Um199015 e

Operation and
Maintenance
Manual
DRAWWORK
Machine type MAS8000
Manufacturing year 2011
Drillmec SpA
Drilling Technologies
12, Via 1 Maggio

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

Mailbox: info@drillmec.com
CAREFULLY READ THIS MANUAL Ph +39.0523.354211
BEFORE OPERATING THE MACHINE Fx +39.0523.524418
MAS8000 - Operation and Maintenance Manual
Document code: UM199015/E - Rev.0 (11/2011)
This document cannot, in whole or in part, be reproduced, memorized as a software file, or handed over to third parties
under any form and by no means, without previous authorization by DRILLMEC S.p.A.
DRILLMEC S.p.A. reserves the right to introduce changes to its products at any time in view of a constant quality
improvement.
Copyright 2011 DRILLMEC S.p.A. - All rights reserved
Printed in Italy
DRILLMEC Drilling Technologies - 12 Via 1 Maggio - Localit 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 MAS8000
Machine serial number
Manufacturing year 2011
Drilling rig type-approval
Power plant type-approval

Intentionally blank page
Operation and Maintenance Manual MAS8000
WARRANTY UM199015/E - Rev.0 - 11/2011
Page III
WARRANTY
All DRILLMEC machines and equipments are covered by warranty as far as any possible manufacturing defects
are concerned, either for a period of 12 (twelve) months, starting from the date of delivery to the final Customer, or
for 18 (eighteen) months, starting from the date of the B/L (Bill of Loading), unless otherwise specified in the supply
agreement.
That WARRANTY is held for applicable only provided that the DRILLMEC manufactured products are correctly used
by the final USER, by fully observing the contents of the Operation and Maintenance Manual. The WARRANTY isnt
applied to machines or equipments which were in any way altered, which were subjected to misuse, negligence,
accidents or were affected in their performances or reliability, such as if repaired in any way not complying with the
DRILLMEC directives.
DRILLMEC obligations in matter of WARRANTY are limited to supplying parts and correcting bad workmanship, up
to an amount not exceeding the estimated costs of the repair itself. WARRANTY doesnt cover any compensation for
revenue losses, transportation, hoisting and trucking expenses, such as direct and/or indirect damages caused to
the goods that arent imputable to DRILLMEC. Products and equipments which are furnished by DRILLMEC but not
manufactured by them, wont carry else but MANUFACTURER WARRANTY alone.
All DRILLMEC responsibilities and obligations are clearly defined in this WARRANTY statement enclosed to the sale
agreement, and no further verbal or written agreement will be considered as being legal. In order to guarantee both
reliability and high performances of the equipments, we strongly recommend to attentively read the SCHEDULED
MAINTENANCE section. If, for any reason, those prescriptions are either ignored or realized by using non-OEM
(Original Equipment Manufacturer) spare parts, this WARRANTY declaration will instantly CEASE.
Customer Care
Drillmec S.p.A.
Drilling Technologies
MAS8000 Operation and Maintenance Manual
UM199015/E - Rev.0 - 11/2011 WARRANTY
Page IV

TECHNICAL SERVICE AND SPARE PARTS UM199015/E - Rev.0 - 11/2011
Page V
TECHNICAL SERVICE AND SPARE

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

a local Service Centre authorized by DRILLMEC Spa. In
such a case, the Customer has to record the identification
data concerning to such a Centre into the relevant space
provided on page I of the subject manual.
For the spare parts, the Customer has to refer to the Spare
Part Catalogue provided with the machine documentation.
If some not very important parts are not directly detectable
into the catalogue, the Customer has to refer to the After
Sale Service of DRILLMEC S.p.A.
HAZARD
Use only the DRILLMEC original spare parts.
The use of original spare parts is coupled not only
to the warranty applicability but also to the perfect
efficiency and safety of the machine all along its
life, according to the specifications provided by the
design and used during the machine manufacturing
procedure.
If the Customer does not use the original spare parts,
in extreme cases, the not acceptable conformity of the
replaced parts can causes serious hazards of injury
and of death. DRILLMEC Spa declines every type or
responsibility n the case of damages to plants or of
injuries to personnel connected to the use of not Fig. 1
original spare parts.
IMPORTANT
When a Customer contacts the DRILLMEC After Sale
Service or others Service Centres to allow a quicker
problem solving procedure, he has always to point
out the machine data signed on the memorandum
reported at page I. This procedure is extremely im-
portant also for the data validity and for the reference
to possible technical updating concerning the spare
parts.
UM199015/E - Rev.0 - 11/2011 TECHNICAL SERVICE AND SPARE PARTS
Page VI

INDEX UM199015/E - Rev.0 - 11/2011
Page XI
INDEX
FOREWORD........................................................................................................................................................VII
INSTRUCTION FOR THE MANUAL READING.................................................................................................. VII
TYPICAL STRUCTURE OF THE PAGES........................................................................................................... VII
SUBDIVISION IN SECTION AND CHAPTERS................................................................................................... VIII
PAGE NUMBERING SYSTEM............................................................................................................................. VIII
TABLE NUMBERING SYSTEM........................................................................................................................... VIII
FIGURE NUMBERING SYSTEM......................................................................................................................... VIII
RECALLING CONNECTION TO OTHER SUBJECTS........................................................................................ VIII
UPDATING...........................................................................................................................................................IX
SYMBOLS............................................................................................................................................................IX
Section A - GENERAL INFORMATION A-1
A-1 GENERAL ...................................................................................................................... A-2

A-2 IDENTIFICATION............................................................................................................ A-3
A-2.1 MANUFACTURER........................................................................................................................... A-3
A-2.2 MODEL AND VERSION.................................................................................................................. A-3
A-2.3 EQUIPMENT IDENTIFICATION PLATE.......................................................................................... A-3
A-3 SAFETY AND IDENTIFICATION PLATE ON DRAWWOrK.......................................... A-4
A-3.1 API INDENTIFICATION PLATE....................................................................................................... A-5
A-4 TECHNICAL INFORMATIONS........................................................................................ A-7
A-4.1 TECHNICAL DATA........................................................................................................................... A-7
A-4.2 PERFORMANCE CHART................................................................................................................ A-7
A-4.3 TRANSMISSION DIAGRAM............................................................................................................ A-8
A-4.4 MAIN SKID BASE & HOUSING...................................................................................................... A-9
A-4.5 motor............................................................................................................................................ A-9
A-4.5.1 COOLING SYSTEM...................................................................................................................... A-9
A-4.6 SHAFT BEARING............................................................................................................................ A-9
A-4.7 clutch........................................................................................................................................... A-10
A-4.8 MAIN DRUM..................................................................................................................................... A-10
A-4.9 MAIN BRAKE................................................................................................................................... A-10
A-4.9.1 hydraulic power unit BRAKE............................................................................................ A-11
A-4.10 AUXILIARY BRAKE....................................................................................................................... A-11
A-4.11 CATHEAD...................................................................................................................................... A-11
A-4.12 LUBRICATION SYSTEM............................................................................................................... A-12
A-4.13 CONTROL PANEL......................................................................................................................... A-12
A-4.14 transmission clutch............................................................................................................ A-12
A-4.15 Air system and controls.................................................................................................... A-12
A-4.16 housing....................................................................................................................................... A-13
A-4.17 sprockets and chains.......................................................................................................... A-13
A-5main dimension and weights................................................................................ A-14
A-6 LIFTING points............................................................................................................. A-15
Section B - SAFETY B-1
B-1 PERSONNEL QUALIFICATIONS.................................................................................. B-2

B-1.1 QUALIFICATION........................................................................................................................................ B-2
B-1.2 WORKING GARMENTS............................................................................................................................ B-2
B-2 MACHINE PLATES ........................................................................................................ B-3
B-3 SAFETY DEVICES.......................................................................................................... B-8
B-4diagram of safety device for emergency stop......................................... B-9
B-5 GENERAL SAFETY DURING THE MACHINE TRANSPORT PHASE.......................... B-10
UM199015/E - Rev.0 - 11/2011 INDEX
Page XII
B-6 GENERAL SAFETY DURING THE MACHINE ASSEMBLY, INSTALLATION AND DISIN-
STALLATION PHASES.......................................................................................................... B-10
B-7 GENERAL SAFETY DURING THE MACHINE OPERATION PHASE............................ B-12
B-8 GENERAL SAFETY DURING THE ROUTINE AND THE EXTRAORDINARY MAINTE-
NANCE PHASES.................................................................................................................... B-12
B-8.1 GENERAL INFORMATION.............................................................................................................. B-12
B-8.2 MECHANICAL PART...................................................................................................................... B-14
B-8.3 ELECTRIC PART............................................................................................................................. B-15
B-8.4 HYDRAULIC PART.......................................................................................................................... B-16
B-9 Safety Rules Regarding Scheduled Maintenance................................... B-17
B-10 GENERAL SAFETY DURING THE OUT OF SERVICE SETTING AND ELIMINATION
PHASE ............................................................................................................................... B-18
Section C - INSTALLATION, MOVING AND RIG UP C-1
C-1 INSTALLATION, MOVING AND RIG-UP........................................................................ C-2

C-1.1 Preparation FOR USE............................................................................................................... C-2
C-1.2 pre-starting instructions................................................................................................... C-3
C-1.3 auxiliary brakes ..................................................................................................................... C-4
C-1.4 cathead........................................................................................................................................ C-4
C-1.5 cooling water for drum brakes....................................................................................... C-4
C-1.6 moving rig.................................................................................................................................... C-4
C-1.7 special instructions.............................................................................................................. C-4
C-1.8 lubrication................................................................................................................................. C-4
Section D - OPERATING INSTRUCTIONS D-1
D-1 CONTROLS AND INSTRUMENTS.................................................................................. D-2

D-1.1 DRAWWORK controls in the driller cabin.................................................................... D-3
D-1.2 AUXILIARY BRAKE LEVER............................................................................................................ D-10
D-1.3 lubrication................................................................................................................................. D-11
D-1.4 AIR PRESSURE............................................................................................................................... D-12
D-1.5 DRIVE BRAKE PRESSURE............................................................................................................ D-12
D-1.6 Control Valve Drive Brake.................................................................................................. D-12
D-1.7 Control Valve Selective Transmission Gear I and Gear II SelectoR................. D-12
D-1.8 Gauge brakes system............................................................................................................ D-13
D-1.9 Gauge Lubrication Oil Pressure....................................................................................... D-13
D-1.10 Gauges drum clutch pressure High and Low .......................................................... D-13
D-1.11 CATHEAD CONTROL VALVES..................................................................................................... D-14
D-1.12 Control Valve Drum High and Drum Low Clutch...................................................... D-14
D-1.13 twin stop and crown block control .......................................................................... D-15
D-1.14 Control Valve Eddy Current Brake ............................................................................. D-15
D-1.15 Control Valve Signal Horn............................................................................................... D-15
D-1.16 key switch power pneumatic system............................................................................. D-16
D-1.17 Emergency Stop . ................................................................................................................... D-16
D-1.18 drawworks throttle........................................................................................................... D-16
D-2 operation of drAWWORK....................................................................................... D-17
D-2.1 transmission.............................................................................................................................. D-17
D-2.2 drum clutches.......................................................................................................................... D-17
D-2.3 summary of operations......................................................................................................... D-18
D-3 DRAWWORKS braking procedure (manual mode)........................................ D-19
INDEX UM199015/E - Rev.0 - 11/2011
Page XIII
Section E - MAINTENANCE E-1
E-1 GENERAL........................................................................................................................ E-2

E-1.1 MAINTENANCE INTERVALS......................................................................................................... E-3
E-1.2 WELDING......................................................................................................................................... E-3
E-1.3 NOTES TO THE MAINTENANCE MANUAL .................................................................................. E-4
E-1.4 BEFORE / DURING /AFTER MAINTENANCE .............................................................................. E-7
E-1.4.1 before maintenance ........................................................................................................... E-7
E-1.4.2 during maintenance............................................................................................................. E-7
E-1.4.3 after maintenance............................................................................................................... E-8
E-1.5 HYDRAULIC HOSES AND HOSE LINES ...................................................................................... E-9
E-1.6 allowable bearings clearance........................................................................................ E-10
E-2lubrication ............................................................................................................... E-12
E-2.1 LUBRICATION INSTRCTIONS........................................................................................................ E-12
E-2.1.1 before starting............................................................................................................................ E-12
E-2.1.2 while is running............................................................................................................................ E-13
E-2.2 SUMMARY OF PERIODIC MAINTENANCE................................................................................... E-14
E-2.3 oil types for drawwork....................................................................................................... E-14
E-2.4 GREASE types for drawwork.............................................................................................. E-14
E-2.4.1 GREASING PLATE OF DRAWWORK LAYOUT.................................................................................. E-15
E-2.5 LUBRICATION CHART POINT AND SCHEDULE.......................................................................... E-16
E-2.6 FORCED LUBRICATION................................................................................................................. E-17
E-2.7 oil changement of drawwork............................................................................................ E-18
E-3 OIL CHECK POINT of hydraulic power unit..................................................... E-19
E-4 CLUTCH MAINTENANCE............................................................................................... E-20
E-4.1 TWIN DISC - DRUM CLUTCHES.................................................................................................... E-20
E-4.1.1 INSTALLATION.................................................................................................................................... E-20
E-4.1.2 irregularitie of performance and corrective measures........................................ E-20
E-4.1.3 Clutch spillage............................................................................................................................ E-20
E-4.1.4 CLUTCH OVERHEATING.................................................................................................................... E-20
E-4.2 CB - CLUTCH................................................................................................................................... E-22
E-4.2.1 WEARING FRICTION MATERIAL....................................................................................................... E-24
E-4.2.2 WEARING DRUM MATERIAL.............................................................................................................. E-24
E-5 WIRE LINE ANCHOR...................................................................................................... E-25
E-5.1 PROCEDURE TO INSTALL THE WIRE LINE ANCHOR................................................................. E-25
E-5.1.1 INSTALLATION AND REMOVAL OF TRAVELING ROPE .................................................................. E-25
E-5.1.2 LAYING-ON OF A NEW TRAVELING ROPE . .................................................................................... E-25
E-5.1.3 CUTTING AND SLIPPING OF EXISTING TRAVELLING ROPE ........................................................ E-27
E-6 CHAINS .......................................................................................................................... E-27
E-6.1 MAINTENANCE .............................................................................................................................. E-27
E-6.1 ADMISSIBLE ELONGATION DUE TO WEAR................................................................................ E-27
E-7 HANDLING OF BEARINGS ........................................................................................... E-28
E-8 TIGHTENING TORQUES OF SCREWS ....................................................................... E-29
E-9 WIRE ROPES ........................................................................................................................................ E-30
E-9.1 WIRE ROPE DAMAGES . ............................................................................................................... E-30
E-9.1.1 Wire rope with corkscrew-shaped deformation ......................................................... E-30
E-9.1.2 Wire rope with basket-cage deformation . ...................................................................... E-31
E-9.1.3 Wire rope with looping of wires ......................................................................................... E-31
E-9.1.4 Wire rope with wires loosened by corrosion and abrasive wear ....................... E-31
E-9.1.5 Wire rope with nodes . .............................................................................................................. E-31
E-9.1.6 Wire rope with constriction ................................................................................................. E-32
E-9.1.7 Wire rope with flat spot ......................................................................................................... E-32
E-9.1.8 Wire rope with kink .................................................................................................................... E-32
E-9.1.9 Wire rope with buckling........................................................................................................... E-32
E-9.1.10 Heat effect................................................................................................................................... E-32
E-10 HOSE FITTING SPECIFICATIONS............................................................................... E-33
E-10.1 STORING OF FLEXIBLE HOSES................................................................................................. E-34
E-10.1.2 STORING TIME................................................................................................................................. E-34
UM199015/E - Rev.0 - 11/2011 INDEX
Page XIV
E-10.1.3 TEMPERATURE AND HUMIDITY..................................................................................................... E-34
E-10.1.4 LIGHT................................................................................................................................................. E-34
E-10.1.5 OXIGEN AND NITROGEN................................................................................................................. E-34
E-10.1.6 CONTACTS WITH OTHER MATERIALS........................................................................................... E-34
E-10.1.7 HEAT SOURCES............................................................................................................................... E-34
E-10.1.8 ELECTRIC OR MAGNETIC FIELDS................................................................................................. E-34
E-10.1.9 STORING CONDITIONS................................................................................................................... E-34
E-10.1.10 RODENTS AND INSECTS............................................................................................................... E-34
E-10.2 NORMS AND METHODS OF USE OF THE FLEXIBLE HOSES.................................................. E-35
E-10.2.1 PRE-ASSEMBLY CHECKS................................................................................................................ E-35
E-10.2.2 HANDLING......................................................................................................................................... E-35
E-10.2.3 PRESSURE AND SEALING TEST.................................................................................................... E-35
E-10.2.4 TEMPERATURE................................................................................................................................ E-35
E-10.2.5 TRANSPORTED PRODUCTS........................................................................................................... E-35
E-10.2.6 ENVIROMMENTAL CONDITIONS..................................................................................................... E-35
E-10.2.7 TORSION........................................................................................................................................... E-35
E-10.2.8 STRETCH.......................................................................................................................................... E-35
E-10.2.9 VIBRATIONS...................................................................................................................................... E-35
E-10.2.10 CUSPS............................................................................................................................................. E-35
E-10.3 MAINTENANCE OF THE FLEXIBLE HOSES............................................................................... E-36
E-10.3.1 MAINTENANCE................................................................................................................................. E-36
E-10.3.2 REPAIRS............................................................................................................................................ E-36
E-10.3.3 CLEANING......................................................................................................................................... E-36
E-10.4 RECOMMENDED TEST SCOPE VISUAL INSPECTION (PRIOR TO INITIAL SETTING INTO OP
ERATION OR PUTTING BACK INTO OPERATION)................................................................................ E-36
E-10.5 RECOMMENDED TEST SCOPE FUNCTIONAL TESTING (PRIOR TO INITIAL SETTING INTO
OPERATION OR PUTTING BACK INTO OPERATION)........................................................................... E-37
E-10.6 RECOMMENDED TEST SCOPE FOR SAFE PROVISION AND USE (RECURRENT OR EX.
TRAORDINARY TEST).............................................................................................................................. E-38
E-10.7 RECOMMENDED TEST CRITERIA FOR HYDRAULIC HOSE ASSEMBLIES............................. E-38
E-10.8 FACTORS INFLUENCING THE TEST PERIODS......................................................................... E-39
E-10.9 RECOMMENDED TEST PERIODS............................................................................................... E-40
E-10.10 INFLUENCING FACTORS WITH REGARD TO THE REPLACEMENT INTERVALS................. E-40
E-10.11 RECOMMENDED REPLACEMENT INTERVALS........................................................................ E-40
E-11 HANDLING OF BEARINGS ......................................................................................... E-41
E-12 BRAKING SYSTEM .......................................................................................................................... E-41
E-12.1 HOIST DRUM DISC BRAKE . ....................................................................................................... E-41
E-12.2 EDDY-CURRENT BRAKE ............................................................................................................ E-41
E-12.3 DRIVE BRAKE.............................................................................................................................. E-42
E-13 CHAINS . ............................................................................................................................................... E-42
E-13.1 MAINTENANCE ........................................................................................................................... E-42
E-13.2 ADMISSIBLE ELONGATION DUE TO WEAR.............................................................................. E-42
E-14 REMOVAL AND INSTALLATION OF DRUM SHAFT COMPONENTS ............................ E-42
E-14.1 DISASSEMBLY OF THE DRUM SHAFT ...................................................................................... E-43
E-14.2 EXCHANGE OF WEAR DISKS..................................................................................................... E-48
E-14.3 EXCHANGE PO CLUTCH 336, POS. 88 . .................................................................................... E-49
E-14.4 EXCHANGE PO CLUTCH 230, POS. 11 ...................................................................................... E-51
E-14.5 EXCHANGE SPROCKET, POS. 54 .............................................................................................. E-53
E-14.6 EXCHANGE SPROCKET, POS. 31 .............................................................................................. E-55
E-14.7 EXCHANGE MAIN BEARING, POS. 36 ....................................................................................... E-57
E-14.8 EXCHANGE BRAKE RIMS, POS. 41 ........................................................................................... E-59
E-15 REMOVAL AND INSTALLATION OF TRANSMISSION SHAFT COMPONENTS ........ E-61
E-15.1 TRANSMISSION SHAFT, POS. 40 ............................................................................................... E-62
E-15.1.1 REMOVAL OF TRANSMISSION SHAFT, POS. 40 .......................................................................... E-62
E-15.1.2 EXCHANGE OF SUPPORTING BEARING, POS. 14........................................................................ E-62
E-15.1.3 EXCHANGE OF SPROCKET, POS. 09 ............................................................................................ E-63
E-15.1.4 EXCHANGE OF SUPPORTING BEARING, POS. 14 CLUTCH END............................................... E-63
E-15.2 TRANSMISSION SHAFT, POS. 39................................................................................................ E-65
E-15.2.1 REMOVAL OF TRANSMISSION SHAFT, POS. 39 .......................................................................... E-65
E-15.2.2 EXCHANGE OF SUPPORTING BEARING, POS. 14, CLUTCH END.............................................. E-65
INDEX UM199015/E - Rev.0 - 11/2011
Page XV
E-15.2.3 EXCHANGE OF SPROCKET, POS. 08 ............................................................................................ E-67

