Preliminary Um191091 - Mud Pump 9t1000 - e

Operation and
Maintenance
Manual
Triplex mud pump - trailer mounted
Machine type
9T1000
Manufacturing year
Y
AR
IN
IM
EL
PR
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
9T1000 - Operation and Maintenance Manual
Document code: UM191091/E - Revision 0 (03/2009)
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 2009 DRILLMEC S.p.A. - All rights reserved
Printed in Italy
WARRANTY
All DRILLMEC machines and equipments are covered by warranty as far as any possible manufacturing defects
are concerned, either for a period of 12 (twelve) months, starting from the date of delivery to the final Customer, or
for 18 (eighteen) months, starting from the date of the B/L (Bill of Loading), unless otherwise specified in the supply
agreement.
That WARRANTY is held for applicable only provided that the DRILLMEC manufactured products are correctly used
by the final USER, by fully observing the contents of the Operation and Maintenance Manual. The WARRANTY isn’t
applied to machines or equipments which were in any way altered, which were subjected to misuse, negligence,
accidents or were affected in their performances or reliability, such as if repaired in any way not complying with the
DRILLMEC directives.
DRILLMEC obligations in matter of WARRANTY are limited to supplying parts and correcting bad workmanship, up
to an amount not exceeding the estimated costs of the repair itself. WARRANTY doesn’t cover any compensation for
revenue losses, transportation, hoisting and trucking expenses, such as direct and/or indirect damages caused to
the goods that aren’t imputable to DRILLMEC. Products and equipments which are furnished by DRILLMEC but not
manufactured by them, won’t carry else but MANUFACTURER WARRANTY alone.
All DRILLMEC responsibilities and obligations are clearly defined in this WARRANTY statement enclosed to the sale
agreement, and no further verbal or written agreement will be considered as being legal. In order to guarantee both
reliability and high performances of the equipments, we strongly recommend to attentively read the “SCHEDULED
MAINTENANCE” section. If, for any reason, those prescriptions are either ignored or realized by using non-OEM
(Original Equipment Manufacturer) spare parts, this WARRANTY declaration will instantly CEASE.
9T1000 Operation and Maintenance Manual
UM191091/E - Rev.0 - 03/2009 COVER
Page IV
TECHNICAL SERVICE AND SPARE

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

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

This area is reserved to take note of the identification data of Your Dealership and of the possible
Authorized Service Centre of Your Country.
MEMORANDUM OF THE MACHINE IDENTIFICATION DATA
This area is devoted to take note of the identification data relevant to Your own machine.
When You want to contact the DRILLMEC After Sale Service, it is necessary to point out always the
following identification data to ensure a quicker solving of the involved technical service problems:
9T1000
Machine type
--------
Machine serial number
Manufacturing year
2008
Drilling rig type-approval
Power plant t ype-approval

INTENTIONAL WHITE PAGE
Operation and Maintenance Manual 9T1000
INDEX UM191089/E - Rev.0 - 12/2008
Page VII
INDEX
TECHNICAL SERVICE AND SPARE PARTS...........................................................................................................IV
FOREWORD XI
INSTRUCTION FOR THE MANUAL READING................................................................................................................. XI
TYPICAL STRUCTURE OF THE PAGES........................................................................................................................... XI
SUBDIVISION IN SECTION AND CHAPTERS................................................................................................................. XII
PAGE NUMBERING SYSTEM.......................................................................................................................................... XII
TABLE NUMBERING SYSTEM......................................................................................................................................... XII
FIGURE NUMBERING SYSTEM....................................................................................................................................... XII
RECALLING CONNECTION TO OTHER SUBJECTS...................................................................................................... XII
UPDATING ......................................................................................................................................................... XIII
SYMBOLS ......................................................................................................................................................... XIII
SECTION A - GENERAL INFORMATION.............................................................................A-1

A-1 CONVENTIONAL REFERENCE..................................................................................................................... A-2
A-2 REFERENCES . ....................................................................................................................................... A-3
A-2-1 ORIENTATION........................................................................................................................................................ A-3
A-3 MACHINE IDENTIFICATION........................................................................................................................... A-4
A-3-1 MANUFACTURER.................................................................................................................................................. A-4
A-3-2 Model ......................................................................................................................................................... A-4
A-3-3 IDENTIFICATION PLATES..................................................................................................................................... A-4
A-4 GENERAL DESCRIPTION.............................................................................................................................. A-7
A-4-1 MAIN COMPONENT DESIGNATIONS................................................................................................................... A-7
A-5 TECHNICAL SPECIFICATION...................................................................................................................... A-10
A-5-1 main DIMENSIONS............................................................................................................................................. A-10
A-5-2 WEIGHTS ....................................................................................................................................................... A-11
A-6 Power pump performance curves................................................................................................. A-12
A-7 TECHNICAL DATA . ..................................................................................................................................... A-13
A-7-1 ELECTRIC MOTOR.............................................................................................................................................. A-13
A-7-2 TRIPLEX PUMP.................................................................................................................................................... A-13
A-7-3 DRIVE ....................................................................................................................................................... A-13
A-8 machine use destination..................................................................................................................... A-14
A-8-1 PROPER USE....................................................................................................................................................... A-14
A-8-2 MACHINE LIFETIME LIMITS................................................................................................................................ A-14
A-8-3 FORESEEABLE OPERATORS’ TRAINING, EXPERIENCE OR ABILITY LEVELS ............................................ A-14
A-9 TECCHNICAL SERVICE AND SPARE PARTS............................................................................................ A-16
Section B- SAFETY.........................................................................................................B-18
B-1 PERSONNEL QUALIFICATIONS................................................................................................................ B-19
B-1-1 QUALIFICATION................................................................................................................................................... B-19
B-1-2 WORKING GARMENTS....................................................................................................................................... B-19
B-2 MACHINE PLATES ...................................................................................................................................... B-20
B-3 SAFETY DEVICES . ..................................................................................................................................... B-24
B-4 GENERAL SAFETY DURING THE ROUTINE AND THE EXTRAORDINARY MAINTENANCE PHASES.B-24
B-4-1 MECHANICAL PART............................................................................................................................................ B-24
B-4-2 ELECTRIC PART.................................................................................................................................................. B-26
B-4-3 HYDRAULIC PART............................................................................................................................................... B-26
B-5 Safety Rules Regarding Scheduled Maintenance................................................................. B-27
B-6 GENERAL SAFETY DURING THE OUT OF SERVICE SETTING AND ELIMINATION PHASE................. B-28
Section C- OPERATING INSTRUCTIONS......................................................................C-29

C-1 CONTROLS AND INSTRUMENTS............................................................................................................... C-30
UM191089/E - Rev.0 - 12/2008 INDEX
Page VIII
C-2 MACHINE DEVICES..................................................................................................................................... C-31

C-3 COMMISSIONING . ..................................................................................................................................... C-32
C-3-1 POSITIONING THE PUMP...................................................................................................................................C-33
C-3-2 SUCTION PLANT.................................................................................................................................................C-34
C-3-3 DELIVERY LINE...................................................................................................................................................C-34
C-3-4 PRELIMINARY ACTIONS.....................................................................................................................................C-34
C-4 USER INSTRUCTIONS................................................................................................................................. C-37
C-4-1 setting operational parameTers...........................................................................................................C-37
C-4-2 running-in cycle...........................................................................................................................................C-38
C-5 PARKING AND STORAGE........................................................................................................................... C-39
C-5-1 STORAGE .......................................................................................................................................................C-39
C-5-2 DISUSE .......................................................................................................................................................C-39
C-6 TRANSPORT INSTRUCTIONS.................................................................................................................... C-41
C-6-1 LIFTING THE PUMP.............................................................................................................................................C-41
C-6-2 ANCHORING TO THE TRANSPORT VEHICLE...................................................................................................C-44
Section D - MAINTENANCE............................................................................................D-45
D-1 PREFACE . ..................................................................................................................................... D-46
D-1-1 MAINTENANCE LAYOUT.....................................................................................................................................D-47
D-1-2 MAINTENANCE AND LUBRICATION POWER PUMP.........................................................................................D-48
D-1-3 MAINTENANCE AND LUBRICATION INTERVALS PUMP..................................................................................D-49
D-1-4 LUBRICATION AND greasing points...........................................................................................................D-52
D-1-5 BOLT TIGHTENING POINTS...............................................................................................................................D-52
D-2 TABLES AND SPECIFICATIONS................................................................................................................. D-52
D-2-1 GREASES .......................................................................................................................................................D-52
D-2-2 ANTI-CORROSION PRODUCTS.........................................................................................................................D-53
D-3 LUBRICATION instructions.................................................................................................................. D-53
D-3-1 MOTOR PUMP.....................................................................................................................................................D-53
D-3-2 OIL LUBRICATION OF PUMP..............................................................................................................................D-53
D-3-3 JACKET/PISTON COOLING SYSTEM................................................................................................................D-54
D-3-4 Transmission belts tensioning...............................................................................................................D-54
D-4 ROUTINE MAINTENANCE........................................................................................................................... D-55
D-4-1 EVERY DAY D-55
D-4-2 WEEKLY MAINTENANCE....................................................................................................................................D-55
D-4-3 MONTHLY MAINTENANCE..................................................................................................................................D-55
D-5 BOLT TIGHTENING SPECIFICATIONS....................................................................................................... D-56
D-6 HOSE FITTING SPECIFICATIONS............................................................................................................... D-57
D-6-1 STORING OF FLEXIBLE HOSES........................................................................................................................D-57
D-6-2 NORMS AND METHODS OF USE OF THE FLEXIBLE HOSES.........................................................................D-58
D-6-3 MAINTENANCE OF THE FLEXIBLE HOSES......................................................................................................D-59
SECTION E - FLUID END MAINTENANCE........................................................................ E-61

E-1 FLUID-END CONSUMABLES.......................................................................................................................E-62
E-2 REPLACING THE SEALS..............................................................................................................................E-62
E-3 VALVES REPLACING (SUCTION and DELIVERY).....................................................................................E-63
E-3-1 VALVES REMOVAL............................................................................................................................................... E-63
E-3-2 VALVES INSTALLATION....................................................................................................................................... E-63
E-3-3 FLUID END BOLT TIGHTENING SPECIFICATIONS........................................................................................... E-64
E-4 VALVE SEATS REPLACING..........................................................................................................................E-65
E-4-1 VALVE SEATES REMOVAL.................................................................................................................................. E-65
E-5 PISTONS AND PISTON RODS REPLACING................................................................................................E-67
E-5-1 PISTONS AND PISTON RODS REMOVAL.......................................................................................................... E-67
E-5-2 PISTONS AND PISTON RODS INSTALLATION.................................................................................................. E-68
E-6 LINERS REPLACING.....................................................................................................................................E-69
E-6-1 LINERS REMOVAL............................................................................................................................................... E-69
E-6-2 LINERS INSTALLATION....................................................................................................................................... E-69
INDEX UM191089/E - Rev.0 - 12/2008
Page IX
E-7 ACCESSORIES . ......................................................................................................................................E-70

E-7-1 sUCTION PULSE DAMPENER............................................................................................................................ E-70
E-7-2 FILTER UNIT E-71
E-7-3 DELIVERY PULSATION DESURGER.................................................................................................................. E-71
SECTION F - TROUBLESHOOTING.................................................................................. F-75

F-1 TROUBLESHOOTING....................................................................................................................................F-76
SECTION G - OTHER RISK................................................................................................G-81

G-1 OTHER RISKS . ..................................................................................................................................... G-82
G-1-1 PRESSURIZED ACCUMULATORS......................................................................................................................G-82
SECTION H - DISMANTLING AND DEMOLITION.............................................................H-83

H-1 DISMANTLING AND DEMOLITION.............................................................................................................. H-84
UM191089/E - Rev.0 - 12/2008 INDEX
Page X
GENERAL INFORMATION UM191089/E - Rev.0 - 12/2008
Page XI
FOREWORD 4 Mark and logotype of DRILLMEC SpA.

