AF120 IMT Piling Rig Agip PDF

MANUAL FOR USE
OF THE HYDRAULIC DRILLING RIG
AF120
Serial Number :
Language: English REV.00-B
Carried out by: Q.P. 28/01/02
Approved by:
Rev. Carried out by: Date: Approved by: Date:
M A N U A L f o r U S E o f t h e AF120 pag. 1
INDEX 0
1. SAFETY MEASURES ____________________________________________________4

1.1 INTRODUCTION _________________________________________________________4
1.2 CERTIFICATE OF COMPLIANCE ______________________________________________5
1.3 IDENTIFICATION OF THE MACHINE ______________________________________6
1.4 GENERAL WARNINGS PULLBACK ___________________________________________7
1.5 PLANNED USE OF THE RIG _____________________________________________7
1.6 SAFETY WARNINGS ______________________________________________________7
1.7 WARNING SIGNS ________________________________________________________9
1.8 TRAINING REQUIRED OF OPERATORS__________________________________10
1.9 SAFETY AND CHECKING DEVICES ___________________________________________10
1.10 GENERAL SAFETY RULES ___________________________________________12
1.10.1 Safety rules for loading and the transporting machine____________________12
1.10.2 Safety rules during working phases _________________________________13
1.10.3 Work in proximity of electrical cables _________________________________14
1.10.4 Noise emission __________________________________________________14
1.10.5 Vibration _______________________________________________________14
1.10.6 Seat ___________________________________________________________15
1.10.7 Ground pressure ________________________________________________15
1.10.8 Wind force ______________________________________________________15
1.10.9 Fire extinguishers _______________________________________________15
2. GENERAL INFORMATION _______________________________________________16
2.1 AIM OF GENERAL INFORMATION _______________________________________16
2.2 IDENTIFICATION DATA OF MACHINE MANUFACTURER ____________________16
2.3 CONDITIONS TO MAINTAIN WARRANTY VALIDITY_________________________16
2.4 INFORMATION REGARDING CUSTOMER - IMT S.P.A. RELATIONS ___________________16
2.4.1 General information on technical assistance and spare parts ________________16
2.4.2 Procedure for requesting Technical Assistance ___________________________17
2.4.3 Procedure for spare parts request _____________________________________17
2.4.4 Procedure for giving technical advice___________________________________18
2.5 GENERAL DESCRIPTION __________________________________________________18
2.5.1 Description of hydraulic installation ____________________________________19
2.5.2 Description of electrical installation ____________________________________19
3. TECHNICAL CHARACTERISTICS _________________________________________20
3.1 DATA REGARDING THE BASIC MACHINE ______________________________________20
3.2 DATA OF DRILLING RIG __________________________________________________21
Mast extension___________________________________________________________21
Lower mast attachment ____________________________________________________21
Slewing upperstructure ____________________________________________________21
MASS__________________________________________________________________25
DIMENSION ____________________________________________________________25
3.2.1 Maximum working slope _____________________________________________26
3.2.2 Maximum slope for movement ________________________________________26
3.3 TECHNICAL DATA OF THE CASING OSCILLATOR __________________________________27
4. TRANSPORT __________________________________________________________28
4.1 MACHINE CONFIGURATION FOR ROAD TRANSPORT ______________________28
4.2 MACHINE LOADING AND UNLOADING ___________________________________28
4.3 PREPARATION FOR TRANSPORT_______________________________________29
4.4 TRANSPORT ON SEMI-TRAILER ________________________________________30
5. OPERATION INSTRUCTIONS ____________________________________________31
5.1 AIM OF OPERATION INSTRUCTIONS __________________________________________31
INDEX 0
5.2 DRILLING _____________________________________________________________31

5.3 MOVING IN WORKING PHASES______________________________________________32
5.3.1 Moving about on soft or damp terrain___________________________________32
5.4 WARNING! AVOID THE FOLLOWING MANOEUVRES _____________________________32
5.5 CONTROL SYSTEMS AND CABIN CHARACTERISTICS ______________________________33
6.DRILLING EQUIPMENT CONTROLS __________________________________________34
6.1 GENERAL MACHINE CONTROLS ______________________________________________34
6.2 EQUIPMENT CONTROL LEFT-HAND LEVER. ______________________________________35
FIGURE 17 6.3 EQUIPMENT CONTROL RIGHT-HAND LEVER. ____________________________35
6.4 FRONT DASHBOARD ______________________________________________________36
6.5 FRONT DASHBOARD LEFT SIDE ______________________________________________37
6.6 FRONT DASHBOARD RIGHT-HAND SIDE _________________________________________38
6.7 TILTING CYLINDER CONTROL JOYSTICK ________________________________________39
6.8 COMPUTER _____________________________________________________________40
6.9 LEFT-HAND LATERAL CONTROLS _____________________________________________41
6.10 DIRECTIONS FOR USE ____________________________________________________42
6.11 CRAWLER TRACK TRAVEL _________________________________________________43
6.12 ROD LIFTING GROUP ____________________________________________________43
7. INSTRUCTIONS FOR USE _______________________________________________44
7.1 STARTING UP THE MACHINE __________________________________________44
7.2 PROCEDURE FOR POSITIONING MAST __________________________________44
7.3 POSITIONIG OF THE RIG DURING WORK PHASES _______________________________44
8. MACHINE IN NON-WORKING PERIODS ____________________________________45
8.1 TEMPORARY STOPPAGES _______________________________________________45
8.2 DISPOSAL __________________________________________________________45
9. MAINTENANCE ________________________________________________________46
9.1 GENERAL RULES _____________________________________________________46
9.2 MAINTENANCE PROGRAM _________________________________________________48
9.3 GREASING POINTS_____________________________________________________49
9.5 LUBRICATION ________________________________________________________50
9.6 CABLE ROPE MAINTENANCEI ______________________________________________51
9.6.1 MOUNTING THE CABLE ROPES _____________________________________51
9.6.2 CABLE ROPE DAMAGE ____________________________________________52
10. TESTS - INSPECTIONS - CHECKS ________________________________________55
10.1 MAINTENANCE SUMMARY _______________________________________________57
SAFETY MEASURES 1
1. SAFETY MEASURES
1.1 INTRODUCTION
Dear Customer,
we wish to thank you for having chosen a drilling machine from IMT and are sure you
will always be satisfied with your purchase.
This machine must be used according to the norms and instructions indicated in this
manual to ensure the personal safety of the operator and jobsite workers; moreover,
the following norms and regulations must be adhered to:
• staff safety 89/391/CEE (DL 626/94);

• jobsite safety 92/57/CEE (DL 494/96);
• highway code (during transport).
The machine can only be used by specialized and expert operators and skilled at
driving special means of transport in jobsites, under the supervision of the Supervisor
responsible for the jobsite safety.
The operator must read thoroughly and clearly understand all the procedures described
in this manual and subsequently give the safety Supervisor a written and signed
statement declaring that all the information contained in this instruction manual has
been read, noted and clearly understood.
SAFETY MEASURES 1
1.2 CERTIFICATE OF COMPLIANCE
Certificate of compliance
according to the Machine directives 89/392 CEE and successive amendments in the Enclosed IIA
The undersigned:
I.M.T. S.r.l.
Via d’Ancona 39
60027 Osimo (AN) Italy
Declares on its own liability that the new machine stated here below:
HYDRAULIC DRILLING RIG Model AF120