E-15.2.4 EXCHANGE OF SUPPORTIMG BEARING, POS. 14....................................................................... E-67
E-15.2.5 EXCHANGE OF SPROCKET, POS. 31 - POS. 23, AS WELL AS OF CLUTCH, POS. 28 - POS. 29 E-69
E-16 REMOVAL AND INSTALLATION OF DRIVE SHAFT COMPONENTS ....................... E-71
E-16.1 REMOVAL OF DRIVE SHAFT, POS. 29 OUT OF DRIVE UNIT ................................................... E-71
E-16.2 REMOVAL OF AIRFLEX CLUTCH, POS. 07................................................................................ E-72
E-16.3 REMOVAL OF CLUTCH, POS. 01................................................................................................. E-73
E-16.4 REMOVAL OF SUPPORTING BEARING, POS. 19, AIRFLEX CLUTCH END ........................... E-73
E-16.5 REMOVAL OF SPROCKET, POS. 27 ........................................................................................... E-74
E-16.6 REMOVAL OF CLUTCH, POS. 32................................................................................................. E-74
E-16.7 REMOVAL OF SUPPORTING BEARING, POS. 19...................................................................... E-75
E-16.8 REMOVAL OF SPROCKET, POS. 30............................................................................................ E-75
Section F - TROUBLESHOOTING F-1
F-1 TROUBLESHOOTING..................................................................................................... F-2
Section G - OTHER RISK G-1
G-1 OTHER RISKS................................................................................................................ G-2

G-1.1 PRESSURIZED ACCUMULATORS................................................................................................ G-2
Section H - DISMANTLING AND DEMOLITION H-1
H-1 DISMANTLING AND DEMOLITION................................................................................ H-2

UM199015/E - Rev.0 - 11/2011 INDEX
Page XVI

FOREWORD UM199015/E - Rev.0 - 11/2011
Page VII
FOREWORD TYPICAL STRUCTURE OF THE PAGES
Dear Customer, this Operating, Use and Maintenance The pages of the manual have always a typical structure
Manual has been conceived to provide all information that is always characterized by the following elements:
necessary to allow the functioning, the use and the main-
tenance of the MAS8000 drilling rig according to safety 1 Model of the treated machine or fixture.
and functioning efficiency criteria.
2 Document identification code/language/edition.
Example: UM123456/I - Rev. 12/1996 = Opera-
INSTRUCTION FOR THE MANUAL tion and Maintenance Manual written in Italian
READING language, edition issued on December 1996.
3 Document type (in this case Operation and Main-
This manual provides some different type information tenance Manual).
starting from the instruction for the manual reading up to 4 Mark and logotype of DRILLMEC SpA.
the machine technical performances, the safety rules, the
5 Section and page number.
technical specifications of the maintenance products, the
operating rules, the transport rules, etc. 6 Section title.
As already pointed out into the Section B - SAFETY,

the operators will be required to carefully read and well
understand the contents of the manual before starting to 4 3 1
use the machine. It is necessary the complete understand-
2
5
ing especially of all the aspects relevant to the use, the
maintenance and the lubrication of the machine. Operation and Maintenance Manual
INSTRUCTIONS
HH 102
UM189026/E - Rev.0 - 03/2008
Page C-3
C-1-1 DRILLING CONTROLS AND INSTRUMENTATIONS

Then, the manual does not need only for a first sequential Control panel of Power Control Room (for more
reading of all its information. It has to be used as a con- 6

informations, see proper technical documentation).
From this control panel must be used to switch on
the electric motor.
tinuous reference to make clear every doubt concerning

the machine.
Fig. C-1.1
The manual has to be kept keep in easily accessible H3 H6
areas. The operators must be able to use it through the

A29
A27 A26 A25 A8
H4 H1
consultation of the Index that points out in a quick but H5
complete way the structure of the treated subjects allowing

S3 H2
C4
C48 C29
in such a way a well defined searching procedure.

C52
S6
C28
It is also advisable to know well the methods used to S11
realize the editing and the graphical technique used to

C47 C51
C50
C46
subdivide the subjects and to identify the several parts

of the manual (sections, chapters, figures ect.) in such
Fig. C-1.2
A8 Air pressure gauge C51 Torque wrench suspension up-down

A25 Oil pilot pressure drilling rig C52 Make-up Break-out Torque wrench
a way to be able to familiarize with a sort of navigation A26 Oil pilot pressure control panel
A27 Service oil pressure
H1
H2
Command enabled lamp
Hydraulic oil lter obstruction lamp
inside the document. A29 Mud pressure, standpipe manifold

C4 Oil pump 3 lifting - top drive rotation control
H3
H4
High temperature hydraulic oil lamp
Low level hydraulic oil lamp
The necessary information is reported here below.

C28 Oil pump 1 lifting - top drive rotation control H5 High temperature hydraulic oil pump lamp
C29 Oil pump 2 lifting - top drie rotation control H6 Emergency enabled lamp
C46 Tripping mode - drilling mode selector S3 Emergency
C47 Power slips in-out control S6 Command enabled
C48 Top drive rotation speed selector S11 Lamp check
C50 Inside BOP open-close selector
Fig. 2
UM199015/E - Rev.0 - 11/2011 FOREWORD
Page VIII
Then, according to the subject treated into the pages, the This structure helps in realizing a linear and detailed
following other elements can be present combined one treatment of the different subjects, also making easier the
each other: possible references to other subjects.
7 Chapter title (first, second or third level). PAGE NUMBERING SYSTEM

8 Text
9 Figure The page numbering system adopted into the subject
manual is not a continuous one: at the beginning of ev-
10 Number of figure
ery section, the page number restarts from 1 (Section
11 Identification of section cover).
8 Inside each section, the page numbering system is a

progressive one.
7 Example: Into section A, page A-2, page A-3, . etc.
HH 102 Operation and Maintenance Manual
UM189026/E - Rev.0 - 03/2008 INSTRUCTIONS
Page C-14
C-2 ASSEMBLY, INSTALLATION AND DISINSTALLATION INSTRUCTIONS TABLE NUMBERING SYSTEM

WARNING
Before consulting this section, attentively read para-
The table numbering system adopted into the subject

graph B-5 of Section B: SAFETY. P1
C-2-1 PRELIMINARY CHECKS
1. Before starting to work, it is necessary to make

manual is not a continuous one: at the beginning of every
first level chapter, the table number restarts from 1.
sure that all the checks and maintenance operations
required according with the machine performed working
hours were carried out.
Fig. C-2.1
Inside each first level chapter, the table numbering system

IMPORTANT
Worked hour of total rig, you must be refered to hour-
counter P1
2. Another mainly important check is that relevant

to the machine planarity (P2, A34, A35): when starting
is a progressive one and it is marked by the graphical
again to work (for example, after the night stop), it is
necessary to check that no ground settlings took place
in correspondence of the bearing feet and of the bearing
symbol Tab. X-0.0.
slab placed under the stabilizers. P2
Example: Into chapter A-1, Tab.A-1, Tab.A-2, . etc.
3. It is also advisable to bleed off the hydraulic oil
tank. Anyway, that procedure requires the realization of Fig. C-2.2
some operations at work completion.
WARNING
A34 A35
FIGURE NUMBERING SYSTEM
A machine inclination, especially when the drilling
rods are already driven, compromises the well verti-
cality, and, even worse, can damage the drilling rods 10
The figure numbering system adopted into the subject
string and the top drive.
manual is not a continuous one: at the beginning of every

11 first level chapter, the figure number restarts from 1.
Fig. C-2.3
9 Inside each first level chapter, the figure numbering system

is a progressive one and it is marked by the graphical
symbol Fig. X-0.
Example: Into chapter A, Fig.A-1, Fig.A-2, . etc.
Fig. 3
RECALLING CONNECTION TO OTHER SUB-
JECTS
SUBDIVISION IN SECTION AND CHAPTERS To make easier the consultation of related subjects, the
recalling connections inside the manual are executed
This manual is subdivided into six Sections respectively pointing out the alphanumeric reference code of the
marked through the letters A, B, C, D, E, F, G and H. involved chapter, figure or table. In such a way, it is pos-
sible to avoid the pointing out of too long titles or of the
Section A - GENERAL INFORMATION page numbers.
Section B - SAFETY Example:
Section C - INSTALLATION MOVING AND RIG UP Recalling connection to a chapter: (refer to A) or (refer
Section D - OPERATING INSTRUCTIONS to B-3.1.1);
Section E - MAINTENANCE Recalling connection to a table: (refer to Tab.A-1);
Section F - TROUBLESHOOTING Recalling connection to a figure: (refer to Fig.A-1.);
Section G - OTHER RISKS Recalling connection to a chapter and to a figure:
Section H - DISMANTLING AND DEMOLITION (refer to A-1 and Fig.D-3);
On their turn, the sections are subdivided in Chapters.

There are chapters of first, second and third level.
FOREWORD UM199015/E - Rev.0 - 11/2011
Page IX
UPDATING
Safety helmet
The information pointed out into the subject manual are
based upon the technical document available at the
moment of the manual writing procedure.
According to the machine equipping kit and to the provided Safety gloves
accessories, some differences can be found between the
real machine and the texts and figures into the manual.
This situation can not be used by the Customer to create
some arguing procedure. Safety shoes
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 Breathers or anti dust masks
not loose its validity.
Then, before starting up every operation on the machine, it

is necessary to check to have at disposal all the necessary Ear plugs or noise or noise protective
information. Pay particular attention to the updating code headsets
of the available technical documentation.
For more detailed information, refer to the DRILLMEC

Safety goggles or eyes protective masks
After Sale Service.
SYMBOLS
Hoses burst hazard
In this manual different universal symbols were adopted.
They are illustrated, with the indication of their meaning:
Hot parts hazard

HAZARD
It represents extreme hazard; if you fail taking the
necessary measures you (or others) are very likely
to get killed or severely injured. Accumulator burst hazard
WARNING
It represents a serious hazard. If you fail taking the
necessary measures, there is a risk that you (or oth- SIGNAL TYPE COLOR
ers) get killed or severely injured. It also indicates the Prohibition signals Red, white
possibility to create serious damages to the machine
Warning signals Black, yellow
that can consequently become unsafe.
Information, instructions, Light blue
prescription signals
Fire signals Red
IMPORTANT
It introduce a recall to the safety procedures, some Safety and rescue signals Green
technical information or some practical advises with Hazard signals Black, yellow
the aim to make possible a more efficient and eco-
nomic use of the machine respecting at the same
time the safety and the environment. The respect of
the rules pointed out under this symbol usually helps
the working execution.
UM199015/E - Rev.0 - 11/2011 FOREWORD
Page X

GENERAL INFORMATION UM199015/E - Rev.0 - 11/2011
Page A-1
Section A - GENERAL INFORMATION

UM199015/E - Rev.0 - 11/2011 GENERAL INFORMATION
Page A-2
A-1 GENERAL
The drawworks may only be used for the purpose provided in the order and the quotation, respectively. Any utilization
beyond is regarded as non-purposive. The manufacturer does not assume any liability for damage caused by
inappropriate application.
The guarantees given by DRILLMEC are stipulated in the Conditions of Supply. Guarantee claims are only justified
if, in spite of adherence to the operating instructions, defects to be attributed to DRILLMEC are caused at the
drawworks.
Guarantee claims should be advised immediately after discovery of the defect to the manufacturing works, indicating
drawworks type, the serial number and order number.
IMPORTANT
If defects are remedied by the customer or a third party without consent of DRILLMEC, DRILLMEC are not
obliged to accept claims.
The drawworks may only be operated with parts supplied by DRILLMEC. We do not assume any guarantee for
products from other suppliers.
For repairs, it is recommended to charge service technicians of DRILLMEC with this work. Furthermore, we recommend
to have the drawworks inspected regularly by our service technicians.
DRILLMEC guarantee for the correct operation of the drawworks on condition that the instructions given in the
documentation are adhered to in operation, in service and maintenance work:
Technical data
Operating and functioning description
Lifting & installation instruction
Maintenance
Preservation & storing procedure
The limit values of the drawworks indicated in the documentation must not be exceeded.
All electrical connections laid from outside to the drawworks are to be performed according to the relevant terminal
connection diagrams of the manufacturer of the electric system.
DRILLMEC shall not be responsible for any damages to the drawworks or any other equipment which occur directly
or indirectly by the non-compliance with the above instructions in operation of the drawworks.
Page A-3
A-2 IDENTIFICATION A-2.3 EQUIPMENT IDENTIFICATION PLATE
This equipment is identified through the serial number and/ The equipment identification plate shown in the picture
or the identification numbers on main components. reports all identification data for the machine. The label is
located on the front side. Always check that the equipment
A-2.1 MANUFACTURER part number (CODE N) stamped on the plate matches
with that reported on the front cover of this manual.
DRILLMEC Drilling Technologies Div.
12, Via 1 Maggio - Localit Gariga
I-29027 Podenzano (PC) - ITALY
Tel. +39 0523 354211

Telefax +39 0523 524418
Web: http//:www.drillmec.it
E-mail: info@drillmec.com DRAWWORKS
MAS8000
A-2.2 MODEL AND VERSION
Type
Serial Number 12759
Drawwork model: MAS8000. Month/Year of manufacturing 10 / 2011
Nominal power [kW] 3132
Weight complete [Kg] 70000
Weight without drive [Kg] 52000
DRILLMEC S.p.A. Drilling Technologies

Via 1 Maggio 12
29027 Gariga di Podenzano (PC) - ITALY
Service Tel. +39 0523 354211
0953-4114E
Fig. A-1
Page A-4
A-3 SAFETY AND IDENTIFICATION PLATE ON DRAWWOrK
4 4
6 7 8
4 4
1 2
3
5 4 4 5 8
Fig. A-2
Page A-5
A-3.1 API INDENTIFICATION PLATE
Pos Description Qty S/N
DRAWWORKS
Type MAS8000
Serial Number 12759
10 / 2011
1 Month/Year of manufacturing
1 09534114E
Nominal power [kW] 3132
Weight complete [Kg] 70000
Weight without drive [Kg] 52000
DRILLMEC S.p.A. Drilling Technologies

Via 1 Maggio 12
29027 Gariga di Podenzano (PC) - ITALY
Service Tel. +39 0523 354211
0953-4114E
MAS-8000
HOIST CAPACITY
SPEED MOTOR 12 LINES 14 LINES 16 LINES

2 1 0953 4209E
CL TRANS RPM LBS TON LBS TON LBS TON
LO LO 950 1380000 626 1550000 705 1713000 777

LO HI 950 787000 357 886000 402 976600 443
HI LO 950 454000 206 511000 232 564000 256
HI HI 950 258000 117 291000 132 321800 146
3 1 0953 4018E
4 1 0953 4019E
5 1 0953 4020E
Page A-6
Pos Description Qty S/N
6 1 0953 3920E
7 1 0953 3919E
8 1 0953 4115E
Page A-7
A-4 TECHNICAL INFORMATIONS

A-4.1 TECHNICAL DATA
DESCRIPTION DATA
Input H.P. Rating 3000 HP
No. Speeds 4 + 4 reverse
Drum Size. Diameter x Length 914 mm x 1574 mm
Wire rope diameter 1.3/4
Drum brake. Diameter x Width 1950 mm x 70 mm
Clutch Hi Drum PO336
Cluttch idle gear boxe PO342
Breakout cathead type Air- 24 AH
Spinning cathead type Air- 37AH
Chains, Motor to Motor One (1): 1.3/4 140-3
Chains, Motor to Countershaft Two (2): 1.3/4 140-6
Chains from Countershaft to Drum Two (2): 2.1/2 200-3
Chain from Countershaft to Cathead shaft One (1): 2 160-2
Dimension
Length 8360 mm
Heigth 3188 mm
Width 5234 mm
Weigth Total 70000 kg
Weight Motor 18000 kg
Weight Drum 52000 kg
A-4.2 PERFORMANCE CHART
HOOK LOAD
12 LINES 14 LINES 16 LINES
CLUTCH TRANSMISSION
TON LBS TON LBS TON LBS
LO LO 626 1380000 705 1550000 777 1713000
LO HI 357 787000 402 886000 443 976600
HI LO 206 454000 232 511000 256 564000
HI HI 117 258000 132 291000 146 321800
GEAR RATIO
Speed clutch transmission total ratio
1 lo 4,55 lo 2,4 10,92
2 lo 4,55 hi 1,37 6,25
3 hi 1,5 lo 2,4 3,6
4 hi 1,5 hi 1,37 2,06
Page A-8
A-4.3 TRANSMISSION DIAGRAM
Electric Motor
5 GEB22A
T.2
Electric Motor Electric Motor