5 Section and page number.
Dear Customer, this Operating, Use and Maintenance
6 Section title.
Manual has been conceived to provide all information
necessary to allow the functioning, the use and the main-
tenance of the 9T1000 mud pump according to safety
and functioning efficiency criteria. 3 1
4 2
5
INSTRUCTION FOR THE MANUAL READ-
ING
Operation and Maintenance Manual HH 102
INSTRUCTIONS UM189026/E - Rev.0 - 03/2008
Page C-3
C-1-1 DRILLING CONTROLS AND INSTRUMENTATIONS
This manual provides some different type information • Control panel of Power Control Room (for more
6
informations, see proper technical documentation).
starting from the instruction for the manual reading up to

From this control panel must be used to switch on
the electric motor.
the machine technical performances, the safety rules, the

technical specifications of the maintenance products, the
operating rules, the transport rules, …etc. Fig. C-1.1
H3 H6
A29
As already pointed out into the Section B - SAFETY,

A27 A26 A25 A8
H4 H1
the operators will be required to carefully read and well S3

C4
H5
H2
understand the contents of the manual before starting to C48 C29
use the machine. It is necessary the complete understand- C52
ing especially of all the aspects relevant to the use, the S6

C28
maintenance and the lubrication of the machine. S11

C47 C51
C50
C46
Then, the manual does not need only for a first sequential Fig. C-1.2
reading of all its information. It has to be used as a con- A8 Air pressure gauge
A25 Oil pilot pressure drilling rig
C51 Torque wrench suspension up-down
C52 Make-up Break-out Torque wrench
tinuous reference to make clear every doubt concerning

A26 Oil pilot pressure control panel H1 Command enabled lamp
A27 Service oil pressure H2 Hydraulic oil ﬁlter obstruction lamp
A29 Mud pressure, standpipe manifold H3 High temperature hydraulic oil lamp
the machine. C4 Oil pump 3 lifting - top drive rotation control

C28 Oil pump 1 lifting - top drive rotation control
H4
H5
Low level hydraulic oil lamp
High temperature hydraulic oil pump lamp
C29 Oil pump 2 lifting - top drie rotation control H6 Emergency enabled lamp
C46 Tripping mode - drilling mode selector S3 Emergency
The manual has to be kept keep in easily accessible

C47 Power slips in-out control S6 Command enabled
C48 Top drive rotation speed selector S11 Lamp check
C50 Inside BOP open-close selector
areas. The operators must be able to use it through the

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

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

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

2 Document identification code/language/edition.
Example: UM123456/I - Rev. 12/1996 = Operation
and Maintenance Manual written in Italian langua-
ge, edition issued on December 1996.
3 Document type (in this case Operation and Main-
tenance Manual).
UM191089/E - Rev.0 - 12/2008 GENERAL INFORMATION
Page XII
Then, according to the subject treated into the pages, the atment of the different subjects, also making easier the
following other elements can be present combined one possible references to other subjects.
each other:
PAGE NUMBERING SYSTEM
7 Chapter title (first, second or third level).
8 Text The page numbering system adopted into the subject
9 Figure manual is not a continuous one: at the beginning of
every section, the page number restarts from 1 (Section
10 Number of figure
cover).
11 Indentification of section Inside each section, the page numbering system is a
progressive one.
8 Example: Into section A, page A 2, page A 3, …. etc.
7
HH 102
UM189026/E - Rev.0 - 03/2008
Operation and Maintenance Manual
INSTRUCTIONS
TABLE NUMBERING SYSTEM
Page C-14
C-2 ASSEMBLY, INSTALLATION AND DISINSTALLATION INSTRUCTIONS The table numbering system adopted into the subject
WARNING manual is not a continuous one: at the beginning of every
first level chapter, the table number restart from 1.
Before consulting this section, attentively read para-
graph B-5 of Section B: SAFETY. P1
C-2-1 PRELIMINARY CHECKS
1. Before starting to work, it is necessary to make

sure that all the checks and maintenance operations
required according with the machine performed working Inside each fist level chapter, the table numbering system
hours were carried out.
Fig. C-2.1
is a progressive one and it is marked by the graphical
IMPORTANT
Worked hour of total rig, you must be refered to hour- symbol Tab. X-0.0.
counter P1
2. Another mainly important check is that relevant

Example: Into chapter A-1, Tab.A-1.1, Tab.A-1.2, …. etc.
restarts from 1.
to the machine planarity (P2, A34, A35): when starting
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
slab placed under the stabilizers. P2
FIGURE NUMBERING SYSTEM

3. It is also advisable to bleed off the hydraulic oil
tank. Anyway, that procedure requires the realization of Fig. C-2.2
some operations at work completion.
A34 A35
WARNING
A machine inclination, especially when the drilling
rods are already driven, compromises the well verti-
cality, and, even worse, can damage the drilling rods’ 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
first level chapter, the figure number restarts from 1.
11
Fig. C-2.3
9 Inside each fist level chapter, the figure numbering system

is a progressive one and it is marked by the graphical
symbol Fig. X-0.0.
Example: Into chapter A-1, Fig.A-1.1, Fig.A-1.2, …. etc.
Fig. 3 - Sample of page RECALLING CONNECTION TO OTHER

SUBDIVISION IN SECTION AND CHAPTERS SUBJECTS
To make easier the consultation of related subjects, the

This manual is subdivided into six Sections respectively
recalling connections inside the manual are executed
marked through the letters A, B, C, D, E, F, G, H and I.
pointing out the alphanumeric reference code of the invol-
ved chapter, figure or table. In such a way, it is possible
Section A-GENERAL INFORMATION
to avoid the pointing out of too long titles or of the page
Section B-SAFETY
numbers.
Section C-OPERATING INSTRUCTIONS
Example:
Section D-MAINTENANCE
• Recalling connection to a chapter: (refer to A) or (refer
Section E-OTHER HAZARDS
to B-3.1.1);
Section F-TROUBLE SHOOTING
• Recalling connection to a table: (refer to Tab.A-1);
Section G-OTHER RISKS
• Recalling connection to a figure: (refer to Fig.A-1.);
Section H-REMOVAL AND DEMOLITION
• Recalling connection to a chapter and to a figure:
(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.
This structure helps in realizing a linear and detailed tre-

Page XIII
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 Ear plugs or noise or noise protective
is necessary to check to have at disposal all the necessary headsets
information. Pay particular attention to the updating code
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- TIPO DI SEGNALE COLORE
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.
Page XIV
INTENTIONAL WHITE PAGE

Page A-1
SECTION A - GENERAL INFORMATION

Page A-2
A-1 CONVENTIONAL REFERENCE

In this manual, and on the equipment itself, you will find
warning messages. Each message starts with the word
“signal”. The meaning attached to the word “signal” for
these purposes is explained hereafter.
For immediate understanding of some important informa-
tion, we shall also use the symbols listed here after.
The symbol represents the message explained beside
it.
The requirements for the personnel in charge and more
basic information on the subject are also reported here.
Section A includes basic general information for getting
familiar with the most important parts of the equipment.
Identification data, technical characteristics, etc., are also
included.
HAZARD
It represent extreme hazard; if you fail taking the ne-
cessary measures you (or others) are very likely to
get killed or severely injured.
WARNING
It represent a serious hazard. If you fail taking the ne-
cessary measures, there is a risk that you (or others)
get killed or severely injured. It also indicate a hazard
to the environment. A hazard to the environment can
result from improper use of polluting materials (e.g.
used oil) and/or their improper disposal.
IMPORTANT
It warns you to use caution as, failure of this, you
might risk personal injuries or damage the equipment.
It also provides indications for an efficient and eco-
nomical use of the equipment.
Page A-3
A-2 REFERENCES
A-2-1 ORIENTATION
The machine is considered oriented as shown in the figure.
This convention serves to make all further references in the manual clear and unequivocal.
Any exceptions to this rule will be specified at the time.
TOP
SIDE
REAR FRONT
SIDE SIDE
BOTTOM
SIDE
LEFT
SIDE
REAR FRONT
SIDE SIDE
RIGHT
SIDE
Fig. A-1., Orientation

Page A-4
A-3 MACHINE IDENTIFICATION

A-3-1 MANUFACTURER
DRILLMEC
Drilling Technologies Division
Via 1° Maggio, 12 - Località Gariga

I-29027 PODENZANO (PC) - ITALIA
Phone +39 (0)523 354211
Telefax +39 (0)523 524418
A-3-2 Model
9T1000 Triplex pump with GE 752 electric motor.
A-3-3 IDENTIFICATION PLATES

The machine and its main components are identified by
serial numbers, mainly used by the DRILLMEC After-
Sales Technical Service in order to facilitate the dispatch
of the technical service dossiers.
The following information concerns the dislocation of the

identification plates.
IMPORTANT
Note down the machine’s identification data on page
2 of this manual, so that they are always available in
case of need.
Page A-5
A-3-3-1 Power pump identification plate
The power pump identification plate (See Fig. A-2) is

located on the electric motor frame (See Fig. A-3).
Fig. A-2, Power pump identification
Fig. A-3, Power pump identification -picture

A-3-3-2 Pump identification plate
The pump identification plate (See Fig. A-4) is located it’s

on the left side power-end (See Fig. A-5).
Fig. A-4, Pump identification plate
Fig. A-5, Pump identification plate - picture

Page A-6
A-3-3-3 Manufacturer address plate
The manufacturer adderss plate (See Fig. A-6) is located

it’s on the left side power-end (See Fig. A-5).
DRILLMEC S.p.a
12, Via 1° Maggio Gariga 29027 Podenzano (PC)-ITALY
Tel.+39.0523.354211 Telefax +39.0523.524418
Web: http//:www.drillmec.it E-mail: info@drillmec.it
0953 4151
Fig. A-6, Manufacturer identification plate
A-3-3-4 Other plates
The plates of all the main mechanical, hydraulic and elec-

tric components not manufactured by DRILLMEC (pumps,
motors, etc.) are located on the relevant components, in
the positions where the respective manufacturers decided
to place them.
Page A-7
A-4 GENERAL DESCRIPTION

A-4-1 MAIN COMPONENT DESIGNATIONS
A-4-1-1 COMPLETE PUMP

11
7
6
10
5
1 9 12 4
1 2 3
10 9 12
Fig. A-7, Esempio scatola ricambi
1 Main skid 7 Jib crane

2 Mud pump 8 Electric motor
3 Gate valve 4” 9 Liners cooling fluid reservoir
4 Suction discharge 10 Belt transmission
5 Pulsation dampener 11 Relief valve
6 Pressure gauge 12 Gate valve 2”
Page A-8
A-4-1-2 TRIPLEX PUMP
Longitudinal section (see Fig.A-7).
F E G C B
D A
Fig. A-8, Longitudinal section
Table A-3.2
Pos. Description
A Fluid-End
B Suction valves
C Delivery valves
D Power-End
E Piston-liner assembly
F Cross head
G Jib Crane
Detail of the Power-End crank gear of the lube system

(see Fig. A-8).
Fig. A-9, Power end lubrication

Page A-9
Longitudinal section of the jacket/piston system (see

Fig. A-9).
Fig. A-10, Section of plunger

Detailed view of the jacket/piston cooling system (see
Fig. A-10)
Fig. A-11, Section of cooling system

Page A-10
A-5 TECHNICAL SPECIFICATION

A-5-1 main DIMENSIONS
Fig. A-12, Main diemension

Page A-11
A-5-2 WEIGHTS
Only pump weight: approx. 19000 kg
Fig. A-13, NOME
Engine skid (without pump) weight: approx. 34000 kg
Fig. A-14, NOME

Page A-12
A-6 Power pump performance curves
IMPORTANT
The data showed in the table have been calculated according to full volumetric efficiency (h =1) and to 90%
of the mechanical efficiency (h = 0,90).
IMPORTANT
The dataplate with these ratings is also located on the pump and remote control panels.
Table A-5.1
RATED INPUT: 1000 HP @ SPM 130 GEAR RATIO: 3.222
9T1000 TRIPLEX MUD PUMP

PERFORMANCE DATA SHEET
[in] 9
STROKE 90% pump mechanical efficiency - 100% pump volumetric efficiency
[mm] 228.60
[in] 7 6 1/2 6 5 1/2 5 4 1/2 4
LINER SIZE [mm] 177.80 165.10 152.40 139.70 127.00 114.30 101.60
[psi] 2625 3060 3582 4264 5000 5000 5000
MAX. DISCHARGE [kg/cm ] 185 215 252 300 352 352 352
PRESSURE
[bar] 181 211 247 294 345 345 345
[gal/rev] 4.498 3.879 3.305 2.777 2.295 1.859 1.469
VOLUME/STROKE
[l/rev] 17.027 14.682 12.510 10.512 8.687 7.037 5.560
HYDR.
SPEED INPUT POWER U.S. G.P.M.
[HP] [HP] l/min
585 504 430 361 298 241 191

130 1000 895
2213 1908 1626 1366 1129 914 722
540 465 397 333 275 223 176
120 918 826
2043 1761 1501 1261 1042 844 667
495 427 364 305 252 204 161
110 842 758
1873 1615 1376 1156 955 774 611
450 388 330 278 229 186 147
100 765 689
1702 1468 1250 1051 868 703 555
405 349 297 250 206 167 132
90 689 620
1532 1321 1125 946 781 633 500
360 310 264 222 183 148 117
80 612 551
1362 1174 1000 840 694 562 444
315 271 231 194 161 130 103
70 535 482
1191 1027 875 735 608 492 389
270 232 198 166 138 111 88
60 459 413
1021 880 750 630 521 422 333
225 194 165 139 115 93 73
50 383 344
851 734 625 525 434 351 277
0953-3746E
Fig. A-15, Performance table
Page A-13
A-7 TECHNICAL DATA
IMPORTANT
Unless otherwise indicated, the ratings are calculated
net of efficiency (η =1).
A-7-1 ELECTRIC MOTOR
Manufacturer ......................................................GE 752

Type .........................................................................RB3
Power ...........................................1130HP at 1040 RPM
A-7-2 TRIPLEX PUMP
Piston stroke ...............................................................9”