Serial no.: ***AF120 *** Year of Construction: 2002
Power 110 KW
Is built in conformity to the legislative provisions that transpose the directive for Machines
89/392 EC and its successive amendments
----------------------------- Harmonized Norms ----------------------------

UNI EN 292/1 (Machine Safety)
UNI EN 292/2 (Machine Safety)
UNI EN 294 (Safety, spaces to reach dangerous areas)
UNI EN 418 (Safety, emergency stop devices)
UNI EN 7349 (Safety, spaces to avoid crushing)
EN 791 (01/96) (Safety of the drilling machine)
UNI ISO 7000 (Graphic symbols and signs)
UNI EN 60204/1 (Safety of the electrical equipment)
CNR UNI 10011 (Constructions in steel: calculus, execution, etc.)
Furthermore it declares as forseen in enclosed appendix V of the Directive for Machines 89/392 EC:
The marking of the symbol “EC” is affixed onto the machine.

The technical booklet is available at the Manufacturer’s main office;
EMC Technical file, in compliance to the 89/336, is available at the Manufacturer’s main office.
SAFETY MEASURES 1
1.3 IDENTIFICATION OF THE MACHINE
The machine is identified by its name plate which indicates the model, year of manufacture and
serial number.
This is placed underneath the name plate of the machine base of the boom on the cabin side.
Machine Weight without kelly 54.000 Kg

Main Winch Hoisting capacity 150 KN
Auxiliary Winch Hoisting capacity 82 KN
Rotary Torque 137 KNm
Engine Maximum Power 110 KW
SAFETY MEASURES 1
1.4 GENERAL WARNINGS PULLBACK
The present manual relative to the drilling equipment installed by IMT

S.p.a. is integrated with originali Caterpillar manuals, that are delivered
togetherr with the manual, and called: “Maintenance and Operation
Manual” of the excavator CAT320B (SEBU 7021-01 Feb. 98)
The manuals are completly read and understood before attempting to

operate the machine controls or carry out maintenance operations.
In the pages that follow we will indicate CAT the Caterpillar manual of the hydraulic
excavator 320B and Feb. 98 code SEBU 7021-01.
In the most important points where you should proceed to immediatelly read the Cat
manual, page references are indicated for a fast and efficient search for relative
information, therefore it should never be separated from the Caterpillar manual and in
the case of purchase, must go together with the machine.
The manuals must be kept in the back seat pocket of the operator’s seat.
All the safety measures, operation instructions, transport and maintenance are clearly
indicated in the manual regarding the IMT AF120 drilling rig.
1.5 PLANNED USE OF THE RIG
The IMT AF120 drilling rig has been specifically designed to bore holes in every type of
terrain to produce medium and large size diameter (500-2000 mm).
The rig operates the drilling technique by rotation of a tool (auger or bucket) connected
to a telescopic kelly bar. The maximum depth depends on the length of the tool and
kelly bar used.
The machine is equipped with two lifting winches which carry out the drilling operation
and changing of tool.
It is strictly forbidden to use these winches for other lifting operations that are not
directly related to the drilling operation itself.
IMT S.p.a. reserves the right to take legal action against the illegal and unauthorised
use of the machine.
1.6 SAFETY WARNINGS

Most accidents that occur during the use and maintenance of the drilling machine are
due to negligence of the most fundamental safety measures and risks of potentially
dangerous situations inherent in many operations. Whoever places themselves at the
SAFETY MEASURES 1
machine controls must have the skills and knowledge required for working in a jobsite,
so as to not endanger their own life as well as that of other workers.
The use, lubrication, maintenance or repair of the machine carried out improperly can
either lead to fatalities or cause serious harm to personnel.
Never operate the machine or carry out maintenance and repair operations without
having first read and understood the procedures described in this manual.
Furthermore, the operator is the only one who can really be aware of the safety limits of
the actual work he is carrying out.
In order to simplify matters, la IMT has tried to illustrate all the possibilities of dangerous
situations that may arise when working in a jobsite in the best and most complete way.
The proper working and safety of the machine depend mostly on correct and regular
maintenance of its parts. Therefore it is of utmost importance that the checking and
specified operations in the manual are carried out carefully.
Always remember that the thorough knowledge of maintenance jobs and the care and
precision they are carried out with are of fundamental importance in order to maintain
machine safety standards as well as the efficiency and value of the rig in they years to
come.
The indications for use describe the manoeuvres required in order to start up, turn off
and use the machine in its various functions can be applied, after the operator has
carefully studied and understood the manual.
Experience plays an essential role regarding safety, seeing that dangerous situations in
the job site are not easily to illustrate in a manual and their true evaluation requires
personnell that is professionally experienced.
Prudence is the best safeguard against accidents.
A copy of this manual is supplied with every machine and placed in the appropriate
container behind the operator’s seat. If on the point of beginning your work, you are
without the manual, please request a copy immediately from IMT.
Some information in this manual show details and spare parts that may be different
from those of the drilling rig, however the basic concepts remain the same.
Due to the constant product improvement that IMT carries out, some component parts
of the machine may have a slightly different appearance from what is described in this
manual. We remind you, however, that the procedure to be followed is what is
described.
Characteristics, protection and accessories may vary in countries destined to receive

the machine, and be in conformity to law requirements and regulations of that country, it
being understood that the machine in your possession satisfies completely all the
requirements stipulated by EC rules.
SAFETY MEASURES 1
1.7 WARNING SIGNS
Some important signs regarding safety during working phases will be indicated as follows:
Warning Danger !
Danger High voltage-electrical parts !
Danger of falling materials !
Danger, use of naked flamme or smoking forbidden !
Danger of explosions !
Danger of corrosive material !
wrong interpretation of these instructions may lead to accidents with serious

repercussions to persons and property.
Very important information
• Important information
Ö General information
Strictlly adhere to safety measures indicated in the the “Operation and Maintenance Manual” of
the crawler excavator CAT320B .
SAFETY MEASURES 1
1.8 TRAINING REQUIRED OF OPERATORS
Before beginning to work in a jobsite, the operator must acquire the necessary knowledge
regarding the machine so that all the required manoeuvres to activate the drilling rig can be
carried out promptly and safely.
It is important for the operator to be aware of the methods and techniques used in foundations
and jobsite works, seeing that he must coordinate his own work with that of the other machines
and other auxiliary labour.
As welll as being responsibile for his work, the drilling rig operator is also responsible for the
proper use of the machine and its safety with respect to other personal working in the zone.
The operator is obliged to inform the Safety Supervisor of any anomaly in the working of the
machine for his own as well as others safety.
Even if the instructions for the operation of the rig and the description of working methods are
limited to basic ideas they must be well understood and the manoeuvre must be exercised and
repeated with accuracy and safety until promptness and confidence is gained, which is the
basis of proper execution of work.
Only through repeated exercise can working techniques improve and the potentiality and
efficiency of the machine can be fully exploited.
Always remember that the operator is always the main person in charge of
safety as he is the one who must evaluate the risks linked to every
manoeuvre of the machine and is the first one to detect an anomaly in the
machines functions.
1.9 SAFETY AND CHECKING DEVICES