5 GEB22A 5 GEB22A
T.3 T.4
T.1
T.5
T.6
Auxiliary
Clutch Clutch Brake
PO342 PO336 AKER WN72
CHAINS LIST
T.1 01990805 Roller chain ANSI B29,1 - 2 160-2 OF (98 links)
T.2 01991891 Roller chain ANSI B29,1 - 1.3/4 140-3 OF (80 links)
Fig. A-3
Page A-9
A-4.4 MAIN SKID BASE & HOUSING
The housing is fabricated from heavy steel plate welded to structural frame members. An advanced, balanced weldment
design, using heavy components where needed. The sectionalized drawworks frame is constructed, heavy section
beams. Hevy wall casing cross-members are welded between the beam ends to facilitate skidding and loading.
A-4.5 motor
Motor gives power to the drawwork. The motors are positioned on rear separeted skid on drawwork, and they are
moved separeted from drawworks main skid.
DESCRIPTION DATA
Motor Type 5GEB22A General Electric
Intermittent power 1400 HP
Voltage 600/690 VAC
Current 1380 Amp
Rotation speed, Max 800 rpm
A-4.5.1 COOLING SYSTEM
Large water cooled brakes are offered in the 3000 Drawworks. The ratio of the brake flange diameter to drum spool
diameter is among the highest offered by the trade in this class rig. This ratio is an indication of braking capacity. By
keeping this ratio high, it is possible to obtain maximum advantage from a given braking system.
The water piping to the brake water jackets has been improved by providing easily removed water hoses of simplified
design. An improved water jacket design is provided on the brake flanges. This new design provides for a breathing
action on the water jacket to avoid cracks in water jacket welds.
An improvided water stuffing box design is provided on the end of the drumshaft for admitting brake cooling water. A
lantern spacer ring is provided between both rows of outer packing while still spring loaded. Grease relief fittings are
provided on the water stuffing box to relieve high grease pressure which might tend to collapse packing rings in the
seal. A new semplified water tube packing features the use of O rings.
A-4.6 SHAFT BEARING
All shaft sizes have been proportioned to assure trouble-free operation with rated power input. Unnecessary over-
design has been avoided in the interest of keeping weight in line and at the same time keeping maintenance costs
trimmed. The shafts and shaft members have been designed for severe use. The transmission shafting used in this
drawworks is short, providing maximum rigidity and strength. All shafts are supported on self aligning spherical roller
bearings.
Transmission clutch sprockets are mounted on straight roller bearings.
Tapered shaft ends are use on tha drawworks shafts to provide quick removal of all end members on the shafts. This
permits quick disassembly when necessary. All hub members fitted on the shafting are provided with puller holes of
adequate size and capacity.
The transmission input shaft can be removed from the drawworks by removal of plate segments in the plate walls
which support the shaft. The transmission output shaft and low drive shaft are pulled endwise through suitable size
bored openings. The drumshaft assembly and catshaft assembly are removed by unbolting plate segments in the
housing walls. The rotary countershaft is removable end-wise.
The imput sprocket size on the drawworks can be varied to siute the drive applied and to adjust input drive ratio.
All labyrinth seals used in rotating parts of the shafting ride over wear sleeves, which may replaced in the event of
bearing failure causing the labyrinth to ride on the spacers. The shafting is protected.
Non-adjustable heavy duty straight roller bearings are used in the drum clutch sprockets. No adjustment of these
bearings is necessary. They are a large heavy duty design and should provide and long troble-free life.
Substantial chain capacity is provided, exceeding appreciably that of other rigs in its class. This has been accompli-
shed of sprockets size and shafts speeds.
The transmission chains are 2 pitch. four strand. Drum drive chains are 2-1/2 pitch triple strand heavy series. The
catshaft drive chain is 2 pitch double strand.
An improvide neutral brake has been provided on this drawworks. It is a simplified design and is located in an oil-proof
Page A-10
compartment. Two neutral brakes are provided, one installed on the transmission and the other on the rotary drive.
A-4.7 clutch
The high and low drum clutches used on the MAS8000 are the Twin Disk PO friction disc type. This design has been
selected for its high torque capacity and excellent heat dissipating capacity required in the rugged use of drum clutches.
Both clutches are the same size to provide interchangeability. The oversize high drum clutch provides the generous
heat dissipating capacity required to handle the frequent load engagements characteristic of high drum clutch service.
Friction plates may be replaced in this clutch w/o removing. Clutch lock bolts are provided for all friction clutches for
emergency operation.
A simplified air-shifting mechanism is provided in the drawworks transmission for the engagement of spline type
clutches. It is a very simple unitized mechanism., easily removed or assembled in the drawworks, and can be serviced
by the removal of an access cover at the back of the drawworks housing. Simple three-position type shift cylinders
are used, which require no springs for clutch release. The clutches are air shifted and air released.
An interlock system is provided so that only one drive may be engaged at a time. The complete mechanism is protected
from damage by chain failure. Shifter forks are pivoted so as to reduce friction in shifting the clutch blocks. Bronze
thrust shoes are provided on the shifter forks which ride in a groove on the clutch blocks. This design minimizes friction
and wear between the shifter and the clutch block.
Transmission clutches are spline type and air shifted from the drillers position. The spline type clutch has been provided
to obtain minimum backlash and reduce impact or shock loads as compared to the jaw type clutch. These spline are
accurately machined by gear hobbing machines and hardened for long life. A disconnect clutch has been provided
between the transmission output shaft and the low drum drive shaft to disconnect the catshaft while drilling.
The hydromatic brake clutch is manually shifted spline type. An overrunning clutch also can be applied.
A-4.8 MAIN DRUM
The large fabricated steel drum is pressed and keyed to the drumshaft. Reinforced radial ribs on the drum ends pre-
vent spreading. Spooling surface can be furnished plain or with LeBus grooving.
DESCRIPTION DATA
Drum Size. Diameter x Length 914 mm x 1574 mm
Wire rope diameter 1.3/4
Clutch Hi Drum PO336
Cluttch idle gear boxe PO342
Weigth Total 14000 kg
A-4.9 MAIN BRAKE
Ta main brake system of drawwork s composed by two disc brake, they are controlled by means a hydraulic power
unit, controlled by hand control. Main drum brake will be composed by two (2) water cooled brake discs, directly bolted
on main drum. Each disc will be equipped with three (3) active calipers and three (3) passive calipers for emergency
braking. The passive calipers are actived in case of brake failure (exp: lost of hydraulic power system). The active
system and emergency system are designed to hold safety the maximum rig load capacity.
DESCRIPTION DATA
Page A-11
A-4.9.1 hydraulic power unit BRAKE
The hydraulic power unit is installed on main skid of drawwork. The hydraulic power unit is composed by:
One structure that it permit to lift the hydraulic power unit
Double components: in drilling condition only one electric motor and one gear pump is necessary for the
brake, the other is actived only in emergency case.
Two pistons hydraulic pump
Relief valve
Hand pump
Hydraulic oil cooler with hydraulic fan motor
Electric alarm outputs for high temperature and low level alarms
DESCRIPTION DATA
Oil tank 100 l
Electric motors 20Hp, 460V, 60Hz
Max oil pressure 250 Hp
Pressure gauge 0-400 bar
A-4.10 AUXILIARY BRAKE
The drawworks is complete with water cooling system and hydromatic brake composed as follows:
DESCRIPTION DATA
Type Aker model WN72
Rated torque 96,000 lbft 50 rpm
Number of magnet 2
Number of coils 4
Voltage 250 VDC
Current 74,07 amps
Inlet water flow 150 GPM
Housing dimension 38 x 78
A-4.11 CATHEAD
Universal cathead adapters provide for interchangeable mounting of Foster cathead.
Spinning cathead Foster 37 AH

Break-out cathead Foster 24 AH
Page A-12
A-4.12 LUBRICATION SYSTEM
A simple but highly improved lubrication system is offered in the MAS 7500. Spray nozzles, which provide a fan type
spray, lubricate as well as cool the drawworks as chains. The same spray nozzle is used throughout. The location of
these spray nozzles is such that they are protected from damage due to chain failure. This design will provide ample
amounts of oil for the chains, materially increasing change life.
One electric pump of large capacity is furnished in the drawwork. Its installed on main skid of drawwork.
An oil strainer mounted on the drawworks transmission space with simple piped connections, is provided to clean the
oil before recirculation.
All bearings in the drawworks are grease lubricated, eliminating troublesome oil seals. All shaft support bearings are
centrally lubricated from conveniently located greasing panels. All clutch sprockets are easily lubricated through a
multiple fitting design accessible through large openings in the drawworks housing. These openings are fitted with
hinged covers and are readily accessible.
Clearly detailed greasing instructions are provided where necessary. instruction plates indicate greasing points.
A-4.13 CONTROL PANEL
The main control panel is located on driller cabin National.
A-4.14 transmission clutch
Heavy-duty spline-type positive cluthes are used in the transmission. Splines are surface hardened afer machining
for resistance to wear.
A simplified band-type neutral brake on the input shaft stops the transmission for shifting.
Clutch shifting is completely air controlled from the drillers console. Simple three-position shift cylinders operate
shifter forks which ride in grooved clutch blocks. An interlock system prevents accidental engagement of two drives
simultaneously.
A positive clutch is provided to disconnect the low drum drive and cathead shaft while rotating.
A-4.15 Air system and controls
A highly functional, very much siplified control console of pleasing appearance is offered on the MAS7000. this con-
trol console provides for complete accessibility, both through the front and reat, with semplified piping arrangements.
All valves and gauges are mounted on attractive aluminum panels with instructions in raised easy-to-read letters.
All hoses connecting to the drawworks air system are equipped with quick disconnect couplers of high quality. The
console may be removed from the drawworks in a matter of minutes. Gauges of the heavy duty oil field type of good
appearance are provided. The same gauge is used throughout. The vacuum gauges of similar construction are pro-
vided when gas engines are used. The control valve for high and low clutch and for the rotary clutch and breakout
cathead is provided with an improved control handle of different design from the other valves. Thus, the driller knos
by touch when his hand is on these control.
A feature of this control console is a simplified push button throttle compounding arrangement, which provides for foot
or hand throttle control of engines as required by the driller. A newly designed transmission air shift valve of simlified
and fool proof construction is provided. The console provides a pleasing silhouette and his low enough for for even
the shortest driller to conviently see over. The breakout and make-up catheads are air controlled from the console.
Foot operated valves are provided for engine speed control and control of the rotary brake.
Air relay valves fro the drum clutches are an improved, highly reliable type which need the very minimum of servicing.
These relays provide for abundant air supply to the drum clutches when necessary. The drum clutches are provided
with suitable flow restrictors to prevent too rapid engagement. An air volume tank is provided to prevent pressure
drawdown in the air system when large volumes are required for the drum clutches. Interlock valves are provided
between the high and low drum clutches to prevent simultaneous engagement of both clutches. The tachometer used
to indicate transmission input shaft speed is a simple mechanical type of a highly dependable design. A short slow
speed cable is used which has no abrupt turns or kinks assuring long cable life.
A hook load chart is provided near the control console so that the driller may quickly determine limiting hook loads to
protect the drawworks when powered with more than rated horsepower.
Page A-13
A-4.16 housing
The housing is fabricated from heavy steel plate welded to structural frame members. an advanced, balanced weld-
ment design using heavy components where needed, but reduced thickness where practical, results in efficient and
proper disposition of weights.
All machining of the through-bore housing is done after welding to insure perfectly aligned and accurately located
shaft centers.
A-4.17 sprockets and chains
Transmission chains are 2.1/2 pitch four strand, running on surface hardened machined-tooth sprocket. All chain
transmitting power to the drum is a 1.3/4 triple width heavy series. Rotary countershaft & catshaft drive chains are
2 pitch double width.
Sprocket sizes and sprockets rotating speeds have been carefully selected to maintain a proper balance among
all component parts. The low drum clutch sprocket is of the bolt rim type. This permits unbolting the sprocket rim
from its carrier and removing the complete low drum clutch hub assembly without removing yhe drumshaft from the
drawworks.
All interior parts are protected from damage due to chain failure.
Page A-14
A-5 main dimension and weights
3200
2550 2261
465
2598
3595 4535 2443 2791
8130 230 5234
5234
Total weight: 70000 kg
Motor weight: 18000 kg
Drum weight: 52000 kg
Fig. A-4
Page A-15
A-6 LIFTING points
Fig. A-5
IMPORTANT
The lifting must be executed with separated racks.
WARNING
During the drawworks lifting operation take care to the lifting ropes, that not damage the drawworks parts,
use appropriate equipments.
Page A-16

SAFETY UM199015/E - Rev.0 - 11/2011
Page B-1
Section B - SAFETY
UM199015/E - Rev.0 - 11/2011 SAFETY
Page B-2
FOREWORD
In this manual, for example, the safety symbology Safety shoes

(SYMBOLOGY) was adopted, in order to signal possibly
dangerous situations.
Breathers or anti dust masks
IMPORTANT
Dont remove the plates present on the machine. In
Ear plugs or noise or noise protective
case of loss or deterioration of them, it is obligatory
headsets
for the User to promptly provide to replace them.
B-1 PERSONNEL QUALIFICATIONS

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

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

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

vidual safety means:
Safety helmet
Safety gloves
SAFETY UM199015/E - Rev.0 - 11/2011
Page B-3
B-2 MACHINE PLATES

Meaning:
It is forbidden the entrance of not authorized personnel.
Part code number:

09531098
Fig. B-1
Meaning:
Accumulator burst hazard.
Part code number:

09531095
Fig. B-2
Meaning:
Hoses burst hazard.
Part code number:

09531097
Fig. B-3
UM199015/E - Rev.0 - 11/2011 SAFETY
Page B-4
Meaning:
Extremely hot parts: scorching hazard
Part code number:

09531096
Fig. B-4
Meaning:
Danger of suspended loads.
Part code number:

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

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

09531111
Position:
- Batteries
Fig. B-7
SAFETY UM199015/E - Rev.0 - 11/2011
Page B-5
Meaning:
Danger. Explosive gas.
Part code number:

n/a
Position:
- Batteries
Fig. B-8
Meaning:
Danger of hand crushing.
Part code number:

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

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

09531107
Position:
- Alternator
- Electric panels
Fig. B-11
UM199015/E - Rev.0 - 11/2011 SAFETY
Page B-6
Meaning:
It is forbidden to remove the guards and the safety de-
vices.
Part code number:

09531116
Position:
- Safety ropes
- Cardans
Fig. B-12
Meaning:
It is forbidden to repair, to lubricate and to clean moving
parts.
Part code number:

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

09532167E BEFORE MAINTAINING REMOVE
THE ENGINE STARTING KEY
Position: FROM THE CONTROL PANEL
- Cardans
- Power swivel shifting chains BEFORE OPERATING THE ENGINE
REMOUNT THE PROTECTION COVER
Fig. B-14
Meaning:
It is mandatory to use proper ear plugs or acoustic protec-
tion headsets.
Part code number:

09531099
Fig. B-15
SAFETY UM199015/E - Rev.0 - 11/2011
Page B-7
Meaning:
Grounding instructions.
Part code number:

09532639E
Fig. B-16
Meaning:
Welding instructions.
Part code number:

09532640E
Fig. B-17
Meaning:
Warning plate
Fig. B-18
UM199015/E - Rev.0 - 11/2011 SAFETY
Page B-8
B-3 SAFETY DEVICES

The machine is fitted with the following buttons for emer-
gency stop and mechanical locking devices.
- Accesses to emergency-off switches and escape rou-
tes are always to be kept free.
Pos Description
Crown O Matic System
Crown O Matic
Fig. B-19
Pos Description
Twin Stop System
HAZARD
Before operating the machine, verify all safety devices
are present and properly working.
Twin Stop System
Fig. B-20
SAFETY UM199015/E - Rev.0 - 11/2011
Page B-9
B-4 diagram of safety device for emergency stop
Twin Stop System
Crown O Matic
Fig. B-21
UM199015/E - Rev.0 - 11/2011 SAFETY
Page B-10
B-5 GENERAL SAFETY DURING THE MACHINE TRANSPORT PHASE

The rig is transported like:
skid complete with all drawworks

wooden boxes
On every wooden case, the weight and the indication of the usable handling means are reported.
WARNING
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.
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.
B-6 GENERAL SAFETY DURING THE MACHINE ASSEMBLY, INSTALLATION

AND DISINSTALLATION PHASES
The operators must wear the here following enlisted individual safety devices (PPE):
Safety helmet
Safety gloves
Safety shoes

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.
Never go to work on a condition 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 specific warnings about operating machi-
nery after taking the medication.
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
SAFETY UM199015/E - Rev.0 - 11/2011
Page B-11
WARNING
It is recommended to get informed about the possible
presence of any underground long-distance lines and
about their characteristics.
Make sure that the electric current generator exhaust

gases dont invest the personnel operative stationary
area. It is charged to the User, to provide making avai-
lable the means required for discharging the fumes in
a safe area.
Check that there arent any leaks or leakages of
hydraulic fluids. Fig. B-22
WARNING
Provide to the elimination, by means of a safe treat-
ment, of the drilling muds.
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 specific
warnings about operating machinery after taking the
medication.
Fig. B-23
Fig. B-24
UM199015/E - Rev.0 - 11/2011 SAFETY
Page B-12
B-7 GENERAL SAFETY DURING THE MACHINE OPERATION PHASE

The operators must be equipped with the following individual safety means (DPI):
Safety helmet
Safety gloves
Safety shoes

headsets
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.
B-8 GENERAL SAFETY DURING THE ROUTINE AND THE EXTRAORDINARY

MAINTENANCE PHASES
B-8.1 GENERAL INFORMATION
Before any maintenance work is carried out, the following safety measures should be observed:
There may only be charged those persons
who have reached the age of 18 years
who are physically and mentally capable to this work
who have been instructed in operations on the drawworks and have proved their capability to do so towards
the user, and from whom it can be expected that they reliably fulfill the tasks entrusted to them.
The operators permit to work system must be adhered to.
The drawworks must be stopped and isolated from the power.
The work area must be adequately lighted so that good all round vision is assured.
Audible warning signals provided by the operator in the drawworks area shall be of sufficient volume to be heard
by the attending personnel, even if the drawworks is in full spectrum operation.
Visual warning signals provided by the operator in the drawworks area shall be located such that they are clearly
visible to attending personnel.
Safe access must be provided to all items of equipment that cannot be reached from floor level.
I n supplement to the Maintenance Manual consider and instruct any general, legal and otherwise binding regula-
tions to accident prevention and environmental protection!
Complete the Maintenance Manual by instructions including supervision and registration obligations with regard
to the consideration of company internal particularities, e.g. organization of work, operation sequences, charged
personnel.
SAFETY UM199015/E - Rev.0 - 11/2011
Page B-13
Before starting any work, the personnel charged with the operations at the drawworks must have read and un-
derstood the Maintenance Manual, here, especially the chapter Safety Regulations. During working proper, it
will be too late. This especially applies to staff that only occasionally works at the drawworks, e.g. for rigging-up,
maintenance, etc.
Verify the safety and risk conscious working of the personnel on the basis of the Maintenance Manual, at least
occasionally!
The personnel must not wear long open hair, loose-fit clothes or jewelry including rings. There is the risk of injuries,
e.g. by getting stuck or seized.
Wear personal protective equipment to the required extent and as demanded by prescriptions!
Keep all safety and caution notes on the drawworks in mind!
Keep all safety and caution notes at/on the drawworks fully in legible condition!
In case of safety-relevant modifications to the drawworks or its operational attitude, stop drawworks immediately
and inform competent service / person!
Never make any changes on, attachments to and restructuring of the drawworks that could affect safety without
suppliers prior approval! This applies to both the installation and setting of safety units and valves and to welding
of supporting elements.
Spare parts should always meet the technical requirements defined by the manufacturer. This is always ensured
using DRILLMEC original spare parts.
Adhere to prescribed terms or those indicated in the Maintenance Manual for repeating checks / inspections!
To carry out maintenance measures a workshop equipment as required by the level of work is indispensable.
Make public place and use of fire extinguishers!
Consider fire alarm and fire fighting possibilities!
Definitely charge trained and instructed personnel, only, for operation, rigging-up, maintenance and repair work!
Make sure that only authorized personnel operates and works at the drawworks!
Staff to be trained, instructed or informed or personnel acting within the scope of a general training measure may
only become active at the drawworks under the permanent supervision of an experienced person!
All auxiliary lifting equipment (slings, shackles, chains, etc. ...) must have been tested and have a valid test cer-
tification.
Repairs shall be effected immediately after having detected a defect.
Unauthorized modifications and changes to the drawworks are not allowed.
WARNING
To comply with EC Regulations, each drawworks shall be fitted with emergency stop breakers located on
each side of the drawworks. All electrical drawworks drives shall be provided with a load circuit breaker (key
switch) for maintenance purposes. Emergency stop breakers and key switches are not supplied as part of
the drawworks. They are not WIRTH scope of supply.
WARNING
For adherence to the EC directives, each drawworks must be equipped with emergency stop switches on
each drawworks side. All electric drawworks drives must be equipped with a load circuit breaker (key switch) for
maintenance work. Emergency stop and key switches are not supplied as integral part of the drawworks.
They shall be supplied and fitted by others.
UM199015/E - Rev.0 - 11/2011 SAFETY
Page B-14
B-8.2 MECHANICAL PART
Safety helmet
Safety gloves
Safety shoes