Piston/jacket configuration from .........................4” to 7”
Suction dia ..................................................................8”
Delivery dia .................................................................4”
Max delivery ..................................................2213 l/min
Max pressure ...................................5000 PSI (344 bar)
A-7-3 DRIVE
Belt transmission type with fourteen belts V types. Com-

plete with tensioning system.
Page A-14
A-8 machine use destination

The pump comes under the category of worksite machinery, with a range of application which is both various and at the
same time requires careful classification to avoid improper and hazardous use, having the following characteristics:
• temperature min. –20°C, max. 50°C.
• relative humidity, max. 100% RH
A-8-1 PROPER USE
The pump is designed for pumping: bentonite mud, concrete mixes and water.
HAZARD
Those works can be exclusively carried out by strictly observing the instructions and the limits reported in this
manual. It is absolutely forbidden to try performing any works for which the machine wasn’t conceived.
A-8-1-1 IMPROPER USE
By improper use, the use of the machine for performing any work not expressly foreseen, for different purposes with
respect to those the machine was designed for, or with modalities not foreseen in this manual, is meant.
- Use of the machine for pumping liquids other than those indicated in A-5.1.
- Forcing the performance of the machine by continuous use of the manual emergency mode, thus exceeding the
limits given in Table A-4.2.
IMPORTANT
In case of inobservance of even only one of the above described conditions, DRILLMEC S.p.A. decline every
responsibility to the Customer, as this would be considered “IMPROPER USE”.
A-8-2 MACHINE LIFETIME LIMITS
As far as the safety matter is concerned, the machine operative lifetime is unlimited, provided that the prescriptions
both for the routine and for the extraordinary maintenance of the safety means and devices indicated in the Instruction
Manual are strictly observed.
A-8-3 FORESEEABLE OPERATORS’ TRAINING, EXPERIENCE OR ABILITY LEVELS
A-8-3-1 OPERATORS
The machine was designed for being used by operators having the following characteristics:
• to belong either to masculine or to feminine sex
• to be aged at least 14 years
• to operate with both their hands
• to have no limits in their physical abilities
• to have got a specific training

Page A-15
A-8-3-2 PUPILS/APPRENTICES
The machine was designed for being used by pupils/apprentices having the following characteristics:
• to belong either to masculine or to feminine sex
• to be aged at least 14 years
• to operate with both their hands
• to have no limits in their physical abilities
• to have got a specific training
A-8-3-3 GENERIC PERSONNEL
During the working operations, the access to the field must be forbidden to generic personnel.
Anyway, the machine was designed by considering that the generic personnel who could possibly be within the ma-
chine respect area have the following characteristics:
• are aged at least 14 years
• haven’t any limits in their physical abilities
• have got a specific training or are accompanied and assisted by qualified personnel having got a specific
training.
Page A-16
A-9 TECCHNICAL SERVICE AND SPA-

RE PARTS
The requests for technical service and spare parts has to
be sent to the After Sale Service of DRILLMEC S.p.A.
The addresses, the telephone and fax numbers are re-
ported in page IV 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 S.p.A. In
such a case, the Customer has to record the identification
data concerning to such a Centre into the relevant space
provided on page IV 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 S.p.A. declines every type
or responsibility n the case of damages to plants or
of injuries to personnel connected to the use of not
original spare parts.
IMPORTANT
When a Customer contacts the DRILLMEC After Sale
Service or others Service Centres to allow a quicker
problem solving procedure, he has always to point
out the machine data signed on the memorandum
reported at page II. This procedure is extremely im-
portant also for the data validity and for the reference
to possible technical updating concerning the spare
parts. Fig. A-16, Esempio scatola ricambi
Page A-17
WHITE INTENTIONAL PAGE

UM191091/E - Rev.0 - 03/2009 SAFETY
Page B-18
Section B- SAFETY
SAFETY UM191091/E - Rev.0 - 03/2009
Page B-19
FOREWORD
Safety gloves
In this manual, for example, the “safety symbology”
(SYMBOLOGY) was adopted, in order to signal possibly
dangerous situations.
Safety shoes
IMPORTANT
Don’t remove the plates present on the machine. In
case of loss or deterioration of them, it is obligatory Breathers or anti dust masks
for the User to promptly provide to replace them.
B-1 PERSONNEL QUALIFICATIONS Ear plugs or noise or noise protective

headsets
B-1-1 QUALIFICATION
The personnel using the machine or operating on it
must be competent, and obligatorily have the following Safety goggles or eyes’ protective masks
characteristics:
Physical: Good sight, hearing, coordination, and the

ability to safely carry out all the functions required for the
machine use.
IMPORTANT
Exclusively use type-approved and well preserved
Mental: Ability to understand and to apply the established
safety material.
rules, the specifications and the safety precautions. The
personnel must be attentive, use good sense for their own
safety and for that of other people; they must be willing to
carry out the work in a correct and responsible way. IMPORTANT
Avoid wearing rings, swatches etc…., and approa-
Emotional: The personnel must be calm and able to stand ching to the moving parts with undressed long hair,
the stress and to use good sense, as far as their physical which could get caught into those parts and cause
and mental conditions are concerned. serious damages. Also avoid using greasy clothes
because they are easily inflammable.
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
UM191091/E - Rev.0 - 03/2009 SAFETY
Page B-20
B-2 MACHINE PLATES

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

09531098
Meaning:
Accumulator burst hazard.
Part code number:

09531095
Meaning:
Hoses burst hazard.
Part code number:

09531097
Meaning:
Extremely hot parts: scorching hazard
SAFETY UM191091/E - Rev.0 - 03/2009
Page B-21
Part code number:

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

n/a
Position:
Service crane.
Meaning:
Danger of fire.
Part code number:

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

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

n/a
Position:
- Batteries
UM191091/E - Rev.0 - 03/2009 SAFETY
Page B-22
Meaning:
Danger of hand crushing.
Part code number:

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

n/a
Meaning:
Danger. High voltage.
Part code number:

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

09531116
Position:
- Safety ropes
- Cardans
SAFETY UM191091/E - Rev.0 - 03/2009
Page B-23
Meaning:
It is forbidden to repair, to lubricate and to clean moving
parts.
Part code number:

09531113
Position:
- Power swivel shifting chains
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 OPERETING THE ENGINE

REMOUNT THE PROTECTION COVER
Meaning:
It is mandatory to use proper ear plugs or acoustic protec-
tion headsets.
Part code number:

09531099
Meaning:
Warning plate
UM191091/E - Rev.0 - 03/2009 SAFETY
Page B-24
B-3 SAFETY DEVICES

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

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

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

MAINTENANCE PHASES
B-4-1 MECHANICAL PART
The operators must be equipped with the following individual safety means (DPI):
Safety helmet
Safety gloves
Safety shoes
SAFETY UM191091/E - Rev.0 - 03/2009
Page B-25
Breathers or anti dust masks
Ear plugs or noise or noise protective

headsets
Safety goggles or eyes’ protective masks
Safety sling
When You are working, carrying out maintenance interventions or repairs, always use the utmost prudence:
• Before carrying out the maintenance or the repairing operations, clean the machine, especially the joints and
the screw connectio ns, from any oil, fuel or detergents’ residuals. Don’t use any aggressive detergents. Exclusively
use filament-free wiping clothes.
• Clean all the handles, footboards, rails, platforms and ladders from any dirt, snow and ice.
• Before cleaning the machine with water or a steam jet (high pressure sprayers) or by using other cleaners,
close and seal all the openings into which, for either safety and/or operating reasons, neither water, steam or deter-
gents must get infiltrated. This is particularly important for electro-motors and electric panels.
• Exclusively use hoisting equipments suitable and technically fit, as well as hoist means having an adequate
hoisting capacity.
• Before starting any maintenance operation, insert the safety retainers both for the equipments and for the
control levers; the machine must be positioned on a flat ground and the equipments must lean on the ground.
• Before carrying out the maintenance, hang on the control levers and on the ignition key the relevant hazard
warning plates (see Fig. B-7.1); if You hold it as being necessary, apply warning plates also around the machine.
• Exclusively carry out the maintenance by still standing, cooled-down and safe-positioned machine.
• In order to protect the machine against the possibility of being accidentally started-up:
• Close the main control devices and take off the key.
• Apply on the cut-out switch a hazard warning plate.
• Disconnect the electric motor.
• Only use original equipment and high quality tools.
• During of the operations to dangerous heights, always provide with the safety harness and proceed as re-
quired by the specific directions.
• On completion of servicing and repairs, before starting the machine, check that no tools, rags or other mate-
rials are left next to the moving parts.
WARNING
Safely treat, if possible, with biodegradable treatment, and dispose of consumable and auxiliary materials as
UM191091/E - Rev.0 - 03/2009 SAFETY
Page B-26
well as of the old parts that have been replaced.
B-4-2 ELECTRIC PART
Safety helmet
Safety gloves
Safety shoes
• The works to be executed on either electric plants or operating means can be exclusively carried out either by
an electrician or by qualified personnel, under the supervision of an electrician and in a fully complying way with
respect to the electro-technical rules.
• Parts of the machinery subject to inspection, maintenance and repair interventions must be stress-relieving con-
nected, if prescribed. First check if such 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
actuate the cut out switch . Protect the working place with a white/red chain and mount a hazard warning signal.
Use only tools insulated against electric voltage.
• When working on high voltage components, connect the power supply cable to the ground, after having cut out
the voltage.
WARNING
The electrolytic accumulators contain sulphuric acid which can provoke scalds.
• When working on accumulators, always wear goggles.

• The accumulators produce hydrogen, which is highly explosive and easily inflammable by sparks or free fla-
mes.
WARNING
Provide to eliminate the electric/electronic wastes (RAAE) in full compliance with the relevant laws in force
in the country in which the wastes’ elimination must be performed.
B-4-3 HYDRAULIC PART
Safety helmet
SAFETY UM191091/E - Rev.0 - 03/2009
Page B-27
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 ( 45°C).
• For disassembling the hydraulic accumulators, strictly observe the instructions supplied by the manufacturer.
WARNING
Provide to the safe and possibly biodegradable elimination of the hydraulic fluids and of the replaced
parts.
B-5 Safety Rules Regarding Scheduled Maintenance
WARNING
Do not change the maximum relief valve setting on any hydraulic circuit without permission from the manu-
facturer. Never change an accumulator circuit pressure setting without specific instructions from the manu-
facturer.
WARNING
Never make unauthorized modifications to structural members or pressure circuits.
WARNING
You must replace, not repair damaged hydraulic or concrete hoses or pipes.
WARNING
Electronic components can be destroyed by welding current.
Before welding on the unit, unplug all radio remote control power wires. If you have a proportional boom
system, the proportional amplifiers must be removed from the mother board before welding.
If in doubt, contact the service department of the manufacturer for instructions before proceeding.
WARNING
Never activate the system hydraulics without checking ifanother workman is in a hidden position. Always yell
“clear” before starting the engine or electric motor, and allow time for response.
UM191091/E - Rev.0 - 03/2009 SAFETY
Page B-28
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! (Fig. 5-1.3) Never open a pipeline that is under pressure. The pump must be run in reverse
for at least two strokes and then stopped before opening a pipeline. If you don’t know how to reverse the
pump, have the operator do it. If the pipeline is pressurized with air, do not open it. The operator is responsible
for knowing how to safely release the air pressure.
WARNING
Never open a pressurized pipeline. The pump operator must release the pressure before you open the line.
If the line is pressurized with compressed air, let the operator release the pressure and verify that the air has
escaped before you proceed.
B-6 GENERAL SAFETY DURING THE OUT OF SERVICE SETTING AND ELIMI-
NATION PHASE
WARNING
Provide to the safe and possibly biodegradable elimination of the demolition resulting materials.
WARNING
Provide to the elimination of the electric/electronic materials (RAAE), in full compliance with the relevant laws
in force in the country in which the elimination must be performed.
WARNING
Provide to the safe and possibly biodegradable elimination of the lubricating oils, the greases and the hy-
draulic fluids.
OPERATING INSTRUCTIONS UM191091/E - Rev.0 - 03/2009
Page C-29
Section C- OPERATING INSTRUCTIONS

UM191091/E - Rev.0 - 03/2009 OPERATING INSTRUCTIONS
Page C-30
C-1 CONTROLS AND INSTRUMENTS

The following chapters explain the controls and instruments with which the machine is equipped, starting with the
main control panel.
The controls (regulator, switch, etc.) are numbered in sequence, preceded by a letter as explained below, to facilitate
their unequivocal identification.
C1
DEVICE IDENTIFICATION LETTER SEQUENTIAL NUMBER
Legend:
C Control
R Regulator
S Selector or switch
A Hydraulic-Pneumatic
Instrumentation
H Visal and Acousticelectric signals
HAZARD
Do not attempt to operate the machine before having read and understood the contents of this manual and
having familiarised yourself with the controls.
Study the correct procedures of use and forbidden manoeuvres to be sure of avoiding serious personal injury
and damage to property.
Page C-31
C-2 MACHINE DEVICES

R1
A4 Power end oil temperature
C1 Mud delivery line pressure
C2 Hydraulic oil pressure
C2 A4
R1 Hydraulic oil level C1
Fig. C-2, Discarge line