The machine is equipped with safety measures that are integrated into its structure:
a) The hydraulic installation is equipped with a blocking lever positioned in the cabin; this
blocking device must be engaged before the operator leaves his control postion and then
only disengaged after the operator has returned again to the sitting position inside the cabin.
b) The hand levers are equipped with automatic returns in the neutral position (hold function)
c) All the cylinders are supplied with valves to allow the immediate blocking of the piston in the
case of the connecting tubes breaking.
d) All the winches are equipped with a laminar brake that prevents the sliding of the cable ropes
in the case of breakdown of the oleodynamic installation.
e) The electronic depth counters in the cabin measure the drilling depth.
f) The electronic inclinometer in the cabin checks the mast slant.

g) Microswitch of mast end stroke controlled by the kelly bar guide
h) Microswitch of auxiliary winch end stroke
i) Microswitch of boom end stroke
SAFETY MEASURES 1
l) Limit microswitch for mast swing to the right and to the left
m) Automatic verticalization system
n) “0” point (Automatic return to working position)
SAFETY MEASURES 1
1.10 GENERAL SAFETY RULES

With consideration to the type of machine used, the following rules must be applied:
• Read and observe all the danger warnings and safety rules regarding work issued by the
Organisations existing in the countries you are working in.
• The operator must be taught and instructed on the operation of the rig before working
autonomously.
• The operator must be experienced in jobsite work so that he can coordinate his own work
with that of the other personnel.
• It is strictly forbidden to use the machine for other uses than its designed applications (see
the machine general description).
If is forbidden too approach the working area (a radius of 15 metres from the
machine).
During re-fuelling and the use of inflammable substances, smoking is strictly

forbidden.
• During re-fuelling, checks and maintenance as well as in all the periods in which there may
be oil or fuel leakages, any polluting of the ground environment must be avoided.
• Ensure that the windscreens of the cabin have perfect visibility.
• Approach the working area of the machine only for changing the tools; in this case, use only
the directional controls of the kelly bar and rotation of the platform, taking care to ensure the
stability of the machine (danger of overturning).
• Do not pass under the kelly bar or near the drilling hole.
• In the event of temporary stoppage, make sure that the hole is left well covered with sturdy
material.
• Never operate the rig if you are not in the correct seating postion in the cabin.
• If for some reason the machine controls must be abandoned, before doing this ensure that
the hydraulic block is engaged.
1.10.1 Safety rules for loading and the transporting machine

• Do not attempt to lift the complete.machine.
• Choose land that is flat and not prone to landslides.
• The loading and unloading of the machine to and from the articulated lorry without suitable
loading/unloading ramps is forbidden.
• During transport, ensure that the drilling rig is firmly fixed using tie ropes on the crawler,
blocks against translation, and ensure there are no parts or components of the drilling rig
that are moving freely and are untied. The kelly bar must be firmly attached to the machine
and the blocking pin against platform rotation must inserted.
• Ensure that the outline of the dimensions is not greater than the highway code specifications
and adopt all the necessary signs required for road circulation.
SAFETY MEASURES 1
1.10.2 Safety rules during working phases
Avoid movment with the mast in the vertical position on ground that is uneven
or gravelly. There is danger of overturning.
• Take great care of the positions of electrical wires and other possible obstructions when the
mast in placed into the vertical position.
• Before beginning work, thoroughly inspect the terrain and evaluate every eventual risk and
danger.;
• Respect the limits relative to the maximum working distance as specified in chapter 2 of this
manual.;
• Maintain the safety distance from other machines working in the same jobsite;
• Be aware of the presence of soft ground in the vicinity of walls; be aware of soft ground near
walls which have just been raised; the significant weight of the drilling rig could cause the
wall to collapse;
• Avoid crossing or jumping over obstacles e.g. ground irregularities, heaps, tree trunks,
steps, ditches, crags and tracks;
• During reverse gear, always look in the direction you are going;
• Ensure that you are aware of the load limits for ground, floor and access ramps;
• Stop work if anyone approaches the working radius of the rig;
• Do not supply voltage to cables that are twisted so as to avoid any anormal strain that could
lead to the breakage of the twisted part;
• Do not get into or out of the machine when it is moving;
• Always wear protective gloves when handling cables;
• Always wear clothes that wilI not get caught up in levers and moving parts;
• Stop the machine and disengage all the controls before abandoning the working position in
the cabin or before leaving the machine unattended;
• When using the winches, never exceed the maximum limit described in the technicall
characteristics;
• The auxiliary winch must not be used to lift objects that are not aligned with the vertically of
its cable rope;
• Maintain the control position free from any foreign obstacles;
• Do not transport people inside the machine;
• Adhere to the rest of the safety information stated in the CAT manual.
Before unloading the tool, ensure that nobody is in the vicinity.

Danger of falling objects from above !
SAFETY MEASURES 1
1.10.3 Work in proximity of electrical cables
When working near suspended or underground electrical cables there is the

danger of electrocution. Make sure that all the national and local safety norms
have been carefully followed before beginning to work.
Strictly adhere to the minimum recommened safety distances between the rig and the electrical
cables indicated in table 1; in the event of dampness (humidity relative >70%) or rain, double
the safety distances.
Table 1
Voltage cable Safety distance
[Volts] [Metres]
from 0 KV up to 1 KV 1.0 m
Remember that during working phases, the platform must be able to rotate freely without
approaching any kind of electical cable.
1.10.4 Noise emission

The operator’s cabin has been designed in such a way as to maintain the sound pressure under
74 dB(A) (in the test conditions established by the Norm ISO 6394, 86/662/CEE and ISO/DIS
11201).
The external sound emissions at a distance of 4 mt. from the machine and at a height of 1.6mt.
are always lower than 82 dB(A) (with the engine at the maximum rpm and without tools
working).
In case of hard shocks due to the sudden kelly bar spin inversion, the maximum peak noise is
112 dB. (A proper use of the machine can avoid those shocks!).
In case of the user have to weigh up case by case the use of suitable protection
for the personnel
1.10.5 Vibration
The level of vibration for the operator who is situated in the cabin in test conditions established
by the norm ISO 2631-1 and ISO5349, are:
1. Body, thighs, arms and head subject to an average level of vibration lower than 0.5
2
m/s .
2
2. Feet and legs subject to an average level of vibration lower than 2.5 m/s .
The vibrations felt by the operator during work phases may vary considerably considerably
according to the type of terrain that is being drilled and therefore, as stated by EN791, the use
must weigh up case by case the use of suitable protection for personnel.
SAFETY MEASURES 1
1.10.6 Seat
The machine is equipped with a anti-vibration seat with rubber damping in conformity to ISO
7096; it is essential to regulate the damping according to the operator’s weight by turning the
knob that is positioned at the front part of the seat, until it corresponds to the right weight. (see
page 36 of the CATmanual)
1.10.7 Ground pressure