headsets
Safety sling
When You are working, carrying out maintenance interventions or repairs, always use the utmost prudence:
Before carrying out the maintenance or the repairing operations, clean the machine, especially the joints and the
screw connectio ns, from any oil, fuel or detergents residuals. Dont use any aggressive detergents. Exclusively
use filament-free wiping clothes.
Clean all the handles, footboards, rails, platforms and ladders from any dirt, snow and ice.
Before cleaning the machine with water or a steam jet (high pressure sprayers) or by using other cleaners, close
and seal all the openings into which, for either safety and/or operating reasons, neither water, steam or 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
hoisting capacity.
Before starting any maintenance operation, insert the safety retainers both for the equipments and for the control
levers; the machine must be positioned on a flat ground and the equipments must lean on the ground.
SAFETY UM199015/E - Rev.0 - 11/2011
Page B-15
Before carrying out the maintenance, hang on the

control levers and on the ignition key the relevant
hazard warning plates (see Fig. B-25); if You hold it
as being necessary, apply warning plates also around
the machine.
Exclusively carry out the maintenance by still standing,
cooled-down and safe-positioned machine.
In order to protect the machine against the possibility
of being accidentally started-up:
Close the main control devices and take off the
key.
Apply on the cut-out switch a hazard warning
Fig. B-25
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 purposed safety
sling, complying with the instructions supplied in the relevant specific instructions.
After having completed any maintenance or repair intervention, before starting again the machine, make sure that
no tools, wiping clothes or other materials are left near the moving mechanisms.
WARNING
Provide to the safe and possibly biodegradable elimination of the consumption and auxiliary materials and
of the replaced parts.
B-8.3 ELECTRIC PART
Safety helmet
Safety gloves
Safety shoes
The works to be executed on either electric plants or operating means can be exclusively carried out either by
an electrician or by qualified personnel, under the supervision of an electrician and in a fully complying way with
respect to the electro-technical rules.
Parts of the machinery subject to inspection, maintenance and repair interventions must be stress-relieving con-
nected, if prescribed. First check if such 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 emergency, can
UM199015/E - Rev.0 - 11/2011 SAFETY
Page B-16
actuate the cut out switch . Protect the working place with a white/red chain and mount a hazard warning signal.
Use only tools insulated against electric voltage.
When working on high voltage components, connect the power supply cable to the ground, after having cut out
the voltage.
WARNING
The electrolytic accumulators contain sulphuric acid which can provoke scalds.
When working on accumulators, always wear goggles.

The accumulators produce hydrogen, which is highly explosive and easily inflammable by sparks or free fla-
mes.
WARNING
Provide to eliminate the electric/electronic wastes (RAAE) in full compliance with the relevant laws in force
in the country in which the wastes elimination must be performed.
B-8.4 HYDRAULIC PART
Safety helmet
Safety gloves
Safety shoes
The interventions on hydraulic plants shall be exclusively executed by personnel both trained and, qualified in
the hydraulic field.
When opening any delivery systems and pipes (hydraulic system, compressed air), it is necessary to discharge
them from the pressure, before carrying out the intervention.
Carry out the maintenance interventions only when the temperature values are comprehended within the normal
parameters (45C).
For disassembling the hydraulic accumulators, strictly observe the instructions supplied by the manufacturer.
WARNING
Provide to the safe and possibly biodegradable elimination of the hydraulic fluids and of the replaced
parts.
SAFETY UM199015/E - Rev.0 - 11/2011
Page B-17
B-9 Safety Rules Regarding Scheduled Maintenance
WARNING
Do not change the maximum relief valve setting on any hydraulic circuit without permission from the manu-
facturer. Never change an accumulator circuit pressure setting without specific instructions from the manu-
facturer.
WARNING
Never make unauthorized modifications to structural members or pressure circuits.
WARNING
You must replace, not repair damaged hydraulic or concrete hoses or pipes.
WARNING
Electronic components can be destroyed by welding current.
Before welding on the unit, unplug all radio remote control power wires. If you have a proportional boom
system, the proportional amplifiers must be removed from the mother board before welding.
If in doubt, contact the service department of the manufacturer for instructions before proceeding.
WARNING
Never activate the system hydraulics without checking ifanother workman is in a hidden position. Always yell
clear before starting the engine or electric motor, and allow time for response.
WARNING
Never work on a pressurized hydraulic system. Stop the engine or electric motor and relieve the accumulator
circuit (if so equipped) before you open the hydraulic system.
WARNING
Explosion hazard! Never open a pipeline that is under pressure. The pump must be run in reverse for at least
two strokes and then stopped before opening a pipeline. If you dont know how to reverse the pump, have the
operator do it. If the pipeline is pressurized with air, do not open it. The operator is responsible for knowing
how to safely release the air pressure.
WARNING
Never open a pressurized pipeline. The pump operator must release the pressure before you open the line.
If the line is pressurized with compressed air, let the operator release the pressure and verify that the air has
escaped before you proceed.
UM199015/E - Rev.0 - 11/2011 SAFETY
Page B-18
B-10 GENERAL SAFETY DURING THE OUT OF SERVICE SETTING AND ELIMI-
NATION PHASE
WARNING
Provide to the safe and possibly biodegradable elimination of the demolition resulting materials.
WARNING
Provide to the elimination of the electric/electronic materials (RAAE), in full compliance with the relevant laws
in force in the country in which the elimination must be performed.
WARNING
Provide to the safe and possibly biodegradable elimination of the lubricating oils, the greases and the hy-
draulic fluids.
INSTALLATION, MOVING AND RIG UP UM199015/E - Rev.0 - 11/2011
Page C-1
Section C - INSTALLATION, MOVING AND RIG UP

UM199015/E - Rev.0 - 11/2011 INSTALLATION, MOVING AND RIG UP
Page C-2
C-1 INSTALLATION, MOVING AND RIG-UP

C-1.1 Preparation FOR USE
A. Clean of bolting pads and make sure that dowels enter properly and that pads are securely fitted together.
- Remove wood covers from openings which are protected in this manner and from input guard opening in rear of
drawworks.
- Connect air hoses (equipped with quick-connect couplings).
Fig. C-1
- Connect the electric motor skid to main drawwork skid. Use the pins to allign the skids.
- Connect electric motor chains MAS8000.
- Complete assembly of guard.

B. Remove rust preventive from brake flanges, clutch drums, neutral brake drums and exposed portions of foot throt-
tle valve and control panel valves, using a nontoxic and non-flammable solvent cleaning material.
C. Remove rust preventive from other exposed portions of drawworks where necessary, using a nontoxic and non-
flammable solvent cleaning material. This includes splines and splined shaft at hydromatic brake (where furnished)
and brake adjusting screws.
INSTALLATION, MOVING AND RIG UP UM199015/E - Rev.0 - 11/2011
Page C-3
D. Remove plastic Caplugs from:
Quick release valve exhaust ports (center pipe tap) as follows:
High Drum Clutch on clutch face
Lo Drum Clutch on clutch face
HI Drum Clutch on clutch face
Cathead Air Line on housing wall
Air Tank Drain Cocks.
E. Remove standard pipe plugs from brake cooling water connections and connect to a suitable water supply.
F. Remove masking tape at all locations. It is especially important to check exhaust ports of control panel valves,
inside the control panel and atmospheric vents on air cylinders.
G. Lubricate entire rig in accordance with Maintenance section of this manual.
H. Align with compound drive in accordance with instructions in drive manual and tie down securely. Connect air lines
from compound drive to drawworks. A unitized air hose manifold is provided between the compound drive and the
drawworks which eliminates the necessity for making and breaking numerous air line connections each time the
unit is moved. The stud holes in the air manifold flanges are drilled eccentrically to prevent improper connections
when rigging up.
I. Install catheads and othe parts which have been removed for shipping.
C-1.2 pre-starting instructions
Make the following checks before initial starting rigs:

A. Check compound drive chain housing, drawworks housing and drawworks oil sump for presence of dirt or water.
Clean and drain if necessary.
B. Make absolutely sure that any cocks in oil suction line and oil discharge line between drawworks and drive are
open while operating.
C. Fill drawworks oil sump with 250 l of oil using ISO VIS.GR.220 (SAE 50) for temperature of 55 F, or higher, and
ISO VIS.GR.100 (SAE 30) for 0 to 55 F. Below 0 F use oil with a pour point of at least 5 lower than the lowest
atmospheric temperatures.
D. Grease all points equipped with alemite-hydraulic grease fittings. Refer to lubrications charts in Maintenance and
Operation Manual.
E. Note oil pressure gauge on control panel to be certain that oil is circulating after rig in this operation.
F. Check oil level in sump after rig is in operation and add oil if necessary.
G. Remove plugs and covers from exhaust ports in quick release valves, control valves and relay valve. See air
system diagrams in Maintenance Manual.
H. The compressed-air system must provide a volume from 1 to 1.5 m/min compressed-air at a pressure of at least
7 bar to maximum 12 bar
UM199015/E - Rev.0 - 11/2011 INSTALLATION, MOVING AND RIG UP
Page C-4
IMPORTANT
DO NOT ATTEMPT TO OPERATE DRAWWOKS WITH LESS THAN 7 bar PRESSURE
C-1.3 auxiliary brakes
When auxiliary brakes of any type are ordered with the drawworks, they are installed and aligned at the plant. Shaft
alignement should be checked before operated and should be whitin .010 total indicator runout, between brake shaft
and drawworks drumshaft.
Water hoses on auxiliary brake should be connected to water cooling tank when rig is assembled.
C-1.4 cathead
Cathead shafts are fitted with a Universal cathead adapter at each end. These adapters will take any one of two principal
catheads, Foster or Kelco. If cathead are ordered with the rig, all bolts, anchor fittings, etc., will accompany the rig.
In the case of air or hydraulically operated catheads, air lines or hydraulic lines should be connected and tested for
operation before actually being put in use. The hand operating lever for the manually operated spinning catheads can
be adjusted in height by the adjusting yoke on the rod.
C-1.5 cooling water for drum brakes
It is important that an ample supply of cooling water be provided for the drum brakes. The water supply must ensure
a quantity of 189 l/min at a pressure of 3.1 bar for the disc brake and eddy-current brake.
C-1.6 moving rig
The MAS8000 will ordinarily be moved woth electric motor skid removed and cathead shaft installed. Care should be
taken to keep interior of housing clean. Protect from blowing dust and dirt.
C-1.7 special instructions
Check all air lines and controls for correct operation before putting the rig in actual operation. It is well for the driller
to familiarize himself with the controls before operating rig. Check all air lines for leaks before starting to drill. After air
supply is built up, it is good practice to shut down engines and look for leaks. They are much more readily detected
when engines are silent. Leaks sometimes develop due to vibration in trucking or during operation. Check lubrication
system, by running rig at idling speed and inspecting for oil delivery to all chains and shifters. If sufficient oil is present
at idling speed the supply will be generous at operating speeds.
C-1.8 lubrication
The Drawwork is complete with a lubrication forced system composed by a electro pump and alll components that
they permit to lubricate the drawwork.
OPERATING INSTRUCTIONS UM199015/E - Rev.0 - 11/2011
Page D-1
Section D - OPERATING INSTRUCTIONS

UM199015/E - Rev.0 - 11/2011 OPERATING INSTRUCTIONS
Page D-2
D-1 CONTROLS AND INSTRUMENTS

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 them and to
let them precede by a letter, as here following explained.
C-1
DEVICE IDENTIFICATION PROGRESSIVE

LETTER NUMBER
Legend :
C = Hydraulic/pneumatic controls
R = Hydraulic/pneumatic regulators
S = Electric controls
A = Hydraulic/pneumatic instrumentation
P = Electric instrumentation
H = Visual and acoustic electric signals
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.
Page D-3
D-1.1 DRAWWORK controls in the driller cabin
3
1
5 6
Fig. D-1
Page D-4
CONTROL PANEL 1
H1
H2
H5
H6
C2 SH1
Fig. D-2
C2 Gear selector
H1 Low speed gear 1
H2 High speed gear 2
H5 Service brake on
H6 Parking brake on
SH1 Enable commands
Page D-5
CONTROL PANEL 2
12H2 12H3 12H1
Fig. D-3
12H1 Auxiliary brake alarm

12H2 Auxiliary brake ready
12H3 Auxililary brake modulation
Page D-6
CONTROL PANEL 3
A2
A3
A1
A12
A11
C13
C14
A9
C1
Fig. D-4
A1 Air pressure indicator

A2 High speed clutch air pressure indicator
A3 Low speed clutch air pressure indicator
A9 Inertia brake pressure indicator
A11 Brakes system indicator
A12 Oil pressure of lubrication drawwork indicator
C1 Inertia brake control
C13 Break-out cathead
C14 Spinning cathead
Page D-7
CONTROL PANEL 4
R4
S4
Fig. D-5
S4 Rotation selector of electric motor

R4 Drawworks speed regulator
Page D-8
CONTROL PANEL 5
12S1
C7
12S3
C15
C16
Fig. D-6
12S1 Auxiliary brake joystick control

12S3 Auxiliary brake drillint-tripping selector
C7 Main drum clutch
C15 Reset of Twin-Stop & Crown-O-Matic
C16 Manual insertion Twin-Stop
Page D-9
CONTROL PANEL 6
SM1
SE1
C4
C6
SH10
HA1
P1
Fig. D-7
C4 Key to engage the main feeding of the pneumatic

system
C6 Acustic signal
HA1 Autodriller warning
P1 Automatic driller
SE1 Brakes emergency pushbutton
SH10 Autodriller enable
Page D-10
D-1.2 AUXILIARY BRAKE LEVER
AUXILIARY BRAKE
LEVER
Fig. D-8
Page D-11
D-1.3 lubrication
The Drawwork is complete with a lubrication forced system composed by a electro pump and all components that
they permit to lubricate the drawwork.
Fig.D-9
Page D-12
D-1.4 AIR PRESSURE
A1 Air pressure gauge
A1
This gauge indicates the air control pressure of the pneu-
matic system and should be observed at frequent intervals
to assure proper air pressure is being supplied. Refer to
Technical Data section of this manual.
Fig. D-10
D-1.5 DRIVE BRAKE PRESSURE
A9 Drive brake air pressure gauge
This gauge indicates the pressure of the drive brake.

Check pressure of the drive brake after de-airing.
A9
Fig. D-11
D-1.6 Control Valve Drive Brake
C1 Control valve of drive brake
The control valve of the drive brake supplies air to a relay

valve. The relay valve admits air to an Airflex clutch, which
is mounted on the drive shaft and the motor frame.
Activate the drive brake during motor rotation for a smooth
rotation of the drive shaft when shifting the different
sprockets on the countershaft with the shifting counter-
shaft system.
C1
Fig. D-12
D-1.7 Control Valve Selective Trans-
mission Gear I and Gear II Se-
lectoR
C2 Gear selector
This control valve selects the desired speed range in the

selective transmission for the drawworks. C2
Fig. D-13
Page D-13
D-1.8 Gauge brakes system
A11 Oil pressure of breaks system
This gauge indicates oil pressure of the brakes HPU.

A11
Fig. D-14
D-1.9 Gauge Lubrication Oil Pres-
sure
A12 Oil pressure gauge of lubrication

A12
This gauge indicate the lubricating oil pressure in the
drawworks. Since all chain drives and some bearings
are pressure lubricated, it is important that the oil pres-
sure be maintained as recommended in the Maintenance
Lubrication Section of this manual. Any irregularity in oil
pressure may indicate broken or stopped up oil lines,
faulty oil pump, stopped up suction screens, etc. For
further information on this system, refer to the lubrication
section of this manual. Fig. D-15
WARNING
Always make sure electric motor driven oil pump
at drawworks skids is operating before performing
any functions with the drawworks, by observing this
pressure gauge.
D-1.10 Gauges drum clutch pressure

High and Low
A2 High speed clutch air pressure indicator A3 A2

A3 Low speed clutch air pressure indicator
These gauges are interconnected with the drum high and

drum low air pressure lines. When engaging the drum high
or low clutch, observe these gauges to assure that proper
air pressure is being supplied to the clutch as recom-
mended in the Technical Data Section of this manual.
Fig. D-16
Page D-14
D-1.11 CATHEAD CONTROL VALVES
C13 Break-out clutch cathead

C14 Spinning clutch cathead
These controls valve are need to engage or disengage

the cathead on each side of drawwork C13
C14
D-1.12 Control Valve Drum High and

Fig. D-17
Drum Low Clutch
C7 HI-LO drum clutch
The upward movement of this valve handle will supply air

pressure to the relay valve located in the drillers control C7
console. The relay valve will then dup a large volume of
air directly into the drum high clutch located on the drillers
side of the drum shaft.
The downward movement of the valve handle will supply
air pressure to the relay valve located in the drillers control
console. The relay valve will then dup a large volume of
air directly into the drum low clutch located on the drum
shaft site of the eddy current brake.
The purpose of the relay valve is to speed up the response Fig. D-18
of the drum clutches by allowing a low volume of air from
the control valve to actuate the pilot cylinder section of the
relay valve, which in turn will open the port in the lower
section and give a larger volume of air directly into the
clutch air line.
This is a modulating type valve and will supply from 0 to
full air pressure through the full travel of the valve handle.
The relay valve will also follow the same air pressure as
that being supplied by the High-Low drum clutch valve.
IMPORTANT
The air pressure shown on the pressure gauge indi-
cates the air pressure in the line between the relay
valve and the clutch. At frequent intervals, or if clutch
operation should become erratic, check operating
condition of relay valve.
WARNING
DO NOT DOUBLE CLUTCH! i.e. Do not engage the
high drum clutch to start the load moving, and then
immediately shift the control valve lever through neu-
tral into the low drum clutch drive. This can result in
both high and low drum clutches being engaged at
the same time, causing severe shock loading to the
equipment.
Page D-15
D-1.13 twin stop and crown block

control
C15 Reset of Twin-Stop & Crown-O-Matic

C16 Manual insertion Twin-Stop
C15
C16
Fig. D-19
D-1.14 Control Valve Eddy Current
Brake
12S1
12S1 Control of auxiliary brake
12S3 Auxiliary brake drillilng-tripping selector
12H1 Auxiliary brake alarm
12H2 Auxiliary brake ready
12S3
12H3 Auxiliary brake modulation
Refer to manufacturers instruction for proper operation

and maintenance.
To obtain maximum brake rim and brake lining life, use
Eddy Current Brake for controlling rate of descent of drill
Fig. D-20
stem loads, beginning with the first stand of drill collars.
12H2
12H3 12H1
Fig. D-21
D-1.15 Control Valve Signal Horn
C6 Acoustic signal
The control valve delivers air to a pneumatically driven

signal horn.
C6
Fig. D-22
Page D-16
D-1.16 key switch power pneumatic

system
C4
C4 Control key
This key permits to engage the main feeding of the pneu-

matic system.
Fig. D-23
D-1.17 Emergency Stop
SE1 Emergency pushbutton SE1
The emergency switch is a valve which will provide air

to the 3/2 way valve. The 3/2 way valve supplies imme-
diately air to a hydraulic valve that is able to operate the
hydraulic disc brake.
To run the system again, the driller has to apply the main
drum brake with the drum brake lever. Afterwards the posi-
tion of the drum clutch control valve must be controlled.
Then the emergency switch could be released.
Fig. D-24
IMPORTANT
The emergency switch will not shut off the electric
motors.
D-1.18 drawworks throttle

