90
Fig. C19
105
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Operation and Maintenance ManualOPERATING INSTRUCTIONS
Section C page 19
Fig. C20
SC8
SC7
C - 5 TORQUE WRENCH
C - 5.1 TORQUE WRENCH BREAK-OUTSEQUENCE
Turn the selector SC8 on BREAK-OUT position.To activate the
automatic (break-out) sequence, move thelever SC7 upward and hold
it in position till the sequenceis completed.
In the same time:
- DOUBLE HOOK ROTATION IS FREE- TOP DRIVE ROTATION IS FREE
to permit freely upper clamp rotation.
When the sequence is completed, release the lever SC7to return
in neutral position.
106
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Operation and Maintenance ManualOPERATING INSTRUCTIONS
Section C page 20
Fig. C21
Selector SC8 in BREAK-OUT position
HOME position for BREAK-OUT sequence
Lever SC7 upward1st phase of automatic sequence
LOWER CLAMP CLOSE
UPPER CLAMP CLOSE
Lever SC7 upward2nd phase of automatic sequence
UPPER CLAMP ROTATES C.C.W
Lever SC7 in neutral position1st phase of automatic return to
HOME position
UPPER AND LOWER CLAMPS OPEN
Lever SC7 in neutral position2nd phase of automatic return to
HOME position
UPPER CLAMP ROTATES C.W.
107
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Operation and Maintenance ManualOPERATING INSTRUCTIONS
Section C page 21
Fig. C22
C - 5.2 TORQUE WRENCH MAKE-UP SEQUENCE
Turn the selector SC8 on MAKE-UP position. To activate the
automatic (make-up) sequence move the lever SC7upward and hold it
in position till the sequence is completed.
In the same time
- DOUBLE HOOK ROTATION IS FREE- TOP DRIVE ROTATION IS FREE
to permit freely upper clamp rotation.When the sequence is
completed, release the lever SC7to return in neutral position.
Selector SC8 in MAKE-UP position
HOME position for MAKE-UP sequenceLever SC7 upward1st phase of
automatic sequence
LOWER CLAMP CLOSE
UPPER CLAMP CLOSE
Lever SC7 upward2nd phase of automatic sequence
UPPER CLAMP ROTATES C.W
Lever SC7 in neutral position1st phase of automatic return to
HOME position
UPPER AND LOWER CLAMPS OPEN
Lever SC7 in neutral position2nd phase of automatic return to
HOME position
UPPER CLAMP ROTATES C.C.W.
108
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Operation and Maintenance ManualINSTALLATION
Section D page 4
BRACKETSAND PINS
BRACKETSAND PINS
COLLAR
Fig. D3
Fig. D4
The HTD 200 is supplied in a shipping and handling skid.The HTD
200 is supported by two brackets on carriage and by collar on main
shaft.
The HYDRAULIC POWER UNIT has a proper container with old field
supporting frame.
The pipehandler, the links, guide beam group, service loop and
other accessories, are supplied in separate properpackages.
109
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Operation and Maintenance ManualINSTALLATION
Section D page 5
At the reception of the machine, be extremely careful duringthe
down-loading procedures of the fixtures; it is necessaryto check
all the received materials and the status of thefixtures themselves
in such a way to ensure their perfectstatus after the
transport.
IMPORTANT
Every dispute, comment or claim has to be immediatelypointed out
to the transport company. The claimsforwarded with delay will not
be taken into account.
D - 1.1 LIFTING DEVICE
The hoist or the lifting crane for the machine installation
isalways under the customer's responsibility. However, itsloading
capacity has to be not lower than 15 Ton.
110
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Operation and Maintenance ManualINSTALLATION
Section D page 6
1 2 3 4
5
PHASE 1
NOTE:
1 - Assemble the guide beam composed by nr. 4 elements (ref.
1-2-3-4) and its lower attachment ref. 5
Fig. D5
D - 2 INSTALLING THE GUIDE BEAM AND LOWER ATTACHMENT
111
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Operation and Maintenance ManualINSTALLATION
Section D page 7
7 8 9
16
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