A3 Power end oil temperature
A3
Fig. C-3, Oil temperature gauge

C3 Valve of cooling system
C3
Fig. C-4, Valve of cooling system

Page C-32
C-3 COMMISSIONING
WARNING
Before starting any procedure described in this chapter, review the safety information given in Section B of
the manual.
In case of doubt read the section again and only proceed when you are sure of having understood the war-
nings.
This section gives the information required for installing and starting the pump on the boring site. Follow the instruction
when first installing or starting the pump, and in case moving to another position or repairs of a certain seriousness.
SAFETY MUD
VALVE PRESSURE
SERVICE GAUGE
CRANE
PULSATION
DAMPENER
DELIVERY
LINE
SKID SUCTION
DESURGER
MUD
PUMP
V-BELT
ELECTRIC
TRANSMISSION
MOTOR
Fig. C-5, Main parts
Page C-33
C-3-1 POSITIONING THE PUMP
HAZARD
Never pump against closed valves (all discharge valves closed).
Stop pump operation before attempting repairs.
Properly lock-out or disconnect main power source to the pump before conducting inspection, maintenance
or repair.
Completely bleed all pressure from fluid end before attempting maintenance or repair.
1. Be sure that the pump foundation is level and able to support the weight of the pump.
2. lnstall the pump as close as possible to the mud tank or pit to reduce the pressure drop in the suction line.
MUD TANK
Fig. C-6, Mud pump configuration

Page C-34
C-3-2 SUCTION PLANT
• The diameter of the suction line must be equal to or exceed the diameter of the pump suction connection.
• Use as short a suction line as possible.
• lnstall the suction line in as straight a line as possible. If turns are necessary, use long radius ells.
• Be sure there are no air traps or air leaks in the suction line.
• A suction desurger is installed to prevent mud cavitation (Refer to FLUID END MAINTENANCE AND AC-
CESSORIES in Section E).
• Fully open all valves in the suction line before operating the pump.
C-3-3 DELIVERY LINE
HAZARD
The delivery line runs at high pressure. Do not modify it without authorisation.
HAZARD
If you do not use approved welding procedures for high pressure piping, the line can be damaged and cause
personal injury or damage to preperty.
WARNING
The maximum working pressure setting on the safety valve must be suitable for the pump piston diameter
(see Table SECTION A).
Note:
The pump pressure settings are given in the specification tables in this manual. They are also given on the pump
dataplate.
The delivery line is equipped with a pulsation damper to reduce vibration and increase component life (see Section
E of this manual).
Nota:
The standard DRILLMEC filter unit is fitted with an: API 41/16” - 5000 psi WP RTJ flange for the damper.
C-3-4 PRELIMINARY ACTIONS
Take special care when operating the pump for the first time or after maior repairs have been made. Refer to caution
remarks under STARTUP.
WARNING
Be sure pump is properly lubricated before operating.
Page C-35
C-3-4-1 PREPARATION
If the pump has not been completely assembled before de-

livery, complete assembly according to the instructions.
Power-end
- Make sure the suction and exhaust plants have been drain cap
correctly installed (see Fig. C-2).
- Remove the power-end housing plates.
- Make sure the power-end is clean and clean if neces-

sary.
- Drain all condensation out of the casing (see Fig.

Fig. C-7, Drain cap
C-7).
IMPORTANT
Do not attempt to drain condensation from the power Liner cooling
end housing if it is filled with lubricant. liquid tank
- Refit the housing plates.
- Check that the housing drain cap is installed and clo-

sed.
- Fill the power-end with the appropriate lubricant.

Note: Fig. C-8, Cooling system
Lubrication specifications and quantities for each type
pump are listed in the Section D of this guide and on the
pump dataplate.
- Lubricate the piston washing plant greasers.
- Check that all covers are installed and the fastenings fully
tightened down to the torques given in this manual.
- Check that all valves and taps are correctly set.
- Fill the liner cooling plant reservoir with coolant (see

fig. C-8).
IMPORTANT
If there is danger of sub-zero temperatures, add anti-
freeze to the liner cooling plant.
Page C-36
C-3-4-2 START UP
WARNING
In case of unusual sounds or other signs of malfunction, stop the pump immediately and solve the problem
before proceeding.
1. Start the pump slowly (max 50 pulses a minute) for at least 5 minutes without sending pressure to the fluid-
end.
2. Check the liner and make sure the cooling plant is operating correctly.
3. After 5 minutes idling, stop the pump. Wait for 10 minutes for the oil to settle and check the lubricant level. Top
up to the maximum marking on the dipstick if necessary. (see Section D).
4. Check the jackets and make sure the cooling plant is working correctly.
5. Gradually increase the pressure at the fluid-end to the required operating pressure.
HAZARD
Do not exceed the maximum operating pressure given in the technical specification tables of this manual and
on the pump dataplate. Do not attempt to run the pump with the delivery valves closed.
6. Run the pump for 30 minutes at the required operating pressure. Check that the jackets, cylinders and valves
do not leak. In case of leakage, stop the pump immediately, repair and restart.
7. Stop the pump after 30 minutes.
8. Check all stud bolts, nuts and quick releases. Tighten down if necessary. The tightening torques are given in
this manual.
9. The pump is now ready for normal operation.

Page C-37
C-4 USER INSTRUCTIONS
WARNING
the manual.
nings.
C-4-1 setting operational parameTers
The operating parameters for the work in hand must be set before starting the work itself.
First determine the flow rate and pressure at which the fluid is to be pumped.
Check that the desired values are compatible with the operational range of the pump as given in the performance
table (Table A-5.1).
WARNING
Do not operate the pump in excess of the limits given in the performance table. The pump can be seriously
damaged in these conditions.
Once the flow rate and pressure have been determined, adjust the pump with the following parameters:
• Diameter of the piston/liner unit
• Engine rpm.
C-4-1-1 SAFETY VALVE

ADJUSTEMENT NUT
PUSH TO OPEN
The main features of the safety valve are as follows:
1. The maximum working pressure can be set with a

single nut, and the valve can be adjusted while it
is pressurised.
2. The calibrated value is not affected by continuous

vibration or pressure variations.
RESET
3. When the safety valve trips it can be reset with a

single lever.
Fig. C-9, Relief valve
4. The set value is not affected by the fact that the
valve has tripped once or many times.
5. The valve can be tripped manually at any time using

the trip button on the valve body itself.
6. The state of the valve (tripped or set) is shown by
the position of the trip button.
7. The levers are enclosed and protected against dirt

and corrosion.
Page C-38
C-4-1-2 ADJUSTING THE SAFETY VALVE SETTING
If the valve setting has to be adjusted, the pressure can be set by reading the pressure gauge.
Connect a precision pressure gauge to read the line pressure. If the pressure gauge has an integral surge damper,
slowly increase the line pressure to account for the reading delay. If possible, the line pressure should be increased
without or with few surges.
Adjust the valve to the desired value as indicated on the dataplate and the pressure gauge. Increase the pressure
until the valve trips and note down the pressure gauge reading. If the pressure gauge reading is low, tighten down
the adjuster nut; if it is high, back off the nut. Fully tightening down the nut corresponds to a pressure of around 38.7
bar. Repeat the operation and adjustment until the valve trips at the required pressure reading.
C-4-2 running-in cycle
A correct and adequate running-in cycle ensures the long life of the motor pump.
Pump
1. During the first 200 hours of operation, the pump speed should not exceed 90-100 shots/min and the max.
pump pressure must correspond to 50% of the figures shown in the performance table. (see Tab.A-SECTION A).
2. Oil replacement as per Tab. SECTION D.
3. Adjust the chain to avoid any initial elongation.
4. After the first 1000 hours of operation, check that the bolts and nuts are correctly fastened.
Electric motor
Refer to the Manufacturer’s Instructions.

Page C-39
C-5 PARKING AND STORAGE
WARNING
the manual.
nings.
C-5-1 STORAGE
When stopping the machine at the end of a work cycle, for overnight stoppage or over the weekend, it should be
considered to be parked.
From the technical point of view, the following precautions should be taken when parking the machine.
1. Pump clean water for a few minutes to clean out the hoses and the booster pump so as to avoid sedimentation
of solid matter.
2. Check that the fluid-end has been thoroughly cleaned through the front caps. Otherwise disassemble and clean
it.
IMPORTANT
These operations are very important inasmuch as sedimentation in the pump’s manifolds during periods of
disuse (especially concrete mixes and bentonite muds) can cause serious damage at the next start up, and
compromise the pump’s operation at the very least.
Take the following precautions to eliminate any risk for persons in the vicinity of the machine during the period of
disuse.
3. Disconnect the plant air line from the air tank, discharge the residual air from the tank, in order to avoid acci-
dental start of the motor.
HAZARD
Never leave the pneumatic circuit on if accidental start up is at all possible. This is a serious potential risk:
anyone may be able to start the machine and execute dangerous manoeuvres or tamper with the machine.
C-5-2 DISUSE
When stopping the machine for maintenance or for prolonged inactivity, it should be considered to be out of servi-
ce.
1. Adopt the safety precautions explained in the previous paragraph (see point 3 and 4).
2. From the technical point of view, of possible, execute the procedure in the previous paragraph (see points 1
and 2).
3. In case of prolonged disuse, following proceed as follows:
• Disassemble the suction and delivery valves.
• Clean the fluid-end lines and cover the surfaces with protective corrosion resistant product.
Page C-40
• Clean all parts removed the pump with care. Cover them with protective materials and store them as if they
were new spare parts.
• Grease the interior of the jackets and move the piston for a few strokes at minimum speed to make sure
that the grease is evenly spread over the entire jacket surface.
IMPORTANT
Bear in mind that the pump is constructed with sophisticated materials and that the most highly stressed
surfaces are machined to a precise finish.
Even storage should thus be done with care: metal parts should be protected form blows and corrosion,
rubber parts from deformation and perishing: do not suspend or pile them up at random, do not expose them
to sunlight, intense heat, or in contact with oils or solvents.
IMPORTANT
During periods of storage periodic maintenance should be done as normally, especially as regards the repla-
cement of lubricants which age and oxidise over time, thus losing their effectiveness.
In any case, before using the machine again after a period of disuse, carefully inspect and check all parts.
Page C-41
C-6 TRANSPORT INSTRUCTIONS
WARNING
Before starting any procedure described in this chap-
ter, review the safety information given in Section B
of the manual.
In case of doubt read the section again and only
proceed when you are sure of having understood
the warnings.
C-6-1 LIFTING THE PUMP
WARNING
Incorrect lifting can result in the load shifting, with
consequent personal injury and damage to proper-
ty.
Scrupulously follow the procedure given below:
1. Disconnect the universal coupling and support it

with the triplex pump’s hoist.
2. Make sure that all compartments are closed and no

materials (hoses, mechanical parts, etc.) are free
to move on the base.
IMPORTANT
If you intend to use free areas of the base for tran-
sporting other materials, make sure that they cannot
damage the pump’s components and that they are
securely fixed to the pump.
3. Fit the ropes to the attachment points indicated (Fig.

C-6.1 and Fig. C-6-2) and hook the other ends to
the crane’s hook.
LIFTING
POINT ON SKID
Fig. C-10, LIfting points

Page C-42
Attach some hemp ropes the ends of the base, so as to

be able to manoeuvre it in the raised position from a safe
distance.
4. Use ropes of adequate rating for the load being

lifted (A-4.1) and the size of the machine (Fig.
C-6.3).
HAZARD
Do not walk beneath or near to the raised load. DAN-
GER OF DEATH.
Fig. C-11, Esempio scatola ricambi

Page C-43
Fig. C-12, Esempio scatola ricambi

Page C-44
C-6-2 ANCHORING TO THE TRANSPORT

VEHICLE
The customer is responsible for using appropriate means

for anchoring the pump to the vehicle’s load bed.
HAZARD
Do not use other points than those indicated for lif-
ting or anchoring the load: potential serious personal
injury or damage to property.
MAINTENANCE UM191091/E - Rev.0 - 03/2009
Page D-45
Section D - MAINTENANCE
UM191091/E - Rev.0 - 03/2009 MAINTENANCE
Page D-46
D-1 PREFACE
The safety of the operators, the function and service of the machine in conformity with the declared speci cations,
depend on scrupulous observation of the instructions given in this chapter.
Failure to observe the maintenance schedule is hazardous inasmuch as the machine may fail to be in the condition
required for its intended use.
IMPORTANT
Failure to observe the maintenance schedule voids the warranty. DRILLMEC declines all liability for and
resulting damage and injury.
Page D-47
D-1-1 MAINTENANCE LAYOUT

3
12
11 5 12
6 7-8-9 12
10 4 12 2
Fig. D-1, Maintenance layout
Caption: 11. Skid
1. Fluid-end 12. Gate valve
2. Valve unit
3. Hoist
4. V-Belt transmission
WARNING
5. Liner cooling system
Before starting any procedure described in this chap-
6. Power-end cross ter, review the safety information given in Section B
7. Cylinders and stuf ng box of the manual.
8. Pistons
9. Rod and piston extension
10. Electric motor
Page D-48
D-1-2 MAINTENANCE AND LUBRICATION POWER PUMP
* NOTE: Clean the interior of the casing thoroughly before lling with new oil.
Maintenance Operation Frequency (hours) Ref.