S4
R4 Drawworks speed regulator
S4 Rotation selector of electric motor R4
The drawwork takes power from the eletric motor. The

increase of power is controlled by r4 regulator on control
panel of control cabin.
Fig. D-25
Page D-17
D-2 operation of drAWWORK

D-2.1 transmission
In selecting transmission speeds the following shifting procedure should be strictly observed.
Disengage the master clutch and engage the inertia brake
When shafts have stopped turning, move transmission selector valve to desired position. The transmission clutches
are a positive spline type and to avoid damage to splines, shafts must be stopped before shifting. The transmission
should be left in gear until the neutral brake has been applied. This allows the driller to observe shaft movement
by watching the tachometer to be sure that shafts are stopped. If this procedure is not followed the transmission
output shaft may be free wheeling when engagement is attempted.
Slowly move the valve from the neutral brake position to the master clutch position. This procedure of slowly
engaging the master clutch is necessary to determinate if the splines are properly engaged. Although the spline
ends are tapered to lead the spline into engagement, it is possible for the spline to be angularly displaced so as to
an audible clatter will be heard as the splines ratchet. When this condition is encountered quickly return the valve
to the neutral brake position and re-engage. after making sure shafts are stopped.
D-2.2 drum clutches
The high and low airflex clutches are controlled from an air valve mounted in the control panel. The drum clutch valve
located in the panel operates relay valve, which admit supply air directly to the clutches. The clutch relay valves are
actuated through air interlock valves, which insure against simultaneous engagement of the high and low clutches.
Air is released from clutches through quick release valves, which speed emptying of clutch air tube.
Page D-18
D-2.3 summary of operations
Select 1st or 2nd speed via control valve C2 depending

on the load to be pulled. Shifting may only be done
in standstill or at a very low number of revolutions of
the drive shaft, adding the Airflex clutch by valve C1
as braking load. C2
If required so, the eddy-current brake can be coupled
using the hand shifting lever 12S1 beside the eddy-
current brake. Connection may only be done in stand-
still or at very low drum speed.
Connection of one of the two pneumatic hoist drum
clutches depending on the load and the desired speed
via control valve Drum Clutch High / Low C7. Fig. D-26
The hoist drum can be braked by hand brake lever of
the disc brake, beside the control console.
The crown block saver system can be set in over-
travel mode by valve C15, C16. See manufacturers
documentation.
By actuating emergency stop SE1 the hoist drum
can be braked very quickly and uncoupled from the
transmission shaft.
A signal horn C6 can be actuated from the control
desk.
C1
Fig. D-27
12S1
C7
C15
C16
Fig. D-28
SE1
C6
Fig. D-29
Page D-19
D-3 DRAWWORKS braking proce-

dure (manual mode)
Disable AUTODRILL function by means the pushbutton
SH10. When the AUTODRILL control is OFF the lamp SH10
of pushbutton is off.
Fig. D-30
Hold on the joystick pushing the button dead man.

Keep moving the joystick SM1 forward all the way, the
brakes will start to be activated, at the end of the stroke
a contact gives the permission to release (open) the
SM1
parking brake.
At this point the drawwork brake system is activated and
it can be modulated with the joystick SM1.
IMPORTANT
In case of loss of hydraulic pressure or the release
of the dead man button the parking brakes automati-
cally turn on. Fig. D-31
Joystick control
brake service
Dead man button
Fig. D-32
Page D-20
White intentional page

MAINTENANCE UM199015/E - Rev.0 - 11/2011
Page E-1
Section E - MAINTENANCE
UM199015/E - Rev.0 - 11/2011 MAINTENANCE
Page E-2
E-1 GENERAL
The irreproachable function and operational safety of the drawworks depend on the thorough care and maintenan-
ce.
This section covers, beneath the regular maintenance activities, the replacement of items that may require renewal
as part of a regular maintenance program or items that need replacing as part of the operational requirement.
Never try to remedy defects or to carry out any repairs for which you do not dispose of the required experience and
special tools.
We do not assume any liability for damage caused by the non-observance of maintenance instructions.
Safety helmet
Safety gloves
Safety shoes

headsets
Danger
DANGER : SELF PROTECTING EQUIPMENT

Before starting setting, maintenance and repair work the self protecting equipment required by the safety
regulations must have been made available to the personnel, and the personnel should use them, such as
gloves, goggles, helmet, non-skid safety shoes, etc.
Page E-3
Danger
ATTENTION WORKING IN INSUFFICIENTLY ILLUMINATED AREAS

If the operator at the drawworks has to work in dark areas, he should use a portable lamp with magnet.
THE LAMP SHOULD COMPLY WITH THE REGULATIONS !
Danger
Danger mechanical device
DANGER:
Any work relating to setting, maintenance and repair may only be carried out after the drawworks has been
set off operation and cut-out.
E-1.1 MAINTENANCE INTERVALS
After certain periods of time / intervals, maintenance work has to be carried out on the drawworks. This work is de-
termined either by the operating hours (see hourmeter) or by calendar periods (daily, weekly, etc. ). If maintenance
work is done in accordance with calendar periods, those must approximately correspond to the number of operation
hours.
IMPORTANT
Extreme conditions, e.g. dust production, may require more frequent maintenance.
If, due to reduced use of the drawworks, these intervals exceed half a year, all outside parts to be greased should be
greased, at least, every six months.If the drawworks is off operation for more than 3 months, all blank parts should be
preserved against weather influences.Pressure setting should be done regularly by qualified personnel.
E-1.2 WELDING
If welding work is to be done on the drawworks, following precaution measures must be adhered to:
Welding work on statically important components may only be done after written approval by DRILLMEC.
Welding work may only be done by qualified personnel.

The earthing terminal of the welding machine is to be connected directly to the part to be welded. The welding current
must in no case be conducted detouring via electronic components.
WARNING
Do not connect the earthing terminal of the welding machine to the assemblies (motor, gear-box, etc.). The
welding current can provoke spark discharge at bearing points inside the assemblies. The texture alterations
caused hereby at the contact points of bearings can distinctly be evidenced as new hardening zones. This
previous deterioration causes the premature failure of the gear-box. Do not touch housings of electronic
components (e.g. control instruments) and electric lines with the welding electrode or earthing terminal of
the welding machine.
Page E-4
Welding must not be carried out:

On units such as motor, gear-box etc.
On the skid
E-1.3 NOTES TO THE MAINTENANCE MANUAL
From next pages, there are listed charts with execution remark for maintenance and for listing of defects (hydraulic,
mechanical or control system defects).
An uninterrupted listing of maintenance work and defects is obligatory for detection of reasons and remedy.
IMPORTANT
During the guarantee period, the acceptance of guarantee performance depends hereon.
MAINTENANCE CHART
Page E-5
Maintenance _______ OH Carried-put by company / date / name Remark

( Operating Hours )
Page E-6
Trouble shooting chart
Consecutive n Date/ OH Type of defect Solution to remdy Remedied: Remedied:

( Operating Hours ) defect Customer DRILLMEC
Date / Name Data / Name
Page E-7
E-1.4 BEFORE / DURING /AFTER MAINTENANCE
Projecting pressurized oil can cause injuries.
Never work at the drawworks in operation.
E-1.4.1 before maintenance
Secure drawworks and equipment against unintended movement and starting.
Carry out maintenance work only with technically perfect tools suitable for just this type of work.
When working at the electric system or on parts, tools, etc. that are in contact with electric system parts isolate
them from power supply.
Open or remove protective units only at stopped drive or drive secured against unintended starting.
Before cleaning the drawworks, cover or tape all openings where no water, vapor or detergent may penetrate
for safety and function.
Keep tools, work place and drawworks clean. Before doing maintenance work, clean all connections and threaded
unions from oil or grease. Do not use any aggressive detergents. Only take non-fluffing cloths for cleaning.
WARNING
Detergents must not attack gaskets, etc. Test detergents for suitability, before using them.
DANGER
The electric system is only splash-proof. When cleaning the drawworks with a HP cleaner do not spray elec-
tric parts with the lance.
Penetrating water can otherwise damage the electric system of the drawworks. In an extreme case, this can
even cause sudden, unintended operational movements. Never direct the water jet onto electric contacts
and modules.
After cleaning, check all lines for leakages, loose joints, abrasion and defects. Immediately eliminate detected
faults.
Re-usable parts are cleaned and then dried with a non-fluffing cloth or dry, filtered compressed air of max. 2
bar.
E-1.4.2 during maintenance
WARNING
Only the oils and lubricants prescribed by WIRTH and/or being suitable for the purpose may be used. Non-
observance will make any guarantee claim for the drawworks null and void.
Check oil levels.
Make oil changes.

Page E-8
IMPORTANT
Carry out oil changes with power pack at operation temperature to enable a better run-off of any dirt in the
oil.
IMPORTANT
Catch oils and lubricants in a suitable bin and dispose them as prescribed.
IMPORTANT
Clean lines, oil measuring stick, etc. only with non-fluffing cloths.
In case of oil losses determine the reason and eliminate it promptly.
WARNING
A change-over from synthetic oil to mineral oil and vice-versa is not permitted.
Renew sealing elements when mounting.
Exchange defective hydraulic lines, pipes and hoses.
Re-tighten threaded-unions only in pressure-less condition.
When mounting pre-fill the hydraulic pump through the leakage line connection.
WARNING
It is forbidden to modify set values of pressure limiting valves without the prior approval of DRILLMEC.
Check fastening and securing elements and renew them, if required so.
Exchange defective components.
Clean filling ports and lubricating nipples before filling. After filling, shut ports immediately.
Remove protective caps and coverings only just before starting work.
When removing plugs, set dust protection caps on the plugs and the machine.
E-1.4.3 after maintenance
Check all units for tightness.
Mount the protective devices and carry out a functioning test of the drawworks.
IMPORTANT
When disposing detergents, oil-containing components and waste oil, consider the environmental protection
rules.
Page E-9
E-1.5 HYDRAULIC HOSES AND HOSE LINES
DANGER
Repairs of hydraulic hoses and hose lines are not permitted!
Check all hoses, hose lines and threaded-unions regularly, at least once (1x) per month for leakages and externally
visible defects! Remove defective parts immediately! Projecting oil can cause injuries and fires.
Even with correct storing and admissible straining, hoses and hose lines are subject to natural aging. This limits their
duration of use. Improper storing, mechanical defects and inadmissible straining are the most frequent reasons of failure.
The duration of use of a hose line should not exceed six (6) years, including a storing time of maximum two years (look
at manufacturing date on the hoses!). A use at the limit of admissible straining can reduce the duration of utilization
(e.g. high temperatures, frequent movements, extremely high impulse frequencies, multiple shift operation).
Hoses and hose lines should be replaced, if detecting the following when inspecting:
damage to the outer coat continued down to the inner layer (e.g. abrasion points, cuts and cracks);
brittling of the outer coat (cracks of the hose material);
a deformation that does not correspond to the natural shape of the hose or the line, both in pressure-less and
pressurized condition or if bending, e.g. separation of the coats, formation of bubbles;
leakages;
non-observation of installation requirements;
damage to or deformation of a hose fitting reducing rigidity of the fitting or of the connection hose/fitting;
wriggling of the hose out of the fitting;
corrosion of fitting deteriorating function and rigidity;
excess of storing and utilization duration. When exchanging hoses and hose lines, exclusively use original
spare parts.
Lay and mount hoses and lines professionally. Do not change connections by mistake.
Page E-10
E-1.6 allowable bearings clearance
Pos. Description Check done Clearance after Limit to be obser-

installation ved suggested
1 Bearings motor shaft Bearing races clearance 0,14 019 mm 0,38 mm
2 Bearings cathead shaft Bearing races clearance 0,12 018 mm 0,40 mm
3 Bearings gear countershaft Bearing races clearance 0,20 0,26 mm 0,44 mm
4 Bearings main drum Bearing races clearance 0,19 0,28 mm 0,49 mm
5GEB22A
5GEB22A 5GEB22A
3 3
2 2
AKER
Clutch
Clutch WN72
PO336
PO342
4 4
Fig. D-1
Page E-11
There is no exact science in being able to determine when to replace bearings based on clearance.
However there are cases where bearings fail before this limit and there are others where bearings have run for years
at greater than these limits.
A good recommendation is to keep records of clearance on a 6 month basis and monitor the changes in clearan-
ces.
If there is a large jump in clearances from one inspection to the other, can indicate that replacement is needed.
Page E-12
E-2 lubrication
E-2.1 LUBRICATION INSTRCTIONS
E-2.1.1 before starting
In order to assure good performance of any mechanical equipment, it is necessary to maintain good alignement and
good lubrication with clean oils and greases.
Before starting a new machine the operator must grease all parts and fill all reservoirs with the prescribed lubricatns.
New units should be drained and refilled with oil after the first few weeks of service. Thereafter, it should not be neces-
sary change the oil before that frequency indicate on manual, except where the oil may have become contamined by
water or other foreign matter before that time or temperature changes sufficiently to require a change in the viscosity
of the oil being used. The oil level should be checked a few minutes after all shafts are shut down to allow circulating
oil to accumulate in the sump.
Oil reservoirs should b tested for and drained of condensate at regular intervals, particulary a few hours after shut-
down.
When for maintenance or other reasons there are exposed openings, they should be covered to assure that no dirt,
water or other foreign matter will reach the working parts.
Check drawwork housing and oil sump for presence of dirt or water. Clean and drain if necessary.
All chains and gear boxes are lubricated by a pressure spray system to provide maximum chain and bearing
life. The guards are designed to assure return of oil to the sump and prevent any oil from entering the clutch
elements. The sump should be filled with the quantity and viscosity of oil indicates on this section. Use a non-
detergent oil with rust and oxidation inhibitors.
Grease all points equipped with a alemite-hydraulic grease fittings. Refer to attached charts for location of
fittings. Where toggle pins and lever bracket bearing are lubricated direct, sufficient grease should be added at
each lubrication until grease just begins to seep put around the hub. Self-aligning roller bearings in weatherproof
housings need only a small amount of grease at each application (three or four grease gun shots per bearing).
If the grease seeps out through the labyrinth seal or relief fittings while lubricating, it is an indication the bearing
has sufficient grease. Its not necessary to keep these housing completely full of grease as it only expands
due to heat of operation and is forced out through the labyrinth seal or relief fittings. For all grease lubricated
bearings except te hydromatic brake and water stuffing box, use a multi-purpose lithium base grease.
For the hydromatic brake use a grease indicates on Manufacturer manual attached.
Page E-13
E-2.1.2 while is running
Check oil pressure gauge. It should be indicate from 0.4 to 1.7 bar (5,8 - 24 PSI).
If pressure is too high
Check oil spray nozzle for stoppages. Remove and wash in gasoline
Remove plugs at each and of spray pipe header and clean.
Adjust pump by-pass relief valve.
If gauge show no pressure
Check oil level in reservoir and add oil if necessary
Check pump suction strainer and clean if necessary by washing in gasoline
Check by-pass relief valve on oil maifold in transmission. Turn adjusting screw inward to in-
crease by-pass pressure
If all spray nozzles are delivering adequate oil, check pressure gauge tubing for damages or
stoppage
Check all oil spray nozzle - as certain that all oil holes are open and delivering oil.
Page E-14
E-2.2 SUMMARY OF PERIODIC MAINTENANCE
Frequency ( days/months )
MAINTENANCE OPERATION
daily 50 200 400 1000 2000
Check oil level in drawworks x
Grease stuffing box of water swivel joint x
Check oil level of hydraulic oil tank x
Grease bearing of auxiliary brake x
Grease idle gear box x
Grease cathead countershaft x
Grease main greasing plate of drawwork x
Grease clutch x
OIl sump - Drain, clean and refill, change oil filter O x
Air valves - Disassemble and clean. x x
Air cylinder - Lubricate, remove air connection and inject grease
x
through air inlet
Guide roller of wireline x
O = Only first time
X = Normal frequency
IMPORTANT
(*) Oil replacing of main hydraulic system could be change with a frequency of table, but to a better monitoring
of oil wearing, you can make a analisys of oil parameters. For more information on oil analysis you can see
item Hydraulic system oil change
E-2.3 oil types for drawwork
EQUIPMENT OIL TYPE

Drawwork SHELL OMALA 220
E-2.4 GREASE types for drawwork
EQUIPMENT GREASE TYPE

Drawwork SHELL SUPER GREASE EP2
Page E-15
E-2.4.1 GREASING PLATE OF DRAWWORK LAYOUT
The drawworks is equipped with greasing plate that it permit to grease all parts of drawwork with only once connection
of greasing gun.
Grease fittings Greasing hoses
Fig. D-2
Page E-16
E-2.5 LUBRICATION CHART POINT AND SCHEDULE
Lubrication chart
Kind of lubrication
A oil SHELL OMALA 220

B Grease SHELL SUPER GREASE
Viscisity 220mm/s at 40C
Operating temperature
-20C to +120C
Oil volume ca . 250 lt r.
Lubrication times
Every 200 working hou rs Every 24 working hou rs
Every 50 working hou rs
Spr ay lubrication
A
B
Fig. D-3
Page E-17
E-2.6 FORCED LUBRICATION
The gear pump is connected to the Power Take Off of engine to permit the lubrication when engine is switched on.
LUBRIFICATING HYDRAULIC PIPE
25
3.5 bar
EM
P 10
Fig. D-4
Page E-18
Lubrication of all chains as well as of the supporting

bearings of the transmission shaft is done by a pressure
circulation lubrication system (see maintenance scheme).
Supply is done by a gear pump driven by electric motor. G
Check the oil level daily before starting the system, at the
measuring rod of the oil tank G. P
When running-up the pump, pay attention to that the E
pressure gauge in the control console. The oil pressure H
is measured behind the lubrication circulation filter.
Other pressure gauge indicate pressure in front of A30
and filter 5 (are mounted to the lateral drawworks wall, at
the control console side). In case of too much pressure
F
drop at the oil filter, exchange the filter. The suction filter N
in the oil tank should be cleaned, at the same time.
Fig. D-5
If pressure of all pressure gauges increases, check
throttle points and oil penetration points at the chains
and bearings. If pressure drops, check suction filter N,
the oil supply channels and the gear supply pump with
electric motor.
Change of the gearing oil largely depends on the aging

resistance of the used oil as well as on the operation and
environmental conditions. L
Aggressive condensate water prematurely decreases
lubrication ability of the oil, very much.
If the oil shows a strong yellowish colouring, change the
oil immediately.
Fig. D-6
OIL PRESSURE
PRESSURE PSI (bar)
COMPONENT LEVEL INDICATOR PLACE OF CONTROL
Max. Nom. Min.
72 58 43
Drawworks and Transmission Dipstick Control Panel-Oil filter
(5) (4) (3)
E-2.7 oil changement of drawwork
IMPORTANT
Change oil when the unit has operation temperature to allow a better run-off of dirt in the oil.
Proceeding on cleaning and oil change:

Remove covering sheet-plates underneath the cathead shaft on drillers side.
Drain oil via shut-off valve F and outlet E and dispose it in accordance with prescriptions.
Dismount front cover P of oil tank including connections from tank, and deposit it, at the right side on the co-
vering sheet above the pump.
Remove deposited dirt with a puller through the opening at the front, out of the oil tank and dispose it.
Clean suction filter N (see manufacturers documentation).