2
The rig in static conditions has a ground pressure lower than 1 Kg/cm , and this can reach a
2
value of 1.3 Kg/cm during working phases (a value calculated in conformity to EN 791).
1.10.8 Wind force

The rig can be used as long as the wind speed measured on the ground does not 20m/s. Once
this limit has been reached the work must be interrupted immediately.
The machine should not be parked on the yard with an upright mast if the wind speed exceeds
28 m/s (danger of overturning).
1.10.9 Fire extinguishers
The machine is equipped with a powder fire extinguisher situated in the

bonnet behind the control cabin; it must be checked by expert personnel at
least every six
A prompt intervention is essential for extinguishing the beginnings of a fire. For this reason, the
personnell must be instructed on the correct procedure to be followed in order to stop the fire
from spreading.
The safety Supervisor of the jobsite must instruct the personnell so that their actions can be
coordinated and ensure that the fire is put out as quickly as possibly. With this in mind, it is
better for the operator handling the extinguisher to be backed by all the personnel available.
Remember that extremely desperate situations or in absence of fire extinguishers, workers can
throw earth onto the fire (for systematic organisation look at current legislation).
GENERAL INFORMATION 2
2. GENERAL INFORMATION
2.1 AIM OF GENERAL INFORMATION

This manual describes the use and maintenance of the IMT drilling apparatus mounted on the
excavator base CAT320B and aims to give the operator a user’s guide for the proper and safe
use of the drilling rig and a comprehensive and logical maintenance.
Carefully read every section of the present manual before carrying out operation of the rig in
order to avoid making mistakes in manoeuvres that could endanger your personal safety and
damage the machine.
The correct procedures for carrying out manoeuvres are described in the manual, as well as
operating and utilizing the machine.
The manufacturer declines responsibility or liability for damage caused

to the machine due to its improper use.
The manufacturer reserves the right to take legal action for any modification
carried out to the machine of its production, without prior written authorization.
2.2 IDENTIFICATION DATA OF MACHINE MANUFACTURER

The drilling rigs of the AF SERIES an derived models are manufactured exclusively by:
I.M.T. S.p.a.
Via d’Ancona 39, 60027 Osimo (AN) Italy
Rag. Soc. 6346, C.C.I.A.A. 69429, C.E. 031153, C.F. e P.IVA 00194370425
Tel. +39-(0)71-723341 r.a., Telex 561349 IMT I, Telefax +39-(0)71-7133352
2.3 CONDITIONS TO MAINTAIN WARRANTY VALIDITY

The warranty issued for the drilling rig is subject may be invalid in the event of non-observance
of the Use and Maintenance instructions illustrated in this manual. It must be noted that the
warranty does not cover the parts that are subject to wear and tear, filters, oil and other
materials of consumption. IMT S.p.a. makes available its Technicalll After Sales Service at for
all customers while Caterpillar handles all technical assistance and warranty for the machine
base.
2.4 INFORMATION REGARDING CUSTOMER - IMT S.P.A. RELATIONS
2.4.1 General information on technical assistance and spare parts

IMT S.p.a. puts its own Technical After Sales Service and Spare Parts Service at the
customers’ disposal.
These services allow the customer to promptly solve any eventual breakdown of the machine
assuring against loss time and productivity.
2.4.2 Procedure for requesting Technical Assistance
In order to ensure the maximum promptness and efficiency of execution of technial assistance,
the best procedure is to immediately call IMT S.p.a. or send a fax to the Technical After Sales
Service describing the following:
1. the nature of the breakdown in detail, so that the technical personnell can get ready the
required spare parts or tools for the intervention;
2. the exact place where the machine is situated;
3. the personnel eventually available at the jobsite who can cooperate with the technical
operators in the maintenance and repair operation.
Generally the technical assistance is available in very short period of time.
Always follow the instructions that will be provided so that any further damage will be avoided
and the intervention time will be reduced to a minimum.
2.4.3 Procedure for spare parts request

Send via fax a copy of the following form duly filled in:
Spare parts purchase order
Order details:
Sent by:
For the attention of: IMT spa, Italy
Company name:
HYDRAULIC DRILLING RIG AF120

YEAR OR MANUFACTURE:
SERIAL NO.:
Qty Code Description
note:
note:
Type of delivery: Urgent / Not urgent Note:
2.4.4 Procedure for giving technical advice
Sometimes it may be possible to make improvements to a machine following advice from those
who use these kinds of machines every day.
In the event of your having an idea about an improvement, please send a fax or make a call to
IMT ; we will be glad to listen to your recommendations.
2.5 GENERAL DESCRIPTION

The drilling rig AF120 is expressly used for the realisation of water wells and bored piles of
medium/large diameter (500 - 2000 mm).
The rotary has a hydraulic function and is composed of a transmission unit with power-shift
gear to guarantee a high torque level during drilling and high rotations speed during unloading.
The rotary unit is pre-set for operations which require working with manoeuvring pipes (lining
pipes).
The rotary runs vertically along the mast guide by means of a slider activated by a hydraulic
cyilinder for pull-down. The sliding guides are built of self-lubricating material in order to reduce
wear and tear and have setting screws for regulating the play between the slider and mast.
The rig can be equipped wit a telescopic kelly bar that is self-locking (internationally and
nationally patented by IMT) realized with a series of telescopic elements equipped with teeth or
keys that have the role of joining and locking together the various elements.
This system allows all the pulldown force and torque power generated to be transmitted to the
tool.
This type of kelly bar also allows an extraction force that is the sum of the winch pull and pull
back.
The stability of the AF120 is guaranteed by an undercarriage that is suitably dimensioned and
by and auxiliary ballast applied to the machine.
The tool connected to the square joint of the last rod (the smallest one) is pulled up by the main
winch by means of the special cable.
The winch cable is easily guided by the grooved drum and cable clip, and is perfectly visible to
the operator in the operator’s cab: this allows immediate checking of cable correct winding on to
the drum.
A parallelogram articulation, consisting of a triangular element, boom and brace, allows hole
axis displacement with respect to the machine axis. This displacement is controlled by the
boom cylinders without affecting the mast uprightness.
The capacity of the mast to slant both forwards and laterrally allows the operator to also work in
terrain that is slightly sloped and by means of the articulation, it’s possible to carry out drilling at
variable distances from the machine without having to move the whole undercarriage into a
different position.
At the minimum distance of the machine axis from the drilling axis, all the potentiality of the
machine can be exploited (max. extraction force, max pulldown on the tool) while at the max.
distance the max. extraction force must only be used with the mast foot rested on the ground
The drilling distance must always be reduced in terrains that do not guarantee ground solidarity
to the stability of the machine, and must be evaluated case by case (see max. ground
pressure).
2.5.1 Description of hydraulic installation