10 50 100 250 500 1000 2000 3000 10000
Complete machine - General Inspection x
Fluid End - Inspection and cleaning dur- x 1
ing stops
Liners cooling system - Check of uid x 5
level
Cross head lubrication system - Check x 6
of oil level
Bolt transmission - Check tension x 4
Valve assembly - Check the wear x 2
Cylinder Check the wear x 7
Pistons - Check the wear x 8
Extension rod and pistons - Greasing of x 9
seal rings
Liners cooling system - Check of lter x 5
clogging
Gate valve - Greasing x 12
Service crane - Lubrication x 3
Liners cooling system - Replacement of o x 5
the uid and cartridge
Liners cooling system - Tank cleaning o x 5
Cross head lubrication system - Oil re- o x 6
placement
O = Only rst time
X = Normal frequency
IMPORTANT
Greasing the axles of trailer at every changement of camp
IMPORTANT
For electric motor maintenance intervals, refer to the attached manufacturer’s manual.
Page D-49
D-1-3 MAINTENANCE AND LUBRICATION INTERVALS PUMP
FREQUENCY PUMP PART OPERATION

Daily Entire pump Complete visual check
Daily Power end Check the oil level in the pump power end daily. Do this with the pump at
rest. Visual check of oil lter clog.
Daily Fluid end Inspection and cleaning if the pump is stopped
Daily Piston and liners Observe the condition of the liners and pistons. Some “by-pass” of the drilling
uid is normal and does NOT necessarily indicate worn out pistons or liners.
Smooth wear on the liners normally means smooth wear on the pistons. The
combination should be run until such time as the drilling uid “by-pass” is
visible on each stroke or becomes excessive.
Daily Piston gasket seal Check pistons gasket seal ( during pump running )
Daily Liners chambers Clean the liner chambers as required. The nominal “by-pass” of drilling mud
will settle in the bottom of these chambers.
Daily Liner lubrication Check the liner - piston coolant daily. Add as required and replace if dirty.
Dirty coolant will settle in the bottom of these chambers.
Daily R o d a n d l i n e r Recheck the liner and rod clamps for proper tightness after the rst few
clamps hours of operation following assembly. This will prevent operation with a
loose connection should dirt or other foreign material have been caught in
the connection at assembly
Daily Valve covers Recheck the valve cover locking screw, located in the centre of the cover, for
proper tightness after the rst few hours of operation following assembly. This
allow the taper locking assembly to become seated and properly tightened,
insuring minimum movement of the valve cover.
Daily Suction damper Check the suction line pulsation dampener daily. Make sure it contains the
proper charge for the operating conditions. (1-1,5 bar)
Daily Delivery pulsation Check the delivery line pulsation dampener daily. Make sure it contains the
damper proper charge for the operating conditions. ( 24,6 - 70 bar)
Daily Safety valve Make sure the delivery line safety valve is operational.
Daily R o d e x t e n s i o n Check seals to avoid water or mud contamination of the power-end lube
seals oil.
Daily Compound Check oil level. Check oil pressure gauge of lubrication system of com-
pound.
Daily Oil lters Check all lters
Daily Cooling tank of Check cooling pump tank, for dirty and level. Check the condition of the
liner housing and cooling hoses and clean if locked.
Daily Pistons Loosen the piston rod to intermediate rod clamp once each day and rotate
the piston rod approximately one-quarter turn. This re-positions the piston
in the liner and services to distribute the wear. This can result in increased
wear life for both the liner and piston.
* NOTE: Clean the interior of the casing thoroughly before lling with new oil.
Page D-50

Weekly Valve cover Remove all valve covers every two weeks. Carefully clean all mud and junk
from the threads on the cover screw and in the bolt on ring. Completely grease
the cleaned threads with a heavy duty grade of lead base drill collar thread
compound. It is important that a lead base compound, such as “Jet-Lube
Kopr-Kote”, but used to provide the necessary protection against corrosion,
galling and sizing. Do not use an ordinary tool joint “thread dope” as these
materials lack the ability to effectively protect the joint.
Thoroughly clean both sides of the valve cover taper locking wedges. Coat
these parts with the same heavy duty lead base drill collar thread compound
used on the cover screw threads. Made sure the threads and tapered por-
tion of the wedge adjusting screw are also cleaned and coated with the
compound.
Weekly Valve cover and ta- NOTE: Before placing the cover screw back into the cylinder, assemble the
per locking wedge tapered wedges and adjusting screw to the cover. It is important that the bot-
assembly tom of the adjusting screw be even with the bottom of the tapered wedges
and that the assembly is loosely held against the cover screw. This is easily
done be setting the assembly on the wedges, pushing down on the cover,
and then turning the nut on the adjusting screw nger tight. This is neces-
sary to provide enough space for proper release of the adjusting screw at
disassembly, as well as provide suf cient travel of the adjusting screw to
properly tighten and lock the assembly. Sledge the cover assembly tight. Use
a 60 cm bar through both sides of the cover screw and hammer tight with
three of four solid blows of 6-8 kg. sledge. Then securely tighten the nut on
the adjusting screw with the pull of one man on 2 mt extension bar. NOTE:
Screw the valve cover into a clean valve pot. Prime the pump by operating
with charging pump on suction line and discharge open to by-pass line.
Weekly Valve cover plug Clean and coat the tapered portion of the valve cover plug with the same
and packing heavy duty lead base compound used on the valve cover threads. Inspect the
valve cover packing and carefully clean and coat the shoulder in the cylinder
above the packing before installing the plug. This is necessary to prevent
cocking of the plug and allows a full metal-to-metal lock-up of the cover.
Weekly Valve guide bush- Inspect the upper valve stem guide and replace if visibly worn. A out-of-round,
ing or egg-shapped, guide bushing cannot properly guide a valve and will cause
increased valve wear.
Weekly Valve and seats Check the valves and seats for wear. Replace cut or worn inserts. Replace
the valve locks if loose or worn. Make sure the cotter pin used to retain the
lock is bent back out of the way of the valve spring.
Weekly Piston cups Never change the front pressure sealing piston cup without changing the
rear sealing cup. These cups are both necessary for good operation and
must be changed together when worn. Make sure the seal in the piston hub
is correctly placed in the groove.
Weekly Piston hub seal This is compression seal, tting against the ange and radius on the piston
rod, ad must not be altered or damaged. The rear sealing cup must be cen-
tered on the piston hub before the hub can be drawn squarely metal-to-metal
against the piston rod. Failure to do this will result in a cocked piston, which in
turn can damage a liner and/or rapidly wash out the piston cups and hub.
Weekly Piston rod lock nut Replace the piston rod lock nut if ti has been damaged or corroded, or it the
locking ber has lost its ability to effectively grip the threads. Any nut that
has been used six time should be replaced.
Weekly Power end lubrica- Drain and clean the power end oil sump and the setting tank under the cross
tion heads every six months. Re ll with proper grade of gear oil.
Page D-51

Monthly Bolts, studs and Check all uid end inside uid chamber. Check valve seat.
nut
Monthly Gasket and seals Check all of the uid cylinder studs and nuts for tightness, including the valve
cover bolt on rings, cylinder to frame studs, and liner pilot bushing studs.
Monthly Fluid end leaks Inspect the power end for badly leaking gaskets or loose cap screws; replace
as required.
Six month C o m p o u n d - Some leaks my from inside the uid-end, due to cycle stress and corrosion.
S p r o c k e t a l i g n - Visual checks of seals mounted inside uid-end, and wear of seat of these
ment seals.
Six months C o m p o u n d - Excessive tooth wear will result in hook shaped teeth. When sprockets are
S p r o c k e t t o o t h found in this condition, they should be replaced. If new sprockets are not
wear immediately available, tho hook can be dressed off, or if design permits, the
sprockets can be reserved to present the unworn tooth, faces the chain.
Yearly Entire pump It is recommended that the pump be given an inspection every two or three
years, checking for looseness in the main, connecting rod, pinion, and cross-
head pin bearings, as well as the crosshead ways. If looseness if found, the
pump should be given a more thorough inspection and corrective measures
taken.
Storage Power end If the pump is to be idle for longer than one week, it should be prepared for
storage by raising the uid cylinder end of the pump and blocking it up to that
the pump slopes downward toward the power end. Then drain and clean the
main sump and setting tank thoroughly. Leave the main sump drain plug out
and install a 90° elbow. Point the elbow down and cover the opening with a
cloth sack. This will permit air circulation and prevent condensation build-up.
Coat bearings, nished surfaces, and the entire inside surface of the power
end with a rust inhibiting oil.
Storage Fluid end Remove the uid cylinders valves, pistons, piston rods and liners. Thoroughly
clean the inside of the uid cylinder and all parts. Coat the entire cylinder,
valves and parts, with a rust inhibiting oil. Clean the liner spray system and
setting tank. Induce clean oil into the liner spray pump to prevent rusting.
Coat the tank and liner spray parts with a rust inhibiting oil.
Storage Entire pump Thoroughly inspect the pump and rotate the gears once each month. Re coat
with a rust inhibiting oil where necessary.
Start up after Entire pump Any pump that has been in storage, either after eld use or as shipped from
storage the plant, will need a thorough inspection to make sure it has not been dam-
aged in any way and that all parts are properly in place. Failure to observe
the following points can result in serious damage.
Start up after Power end Remove all of the covers on both the power end and the uid end; thoroughly
storage clean and inspect all of the parts and the nished surfaces. Check all of
the bearings to make certain they are clean and in good condition. Fill the
power end to the proper level. Use a clean gear oil of the proper viscosity.
Make sure oil is poured into the oil distribution trough and is worked into all
of the bearings.
Start up after Fluid end The valves, pistons, liners and all uid end parts must be properly installed
storage and in good condition. Carefully tighten all of the bolts, nuts, suds and working
connections. Fill the liner spray system with a clean coolant-lubricant.
Page D-52
D-1-4 LUBRICATION AND GREASING POINTS

10 50 100 250 500 1000 2000 3000 10000
Service crane greasing x 3
Extension rod and pistons greasing x 9
Gate valve greasing x 12
O = Only rst time

D-1-5 BOLT TIGHTENING POINTS

10 50 100 250 500 1000 2000 3000 10000
Check of bolt tightening of main compo- x
nents
Check of bolt tightening of uid end x
O = Only rst time

D-2 TABLES AND SPECIFICATIONS

COMPONENT CAPACITY (liters) Ref.
Power end lubrication 350 Lubrication table
Liners cooling system 210 Lubrication table
Mud pump is supplied with following lubricating oil:
COMPONENT CAPACITY (liters) Ref.

SHELL OMALA 220 Power end ( cross head ) lubricating Lubricating table
system
WATER AND EMULSIFY Liners cooling system Lubricating table
IMPORTANT
Do not mix mineral oil with synthetic oil: they don’t have the same characteristics!
This could cause formation of FOAM which could negatively influence on good operation of the various units
hydraulic components.
SHELL AGIP ESSO MOBIL BP TEXACO API

Omala 220 BLASIA 220 SPARTAN EP220 M O B I L G E A R ENERGOL GR ROTEP 220 DT-220
XMP 220 220
D-2-1 GREASES
Use the following products for grease lubrication:
SHELL SUPER GREASE EP2
SHELL RETINAX HD2 (PISTON ROD EXTENSION)

Page D-53
WARNING
Do not mix different greases; do not use greases with lower specifications.
D-2-2 ANTI-CORROSION PRODUCTS
For treating machined metal surfaces, which are subject to ageing and corrosion, we recommend the use of CHES-
TERTON RUST GUARD HEAVY DUTY, or other similar products, which form a thin, effective, long-lasting protective
lm on the surface.
These products are required for storing spare parts or disassembled mechanical parts when the pump is being stored.
Also apply to the uid-end for this purpose.
WARNING
When parts treated with these products are operated in contact with gaskets or other machined surfaces
(such as jackets/pistons) the protective film must be removed with the appropriate solvent before assembly.
Failure to do so risks damaging the parts in contact. Do not use these products on rubber parts.
D-3 LUBRICATION INSTRUCTIONS

D-3-1 MOTOR PUMP
Refer to g. D-1.1 and follow the instructions of the table in par. D-1.2 for:
- greasing points (also marked on the motor pump itself)
- greasing intervals
For the type of grease to be used, see the table in par. D-2.3
D-3-2 OIL LUBRICATION OF PUMP

Refer to and follow the instructions of table D-1.1 for:
• - points to be lubricated
• - lubrication frequency
• - type of oil
The triplex mud pump has a splash-gravity lubrication system for connecting rod bearings, which relies upon the rota-
tion of the crankshaft to pick up lubricant from the sump.
Lubrication tank, xed inside pump frame, catch the oil drawn up by the circulating pump and distribute it to the bear-
ings and cross heads.
Oil then ows into the sump, constructed as an integral part of the power-end frame. The sump contain magnetic bar
to catch contaminant particles and a mesh suction lter. It can be easily inspected, for maintenance, by opening the
top cover with breather cap.
A Flow rate indicator and an oil dipstick are located on one side of the power-end.
The rst oil chance has to be made after completion of the braking-in period.
To obtain the best lubrication and to protect gaskets, oil temperature should not exceed 65°C.
Page D-54
D-3-3 JACKET/PISTON COOLING SYSTEM
Failure of coolant ow can cause almost immediate dam-