Page E-19
Mount front oil tank cover P including connections

to the tank.
Remove locking screw, at the top of the oil tank and G

top tank up with oil.
P
Fill the tank by means opening G and chack the E
level by means level dipstick H H
Mount locking screw and covering sheet-plates.
If required, exchange oil filter L in the circuit, placed F

on the lateral wall of drillers side. N
Fig. D-7
IMPORTANT
After oil changement its important check the oil pres-
sure by means pressure gauge A30.
A30
Fig. D-8
E-3 OIL CHECK POINT of hydrau-

lic power unit
Ref Description
M Oil level of hydraulic power unit
M
IMPORTANT
For more information of hydraulic power unit see
operation and maintenance document supplied with
equipments.
Fig. D-9
Page E-20
E-4 CLUTCH MAINTENANCE

E-4.1 TWIN DISC - DRUM CLUTCHES
IMPORTANT
In any correspondence regarding twin disc equipment refer to the serial number the rig on which it was fur-
nished and to the clutch size. The serial number on the clutch may also be used. It is stamped on the clutch
name plate.
E-4.1.1 INSTALLATION
Shaft fits: clutch hubs should be fitted to the shaft with a light press fit, to eliminate the possibility of shaft keys beco-
ming hammered out due to shock loading.
Alignement: Proper alignement of the clutch with relation to the driving member ( driving ring and driving spider ) is of
the utmost importance in order to obtain satisfactory clutch performance and minimum service requirements.
Noise: Excessive wear of the clutch driving plate and excessive heating is usually accompained by anoisy operating
condition. Therefore, it is suggested that a noisy clutch be checked for proper alignement.
IMPORTANT
When a clutch is equipped with a solid driving plate a certain amount of noise is normal at various speeds
due to the driving plate rattling in the drivinb ring.
E-4.1.2 irregularitie of performance and corrective measures
E-4.1.3 Clutch spillage

Air pressure at the clutch must be as recommended by the original equipment manufacturer. Take this reading
as close to the clutch as possible to eliminate any line pressure drop.
Plate worn out. Maximum allowable standout with clutch engaged indicates clutch facing worn out.
Inspect entire air line installation for any restructions for leaks which could decrease the air supply to the
clutch.
Check the operating valve for full opening
Carefully inspect the clutch for possible ar leakage at the diaphragm.
If operating in cold weather, the air lines may be restricted due to freezing of the moisure in the air line or sy-
stem.The addition of denatured alcohol or Ethylene Glycol in the air received will eliminate this problem. Avoid
the sue of all rust inhibitors of commercial anti-freeze.
E-4.1.4 CLUTCH OVERHEATING
Check all points as listed under Clutch Spillage in paragraph before
Check alignemnt as described on Installation paragraph. If misalignment exist, the clutch may not completely
disengage,
Be sure no dirt or foreign matter has collected in the driving ring or spider which would prevent the driving
plates from working freely.
Check pressure plate and insulator plate for complete release travel.
Page E-21
Fig. D-10
Page E-22
E-4.2 CB - CLUTCH
IMPORTANT
In any case for more information of maintenance of clutch see manufacturer instructions attached with this
documents.
WARNING
Do not inflate the clutch without having the friction drum in place as this may cause permanent damge to
the actuating element assembly.
Since the element assembly can be damaged through contact with mineral oil or grease, we suggest that campa-
ratively oil-free air be used to inflate the clutch, and the installation be made in such a manner that the clutch is not
exposed to lubricants.
If a small amount of oil or grease accidentally gets on a clutch element, the oil or grease should be wiped off with a
clotch dampened with gasoline or naptha, and then wuped dry. If the clutch is badly covered with grease or oil, the
friction shoe assemblies should be removed and cleaned. The rubber tube should b thoroughly cleaned. The friction
shoe assemblies should them replaced on the element. The friction shoe assemblies can be removed as shown in
a letter paragraph. Care should be taken when removing lockwires so that they may be used again. If lockwise are
accidentally damaged or broken and new lockwires are not available, galvanized steel wire should be bent in the exact
shape of lockwire and inserted in ht eshoe pins.
Installation procedure
Piping between valve and clutch. It is important that all piping should be free of cutting compound, metal chips, etc. The
ends of all pipingused should be reamed after cutting so that the air lines may be free and smooth and not reduced
in effective diameter. We recommended fishing a wire with a wet gas swab on one end through the pipe. This should
be followed with a dry swab to pick up any oil or impurities the gas swab has loosened. Any impurities or particles left
in the piping will be invariably carried into the clutch element. Care should be taken when using pipe joint compound.
Compound on the front of the pipe will collect nad restrict the passage of air when it hardens. All air line joints should
be checked to avoid leaks and wastage of compressed air. A soap solution applied to the joints with a small brush
is suggested. if bubbles appear joints should be tightened or disconnected at threads, coated with compound and
reassembled. This assures full operating pressure and avoids wastage of compressed air. Published capacities for
clutches are at 75 PSI operating pressure. Maximum recomended pressure on the drawwork is 110 PSI.
An air pressure gauge should be provided in plain view of the operator so that a close check on air pressure can be
maintained. This will assure proper operating pressure, minimize the danger of slipping operation due to low air pres-
sure, and thereby reduce excessive wear and heat attributable to uncessory slip. When mounting clutch rim flange
to mating spider the small air connection gasket should be placed in position on the shoulder of the air connection
tube. All parts should be checked for proper alignment. As mounting bolts are tightened the gasket is compressed,
thereby preventing leakage of air.
Adjustment unnecessary
Cluthes are completely self-adjusting, making it unnecessary to attempt this operation once proper installation has
been effected.
Points to check when inspecting the clutch
Leaks in the air lines or in the rotorseal
The condition of the friction surface of the drum
The condition of the friction shoe assemblies

Page E-23
T- replacement thickness
Dw- Worn drum diameter
Dn Nominal diameter
Fig. D-11
The condition of the rubber tube
Oil on hte friction surface or on the tube
Friction shoe and clutch drum wear
Replacement of Friction shoe
Friction shoes should be replaced after the friction material has worn down more than two-thirds of its original thick-
ness, or when their condition is such that a small amuont of additional wear could cause friction shoe metal backing
to score hte clutch friction drum.
Steps in replacing friction shoes
remove friction shoe pin lockwires, and withdraw shoe pins
all friction shoe assemblies can then be removed from the clutch element.
place new friction shoe assemblies in position. ( caution on spacing . the shoe pin holes are not evently spa-
ced on all clutch sizes, but are spaced in pairs. Replace friction shoe assemblies in their original position so
that the shoe pins will fit ).
insert shoe pins with holes in the ends of the shoe pins in position to take the lockwires
slide lockwires through the ends of the shoe pins so that scallop or bend in wire points outward from shaft on which
clutch is mounted. Bend each end of wire inward toward clutch shaft.
Page E-24
In detaching the clutch element, care should be taken not to lose the rubber washer which seals the air passage
between the clutch element ad the spider against leakage
Rotorseals
Air to operate the clutch is introduced into the end of the shaft through the rotorseals. The rotorseals should by all
means be connected to the air piping by a flexible hose which will prevent stress and strain on the internal wearing
surfaces and will result in increased life of the rotorseals. Care should be taken not to twist the flexible hose when
tightening the union.
The rotorseal is designed for trouble-free service under the most severe conditions without special attention. Rotor-
seals are grease packed for life.
Due to the extreme accuracy and close tolerances on internal parts, we recommended that if possible the complete
rotorseals be returned to the factory when rebiulding becomes necessary.
E-4.2.1 WEARING FRICTION MATERIAL
If the linings have worn to the minimum aloowable thickness of 1/16 (1,5mm), they must be replaced as a complete
set, with the exception of element size 42CB200, where replacement of the entire element is required when worn to
the minumum lining thickness of 1/32 (0,8 mm)
WARNING
Operation with friction material worn to less that minium allowable thickness will result in damage to the
drum
E-4.2.2 WEARING DRUM MATERIAL
Element size Maximum allowable wear on drum diameter in(mm)

42CB2000 thru 14CB400 ,09(2)
16CB500 thru 24CB500 ,12(3)
26CB525 thru 40CB525 ,19(5)
45BCB525 ,25(6)
Page E-25
E-5 WIRE LINE ANCHOR

The drawwork drum is equipped with a wedge line anchor which assures the safe clamping of the wire line because
of the wedging action which locks the line in place. Increased loads on the anchor increase the clamping effect.
E-5.1 PROCEDURE TO INSTALL THE WIRE LINE ANCHOR
E-5.1.1 INSTALLATION AND REMOVAL OF TRAVELING ROPE
On first laying-on of the traveling rope with rope diameter 1 on the drum, and during the subsequent Cut and Slip
work proceed as follows.
Before starting any work, all personnel charged must have been familiarized with following drawings:
Hoist drum shaft drawing
Protective hoods, complete drawing
E-5.1.2 LAYING-ON OF A NEW TRAVELING ROPE
Unscrew protective sheet 18 in top of the drum, and remove them.
18
Fig. D-12
Page E-26
The driller moves the drum until the anchor block is somewhat above horizontal line. In this position, power
supply to the drawworks is cut-out for safety reasons, until the traveling rope has been laid-on completely.
Lay ready for use: rope cap 6, split rope clamp 4 including screws 2, spacer pipe 5 and clamping cup 3 (all
scope of supply).
Make sure that the end of the new traveling rope is cut clearly. If not so, tie up traveling rope about 60 mm
behind the new cut so that it is tightly bound. Remove tying wire, if there is one.
After the traveling rope has been cut, the rope cap 6 is put over the wire end and cautiously fastened by kno-
cking for securing.
IMPORTANT
Do not strike the cap too much, because it must be removed as soon as the traveling rope is in the anchor
block.
The traveling rope with rope cap 6 is guided through the slot, in the drum flange, until it protrudes by 300 mm,
at the exit.
Remove rope cap.
Mount split clamping shell 3 with conical tip to the anchor block as near as possible at the anchor block, on
the rope.
Put-on spacer pipe 5, and mount the split rope clamp 4 including screws and nuts 1 - 2 behind.
Draw traveling rope back through the drum until the clamping shell 5 is in contact with the stop block, under
tension.
1
2 3
Section C-C
4 5 6
Fig. D-13
Page E-27
WARNING
The screws with nuts 1 - 2 are to be tightened with a torque of 75 Nm.
IMPORTANT
Pay attention to that the anti-torsion device of the clamping shell is guided in the relevant groove of the stop
block.
E-5.1.3 CUTTING AND SLIPPING OF EXISTING TRAVELLING ROPE

All drilling work is finished, and the load is suspended in the rotary table. The traveling block is set down on the
working platform, or the top drive is set on the stops of the guiding rails.
Dismount protective sheet plates (see above).
Reel-off traveling rope.
Push traveling rope through the anchor block, hereby, loosening the clamping shell. It may be necessary to
knock on the anchor block to loosen the shells.
Loosen rope clamp and clamping shell.
Pull back traveling rope to that part which shall be cut, and tie it with wire to avoid it untwists. Cut traveling rope
by about 60 mm above the tied piece.
Again fix traveling rope, as described above.
E-6 CHAINS
E-6.1 MAINTENANCE
The service life of a chain decisively depends on a good lubrication. Wrong lubrication methods and inadequate lu-
bricants cause an anti-lubrication and, thus, a high wear and premature chain failure.
To obtain an effective lubrication, a sufficient quantity of a fluid lubricant must be pressed in the chain articulations.
The oil must always be put on the bracket edges to pass a narrow gap between the brackets and to enter the chain
articulation.
A pressure circulation lubrication system ensures lubrication of the chains in the drawworks. It sprays oil through
nozzles onto the high bracket edges. Also see maintenance of oil lubrication system.
E-6.2 ADMISSIBLE ELONGATION DUE TO WEAR
The roller chains elongate due to abrasion between bolts and sleeves. The used roller chains have a maximum ad-
missible wear elongation of 3 %. This corresponds to lengthening of 30 mm per 1 m of chain. Then the chain must be
replaced. Chains should also be replaced when presenting outer damage. A considerably worn out chain induces a
progressive tooth flank wear when being used longer. Finally, the sprocket teeth have pittings and hooks.
IMPORTANT
The sprocket wear can be reduced essentially when exchanging the chain already at a wear elongation of
1.5 to 2%.
The chains can be mounted using the chain tensioners being scope of supply.
Page E-28
E-7 HANDLING OF BEARINGS
Spherical and cylinder roller bearings are used throughout drawworks shaft assemblies. The bearings are a precision
built item and require careful handling in order to obtain the long service life and high load carrying characteristics
associated with anti-friction bearings.
If bearings are removed and are to be reused, the inner and outer races and roller assemblies of each bearing must
be kept together and reinstalled exactly as they came off.
It is always necessary to completely replace any roller bearing that fails, even though only one part of the bearing
shows damage. Since the running clearances of these bearings are extremely small, excessive clearances, worn or
grooved bearing rings, and any pitting or flaking of the parts is indicative of failure and the entire bearing should be
changed as soon as possible.
Most roller bearings are assembled to their shaft by means of shrink fit. Damaged or worn bearings and bearing rings
can be removed by driving them off the shaft with a bar and hammer. Bearings should always be heated in an oil
bath or an inductive heater, the temperature of which should not exceed 120C. Be certain that both the oil and the
container are very clean. If the oil container is in direct contact with the fire, place a rack into the container so that the
bearings will not rest on the bottom. Do not leave the bearings in the oil bath longer than three minutes.
Once the heated bearings are in position on the shaft, hold it in place until it cools.
WARNING
Never use water or any other liquid to cool a hot bearing.
Rapid cooling will cause the surfaces of the races and rollers to check or crack and the bearing will fail immediately
WARNING
Never strike a roller bearing with a steel hammer.
If the bearing must be driven into position use copper or a soft hammer and strike lightly.
If the inner race of the bearing is to be positioned by means of a hydraulic press, use a mounting tube which has an
inside diameter slightly larger than the shaft and an outer diameter not to exceed the outer diameter of the inner race.
The tube must be faced square on both ends, thoroughly clean inside, and long enough to clear the end of the shaft
after bearing is mounted.
If the outer race is to be pressed into the housing, the outer diameter of the mounting tube should be slightly smaller
than the housing bore and the inside diameter not less than the inner diameter of the outer race.
Always lubricate the shaft or housing before installing the bearing. Oil or anti-seize compound is the best lubricant
for this purpose.
Do not remove a new bearing from the box or wrapping until it is to be installed. Protect it from dirt and other foreign
matter at all times. If a bearing must be cleaned, use clean kerosene or other solvent.
Page E-29
E-8 TIGHTENING TORQUES OF SCREWS

Tightening torques MA for screws with head contact dimensions according to DIN 912, 931, 933 and 7984 as well
as metric standard thread according to DIN 13.
The tightening torques indicated here are to be considered as standard values, because various factors are decisi-
ve here.
Friction value ges = 0.,14
Grade 8.8 10.9 12.9

Diameter MA in Nm
M4 2.9 4.1 4.9
M5 6 8.5 10
M6 10 15 17
M8 25 35 41
M 10 49 69 83
M 12 86 120 145
M 14 135 190 230
M 16 210 295 355
M 18 290 405 485
M 20 410 580 690
M 22 550 780 930
M 24 710 1000 1200
M 27 1050 1500 1800
M 30 1450 2000 2400
M 36 240 3450
M 42 3950 5550
M 48 5950 8400
M 56 9550 13400
M 64 14300 20100
Page E-30
E-9 WIRE ROPES

The wire ropes used on a drilling rig are subject to more or less rapid wear.
In order to ensure safe and reliable operation, the ropes must be inspected daily.
The correct treatment of wire ropes is specified in DIN 15020, sheet 2.
Ropes are supplied in ring form or on a reel. Sidewise removal of ropes from the ring or reel is not permissible under
no circumstances, as the ropes thereby twist or untwist, as governed by the direction of laying. From the very instant
of removal, this rotation results in permanent alterations in the structure of the ropes; these alterations cannot be
corrected any more.
The correct and incorrect unwinding of wire ropes is illustrated in the following figures.
Fig. D-14
For greater lengths of rope supplied in ring form, the use of a dispenser is recommended in order to save time.
An excerpt concerning rope damage from DIN 15020, sheet 2, is detailed on the following pages.
E-9.1 WIRE ROPE DAMAGES
E-9.1.1 Wire rope with corkscrew-shaped

deformation
The corkscrew-shaped deformation initially does not cause

a weakening of the wire rope. However, the rope drive
may run unevenly because of the wire rope deformation.
Consequent damage after prolonged operation time may
be increased abrasive wear and wire breaks.
The wire rope must be discarded, if the deformation x
as illustrated in figure 1 - is equal to or greater than 1/3 x
d (d = nominal rope diameter). The deformation shall be
measured without load, but with the weight of the carrying
means, if it is less than 30 % of the bearing capacity.
Fig. D-15
Page E-31
E-9.1.2 Wire rope with basket-cage defor-

mation
A basket cage deformation can occur in wire ropes with a

steel core, if the outer layer of wires is loose, or if the outer
strands are longer than the inner strands. Displacement
of the outer wire or strand layers with respect to the inner
layers results in shifting of the superfluous length to one
single spot. At the same time, excess length of the core
may occur in relation to the outer strands at another spot;
this condition results in compression or emergence of the
core from the wire rope.
A wire rope with a basket-cage deformation must be
discarded. Fig. D-16
E-9.1.3 Wire rope with looping of wires
In the case of wire looping, individual wires or bundles of

wires with a hairpin shape emerge from the rope on the
side facing away from the rope groove. The loops usually
occur in succession in several strands.
If the looping of wires caused a considerable alteration of
the rope structure, the wire rope must be discarded.
E-9.1.4 Wire rope with wires loosened by Fig. D-17

corrosion and abrasive wear
If individual wires or strands are loosened, the outer

wires or individual strands of the wire rope under load
are displaceable. Consequently, they do not take over the
proportion of tensile force for which they are intended; as
a result, the remaining wires or strands are overloaded.
Excessive flexural stress may thus occur during passage
over rope sheaves, and this in turn leads to premature
wire breaks.
A wire rope in which rust or abrasive wear have caused
loosening of wires must be discarded. In the case of
loosening due to other reasons, the resulting wire breaks
are decisive for disposal. Fig. D-18
E-9.1.5 Wire rope with nodes
Nodes are thickened parts which repeatedly occur over

extended lengths of the rope. The core frequently emerges
from the wire rope at the spots of thickening. At the
constricted rope spots, the strands form arches for mutual
support; this condition can cause wire breaks.
If nodes are present, the wire rope makes additional
movements.
Wire ropes with pronounced nodes must be discarded.
Fig. D-19
Page E-32
E-9.1.6 Wire rope with constriction
Constrictions are decreases in the diameter of the wire

rope over short distances. Sections of rope directly
adjacent to end fasteners must be examined with special
care for constrictions, since they are often difficult to detect
at these spots.
Wire ropes with considerable constriction must be
discarded.
E-9.1.7 Wire rope with flat spot
Flat spots are permanent deformations of a wire rope

resulting from crushing (squeezing). Fig. D-20
Flat spots increase the frequency of wire breaks.
Curl-shaped deformation is caused, when a wire rope
under load is pulled over an edge. Wire ropes with curl-
shaped deformation must be discarded.
E-9.1.8 Wire rope with kink
Kinks are deformations of a wire rope, which are caused

by straightening an eye-shaped rope loop, and the wire
rope cannot compensate the deformation by turning in
the axis.
Wire ropes with one or more kinks must be discarded.
E-9.1.9 Wire rope with buckling