All the movements of the drilling rig are activated by hydraulic activators.
The suitable oil delivery is supplied by 3 pumps of the basic machine that feeds the control
distributors:
2 main pumps for the power use;
1 auxiliary pump for the accessory operation.
The main pumps supply the following devices:

• Rotary (Clockwise, anti-Clockwise, spin off)
• Main Winch (Up - down)
• Auxiliary Winch (Up - down)
• Casing
• Left- Right Tracks (forward, backward)
Be aware that In working position the following manoeuvres as well are activated:
• Left track (Extension/retraction);
• Left track (Extension/retraction);
• Platform Rotation (Clockwise, anti-Clockwise)
• Pull-down (cylinder)
• Mast (sideways movement)
• Articulation (Up-Down)
• Mast (Forward-backward)
• Mast closing
The distributors are controlled hydraulically by hand levers.
2.5.2 Description of electrical installation

The electrical installation includes the ignition connectors of the diesel engine, activation of the
electrovalves and general elements like pilot lights and control panels.
In the electrical installation, other important functions have evolved concerning safety i.e:
• Leveling (by means of electronic system with verticalità sensor);
• Main winch end of run with sensor activated by rod guide;
• Secondary winch end of run with sensor on the derrich;
• Mast right-hand and left-hand limit switch.
The electrical system is powered by two batteries 12 V 110 Ah with a series connection. The
final voltage is 24 V c.c.
TECHNICAL CHARACTERISTICS 3
3. TECHNICAL CHARACTERISTICS
3.1 DATA REGARDING THE BASIC MACHINE
MACCHINE BASED ON CATERPILLAR 320B

HYDRAULIC SYSTEM open circuit quantity 3
DIESEL ENGINE Model Type Cat
Power KW 110
Speed rpm 2000
UNDERCARRIAGE Max traction force KN 220
Speed Km/h 1.76
BASE MACHINE Weight tons 42
3.2 DATA OF DRILLING RIG
Figure 1
A Mast head I Main winch
B Mast extension L Lower mast attachment
C Kelly bar M Slewing upperstructure
D Pull-Down cylinder N Mast cylinders
E Mast O Triangle
F Rotary P Brace
G Tool Q Articulation cylinder
H Auxiliary winch R Articulation: 1st Boom
Figure 2 Figure 3
Figure 4
Figure 5
Figure 6 Figure 7
IMT AF120 on CAT320 base
HYDRAULIC ROTARY Max Torque KNm 137

Drilling speed Rpm. 7-24
Spin off speed Rpm. 140
Drilling width mm 2.000
PULL-DOWN Pull-down KN 180

Pull-back KN 200
Stroke mm 4500
Pulldown speed mm/s 110
Pullback speed mm/s 225
MAIN WINCH Pullback KN 150

Rope speed m/min 80
Rope Diam. mm 22
Rope length m 65
AUXILIARY WINCH Pullback KN 82
Rope speed m/min 80
Rope Diam. Mm 18
Rope length m 65
MASS
Rotary Kg 4.500
Casing oscillator (*) Type MG dia. 1300 Kg 8.000
Maximum drilling depth m 47
Counterweight Kg 8.300
Escavator base Kg 38.000
Machine in order of work with auger Ø1800 mm (*) Kg 66.000
DIMENSION
Track Length mm 5.470
Length on the ground mm 4.600
Min. Width mm 2.500
Max. Width mm 3.600
Height mm 1.095
Track shoes mm 600
Minimum ground height mm 380
Machine (with erected mast) Minimum Length mm 7.600
Maximum Length mm 8.375
Width mm 4.500
Max Height mm 16.400
Minimum drilling radius mm 2.730
Maximum drilling radius mm 3.500
(*) Note: accessories not included.
3.2.1 Maximum working slope

The maximum ground slope allowed for the drilling rig is 5° when the machine is working with
the articulation completely raised (minimum range), otherwise working with maximum range
(articulation lowered) the machine must work on flat ground.
3.2.2 Maximum slope for movement

The maximun slope allowed for the movement of a machine is 10° and is to be carried out with
the mast reclined backwards by 10-15° and the kelly bar and tool near to the ground (20-30
cm).
Figure 8
Figure 9
3.3 TECHNICAL DATA OF THE CASING OSCILLATOR
CASING OSCILLATOR TYPE IMT MG 1300

ROTATION Max Torque KNm 1.540
Oscillation Angle ° 26
Max Diameter mm 1.300
Mix Diameter mm 800
EXTRACTION Lifting force KN 1.600
Clamping force KN 1.110
Lifting stroke mm 500
WEIGHT Casing oscillator without tilting device Kg 8.000
(casing oscillator attachement)
Figure 10
TRANSPORT 4
4. TRANSPORT
4.1 MACHINE CONFIGURATION FOR ROAD TRANSPORT
Road travelling must be in compliance with statutory traffic control regulations; a special trailer
or another transportation vehicle with carrying capacity suitable for the drilling rig’s weight
should be used.
Figure 11
4.2 MACHINE LOADING AND UNLOADING

Loading and unloading must be carried out in compliance with the following instructions (see
Figure 10 ):
• Select a flat area, making sure that the ground is not too soft;
• At least two workers are required (one to clearly signal the required manoeuvres);
• Make sure that there are no unauthorised persons in the area;
• Use ramps having suitable slopes and load-carrying capacities;
• Make sure that the load does not exceed the loading.gauge and use the special warning
signs prescribed by traffic control regulations;
For short-range travelling within the work area, follow these instructions:
• Avoid manoeuvring with vertical mast;
• Bend the mast backwards by approximately 10-15°.
TRANSPORT 4
4.3 PREPARATION FOR TRANSPORT

1. Derrick open;
2. Rotary positioned about ½ meter from end of run (depending on the Kelly bar mountend);
3. Kelly bar slightly inserted in the rotary (square joint side) and restin on the stand (kelly bar
guide side);
NOTE
The Kelly bar must be blocked with chain (between kelly bar guide and counterweight).
4. Closed crawler tracks;
The racks of the kelly bars must be positioned like the foto.
Figure 12
Figure 13
TRANSPORT 4
4.4 TRANSPORT ON SEMI-TRAILER

The following is the recommended machine configuration for transport on semi-trailer:
• mast unit all the way down and folded parallelogram articulation;
• folded mast attachment;
• tracks closed to their smallest overall dimensions;
• slewing upperstructure locked with an inserted locking pin;
• mast head folded to its smallest overall dimensions and locked with the special tie rod;
• doors and guards locked;
• machine fixed to the semi-trailer with steel ropes and tracks wedged to prevent shifting;
do not use too steep loading ramps!
Figure 14
OPERATION INSTRUCTIONS 5
5. OPERATION INSTRUCTIONS
5.1 AIM OF OPERATION INSTRUCTIONS