1
age to the rubber piston gaskets and consequent serious
damage to the jacket.
The coolant is made up as follows:
2
- 10 litres water
- 1 litre emulsi ed (ROLL or equivalent).
Make sure that the coolant stays clean and relatively

cool.
The cooling system is equipped with tank (1, fig. D-2), Fig. D-2, Cooling system
centrifugal pump (2) and exible hoses.
The centrifugal pump delivers the coolant from the tank to

the external circular rim of the steel piston via the hoses.
From here, the coolant runs down to the oor of the piston
chamber and is returned to the tank.
Check the coolant level in the tank frequently through
the cover.
The coolant tank must be emptied and cleaned frequently

to keep the coolant in acceptable condition. In case of pis-
ton malfunction, change the coolant and clean the tank.
D-3-4 TRANSMISSION BELTS TENSIONING
For belt tensioning proceed as follows:

- Loosen the pump from the base frame using the
brackets A (see Fig. D-3)
- Tension the belts using the tie-rods M-N (see fig.
D-3)
- For a correct tensioning follow the instruction
hereafter:
Load “P” 10-15 kg for each belt in order to obtain a 20 A

mm camber “F”.
N
Correct tensioning.
M
In order to obtain a correct belt tensioning to the triplex Fig. D-3, Adjustement system
pump operate on the screws (see Fig.C-3.3).
In order to check the belt-tensioning put a line between
the pulleys (min line length 2100 m/m), apply a 10-15 kg
P
load on the middle of the belt (see diagram) and read a =
20 mm camber “F” using a meter. =
NOTE: The 10-15 kg load has to be applied to each

belt.
F
Fig. D-4, Tension of belt

Page D-55
D-4 ROUTINE MAINTENANCE

D-4-1 EVERY DAY
1) Lubrication
- With the pump stopped, check the following oil levels:
• Power-end
• Cooling pump tank
2) Jackets and pistons
- Check the piston gasket seals (with the pump running)
- Clean the jacket chamber
3) Cooling system
- Check the level and cleanliness of the piston rod coolant (oil/water emulsion)
- Check the condition of the housings and cooling hoses and clean if blocked.
4) Pulsation desurgers
- Check that they are correctly pressurised:
• Delivery: 24.6 70 bar
• Suction: 1 - 1.5 bar
HAZARD
The preload pressure must be equal to 60% of the circuit pressure, but not in excess of 70 bar.
5) Safety valve
- Make sure the delivery line safety valve is operational.
6) Rod extension seals
- Check seals to avoid water or mud contamination of the power-end lube oil.
D-4-2 WEEKLY MAINTENANCE
1) Valves
- Remove covers from the valves, check seals and, if necessary, remplace them. Remove any mud from the
threads. Grease the threads.
D-4-3 MONTHLY MAINTENANCE
1) General Inspection:
- Check the entire pump as follows:
- all bolts and stud. Replace if necessary;
- all rubber seals (piston gasket, valve seals, etc.);
- uid-end interior.
Some leaks may form inside the uid-end, due to cycle stress and corrosion. The point of maxi
mum cyclical stress to the pump occurs between the suction to supply with each shot. Although it
does not cause stress reversal, it may cause leakage.
- Oversall lubrication.
Page
9T1000
D-56
UM191091/E - Rev.0 - 03/2009
SCREW WITH EXAGOANAL HEAD WITH HEAT SCREW WITH EXAGOANAL HEAD WITH HIGH
STADARD SCREW TREATMENT SAE1038 GRADE 5 (8G C45-C50) STRENGTH STEEL SAE1040 GRADE B (40CD4-ASTM
Torque Torque Torque
UNC UNF UNC UNF UNC UNF
Diameter Lb-Ft Kgm Lb-Ft Kgm Lb-Ft Kgm Lb-Ft Kgm Lb-Ft Kgm Lb-Ft Kgm
1/4" 6 0,82 7 0,96 11 1,52 13 1,79 12 1,655 15 2,7
5/16" 13 1,79 14 1,93 21 2,9 23 3,18 25 3,45 30 4,14
3/8" 23 3,17 26 3,59 38 5,24 40 5,52 50 6,9 60 9,75
7/16" 37 5,10 41 5,65 55 7,58 60 8,28 85 11,7 95 13,1
D-5 BOLT TIGHTENING SPECIFICATIONS
1/2" 57 7,86 64 8,83 85 11,7 95 13,2 125 17,2 140 19,6

9/16" 82 11,30 91 12,5 125 17,2 140 19,6 175 24,1 195 26,9
5/8" 111 15,30 128 17,6 175 24,8 210 29 245 33,8 270 37,2
3/4" 200 27,60 223 30,7 300 41,4 330 45,5 425 58,6 460 63,5
7/8" 315 43,50 340 46,8 450 62,1 490 67,6 660 91 700 96,6
1" 400 55,20 460 63,5 680 93,8 715 98,6 990 135,6 1050 14
1.1/8" 570 78,60 635 87,6 885 122,3 990 136,6 1470 212 1655 22
1.1/4" 645 89,00 710 98 1255 173 1380 191 2100 290 2310 31
1.3/8" 845 117,00 960 132 1635 226 1875 259 2750 379 3110 42
MAINTENANCE
Operation and Maintenance Manual
1.1/2" 1120 155,00 1500 207 2180 301 2430 335 3640 503 4100 56
Page D-57
4.8 5.8 8.8

Diametro x passo 0,7 Rs = 224 0,7 Rs = 280 0,7 Rs = 448
Precarico Coppia Precarico Coppia Precarico Coppia
mm N Nm N Nm N Nm
3 x 0,5 1130 0,67 1400 0,84 2550 1,5
4x 0,7 1970 1,5 2500 1,9 3930 3,1
5 x 0,8 3180 3 4000 3,8 6360 6
6x1 4500 5,2 5600 6,5 9000 10,4
8 x 1,25 8200 12,3 10250 15,4 16400 24,6
8x1 8780 13 1100 16,3 17600 26
10 x 1,5 13000 25,1 16200 31,3 26000 50,1
10 x 1,25 13700 26,2 17100 32,7 27400 52,4
12 x 1,75 18900 42,4 23600 53 37800 84,4
12 x 1,25 20600 45,3 25800 56,6 41300 90,6
14 x 2 25800 67,4 32200 84,3 51500 135
14 x 1,5 28000 71,7 35000 89,6 56000 143
16 x 2 35200 102 44000 128 70300 205
16 x 1,5 27400 107 46800 134 74800 214
18 x 2,5 43000 142 53800 177 86000 283
18 x 1,5 48400 154 60500 193 96800 308
20 x 2,5 24900 200 68600 250 110000 400
20 x 1,5 60900 216 76200 270 122000 431
22 x 2,5 67900 266 84800 322 136000 532
22 x 1,5 74600 286 93200 357 149000 571
24 x 3 79100 345 98800 432 158000 691
24 x 2 86000 365 108000 457 172000 731
27 x 3 10300 505 129000 631 206000 1010
27 x 2 111000 534 139000 667 222000 1070
30 x 3,5 126000 686 157000 854 251000 1370
30 x 2 139000 738 174000 923 278000 1480
33 x 3,5 155344 933 194180 1166 310688 1866
33 x 2 170240 994 212800 1243 340480 1989
10.9 12.9
Diametro x passo 0,7 Rs = 630 0,7 Rs = 756
Precarico Coppia Precarico Coppia
mm N Nm N Nm
3 x 0,5 3170 1,9 3800 2,3
4x 0,7 5530 4,3 6640 5,2
5 x 0,8 8950 8,5 10700 10,1
6x1 12700 14,6 15200 17,5
8 x 1,25 23100 34,7 27700 41,6
8x1 24700 36,6 29600 43,9
10 x 1,5 36500 70,5 43900 84,6
10 x 1,25 38500 73,6 46300 88,4
12 x 1,75 53000 119 63700 143
12 x 1,25 58000 127 69600 153
14 x 2 72500 190 86900 228
14 x 1,5 78800 202 94500 242
16 x 2 98900 288 119000 346
16 x 1,5 105000 302 126000 362
18 x 2,5 121000 398 145000 478
18 x 1,5 136000 434 163000 520
20 x 2,5 154000 562 185000 674
20 x 1,5 171000 607 206000 728
22 x 2,5 191000 748 229000 897
22 x 1,5 210000 803 252000 964
24 x 3 222000 971 267000 1170
24 x 2 242000 1030 290000 1230
27 x 3 289000 1420 347000 1700
27 x 2 312000 1500 375000 1800
30 x 3,5 353000 1930 424000 2310
30 x 2 391000 2080 469000 2490
33 x 3,5 436905 2624 524286 3148
33 x 2 478800 2797 574560 3356
Page D-58
D-6 HOSE FITTING SPECIFICATIONS

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

through the coupling. Exceeding that point, does not im-
prove tightness and damages the coupling!
A hose should never be subject to torsion! When tting 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-5, Hose installation
If hoses routing requires the hose to bend, make sure that
the bending radius are correct.
A bending radius too small can cause restrictions in
the section and therefore load losses. Moreover, these
bends can cause torsional stress and even breakage of
the hose!
For correct tting of hoses, elbow tting can be used for

installation in restricted space without impairing hose ef-
ciency and life.
D-6-1 STORING OF FLEXIBLE HOSES
RECOMMENDATIONS FOR A CORRECT STORING Fig. D-6, Hose installation

The rubber is subjected, by its nature, to changes in its
physical properties. These changes, which normally take
place in time, according to the used type of rubber, can
be accelerated by a special factor or by a combination
of factors. The reinforce materials are, in the same way,
damaged by unproper storing conditions. The following
recommendations contain some precautions to take in
order to ensure the minimum wear of the stored goods.
STORING TIME
The storing time should be minimized by means of a
scheduled rotation program. When it is not possible to
avoid long storing times and when the following recom-
mendations are not respected, it is necessary to accurately
check the hose before using it. Fig. D-7, Hose installation
TEMPERATURE AND HUMIDITY

The best temperature for the storing of the rubber hoses is
between 10 to 25 degrees centigrade. The hoses should
not be hold stored with temperature higher than 40°C or
lower than 0°C. When the temperature is under -15°C, it is
necessary to keep precautions when handling the hoses.
The hoses must not be stored near to heat sources nor
in conditions of high or low humidity. A maximum level of
umidity of 65% is recommended.
LIGHT
The hoses must be stored in obscured places, avoiding
the direct exposition to the sunlight or to strong arti cial Fig. D-8, Hose installation
Page D-59
lights. If the store has some glass windows or doors, these must be obscured.
OXYGEN AND NITROGEN

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

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

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

The hoses must be protected against rodents and insects. When this risk is probable, proper precautions must be
taken.
D-6-2 NORMS AND METHODS OF USE OF THE FLEXIBLE HOSES
PRE-ASSEMBLY CHECKS
Before the installation after a replacement, it is necessary to accurately check the hose characteristics to verify that
type, diameter and length are in compliance with the required speci cations. Moreover, a visual check must be executed
in order to ensure that there are not obstructions, cuts, damaged cover or any other evident imperfections.
HANDLING
The hoses must be handled with care avoiding shocks, draggings on abrasive surfaces and compressions. The hoses
must not be pulled with violence when are twisted or contorted. The heavy hoses, generally delivered in horizontal
straight position, must be placed over proper supports for the transport.
If wooden supports are used, these must not be treated with creasote or painted with substances which could dam-
age the rubber.
PRESSURE AND SEALING TEST

The operating pressure, generally marked on the hoses, must be respected. After the installation, when the air balls
have been removed, gradually increase the pressure up to the operating pressure to test the assembly and check
possible leaks.
TEMPERATURE
The hoses must be always used within the generally pointed out temperature ranges. In case of doubts, call the
Page D-60
manufacturer.
TRANSPORTED PRODUCTS
The hoses must be used for the transport of substances, which they have been manufactured for. In case of doubts,
call the manufacturer. As much as possible, the hoses must not be kept under pressure when they are not used.
ENVIRONMENTAL CONDITIONS
The hoses must be used only in the environmental conditions which they have been manufactured for.
TORSION
The hoses have not been manufactured to work in torsion, except for speci c purpose.
STRETCH
The stretch must be within the limits speci ed by the manufacturer.
VIBRATIONS
The vibrations subject the hoses to the stress and to the heat, above all near the joints and premature explosions can
occur. It is then suggested to check that the hoses have been manufactured to withstand these stresses.
CUSPS
Some users blocks the passage of the liquid thought the hose creating cusps in it. This method is not suggested by
the manufacturers, as the reinforcement is subjected to an excessive stress that could bring to explosion.
D-6-3 MAINTENANCE OF THE FLEXIBLE HOSES
MAINTENANCE
The frequency of the hose maintenance is determinated depending on the use of the hose. In the normal checks,
special care must be taken on the connections and on the presence of the following irregularities that point out the
deterioration of the hose:
• ssures, 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.
REPAIRS
The repairs are not suggested. However, if the deterioration is placed at one edge of the hose, this can be cut.
CLEANING
Clean, if necessary, by soap and water avoiding the use of solvents (petroleum, paraf n, etc) or detergents. Never
use abrasive, sharpened or cutting tools (metallic brushes) for the cleaning.
FLUID END MAINTENANCE UM191091/E - Rev.0 - 03/2009
Page E-61
SECTION E - FLUID END MAINTENANCE