Fig. D-21
Buckling are deformations of the wire rope which are
caused by external violent influence.
Wire ropes with buckling must be discarded.
E-9.1.10 Heat effect
Wire ropes which have been exposed to extreme heat (can

be seen externally by tarnishing) must be discarded.
Fig. D-22
Fig. D-23
Page E-33
E-10 HOSE FITTING SPECIFICA-

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

through the coupling. Exceeding that point, does not im-
prove tightness and damages the coupling!
Fig. D-24
A hose should never be subject to torsion! When fitting the

hose, consider that during operation, the hose is subject
to changes in length with consequent torsional effects.
Therefore, hoses should not be too short and the proper
settling should be checked with hose in resting position.
Fig. D-25
If hoses routing requires the hose to bend, make sure that

the bending radius are correct.
A bending radius too small can cause restrictions in the
section and therefore load losses. Moreover, these ben-
ds can cause torsional stress and even breakage of the
hose!
Fig. D-26
For correct fitting of hoses, elbow fitting can be used for

installation in restricted space without impairing hose
efficiency and life.
Fig. D-27
Page E-34
E-10.1 STORING OF FLEXIBLE HOSES
E-10.1.1 RECOMMENDATIONS FOR A CORRECT STORING

The rubber is subjected, by its nature, to changes in its physical properties. These changes, which normally take place
in time, according to the used type of rubber, can be accelerated by a special factor or by a combination of factors. The
reinforce materials are, in the same way, damaged by unproper storing conditions. The following recommendations
contain some precautions to take in order to ensure the minimum wear of the stored goods.
E-10.1.2 STORING TIME

The storing time should be minimized by means of a scheduled rotation program. When it is not possible to avoid
long storing times and when the following recommendations are not respected, it is necessary to accurately check
the hose before using it.
E-10.1.3 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 40C or lower than 0C. When the temperature is under -15C, it is
necessary to keep precautions when handling the hoses. The hoses must not be stored near to heat sources nor in
conditions of high or low humidity. A maximum level of umidity of 65% is recommended.
E-10.1.4 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-10.1.5 OXIGEN 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.
E-10.1.6 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.
E-10.1.7 HEAT SOURCES

When the temperature limits cannot be respected, it is necessary to use a thermal protection.
E-10.1.8 ELECTRIC OR MAGNETIC FIELDS

The variations of the electric or magnetic fields must be removed in the storehouses becuase thay could cause currents
in the metallic connections, heating them. Similar fields could be caused by high-voltage wires or by high-frequency
generators.
E-10.1.9 STORING CONDITIONS

The hoses must be stored in easy conditions, free from stretches, compressions or other deformations and contacts
must be avoided with objects that could cut or drill them.
It is preferable to store the hoses on special shelvings or dry surfaces.
The packaged hoses must be stored in horizontal position avoiding to stack them. When this is not possible, the height
of the stacks must be such to avoid permanent deformations of the hoses placed at the bottom.
The inner diameter of the package must never be lower than the double of the curvature radius declared by the ma-
nufacturer in compliance with the technical standards. It is suggested to avoid to store the packages of hoses on rods
or hooks. It is suggested, moreover, to store the hoses, which are delivered straight, in horizontal position without
bending them.
E-10.1.10 RODENTS AND INSECTS

The hoses must be protected against rodents and insects. When this risk is probable, proper precautions must be
taken.
Page E-35
E-10.2 NORMS AND METHODS OF USE OF THE FLEXIBLE HOSES
E-10.2.1 PRE-ASSEMBLY CHECKS

Before the installation after a replacement, it is necessary to accurately check the hose characteristics to verify that
type, diameter and lenght are in compliance with the required specifications. Moreover, a visual check must be exe-
cuted in order to ensure that there are not obstructions, cuts, damaged cover or any other evident imperfections.
E-10.2.2 HANDLING
The hoses must be handled with care avoiding shocks, draggings on abrasive surfaces and compressions. The hoses
must not be pulled with violence when are twisted or contorted. The heavy hoses, generally delivered in horizontal
straight position, must be placed over proper supports for the transport.
If wooden supports are used, these must not be treated with creasote or painted with substances which could damage
the rubber.
E-10.2.3 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.
E-10.2.4 TEMPERATURE
The hoses must be always used within the generally pointed out temperature ranges. In case of doubts, call the
manufacturer.
E-10.2.5 TRANSPORTED PRODUCTS

The hoses must be used for the transport of substances, which they have been manufactured for. In case of doubts,
call the manufacturer. As much as possible, the hoses must not be kept under pressure when they are not used.
E-10.2.6 ENVIROMMENTAL CONDITIONS

The hoses must be used only in the environmental conditions which they have been manufactured for.
E-10.2.7 TORSION
The hoses have not been manufactured to work in torsion, except for specific purpose.
E-10.2.8 STRETCH
The stretch must be within the limits specified by the manufacturer.
E-10.2.9 VIBRATIONS
The vibrations subject the hoses to the stress and to the heat, above all near the joints and premature explosions can
occur. It is then suggested to check that the hoses have been manufactured to withstand these stresses.
E-10.2.10 CUSPS
Some users blocks the passage of the liquid throught the hose creating cusps in it. This method is not suggested by
the manufacturers, as the reinforcement is subjected to an excessive stress that could bring to explosion.
Page E-36
E-10.3 MAINTENANCE OF THE FLEXIBLE HOSES
E-10.3.1 MAINTENANCE
The frequency of the hose maintenance is determinated depending on the use of the hose. In the normal checks,
special care must be taken on the connections and on the presence of the following irregularities that point out the
deterioration of the hose:
fissures, cuts, scraps, ungluing, tearings of the cover that make the reinforcement visible;
deformations, balls, local bulges in pressure;
hardened or too tender parts;
leaks.
These irregularities justify the replacement of the hose.

When the cover reports the expiry date, this must be respected even if the hose does not show evident signs of
deterioration.
E-10.3.2 REPAIRS
The repairs are not suggested. However, if the deterioration is placed at one edge of the hose, this can be cut.
E-10.3.3 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.
E-10.4 RECOMMENDED TEST SCOPE VISUAL INSPECTION (PRIOR TO INITIAL 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. hydraulic
plan, parts list, description of the plant, drawings, operating / maintenance instructions, hydrostore documents,
safety data sheets for the hydraulic fluid being used etc.)?
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 ma-
nufacturer, 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]:
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;
Damage by running over is avoided by means of hose bridges;

Page E-37
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 a
way, that they:
Cannot be mixed-up and are unambiguously and durably marked;
Are protected against any foreseeable damage, e.g. mechanical or due to environmental influences such as
cooling lubricants; and
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 shielding?
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
Have the installed hydraulic hose assemblies or hoses exceeded the period of storage or use, recommended
by the individual manufacturer
Are the hydraulic hose assemblies over-lacquered (over painted)?
Does the operating manual state testing intervals? If so, what?
IMPORTANT
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)
E-10.5 RECOMMENDED TEST SCOPE FUNCTIONAL TESTING (PRIOR TO INITIAL SETTING

INTO OPERATION OR PUTTING BACK INTO OPERATION)
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?
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?
Page E-38
E-10.6 RECOMMENDED 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?
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 movements, moved/
upheld masses, loading and unloading method of workpieces, place of installation, external 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).
Have the above mentioned preconditions changed, which previously formed the basis for specifying 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 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 ?
Have shortened test intervals been established, e.g. to biannually or quarterly (instead of yearly or biannually)
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
Have those modifications been recorded and have they been considered in the machine documentation ?
E-10.7 RECOMMENDED TEST CRITERIA FOR HYDRAULIC HOSE ASSEMBLIES
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;
Disentanglement of the hose out of the fittings;

Page E-39
Damaging or deformation of fittings which reduces the function and strength of the fittings or the connection
of hose-fittings;
Corrosion of fittings, reducing the function and strength;
Do hydraulic hose assemblies have freedom of movement, or has there been formation of squeeze, shearing
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)?
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?
E-10.8 FACTORS INFLUENCING THE TEST PERIODS
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 pro-
tection concept of the machinery manufacturer and provisions for shortened periods in the operation 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);
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);
Comparison, whether the actual operating conditions / conditions of use comply with those conditions stated
by the manufacturer at acquisition;
General manufacturers 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;
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);
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.

Page E-40
E-10.9 RECOMMENDED TEST PERIODS
Requirements for hydraulic hose assembly Recommended test period

Normal requirements 12 months
Increased requirements for safety, e.g. due to: 6 months
increased operating times (e.g. multiple-shift

operation)
strong external influences
intended prolonged duration of use
(replacement intervals, see. chapter 3.5) or
provisions stated by the machine manufacturer for

particular gravity-loaded axes
E-10.10 INFLUENCING FACTORS WITH REGARD TO THE REPLACEMENT INTERVALS
Statements or instructions given by the manufacturer of the hydraulic hose assemblies or the machinery ma-
nufacturer, particularly provisions given by the manufacturer for gravity-loaded axes;
Conditions of use and environment;
Hazards due to hydraulic fluid, the pipe itself or a hazardous machine or load movement in case of damage 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, (if
necessary shortened) by a competent person.
E-10.11 RECOMMENDED REPLACEMENT INTERVALS
Requirements for the hydraulic hose assembly Recommended replacement intervals

Normal requirements 6 years
Increased requirements for safety, e.g. by: 2 years
increased operating times (e. g. multiple-shift

operation)
strong external influences
provisions stated by the machine manufacturer for

particular gravity-loaded axes
Page E-41
E-11 HANDLING OF BEARINGS

Spherical and cylinder roller bearings are used throughout drawworks shaft assemblies. The bearings are a precision
built item and require careful handling in order to obtain the long service life and high load carrying characteristics
associated with anti-friction bearings.
If bearings are removed and are to be reused, the inner and outer races and roller assemblies of each bearing must
be kept together and reinstalled exactly as they came off.
It is always necessary to completely replace any roller bearing that fails, even though only one part of the bearing
shows damage. Since the running clearances of these bearings are extremely small, excessive clearances, worn or
grooved bearing rings, and any pitting or flaking of the parts is indicative of failure and the entire bearing should be
changed as soon as possible.
Most roller bearings are assembled to their shaft by means of shrink fit. Damaged or worn bearings and bearing rings
can be removed by driving them off the shaft with a bar and hammer. Bearings should always be heated in an oil
bath or an inductive heater, the temperature of which should not exceed 120C. Be certain that both the oil and the
container are very clean. If the oil container is in direct contact with the fire, place a rack into the container so that the
bearings will not rest on the bottom. Do not leave the bearings in the oil bath longer than three minutes.
Once the heated bearings are in position on the shaft, hold it in place until it cools.
WARNING
Never use water or any other liquid to cool a hot bearing.
Rapid cooling will cause the surfaces of the races and rollers to check or crack and the bearing will fail immediately
WARNING
Never strike a roller bearing with a steel hammer.
If the bearing must be driven into position use copper or a soft hammer and strike lightly.
If the inner race of the bearing is to be positioned by means of a hydraulic press, use a mounting tube which has an
inside diameter slightly larger than the shaft and an outer diameter not to exceed the outer diameter of the inner race.
The tube must be faced square on both ends, thoroughly clean inside, and long enough to clear the end of the shaft
after bearing is mounted.
If the outer race is to be pressed into the housing, the outer diameter of the mounting tube should be slightly smaller
than the housing bore and the inside diameter not less than the inner diameter of the outer race.
Always lubricate the shaft or housing before installing the bearing. Oil or anti-seize compound is the best lubricant
for this purpose.
Do not remove a new bearing from the box or wrapping until it is to be installed. Protect it from dirt and other foreign
matter at all times. If a bearing must be cleaned, use clean kerosene or other solvent.
E-12 BRAKING SYSTEM

E-12.1 HOIST DRUM DISC BRAKE
See manufacturers instructions.
E-12.2 EDDY-CURRENT BRAKE
The eddy-current brake can be coupled to the hoist drum shaft by means of a clutch. It serves as auxiliary brake to
minimize the wear of the disc brake and of the brake rims. The brake operates according to the electrical eddy-current
principle, and must be cooled with water. Further information to the functioning principle and maintenance can be
seen from manufacturers documentation.
Page E-42
E-12.3 DRIVE BRAKE
On the drive shaft, there is mounted an Airflex clutch rigidly connected to the skid. A uniform, slow rotation of the
drive shaft for shifting the different speeds of the transmission shaft can be produced by pressurizing the brake with
compressed-air, because it avoids an overspeed of the motors. Functioning principle and maintenance are described
in the Manufacturers documentation.
E-13 CHAINS
E-13.1 MAINTENANCE
The service life of a chain decisively depends on a good lubrication. Wrong lubrication methods and inadequate lu-
bricants cause an anti-lubrication and, thus, a high wear and premature chain failure.
To obtain an effective lubrication, a sufficient quantity of a fluid lubricant must be pressed in the chain articulations.
The oil must always be put on the bracket edges to pass a narrow gap between the brackets and to enter the chain
articulation.
A pressure circulation lubrication system ensures lubrication of the chains in the drawworks. It sprays oil through
nozzles onto the high bracket edges. Also see maintenance of oil lubrication system.
E-13.2 ADMISSIBLE ELONGATION DUE TO WEAR
The roller chains elongate due to abrasion between bolts and sleeves. The used roller chains have a maximum ad-
missible wear elongation of 3 %. This corresponds to lengthening of 30 mm per 1 m of chain. Then the chain must be
replaced. Chains should also be replaced when presenting outer damage. A considerably worn out chain induces a
progressive tooth flank wear when being used longer. Finally, the sprocket teeth have pittings and hooks.
IMPORTANT
The sprocket wear can be reduced essentially when exchanging the chain already at a wear elongation of
1.5 to 2%.
The chains can be mounted using the chain tensioners being scope of supply.
E-14 REMOVAL AND INSTALLATION OF DRUM SHAFT COMPONENTS

The drawworks drum shaft assembly consists of the drum, brake rims, main shaft bearings, high and low drum spro-
cket with PO air clutches, and a spline tooth drive ring connection for the eddy current brake.
IMPORTANT
The drum assembly, complete with brake rims, water cooling piping, and main bearing housing, but less
low and high drum drive sprockets and clutches, is dynamically balanced. Installation or replacement of the
piping or rubber hose connections with other types of materials than that originally furnished can result in
the drum assembly becoming out of balance.
Exchange the wear disks of the PO clutches, sprockets, main bearings and brake rims according to drawing 01990198
as described below:
WARNING
Drawworks, water and the air supply must be shut down before working on the system. Release pressure out
of the air lines. RISK OF ACCIDENT.
Page E-43
E-14.1 DISASSEMBLY OF THE DRUM SHAFT
For exchanging the PO clutches, sprockets, main bearings and brake rims, the whole drum shaft must be disassembled
from the drawworks. First take the drill line from the drum (see Installation and Exchange of drill line) and dismount the
protective hoods, Pos. 01, 05, 07, 10, 11, 12, 13, 17 and 18 according to drawing of Spare part manual. All protective
hoods are provided with fixing points for this. Make sure that the water and air supply are cut off.
7 1 5 17 18 17 10 13 12 11 8
Fig. D-28
Page E-44
Then separate the chains, Pos. 5 and 6, according to drawing 01990358 using chain tensioners A,
5 6
Fig. D-29
Page E-45
and dismount the hydraulic brake support, Pos. 04 according to drawing of Spare part manual (see maintenance
hydraulic brake system).
04
04
A A
04
Fig. D-30
Page E-46
Before the drum shaft can be lifted out of the frame, dismount the bearing shells of the main bearings Pos. 36 and
rotor II, Pos. 01, according to drawing Spare part manual and uncouple the eddy-current brake.
WARNING
When removing the complete hoist drum shaft pay attention to that sufficiently strong ropes are used (total
weight of the hoist drum shaft approx. 14.000 kg) and that the seals, and the pins, Pos. 33, do not get lost.
B A
B A
C
SECTION C-C
C
SECTION D-D
SECTION B-B SECTION A-A
Fig. D-31
Page E-47
33 36
Fig. D-32
Page E-48
E-14.2 EXCHANGE OF WEAR DISKS
Disassembly:
Remove drill line (see Installation and Exchange of drill line)
Dismount drill line kicker.
Dismount wear disks, which are divided into two sections.
For assembly, the operation steps should be carried out vice-versa.
Hoist drum shaft (drawing Spare part manual)
Rope-kicker adapted on assembly

and thread M12 bored on assembly
Section D-D
Fig. D-33
Page E-49
E-14.3 EXCHANGE PO CLUTCH 336, POS. 88
Disassembly:
Cut air supply to clutch
Disassemble drum shaft (see above)
Dismount rotor I, Pos. 65
Pull-off clutch, Pos. 88, using the pull-off bores
For disassembly of the clutch see Twin Disk documentation.
IMPORTANT
Before pushing on the repaired or new clutch, check the carrier ring, for wear or damage and exchange it, if
required so.
When exchanging the carrier ring, pay attention to that the lubrication bore matches the respective bore in the spacer
ring, Pos. 61.
For assembly, the operation steps should be carrier out vice-versa

Page E-50
61
65 88
Fig. D-34
Page E-51
E-14.4 EXCHANGE PO CLUTCH 230, POS. 11
Disassembly:
Cut air supply to clutch
Disassemble drum shaft (see above)
Dismount connection, Pos. 10
Pull-off connecting flange, Pos. 07, using the pull-off bores
Pull-off clutch, Pos. 11, using the pull-off bores
For disassembly of the clutch see Twin Disk documentation.
IMPORTANT
Before pushing on the repaired or new clutch, check the carrier ring, Pos. 12, for wear or damage and ex-
change it, if required so.
For assembly, the operation steps should be carried out vice-versa.

Page E-52
12 11 10 07
Fig. D-35
Page E-53
E-14.5 EXCHANGE SPROCKET, POS. 54
Disassembly:
Dismount PO clutch 342, Pos. 88 (see above)
Separate lubrication line, Pos. 20, at sprocket
Dismount spacer ring, Pos. 61
Dismount/loosen covers, Pos. 52
Pull-off sprocket using the pull-off bores
Pull-off spacer ring, Pos. 53, and bearing, Pos. 28
Pull-off cover, Pos. 52
IMPORTANT
Before mounting the new sprocket check all relevant parts for wear or damage, exchange them, if required
so.
Assembly:
Mount cover, Pos. 52, on sprocket
Insert bearing, Pos. 28, and spacer ring, Pos. 53, in sprocket
Pull-on sprocket with bearings and spacer ring on shaft such that the inner bearing rings and the spacer rings,
Pos. 39, Pos.53 and 63, have tight contact
Measure bearing cover, Pos. 52, and mount with 0.1 mm tolerance to bearing, Pos. 28.
Mount the residual components in the opposite order as for disassembly.