In this section, the controls and operative procedures are illustrated for the correct and proper
use of the AF120 drilling rig.
5.2 DRILLING
• Follow the safety instructions described in chapter 1.
• Choose the tool suitable for the type of terrain to be drilled.
• In order to attach the tool, raise the kelly bar to its vertical position over the tool, insert the
square joint in the appropriate seating and block it with the pin and split pin (see chapter on
assembly).
• Position the tool onto the ground at the point where you wish to begin drilling the hole and
check mast verticality with the appropriate electrical levelling device.
• Lift the rotary to an appropriate height.
• Begin to drill by rotating the kelly bar in a clockwise direction; during the first few metres the
weight of all the elements will guarantee enough force to push the tool forward and down
while an excessive pulldown could deviate the hole verticality.
• When the first element of the kelly bar is completely out, the pulldown of the pulldown
cylinder can be used to obtain a better penetration.
• When the tool is full, before carrying out the raising of the tool, always unlock the kelly bar
elements by rotating the rotary in an anti-clockwise direction which is opposite to the drilling
direction.
• Raise the kelly bar elements activating the main ; if this is not enough, then the pull-back
cylinder should also be used.
• Lift the tool until it is at a useful height and avoid any obstacles; turn the platform up to the
unloading point.
• If the tool is a bucket, it must be positioned in such a way as that the moving bottom does
not hit the mast.
• Lift the kelly bar until the opening lever of the tool is opened by pulling it against the lower
rotary flange.
• Once the unloading has occurred, close the tool by gently resting it on the ground and rotate
simoultaneously the platform in the direction that leads to the closing of the tool. Chek that
the kelly bar elements are unlocked and go back to the working postion.
• If the tool is an auger, in order to unload it, it must be rotated in an anti-clockwise direction,
increasing the rotary speed and if necessary prepare the fast rotary gear change with the
proper button during the raising phase.
• Once the auger has had its rubble unloaded, rest it on the ground and rotate the kelly bar
battery in an anti-clocwise direction in order to be certain that all the kelly bar elements are
unlocked and then return to the working position
The unloading of the tool must be carried out only with the rotation of
the rotary, the use of the main winch for the unloading of the tool may
compromise the perfect functioning of the motor-reducer and the cable rope.
DO NOT ATTEMPT
TO LIFT LOADS
STANDING OUT OF
THE ROPE
VERTICALITY
Figure 15
5.3 MOVING IN WORKING PHASES

• In order to avoid the presence of depressions influencing the machine stability, and leading
to the possibility of overturning, it is best to partially recline the mast while moving about
within the jobsite.
• Remember that the stability of the machine improves if the mast is lowered.
5.3.1 Moving about on soft or damp terrain

Table 2 indicates the maximum ground pressure values in various configurations and the
relative llift values on the ground. Before moving the machine, check that the terrain is not
excessively soft, otherwise the machine could sink into the ground or overturn.
Table 2
Maximum Minimum
Machine configuration
Ground pressure Ground capacity
[Kpa] [KPa]
Mast horizontal 91.5 100
Pull sideways 186 200
Maximum during work with platform 392 400
rotated at 30°
5.4 WARNING! AVOID THE FOLLOWING MANOEUVRES

• Do not move about with the mast in vertical position and the platform rotating when covering
ground that is not perfectly flat and solid (stability).
• Do not give to much slack with the main winch and check the regular winding up of the rope.
• Do not drill with the pin and split pin which serve to block the tool in risky situations.
• Do not work with damaged cable ropes.
• Do not carry out any intervention or maintenance on the hydraulic installation with the engine
running or without having already released the pressure from the oil tank, following the
procedure indicated in the CAT manual.
• Do not work with a insufficent and low oil level.

• Do not carry out topping up with oil that is not in conformity with the recommended oils (see
the recommended oils table).
• Do not carry out soldering on the machine or connected equipment without first having
disconnected the electrical installation.
• Do not tamper without authorisation the hydraulic valves or any component of the hydraulic
installation, as this may invalidate warranty claims.
• Do not work at maximum speed (1975 rpm) for the first 15 days of operation.
• Do not carry out brusque manoeuvres or kickbacks that could damage the rig or
compromise its stability.
• Do not work with the crawler tracks overtight or too loose.
• Do not immediately activate or release the button for the rotary gear change.
• Do not leave rubble in the way of the tool while unloading.
• Do not exceed the maximum drilling distance or be at the hole’s mouth in the event of slightly
sloped terrain.
• Do not work on very sloped terrain (maximum slope 5%).
5.5 CONTROL SYSTEMS AND CABIN CHARACTERISTICS

For this section, please see page 24-37 of the “Operation and Maintenance Manual” of the
crawler tracked excavator CAT320B .
CONTROLS 6
6.DRILLING EQUIPMENT CONTROLS
6.1 GENERAL MACHINE CONTROLS

1 Left-hand console (see caterpillar manual)
2 Hydraulic system enabling lever (see caterpillar manual)
3 Left-hand propel pedal (see caterpillar manual)
4 Right-hand propel pedal (see caterpillar manual)
5 Equipment control left-hand lever (see page 35)
6 Left-hand propel lever (see caterpillar manual)
7 Right-hand propel lever (see caterpillar manual)
8 Hour-meter (see caterpillar manual)
9 Electronic monitoring panel (see caterpillar manual)
10 Equipment control right-hand lever (see page 35)
11 Right-hand console (see caterpillar manual)
12 Electronic control system back-up switches
(see caterpillar manual)
13 Operator’s seat (see caterpillar manual)
14 Front dashboard (see page 36)
15 Lateral controls (see page 41)
16 Pedal for rod lifting (see page 44)
Figure 16
8 10 11
9
7
6
5
15
14
12
4
3
13
16
1
CONTROLS 6
6.2 EQUIPMENT CONTROL LEFT-HAND LEVER.

1 Main winch rope lowering.
2 Main winch rope lifting.
3 Upperstructure clockwise slew.
4 Upperstructure counter-clockwise slew.
5 Mast foot lowering push-button (*).
6 Mast foot lifting push-button (*).
7 Upperstructure automatic return push-button: press shortly to
control the upperstructure automatic return to the drilling position
(the indicator light A starts
flashing).
5
To store the upperstructure stop 6
point, the tool should be
positioned at the required point 1
4
and the push-button should be
held down for a few seconds,
until the indicator A light 7
becomes fixed.
2 3
(*) The foot mast is not found

on all machines.
Figure 17
6.3 EQUIPMENT CONTROL

RIGHT-HAND LEVER.
1 Rotary lowering
2 Rotary lifting
3 Rotary counter-clockwise rotation (drilling)
4 Rotary counter-clockwise rotation (tool discharging)
5 Fast speed change push-button: when pressed, it increases the rotary speed and enables
to instantly shift gears up by three ratios.
CAUTION
Only use this device during the earth discharge phase and not during drilling
6 Rotary sequential gear change push-button: when pressed, it shifts gears up by one
ratio (from 1st to 6th)
The selected gear ratio 7
is displayed. 6
7 Rotary sequential gear
change push-button: when 1 3
pressed, it shifts gears down
th st
by one ratio (from 6 to 1 )
The selected gear ratio is 5
displayed.
4 2
Figure 18
CONTROLS 6
6.4 FRONT DASHBOARD