UM191091/E - Rev.0 - 03/2009 FLUID END MAINTENANCE
Page E-62
E-1 FLUID-END CONSUMABLES

The main fluid-end consumables are:
• valve seats;
• valve heads;
• valve seals;
• springs;
• valve guide bushings;
• cover seals.
WARNING
Never reach into the interior of the pump while it is
running.
Do not run the pump with the delivery valves shut.
Stop the pump before repairing it in any way. Before
inspecting, servicing or repairing the machine, di-
sconnect the pump from the power supply.
Completely depressure the fluid-end before repairing
or servicing the machine in any way.
IMPORTANT
Check that all fasteners are fully tightened down.
The tightening torques are given in paragraph D-5.
E-2 REPLACING THE SEALS

Proceed as described in paragraphs E-3.1 and E-3.2 when
replacing valve seals, and as described in paragraphs
E-6.1 and E-6.2 for the liner gaskets.
Page E-63
E-3 VALVES REPLACING (SUCTION 1

2
and DELIVERY)
3
4 8
E-3-1 VALVES REMOVAL
1
6 5
To unscrew the valve cover (1), first loosen off the lock- 2
nut (2) and completely unscrew the expander pin (3); 7 8
otherwise it is difficult to undo the threads, given that the
expander sections act as a retainer. 3
4
Now completely undo the valve cover (1) using a steel bar
fitted in the hole provided for the purpose. 5
7
Remove the valve guide cover (4) and expander sections
with the provided tool.
6
Remove the seal (5).
Extract the valve head (6) and spring (7).
E-3-2 VALVES INSTALLATION
Proceed with care when installing the valve inasmuch as

it effects the efficiency of the seals (5) under the valve
guide cover (4).
On the fluid-ends of this series of pumps, the valve covers

are equipped with a double locking device which reduces Fig. E-1, Fluid end section
the mud pulse pressure on the threads.
The double locking is obtained by using a series of expan-

der sections (8) above the valve guide cover.
These sections must operate with their upper surface per-

fectly flat to avoid tightening down the valve covers, with
an uneven contrast surface. This would result in irregular
locking of the seal under the valve guide cover, and the
liquid would thus be free to infiltrate the seal seats under
pressure.
High pressure infiltration of the mud quickly wears the seal

seats, reduces their tightness and requires frequent seal
replacement in consequence.
To avoid this, proceed as follows:
1. fit the valve head in the valve seat.

2. fit the spring over the valve.
3. check that the seal seats are in good condition whe-
never disassembling the valve covers
4. fit seals (5) in good condition and with a draught of
at least 1mm (0.045”) relative to the seat itself.
Grease lightly.
Page E-64
5. Fit the valve guide cover (4) over the seal, and then the expander sections. These sections must run in grease
to enable them to move smoothly on the contrast surface, to their final working position.
IMPORTANT
Snug the sections together manually so that they adhere.
6. Turn upwards and fully tighten down the expander pin (3) at the centre of the valve cover.
7. Screw in the valve cover (1) to the fluid-end cylinder block, with a torque of 10÷15 kgm (70÷105 lb/ft).
8. Now tighten down the central cone using the provided wrench, with a torque of 8÷10 kgm (60÷70 lb/ft).
9. The upper ends of the expander sections are now evenly pressed against the contrast surface. Use a steel bar
to lock down the valve cover to a torque of 70÷80 kgm (500÷580 lb/ft) and lock down the expander pin to 30÷40
kgm (220÷290 lb/ft). Now lock down the expander pin locknut (2) to 25÷30 kgm (180÷220 lb/ft). The mud pump
is now ready for operation at the maximum operating pressure.
10. Check from time to time that the valve covers do not pulse excessively. If so, lock them down further and tighten
down the expander pin as well.
11. At least every 400÷500 hours of operation, check the condition of the valve head seal seats.
12. The valve covers should pulse in the range 0.02÷0.07 mm.
The covers and the fifth wheels must be replaced when the threads are worn with a step of 0.5 to 0.6 mm.
Clean and grease the threads whenever reassembling them.
E-3-3 FLUID END BOLT TIGHTENING SPECIFICATIONS
Screw’s no- Maximum preload Ft-Lb (Kgm)

minal diame- 8UN UNC UNF
ter
Ft-Lb Kgm Ft-Lb Kgm Ft-Lb Kgm
7/8” 450 62,1 490 67,6
1.1/4” 1400 193 1255 173 1380 191
1.3/8” 1635 226 1875 259
1" ¼ - 8UN 1" ¼ - 8UN

1" ¼ - UNF
⅞" - UNF
1" ¼ - UNF
1" ⅜ - UNF
1" ⅜ - UNF
Fig. E-2, Fluid end bolts

Page E-65
E-4 VALVE SEATS REPLACING

E-4-1 VALVE SEATES REMOVAL
WARNING
Never use a WeldingTorch to remove the valve seats. Overheating can deform the fluid-end around the valve
seats.
1. Remove the valve cover and head (see Fig. E-1).

2. Use the appropriate puller to remove the valve seat (see Fig. E-3).
IMPORTANT
Valve seat pullers can be ordered from Drillmec. Specify the serial number of the pump when placing your
order.
Fig. E-2, Removing of valve

Page E-66
E-4-1-1 VALVE SEATES INSTALLATION
IMPORTANT
Do not reuse valve seats. Always use new units.
1. Remove the mud/cement residue from the seat contact

surface with a metal brush.
2. Clean the seat contact area carefully with a cloth and
appropriate detergent.
WARNING
Do not use petrol as a detergent.
3. Dry the contact area with a soft, clean cloth. The area
must be completely dry before installing the new valve
seat.
4. Install the valve seat into the tapered zone.
5. Use a wooden wedge and hammer to lock the seat
(see Fig. E-3).
IMPORTANT Fig. E-3, Valve installation

The pump pressure will seat the unit in its final po-
sition.
6. Fit the valve head and spring.

7. Screw down the cap and lock as indicated before.
Page E-67
E-5 PISTONS AND PISTON RODS REPLACING
IMPORTANT
DRILLMEC Triplex pumps are equipped with single acting pistons and piston rods as specified by API
SA-4.
E-5-1 PISTONS AND PISTON RODS REMOVAL
1. Unlock the collars (1) and remove them.

2. Remove the counter-rod (2).
3. Grip the rod (3) and extract the piston (4) from the liner (5).
4. Remove the rod locknut.
5. Replace the damaged parts.
2 3 5 4
Fig. E-4, Fluid end section

Page E-68
E-5-2 PISTONS AND PISTON RODS INSTAL-

LATION Locknut
Piston rod
IMPORTANT
Burrs or rough patches on the piston rod extension
or flanges can cause misalignment of the piston-liner
assembly. Before assembly and installation, check
the extension and flanges. Remove burrs or rough Piston
patches with a file or sanding block.
1. Install the new piston with the O-ring on the piston

rod.
Fig. E-6, Pistoni
2. Fit the locknut to the rod. Tighten down to 1180 Nm.
3. Lubricate the liner boring and the piston with multipur-
pose grease.
4. Fit the piston assembly to the piston rod in the liner.
5. Refit the counter-rod (2).
IMPORTANT
There must be no gap between the counter-rod flange
(2) and the piston rod.
6. Refit the collars (1) and tighten the 5/8” bolts down to
210 Nm.
If the piston rod collar (1) does not fully tighten down,
check the counter-rod tightening faces (2) for grooves or
burrs, along with the piston rod and collar itself. Remove
any grooving or burrs with a file or sanding block.
Page E-69
E-6 LINERS REPLACING
WARNING
Use the service hoist when handling the liners inasmuch as they are heavy and the available space is limi-
ted.
E-6-1 LINERS REMOVAL
1. Unlock the split collar (1) between the rod (2) and the counter-rod (3).
2. Move the rod to its stroke limit.
3. Slacken off the tie (4) and rest it in its place on the base of the case.
4. Extract the liner using a prise-bar to apply force to it.
5. Remove the liner (5) and the piston (6).
6. Check and replace the seal (7) if necessary.
IMPORTANT
If it is not possible to remove the liner with ease, contact DRILLMEC Customer Care for an alternative solu-
tion.
E-6-2 LINERS INSTALLATION
1. Slide the piston, complete with piston rod, into the liner.
2. Fit the new gasket (7), if required.
3. Fit the liner (5) into its seat.
4. Refit the liner tie (4).
5. Approach the rod (4) to the counter-rod (3) and refit the split collar (1).
2 3 5 4
Fig. E-7, Fluid end section

Page E-70
E-7 ACCESSORIES
Suction pulsation
The motor pump is equipped with two pulsation desurgers dampener
which reduce the pressure oscillations in the muds circuit
for more even fluid delivery.
One desurger is fitted to the suction manifold, the other
on the delivery manifold.
E-7-1 sUCTION PULSE DAMPENER
The suction pulse dampener is located inside the suction

manifold. The dampener increases the load pump service Delivery pulsation
life by making the suction flow more uniform. dampener
1. Refer Fig. E-9. Open the needle valve (1). Fig. E-8, Dampener
2. Use a standard tyre pressure gauge to check the air

pressure. The pressure must be 1.4 bar. If the value
is lower, use a standard compressor to charge to 1.4
bar.
3. Close the needle valve (1).
4. If the pressure drops at any time, check that rubber

diaphragm inside the suction manifold for damage, and
replace if necessary.
WARNING
Do not charge the suction pulsedampener before
installing it.
Fig. E-9, Suction dampener

HAZARD
Only use nitrogen or air to charge the unit. Never use
Oxygen for this purpose.
Fig. E-10, Suction dampener

Page E-71
E-7-2 FILTER UNIT
This standard accessory is composed of a filter housing

mounted with stud bolts, and a filtering mesh (Fig. E-10, 1
pos.2). The filter unit mounts the pulsation desurger and 2
filters the mud to impede foreign bodies entering the high
pressure circuit. Check the filter mesh regularly or whe-
never the safety valve trips too frequently.
WARNING
Before any service or repair work, completely depres-
surise the fluid-end. Fig. E-11, Filter
1. Remove the blind flange (Fig. E-10, pos.1)

2. Clean/replace the mesh (2)
3. Refit the blind flange. See the table in paragraph
D-5 for tightening torques.
E-7-3 DELIVERY PULSATION DESURGER
The desurger is fitted with the following plate (see Fig.

E-11).
The pulsation desurger operates most efficiently when the

nitrogen charge is optimal. The charge depends on two
factors: nitrogen leaks and variations in the unit’s ambient
temperature. If all connections are tight, the gas charge will 20 75,7
last for years. But it is likely that a leak which may well be
hard to detect will cause a significant pressure variation.
If the charge pressure drops below the required level,
inspect the points listed below with soapy water before
disconnecting the connections.
1. Charge valve and pressure gauge threaded fit-

tings;
2. Remove the charge valve cap and check that the

valve is fully closed;
3. Check the tightness of the connection between the

cover and the body and around the stud bolts which
mount the cover to the body.
If no leaks are evident at the above points, the diaphragm

Fig. E-12, Pulsation dampener plate
may be perforated. If the leak is significant, replace the
diaphragm at once. If the leak is negligible, it may be
corrected by adding nitrogen to the charge and checking
again after a period of time. Follow the instructions in
paragraph E-7.2 when replacing the diaphragm.
In case of strong ambient temperature variation, for exam-

ple between winter and summer, it may be necessary to
Page E-72
substitute the gas charge appropriately. For example, if the unit is charged to 7 bar at 20°C and the temperature
subsequently drops to 10°C, the charge pressure must be adjusted to 6.7 bar.
If the charge pressure is too low, the desurger will be full of liquid at normal line pressure. The working volume gas
available for the damping effect will be reduced, thus reducing the effectiveness of the desurger itself.
If the charge pressure is too high, the diaphragm insert will touch the base and push the liquid out. In this case there
will be no damping effect until the line pressure exceeds the charge pressure. Over the long term, the line pressure
will equalise to the charge pressure, reducing the service life of the diaphragm.
E-7-3-1 CHARGING INSTRUCTIONS (Fig. E-12)
1. Remove the pulsation desurger cover (1).