Page E-54
61 20
88
63 52 28 53
54 52 39
Fig. D-36
Page E-55
E-14.6 EXCHANGE SPROCKET, POS. 31
Disassembly:
Dismount PO clutch 336, Pos. 88 (see above)
Pull-off spacer ring, Pos. 26
Dismount / loosen covers, Pos. 23 and 29
Pull-off coupling flange, Pos. 15, with sprocket
Pull-off sprocket from coupling flange, Pos. 15
Pull-off spacer ring, Pos. 27, and bearing, Pos. 28
Pull-off cover, Pos. 29
IMPORTANT
Before mounting the new sprocket check all relevant parts for wear or damage, exchange them, if required
so.
Assembly:
Push new sprocket on coupling flange, Pos. 15
Mount cover, Pos. 29, on coupling flange
Insert bearing, Pos. 28, and spacer ring, Pos. 27, in sprocket
Pull-on coupling flange with bearings and spacer ring onto shaft such that the inner bearing rings and the
spacer rings,
Pos. 39 and 27, have tight contact
Measure bearing cover, Pos. 23, and mount with 0.1 mm tolerance to bearing, Pos. 28
Mount the residual components for assembly in the opposite order as for disassembly.
Page E-56
29 27 15 23 26
39 28 31
Fig. D-37
Page E-57
E-14.7 EXCHANGE MAIN BEARING, POS. 36
Disassembly:
Dismount clutches P0 230 and 336 as well as sprocket, Pos. 31 and 54, as described above
Dismount spacer ring, Pos. 39
Dismount / loosen bearing cover, Pos. 40
Pull-off bearing with bearing housing, Pos. 37 and 83
Dismount bearing from bearing housing, Pos. 37 and 83
IMPORTANT
Before mounting the new bearing check all relevant parts for wear or damage, exchange them, if required
so.
For assembly make any working steps in the opposite order.

Page E-58
36
40 37 39 31
Fig. D-38
Page E-59
E-14.8 EXCHANGE BRAKE RIMS, POS. 41
Disassembly Driller side:

Dismount clutch PO 336 as well as sprocket, Pos. 54, as described above
Separate water piping at brake rims
Dismount brake rim
IMPORTANT
Before mounting the new brake rim check all relevant parts for wear or damage, exchange them, if required
so.
For assembly, make any working steps in the opposite order.
Disassembly Eddy current brake side:

Separate water piping at brake rims
Dismount brake rim
IMPORTANT
Before mounting the new brake rim check all relevant parts for wear or damage, exchange them, if required
so.
For assembly, make any working steps in the opposite order.

Page E-60
41 41
Fig. D-39
Page E-61
E-15 REMOVAL AND INSTALLATION OF TRANSMISSION SHAFT COMPO-

NENTS
As illustrated in drawing 01990219, the transmission shaft is split in two separate shafts, pos. 40 and pos. 39, and
connected to the clutch, pos. 35. For the exchange of components, only dismount the shaft concerned. In the following,
there is described the exchange of sprockets, supporting bearings and sliding clutch of the individual shafts.
40 35
39
Fig. D-40
Page E-62
E-15.1 TRANSMISSION SHAFT, POS. 40
E-15.1.1 REMOVAL OF TRANSMISSION SHAFT, POS. 40
To be able to dismount components of the transmission shaft, pos. 40, the shaft must be removed from the drawworks
skid. At first, separate the drawworks unit from the drive unit (see installation of drive and drawworks unit in the oppo-
site order). Dismount the protective hood on the control console side, rear wall of drawworks unit. Then, both shafts
can be uncoupled at clutch, pos. 35. Then dismount both bearing covers and bearing rings from the lateral walls for
to lift the shaft out of the frame, then.
WARNING
When lifting the transmission shaft, pos. 40, pay attention to that sufficiently strong ropes are used (total
weight of the shaft is approx. 700 kg).
Install the transmission shaft in the opposite order. When mounting the clutch, consider grease lubrication in accor-
dance with manufacturers indications.
E-15.1.2 EXCHANGE OF SUPPORTING BEARING, POS. 14
Dismounting:
Remove transmission shaft, Pos. 40 (see above).
Dismount bearing rings, Pos. 42.
Dismount end plate, Pos. 43.
Pull-off supporting bearing, Pos. 14, using the sprocket, Pos. 38 and spacer ring, Pos. 41.
Mounting is done in the opposite order.
42 41 40 35
43 14 38
Fig. D-40
Page E-63
E-15.1.3 EXCHANGE OF SPROCKET, POS. 09
Dismounting:
Dismount supporting bearing, Pos. 14 (see above).
Pull-off sprocket, Pos. 09 together with spacer ring, Pos. 41.
Mounting:
Pull-on sprocket, Pos. 09.
Pull-on spacer ring, Pos. 41.
Mount the other components in the opposite order as on dismounting.
IMPORTANT
Before mounting the new sprocket, check all parts concerned for wear or defects and exchange them, if
required so.
E-15.1.4 EXCHANGE OF SUPPORTING BEARING, POS. 14 CLUTCH END
Dismounting:
Remove transmission shaft (see above).
Dismount cover, Pos. 46, and then pull-off clutch, Pos. 35.
Pull-off supporting bearing, Pos. 14, from the shaft with bearing ring, Pos. 11 and spacer ring, Pos. 36 using
the spacer ring, Pos. 37.
Remove supporting bearing, Pos. 14 out of bearing ring, Pos. 11 and cover, Pos. 15.

Page E-64
41 09 15 36 35 46
14 37 11 14
Fig. D-41
Page E-65
E-15.2 TRANSMISSION SHAFT, POS. 39
E-15.2.1 REMOVAL OF TRANSMISSION SHAFT, POS. 39
To be able to dismount components of the transmission shaft, pos. 39, the shaft must be removed from the drawwor-
ks skid. At first, separate the drawworks unit from the drive unit (see installation of drive and drawworks unit in the
opposite order). Dismount both protective hoods on the rear wall of the drawworks unit. Then, both shafts can be
uncoupled at clutch, pos. 35. Then dismount both bearing covers and bearing rings from the lateral walls for to lift the
shaft out of the frame, then.
WARNING
When lifting the transmission shaft, pos. 39, pay attention to that sufficiently strong ropes are used (total
weight of the shaft is approx. 2300 kg).
Install the transmission shaft in the opposite order. When mounting the clutch, consider grease lubrication in accor-
dance with manufacturers indications.
E-15.2.2 EXCHANGE OF SUPPORTING BEARING, POS. 14, CLUTCH END
Dismounting:
Dismount cover, Pos. 46, and then pull-off clutch, Pos. 35.
Pull-off supporting bearing, Pos. 14 from shaft, with bearing ring, Pos. 33 and spacer ring, Pos. 34 using spacer
ring, Pos. 32.
Remove supporting bearing, Pos. 14 out of bearing ring, Pos. 33.

Page E-66
35 46 34 32
14 33 39
Fig. D-42
Page E-67
E-15.2.3 EXCHANGE OF SPROCKET, POS. 08
Dismounting:
Remove cover, Pos. 01 and spacer ring, Pos. 06.
Pull-off sprocket, Pos. 08.
E-15.2.4 EXCHANGE OF SUPPORTIMG BEARING, POS. 14
Dismounting:
Exchange sprocket, Pos. 08 (see above).
Remove wedge steel, Pos. 09.
Pull-off supporting bearing, Pos. 14, in bearing ring, Pos. 11, spacer ring, Pos. 10 by means of spacer, Pos.
18.
Remove supporting bearing, Pos. 14 out of bearing ring, Pos. 11.

Page E-68
18 11 10 09 08 06
39 14 01
Fig. D-43
Page E-69
E-15.2.5 EXCHANGE OF SPROCKET, POS. 31 - POS. 23, AS WELL AS OF CLUTCH, POS. 28 - POS. 29
IMPORTANT
To be able to ensure shifting ability between the sprockets, Pos. 31 and Pos. 23, using clutches Pos. 28 and
Pos. 29, exchange them always together.
Dismounting:
Remove supporting bearing, Pos. 14 on the clutch end (see above).
Dismount bearing cover, Pos. 22.
Remove angular ring of bearing, Pos. 24.
Pull-off sprocket, Pos. 31 with both bearings, Pos. 24 and spacer ring, Pos. 26.
Pull-off clutch socket, Pos. 28.
Dismount spacer, Pos. 18 (see above)
Dismount bearing cover, Pos. 22.
Remove angular ring of bearing, Pos. 24.
Pull-off sprocket, Pos. 23 with both bearings, Pos. 24 and spacer ring, Pos. 26.
Pull-off inner rings of bearings, Pos. 24, from shaft, as well as spacer ring, Pos. 25 and angular bearing ring
Pos. 24 using coupling wheel, Pos. 29.
Pull-off inner rings of bearings, Pos. 24, from shaft, at the clutch end, as well as spacer ring, Pos. 25, by means
of the angular bearing ring, Pos. 24.
Mounting of sprocket, Pos. 31:

Install both bearings, Pos. 24, with spacer ring, Pos. 25 and Pos. 26 each, into sprockets, Pos. 31 and Pos.
23.
Fill-up intermediate spaces at the bearings with grease, when mounting (see drawing 01990138).
Pull-on angular rings pointing to the coupling wheel, onto shaft.
Over the second angular ring each, pull on sprocket, Pos. 31 and sprocket, Pos. 23 each from one side of the
shaft.
Mount both covers, Pos.22.
Mount the remaining components in the opposite order as on dismounting.
IMPORTANT
Before mounting the new sprockets, check all parts concerned for wear or damage, and exchange them, if
required so.
Page E-70
31 24 25 26 23 24 22 18
14 28 29
Fig. D-44
Page E-71
E-16 REMOVAL AND INSTALLATION OF DRIVE SHAFT COMPONENTS

The drive shaft is connected by two clutches to both drive motors. The drive shaft components are shown in drawing
01990139. In the following, there are described dismounting and mounting of the individual elements.
Fig. D-45
E-16.1 REMOVAL OF DRIVE SHAFT, POS. 29 OUT OF DRIVE UNIT
Dismounting:
Remove protective hoods of drive unit.
Dismount drive chains.
Loosen screws of both drive motors.
Pull motors away from shaft until both clutches, Pos. 01 and Pos. 32 are separated.
Loosen screw connection of trestle, Pos. 09 and both pillow-block bearings, Pos. 21.
Dismount compressed-air feed line of the Airflex clutch.
Lift out drive shaft.

Page E-72
WARNING
When removing the complete drive shaft pay attention to that sufficiently strong ropes are used (total weight
of the drive shaft is approx. 1200 kg).
Mounting is done in the opposite order of disassembly. Then align the motor in accordance with the clutch
manufacturers information, Pos. 01 and Pos. 32, and adjust it to the admissible axial, radial and angular
offset.
E-16.2 REMOVAL OF AIRFLEX CLUTCH, POS. 07
Dismounting:
Removal of drive shaft, Pos. 29 (see above).
Pull-off Airflex clutch from friction drum, Pos. 06.
32 29 01
06
21 07
09
Fig. D-46
Page E-73
E-16.3 REMOVAL OF CLUTCH, POS. 01
Dismounting:
Dismount friction drum, Pos. 06 from clutch, Pos. 01 and push-off from clutch.
Loosen threaded pin, Pos. 03 and pull-off clutch from shaft, Pos. 29.
E-16.4 REMOVAL OF SUPPORTING BEARING, POS. 19, AIRFLEX CLUTCH END
Dismounting:
Removal of clutch, Pos. 01 (see above).
Pull-off friction drum, Pos. 06 from shaft, Pos. 29.
Dismount adjusting spring, Pos. 04.
Pull-off spacer ring, Pos. 14 from shaft, Pos. 29.
Pull-off spacer ring, Pos. 25 and bearing, Pos. 19 with pillow-block bearing, Pos. 21 by means of sprocket,
Pos. 27 from shaft Pos. 29.
Mounting:
Pull onto shaft, individually, each: sprocket, Pos. 27, spacer ring, Pos. 25, pillow-block bearing, Pos. 21 with
supporting bearing, Pos. 19.
The remaining components are mounted in the opposite order as for disassembly.
03 19 29 27 19 14 04 01
25 06
21
Fig. D-47
Page E-74
E-16.5 REMOVAL OF SPROCKET, POS. 27
Dismounting is done as described above for the removal of supporting bearing, Pos. 19, Airflex clutch end.
Mounting is done as described above for the removal of supporting bearing, Pos. 19, Airflex clutch end.
IMPORTANT
Before mounting the new sprocket, check all parts concerned for wear and defects, and exchange, if required
so.
E-16.6 REMOVAL OF CLUTCH, POS. 32
Dismounting:
Loosen threaded pin, Pos. 03, and pull-off clutch from shaft, Pos. 29.
32 03 29 27 19
Fig. D-48
Page E-75
E-16.7 REMOVAL OF SUPPORTING BEARING, POS. 19
Dismounting:
Remove clutch, pos. 32 (see above).
Remove adjusting spring, pos. 04.
Pull-off spacer ring, pos. 31, from shaft, pos. 29.
Pull-off spacer ring, pos. 25 and bearing, pos. 19 with pillow block bearing, pos. 21 using the sprocket, pos.
30 from the shaft, pos. 29.
Mounting:
Pull-on sprocket, pos. 30, spacer ring, pos. 25, pillow block bearing, pos. 21 with supporting bearing, pos. 19,
each individually onto shaft.
Mount the residual components vice-versa as on disassembly.
E-16.8 REMOVAL OF SPROCKET, POS. 30
Dismounting is done as described above for removal of supporting bearing, pos. 19.
Mounting is done as described above for removal of supporting bearing, pos. 19.
IMPORTANT
Before mounting the new sprocket, check all parts concerned for wear and defects, exchange them, if requi-
red so.
32 31 19 30 29 19 04
25 21
Fig. D-49
Page E-76

TROUBLESHOOTING UM199015/E - Rev.0 - 11/2011
Page F-1
Section F - TROUBLESHOOTING
UM199015/E - Rev.0 - 11/2011 TROUBLESHOOTING
Page F-2
F-1 TROUBLESHOOTING
DRAWWORKS TROUBLESHOOTING
TROUBLE CAUSE REMEDY

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 to broken c. Replace broken or worn element
drive chain or worn gears
d. Clogging of filter screen d. Replace filter screen
2. High lubricating oil pressure a. Stopped up oil lines a. Remove obstruction
b. Inadequate viscosity of oil b. See table: recommended lubricants
3. Reduction in breaking capacity a. Improper brake and adjustment a. Adjust tighteners

b. Reduction in linings (blocks) coefficient of b. Clear and replace linings
friction
a. Improper release of brake bands a. Adjust tighteners
4. Kicking brakes
b. Out-of-round brake bands b. Disassemble and replace bands
a. Irregular functioning of control valves a. Dismount vavles and clean or replace worn
b. Stopped up air lines elements
5. Irregular air pressure c. Loosening of joints with air leaks b. Bleed off lines
d. Air leaking clutches and/or quick release c. Tighten joints
valves d. Replace leaking element
OTHER RISK UM199015/E - Rev.0 - 11/2011
Page G-1
Section G - OTHER RISK

UM199015/E - Rev.0 - 11/2011 OTHER RISK
Page G-2
G-1 OTHER RISKS
WARNING
In case of repairs after a fault has been detected or of preventive maintenance, and however for any envisaged
application, the machine can be considered almost free of any risk, provided that the all safety cautions are
taken, as required by the regulations currently in force and as mentioned in Section B of this manual.
G-1.1 PRESSURIZED ACCUMULATORS
On the drawwork are installed some accumulators under pressure.
It is necessary to consider their potential danger during maintenance/repairing of hydraulic and pneumatic
systems.
HAZARD
Before working on pressurized lines (hydraulic oil, compressed air, water or drilling fluids) and/or disconnect
components, make sure that the pressure has been discharged and the fluid contained is not longer hot.
DISMANTLING AND DEMOLITION UM199015/E - Rev.0 - 11/2011
Page H-1
Section H - DISMANTLING AND DEMOLITION

UM199015/E - Rev.0 - 11/2011 DISMANTLING AND DEMOLITION
Page H-2
H-1 DISMANTLING AND DEMOLITION

The demolition of the machine must be exclusively entrusted to Qualified and Trained Personnel.
If the Customer doesnt dispose of the adequate Personnel or instruments for carrying out the demolition procedures
in fully safe conditions and in such a way to grant the Operators safety, get addressed to the DRILLMEC Technical
Personnel.
The machine was realized by prevalently using ferrous materials, aluminium and other metal alloys which can be
re-cycled.
There are some components realized by using technical polymeric materials, glass.
There are also the following materials which, according with the relevant laws in force in the country in which the di-
smantling is carried out, can be considered as special wastes: fuel for endothermic motors, hydraulic oils, lubricating
oils, greases, drilling muds, electric accumulators and electric or electronic wastes.
It is charged to the demolition responsible to get carefully informed, according with the relevant laws in force, about
the modalities foreseen for the elimination of the special wastes and to act in full compliance with them.
HAZARD
Risk of environmental pollution.
Before proceeding to disassemble/demolish the mechanical parts, be sure to:
- Discharge the piping from drilling mud.
- Empty the cooling tank rod, verify the discharge of all the circuit.

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Operation and

Machine type MAS8000

Manufacturing year 2011

12, Via 1 Maggio

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

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

LOCAL AUTHORIZED DEALERSHIP AND SERVICE CENTRE

MEMORANDUM OF THE MACHINE IDENTIFICATION DATA

Machine type MAS8000

Machine serial number

Manufacturing year 2011

Drilling rig type-approval

Power plant type-approval

Intentionally blank page

TECHNICAL SERVICE AND SPARE

The technical service can be executed by an Agent or by

Intentionally blank page

Section A - GENERAL INFORMATION A-1

A-1 GENERAL ...................................................................................................................... A-2

Section B - SAFETY B-1

B-1 PERSONNEL QUALIFICATIONS.................................................................................. B-2

Section C - INSTALLATION, MOVING AND RIG UP C-1

C-1 INSTALLATION, MOVING AND RIG-UP........................................................................ C-2

Section D - OPERATING INSTRUCTIONS D-1

D-1 CONTROLS AND INSTRUMENTS.................................................................................. D-2

Section E - MAINTENANCE E-1

E-1 GENERAL........................................................................................................................ E-2

E-15.2.3 EXCHANGE OF SPROCKET, POS. 08 ............................................................................................ E-67

Section F - TROUBLESHOOTING F-1

F-1 TROUBLESHOOTING..................................................................................................... F-2

Section G - OTHER RISK G-1

G-1 OTHER RISKS................................................................................................................ G-2

Section H - DISMANTLING AND DEMOLITION H-1

H-1 DISMANTLING AND DEMOLITION................................................................................ H-2

Intentionally blank page

FOREWORD TYPICAL STRUCTURE OF THE PAGES

As already pointed out into the Section B - SAFETY,

C-1-1 DRILLING CONTROLS AND INSTRUMENTATIONS

reading of all its information. It has to be used as a con- 6

tinuous reference to make clear every doubt concerning

The manual has to be kept keep in easily accessible H3 H6

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

consultation of the Index that points out in a quick but H5

complete way the structure of the treated subjects allowing

in such a way a well defined searching procedure.

It is also advisable to know well the methods used to S11

realize the editing and the graphical technique used to

subdivide the subjects and to identify the several parts

A8 Air pressure gauge C51 Torque wrench suspension up-down

inside the document. A29 Mud pressure, standpipe manifold

The necessary information is reported here below.

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

8 Inside each section, the page numbering system is a

C-2 ASSEMBLY, INSTALLATION AND DISINSTALLATION INSTRUCTIONS TABLE NUMBERING SYSTEM

The table numbering system adopted into the subject

C-2-1 PRELIMINARY CHECKS

1. Before starting to work, it is necessary to make

Inside each first level chapter, the table numbering system

2. Another mainly important check is that relevant

manual is not a continuous one: at the beginning of every

9 Inside each first level chapter, the figure numbering system

On their turn, the sections are subdivided in Chapters.

DRILLMEC can introduce in every moment some