For a clearer arrangement of controls, the front dashboard is divided as follows:
1 Front dashboard left side (see page 37)
2 Computer (see page 40)
3 Front dashboard right side (see page 38)
3
2
Figure 19
1
1
CONTROLS 6
6.5 FRONT DASHBOARD LEFT SIDE

1 IMT oil filter warning light (red): it lights up to indicate that the filter needs servicing.
2 Maximum rotary distance during work indicator light (red): it lights up to indicate that the
rotary has reached the maximum safety distance from the swivel ring axis.
3 Horn switch: it actuates the horn when pressed
4 Led indicating the good functioning of the pump motor for lubricating the rotary gear boxes
(see figure 20). The red light indicates the pump malfunctioning.
NOTE:At the moment of starting the led remains on for a few seconds.
5 Mast forward stroke limit-switch override control: when pressed, it enables to move the mast
forwards, even if the limit-switch has tripped, exceeding the rotary maximum safety distance
with respect to the swivel ring axis.
6 Auxiliary winch limit-switch override control: when pressed, it enables to operate the winch
even if the limit switch has tripped. This control is especially useful during cable replacement.
7 Main winch limit-switch override control: when pressed, it enables to operate the winch
even if the limit switch has tripped. This control is especially useful during cable
replacement or to take down the rod pack.
8 Derrik opening and closing.
* derrik opening
* derrik closing
9 Track gauge adjustment switch: when pressed, it enables to increase or decrease the track
gauge.
NOTE
Before operating these controls, make sure that the locking devices have been removed.
* track gauge increase (wider)

* track gauge decrease (narrower)
10 Available
11 Metre counter reset push-button: if pressed and held down for three seconds, with the tool
resting on the ground, this control will reset the working depth metre counter.
12 Tilting cylinder control joystick (see page 39)
14 Hole bottom slop ovveside.
15 Automatic operation mode indicator light
(red light): when this indicator is lit and
flashing, the automatic operation mode
(verticalization or upperstructure 12
11 15
automatic return) is in progress.
4
15
1
2
14
3
4
10
5 9
6 8
7
Figure 20 Figure 21
CONTROLS 6
6.6 FRONT DASHBOARD RIGHT-HAND SIDE

1 Manometer: it indicates the IMT distributor working pressure
2 Manometer: it indicates the working pressure of the two caterpillar pumps.
NOTE
If the pump coupling has been disconnected by the special switch, the manometer will read
the main winch working pressure.
3 Manometer: it reads the working pressure of the two caterpillar pumps.
NOTE
If the pump coupling has been disconnected by the special switch, the manometer will read
the rotary working pressure
4 Boom control lever: it can be operated to control boom movements
Position A – it controls the mast forward or downward movement, according to its working
position
Position B - it controls the mast backward or upward movement, according to its working
position
5 Auxiliary winch control lever: it can be operated to control the auxiliary winch
Position A – auxiliary winch rope lowering
Position B – auxiliary winch rope lifting
WARNING - DANGER
Never use the auxiliary winch to pull in other directions than the vertical direction nor to pull
objects located far from the machine, to prevent overturning risks.
6 Pedal for rod loading (see page 44)
4
1 5
1 4
5
3
3
Figure 22 6
2
2
6
7
CONTROLS 6
6.7 TILTING CYLINDER CONTROL JOYSTICK
This joystick controls the mast tilting cylinders to enable mast opening and closing, as well as
verticalization adjustment in the pre-drilling phase.
1 mast opening and front shifting
2 mast closing and rear shifting
3 mast right-hand sideways shifting
4 mast left-hand sideways shifting
5 mast automatic verticalization device actuation (the indicator A flashing light will go on)
NOTE
This function will only be actuated when the mast tilt angle with respect to the vertical line
is 9.9°.
By pressing the joystick once again during automatic operation, the mast will stop in its
current position.
A
5
1 3
2
4
A
Figure 23
CONTROLS 6
6.8 COMPUTER
The computer display enables the operator to obtain all the real-time information listed below,
useful for machine operation.
1 Mast tilt indicator (connected to the electronic level): it shows the mast front and lateral tilt up
to a maximum angle of 9.9°, through the indicators 1a and 1b.
1a front tilt visual indicator
1b lateral tilt visual indicator
2 Mast lateral tilt digital indicator: the displayed value is referred to the vertical line up to a
maximum angle of 9.9°
3 Mast front tilt digital indicator: the displayed value is referred to the vertical line up to a
maximum angle of 9.9°
4 Rotary swing speed indicator
5 Rotary swing torque indicator
6 Drilling depth indicator
7 Rotary change gear ratio indicator
8 Base machine angle
9 Winch speed
10 Display brightness adjustment keys: press to adjust
11 Display contrast adjustment keys: press to adjust
1 4 5 9
3
6
2
10 11
Figure 24
CONTROLS 6
6.9 LEFT-HAND LATERAL CONTROLS

1 Accelerator reduction push-button (AEC): when pressed, it stores the current engine RPM
and brings it down to idling; when pressed again, it brings the RPM up once again to the
stored value.
2 Mast working headlights switch: when pressed, it switches the working headlights on or off.
3 Upperstructure swing brake release switch: this switch is located on the caterpillar; it
enables a useful function for excavators, which is however not suitable for drilling rigs.
NOTE
Make sure that this switch is always turned to "0".
1
2
Figure 25
3
CONTROLS 6
6.10 DIRECTIONS FOR USE

CAUTION: before starting to work with the machine, the operator should read and fully
understand this manual, and carry out a few trial manoeuvres, to become familiar with
the arrangement and functions of the machine controls.
Before starting to work, the machine should be prepared as explained below:
• start the engine (see section 7.1)
• increase the track gauge
• bring up the mast to its vertical position
• fit the rod pack and tool (see section 7.4)
• travel to the drilling area and position the machine.
NOTE
If a rather long trip on bumpy ground is required to reach the drilling area, we recommend to
lower the mast to improve machine stability
• level the mast using the special control
• lower the mast foot
• lower the tool to rest on the ground and store its position for automatic return with the
special control.
• select the required rotary gear ratio.
CAUTION
Make sure that the rod and tool are suitable for the torque applied to the rotary
• control the rotary swing and start drilling as indicated in section 5.2
CAUTION
Never control any articulated joint movement or mast levelling when the rod has been lowered
in the hole.
• when the tool is full, pull it back with the main winch and discharge it
• control the automatic return operation, rest the mast on the ground and lower the tool by the
main winch.
The winch is equipped with a “hole bottom stop” device, which stops the winch going further
down when the tool reaches the hole bottom.
NOTE
If the mast foot must be rested on the ground several times at the same point, we recommend
placing metal sheets on the ground for the mast foot to rest on.
CONTROLS 6
6.11 CRAWLER TRACK TRAVEL
- take out the safety pins
- position the upperstructure longitudinally, then adjust the “track gauge increase” control.
- after increasing the track gauge, insert the safety pins
NOTE
Should it be hard to insert the pin, try slightly moving the track back and forth.
Figure 26
6.12 ROD LIFTING GROUP