2. Make sure the needle valve (2) is completely closed.
3. Remove the needle valve cap (3). Connect the needle valve to the nitrogen canister with a high pressure filling
hose (4).
4. Open the needle valve (2).
5. Slowly open the canister valve to send the gas to the desurger. Do this with the line pressure reduced to a value
no greater than the charge pressure.
6. When the desurger gauge (5) shows the required charge pressure, close the canister valve.
7. Close the needle valve (2).
8. Detach the filling hose (4) from the desurger valve.
9. Refit the needle valve cap (3).
10. Refit the desurger cover (1).
Fig. E-13, Pulsation dampener

Page E-73
E-7-3-2 REPLACING THE DIAPHRAGM (fig. E-13)
1. Make sure the pressurised gas has been completely discharged from the desurger.
2. Remove the upper flange (1).
3. Remove the damaged diaphragm.
4. Check the internal surfaces of the desurger (2) and remove any foreign bodies, rust or incrustations.
5. Fit the new diaphragm (3) in a flat position, folded to assist in inserting it into the body’s opening. Seat the
diaphragm snugly into the desurger casing. Fit the diaphragm collar and ring around the opening of the desur-
ger body without deforming the diaphragm itself. To facilitate this operation, dust the diaphragm with talcum
powder.
6. Fit the stabiliser plate (4) with the flange. Secure it to the diaphragm with the screw (5).
7. Grease the interior of the diaphragm collar.
8. Refit the upper flange without damaging the diaphragm. Tighten down bolts (6) to 3430 Nm. The desurger is
now ready for charging.
Fig. E-14, Pulsation dampener

Page E-74
WHITE INTENTIOANL PAGE

TROUBLESHOOTING UM191091/E - Rev.0 - 03/2009
Page F-75
SECTION F - TROUBLESHOOTING
UM191091/E - Rev.0 - 03/2009 TROUBLESHOOTING
Page F-76
F-1 TROUBLESHOOTING
It is not possible to troubleshoot the causes of problems which occur during pumping itself.
To identify the problem, it is important to analyse the symptoms.
The troubleshooting table gives some of the most common problems, their causes and solutions.
IMPORTANT
If the troubleshooting table is not sufficient to resolve your problem, please contact DRILLMEC Customer
Care.
WARNING
Never reach into the pump while it is operating. Never ruin the pump with the delivery valve closed.
Stop pumping before making any repairs. Before inspecting, servicing or repairing the motor
pump, disconnect the pump from the power supply. Completely depressurise the fluid-end before doing any
service or repair work.
Page F-77
PROBLEM CAUSE SOLUTION

INSUFFICIENT DELIVERY PRES- VALVE OR VALVE SEAT WORN OR REPLACE VALVE/ VALVE SEAT
SURE LOW CUT BY FLUID
VALVE LOCKED OPEN REMOVE FOREIGN BODIES
MESH FILTER BLOCKED CLEAN/REPLACE DELIVERY MESH
FILTER
FLUID LEAKAGE FROM PISTON REPLACE PISTON / JACKET
INCORRECT PRESSURE GAUGE RECALIBRATE / REPLACE PRES-
READING SURE GAUGE
LOW SUCTION PRESSURE LOW FLUID HEAD INCREASE FLUID HEAD INCREASE
BOOST
BOOSTER PUMP WORN CHECK BOOSTER PUMP
FLOW OBSTRUCTED REMOVE OBSTRUCTIONS FROM
SUCTION LINE
INCORRECT PIPE LAYOUT CORRECT LAYOUT
INCORRECT PRESSURE GAUGE CONTACT PUMP MANUFACTU-
READING RER
RECALIBRATE/REPLACE PRESSU-
RE GAUGE
AIR IN THE SUCTION LINE REPAIR SUCTION LINE
AIR IN THE BOOSTER PUMP ADJUST/REPLACE STIFFING BOX
ON SHAFT OR GASKET
LACK OF PRESSURE IN THE SUC- CHECK/CHARGE
TION DESURGER
PASS MUD THROUGH DEGASSER
FLUID HAMMERING WITH SUCTION COMPRESSOR
ALLOW PIPES TO FILL COMPLE-
AIR/CAVITATION IN THE PUMPED TELY
FLUID
REDUCE PUMP SPEED
ADJUST DESURGER SUCTION
PRESSURE
LOW DELIVERY PRESSURE SEE “LOW DELIVERY PRESSURE”
DELIVERY DESURGER REPAIR / CHARGE / REPLACE
DELIVERY LINE NOT SECURED INSTALL SUPPORTS OR LOCKS
DELIVERY LINE VIBRATION LOW DELIVERY PRESSURE SEE”LOW DELIVERY PRESSURE “
LOW SUCTION PRESSURE SEE “LOW SUCTION PRESSURE”
FLUID HAMMERING SEE “FLUID HAMMERING”
VALVE CAP/FRONT PANEL LOO- TIGHTEN DOWN CAP/FRONT PA-
SE NEL
REPLACE GASKET REPLACE GASKET
SIGNIFICANT LEAKAGE
GASKET SURFACE / SEAT DAMA- REPLACE VALVE CAP/FRONT
GED PANEL
REPAIR FLUID-END
Page F-78

ABRASIVE PARTICLES IN THE CHECK DESILTER
FLUID
LARGE PARTICLES IN THE FLUID CHECK DESANDER
VALVE SEAL COMPROMISED VALVE SPRING BROKEN - REPLA-
CE
SHORT VALVE LIFE EXCESSIVE
VALVE GUIDE WORN - REPLACE
VALVE WEAR
VALVE OR VALVE SEAT WORN -
REPLACE
LOW FLUID SUPPLY TO THE SEE “LOW SUCTION PRESSURE”
PUMP
DEFECTIVE PULSATION DAMPER REPAIR/REPLACE
ABRASIVE PARTICLES IN THE PUMP FILTERED FLUID AND CLE-
FLUID END AN THE PISTON THOROUGHLY
DRY FRICTION REPAIR JACKET COOLING SY-
E X C E S S I V E P I S TO N / J A C K E T STEM
WEAR EXCESSIVE JACKET WEAR USE HIGH CHROME STEEL JA-
CKET
EXCESSIVE PISTON WEAR TIGHTEN DOWN THE ROD CLAM-
PS
PISTON ROD EXTENSION WORN/ REPLACE THE PISTON ROD EX-
DAMAGED TENSION
PISTON ROD EXTENSION SCO- CLEAN THE GASKETS AND PISTON
LEAKAGE FROM THE PISTON ROD RED ROD WHEN INSTALLING
EXTENSION GASKET SEAT WORN SEAL RINGS REPLACE
SCRAPERS NOT TIGHT CHECK ASSEMBLY ORIENTATION
PRESSURE IN THE POWER-END CLEAN/REPLACE AIR BLEED VAL-
CASING VE
LEAKAGE FROM THE LUBRICATON WORN SEALS REPLACE
SYSTEM OIL GASKETS DAMAGED SEALS REPLACE
EXTERNAL EDGE OF GASKET IN- CLEAN AND POLISH THE INTERIOR
CORRECTLY SEATED OF THE LUBRICATION OIL SEAL
SEAT
CLEAN AND POLISH THE RING ON
FOREIGN BODY IN THE SEAL WHICH THE SEAL RESTS
REPLACE THE RING
PRESSURE IN THE POWER-END CLEAN / REPLACE THE AIR BLEED
CASING VALVE
LOW OIL LEVEL CHECK AND TOP UP
LUBRICATION FAILURE IN THE
OIL TEMPERATURE TOO HIGH SEE “HIGH OIL TEMPERATURE”
POWER-END/CROSS-HEAD
DIRTY OIL CHANGE OIL AND FILTER
HIGH OIL TEMPERATURE >=80°C UNSUITABLE OIL TYPE CHECK OIL TYPE
SLACK PISTON / RODSLACK ROD CHECK AND TIGHTEN DOWN
EXTENSION
WORN BEARINGS REPLACE
NOISE IN THE POWER - END
PLAY IN CROSS-HEAD PIN CHECK AND TIGHTEN DOWN
WORN CAMSHAFTWORN CROSS- REPAIR/REPLACE
HEAD
Page F-79

DIRTY OIL CHANGE OIL AND FILTER
INCORRECTLY SET/BLOCKED SA- ADJUST / REPLACE SAFETY VAL-
FETY VALVE VE
OIL FILTER BLOCKED CHANGE OIL AND FILTER
HIGH OIL PRESSURE REDUCED OIL LINE CROSS-SEC- CLEAN OUT
TION
OIL LINE BENT / CRIMPED CHECK
INCORRET PRESSURE GAUGE REPLACE PRESSURE GAUGE
READING
SAFETY VALVE ( WHERE FITTED CHECK SETTING NOT TOO LOW
)
INCORRECT OIL TYPE CHECK OIL TYPE
HIGH OIL TEMPERATURE
OIL LINE CRIMPED CHECK LINES
HEAT EXCHANGER (WHERE FIT- CHECK WATER PUMP OPERA-
TED) TION
Page F-80
WHITE INTENTIONAL PAGE

OTHER RISK UM191091/E - Rev.0 - 03/2009
Page G-81
SECTION G - OTHER RISK

UM191091/E - Rev.0 - 03/2009 OTHER RISK
Page G-82
G-1 OTHER RISKS
WARNING
In case of repairs after a fault has been detected or of preventive maintenance, and however for any envisaged
application, the machine can be considered almost free of any risk, provided that the all safety cautions are
taken, as required by the regulations currently in force and as mentioned in Section B of this manual.
G-1-1 PRESSURIZED ACCUMULATORS
On the rig are installed some accumulators under pressure.
It is necessary to consider their potential danger during maintenance/repairing of hydraulic and pneumatic systems.
The tank of compressed air is positioned on the carrier and one is used as an auxiliary tank for normal machine
operations.
The drilling fluid system (air / mud) has parts that remain pressurized also when the machine is not working
One hydraulic accumulator is located on mud pump as pulsation dampener.
HAZARD
Before working on pressurized lines (hydraulic oil, compressed air, water or drilling fluids) and/or disconnect
components, make sure that the pressure has been discharged and the fluid contained is not longer hot.
DISMANT. AND DEMOLITION UM191091/E - Rev.0 - 03/2009
Page H-83
SECTION H - DISMANTLING AND DEMOLITION

UM191091/E - Rev.0 - 03/2009 DISMANT. AND DEMOLITION
Page H-84
H-1 DISMANTLING AND DEMOLITION

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

Preliminary Um191091 - Mud Pump 9t1000 - e

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Preliminary Um191091 - Mud Pump 9t1000 - e

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Operation and

Triplex mud pump - trailer mounted

12, Via 1° Maggio

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

© Copyright 2009 DRILLMEC S.p.A. - All rights reserved

TECHNICAL SERVICE AND SPARE

The technical service can be executed by an Agent or by

LOCAL AUTHORIZED DEALERSHIP AND SERVICE CENTRE

MEMORANDUM OF THE MACHINE IDENTIFICATION DATA

Drilling rig type-approval

Power plant t ype-approval

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

Section C- OPERATING INSTRUCTIONS......................................................................C-29

C-2 MACHINE DEVICES..................................................................................................................................... C-31

SECTION E - FLUID END MAINTENANCE........................................................................ E-61

E-7 ACCESSORIES . ......................................................................................................................................E-70

SECTION F - TROUBLESHOOTING.................................................................................. F-75

SECTION G - OTHER RISK................................................................................................G-81

SECTION H - DISMANTLING AND DEMOLITION.............................................................H-83

FOREWORD 4 Mark and logotype of DRILLMEC SpA.

C-1-1 DRILLING CONTROLS AND INSTRUMENTATIONS

starting from the instruction for the manual reading up to

the machine technical performances, the safety rules, the

As already pointed out into the Section B - SAFETY,

the operators will be required to carefully read and well S3

understand the contents of the manual before starting to C48 C29

use the machine. It is necessary the complete understand- C52

ing especially of all the aspects relevant to the use, the S6

maintenance and the lubrication of the machine. S11

tinuous reference to make clear every doubt concerning

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

The manual has to be kept keep in easily accessible

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

It is also advisable to know well the methods used to

TYPICAL STRUCTURE OF THE PAGES

The pages of the manual have always a typical structure

1 Model of the treated machine or fixture.

C-2-1 PRELIMINARY CHECKS

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

2. Another mainly important check is that relevant

FIGURE NUMBERING SYSTEM

9 Inside each fist level chapter, the figure numbering system

Fig. 3 - Sample of page RECALLING CONNECTION TO OTHER

To make easier the consultation of related subjects, the

This structure helps in realizing a linear and detailed tre-

DRILLMEC can introduce in every moment some

Hot parts hazard

INTENTIONAL WHITE PAGE

SECTION A - GENERAL INFORMATION

A-1 CONVENTIONAL REFERENCE

The machine is considered oriented as shown in the figure.

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

Fig. A-1., Orientation

A-3 MACHINE IDENTIFICATION

Via 1° Maggio, 12 - Località Gariga

9T1000 Triplex pump with GE 752 electric motor.

A-3-3 IDENTIFICATION PLATES

The following information concerns the dislocation of the

A-3-3-1 Power pump identification plate

The power pump identification plate (See Fig. A-2) is

Fig. A-2, Power pump identification

Fig. A-3, Power pump identification -picture

The pump identification plate (See Fig. A-4) is located it’s