-activate the pedal to lift rod
Figure 27
USE 7
7. INSTRUCTIONS FOR USE
7.1 STARTING UP THE MACHINE

• Remove the blocking pin situated in the control cabin that locks the revolving platform.
• Check that the blocking lever on the left of the operator’s seat for the hydraulic controls is
engaged (in the raised position).
Keep the engine running for at least 5 minutes before beginning work in order
to allow all the systems to reach the working temperature.
7.2 PROCEDURE FOR POSITIONING MAST

In order to lift the tool follow these instructions given here below:
• First activate the positioning piston in order to lift the mast.
• Act simoultaneously on the articulation pistons and the positioner in order to lift the tool.
• With the tool completely raised, activate the tilting pistons for mast verticality.
7.3 POSITIONIG OF THE RIG DURING WORK PHASES

Before beginning the work phases, carry out the following operations.
• Remove the pin that locks the kelly bar battery.
• Lift the mast to the vertical position and slide the kelly bar elements through the inside of the
rotary so that the kelly bar guide is positioned on the trestle guides at the height of the
mobile shoes.
• Re-lower the mast and fix the clamps of the kelly bar guide with pins.
• Remove the mobile shoes.
• Lift the mast and ensure that the kelly bar guide has been well attached.
NON WORKING 8
8. MACHINE IN NON-WORKING PERIODS
8.1 TEMPORARY STOPPAGES

• Never leave loads hanging;
• Rest the tool on the ground;
• Shut down controls by engaging the block of hydraulic functions incorporated in the left seat
arm rest of the control seat;
• Lock the control cabin and the bonnets to stop outsiders gaining access to the machine;
• Leave the machine in places that are off-limits to outsiders and on stable terrain. Check
regularly the ground consistency after heavy rainfall;
• Take advantage and make good use of temporary stoppages to carry out all the routine
checks of the rig and eventually any extra interventions.
8.2 DISPOSAL
Since the rig disposal will happen a very long time after the first use of the rig, it’s possible that
during this time the legislation that governs these operations will have changed.
If is therefore necessary to find out this information and follow the latest procedures stated
regarding the salvaging and disposal of the various parts.
All the materials must be salvaged and disposed of in conformity with the current laws ruling at
the moment of disposing the rig.
The operations of disposal of the rig must be carried out only by authorised
experts in this activity and who are aware of the current rules and regulations
of such an operation.
In general, in order to dispose of a rig, the following must be carried out:

• Take the rig to a suitable place in order to disassemble the parts and be well equipped with
containers to collecto oil or fluids present within the machine;
• Empty the fuel tank and collect the contents without spilling anything and polluting the
environment;
• Empty the oil tank and collect the contains with spilling anything and polluting the
environment;
• Drain the oil and grease from the reducers;
• Proceed to disassemble the machine using the appropriate lifting devices;
• Separate the metal parts that can be recycled (e.g. undercarriage and drilling tools) and
glass (e.g. cabin glass) from the plastic parts or plastic/metal parts (e.g. seals, flexible tubes,
etc.).
IMT is at your service to provide detailed instructions regarding the operations to be carried out
for disassembly of various machine parts and advice on the best techniques to be adopted
according to the means at your disposal.
MAINTENANCE 9
9. MAINTENANCE
The proper working and high performance in time depend on heeding to the information
contained in this chapter, as well as the main essentials required to maintain the safety
and efficiency of the machine.
A careful and regular maintenance keeps the value of your investment
Neglecting the maintenance standards may eventually lead to hazards as

the rig could end up in conditions different from what it has been
designed for.
9.1 GENERAL RULES

The information contained in this section are addressed to the person in charge of the machine
and to all those people who will be employed in the works of repairs and maintenance, as well
as the operator.
• Do not allow non-authorised people to repair or carry out interventions on the rig;
• Do not lubricate, repair, or set the machine with the diesel engine running unless absolutely
required due to the nature of the intervention;
• Bring the rig to a standstill and rest the mast base on the ground, or if required by the nature
of the intervention, completely lower the mast.
• Avoid environmental pollution. Fluids, oils, and filtered elements (classed as harmful
waste) must be disposed of according to the procedures dictated by Law (in Italy the
collection of used oils is free at various collection centres located in the national
territory).
• Respect the procedures and information given regarding maintenance;
• Do not use the controls or flexible tubes as grips as these components are mobile and do
not give firm holds;
• Do not carry out any maintenance on the rig with a person occupying the control cabin seat,
unless they are specifically required to cooperate in the maintenance job;
• When maintenance has to be carried out inside open bonnets, remove the keys from the
panel;
• Before starting up the rig or activating the tools, signal the move with an acustic sound
device. Lift and move the equipment slowly.
• The components must be handled with care avoiding catching hands or fingers in the cracks
or moving parts;
• Never align holes or slots using your hands; always use the appropriate tools;
• Eliminate every trace of sharp edges and clippings from the replaced parts;
• When the maintenance operation requires access to drilling rig parts that are not able to be
reached from the ground, use the appropriate equipment in conformity with safety
regulations against personal injury;.
• When maintenance operations have to be carried out that are not indicated in this manual do
not hesitate to contact the IMT Technical After Sales Service which will immediately give you
helpful advice on the best methods to follow;
• Disconnect the batteries before any kind of intervention, or before carrying out electrical
soldering on the machine structure;
• Do not check or fill up the fuel and hydraulic oil tanks or batteries, etc. while smoking or in
the vicinity of a naked flamme;
MAINTENANCE 9
• Avoid the accumulation of dirt on the air grills and do not allow the accumulation of foreign
bodies (leaves, paper, bags, etc.) on the machine (risk of fire);
• In case of need, use only auxiliary supply sources of electrical current that is earthed;
• If you have to lift or transport heavy parts, use hoists or similar devices of suitable capacity.
• Check that the harness is suitable for the load to be lifted and fitted correctly;
• During lifting, take care that of workers in the vicinity;
• When using compressed air for cleaning, use protective eye goggles with lateral guards
Keep the pressure under 2 Bar (100 KPa);
• Do not carry out any modification unless authorized in writing by IMT to the tools or
components of the drilling rig;
• In the event of repairs outside the warehouse, position the drilling rig on flat ground and
block its movments. If the repairs have to be carried out on a slope, block all movements of
the machine and its tools. Move it to flat ground as soon as possible;
• The place where the maintenance and repairs are carried out must be kept clean and dry.
Do not accumulate dirty or greasy oil rags in the vicinity as they constitute a fire risk. Throw
them into a closed metal container;
• Before beginning maintenance, bring the tool to rest on the ground and leave it securely
positioned;
• The machine is activated by a high pressure hydraulic installation; oil leakages that come
into contact with skin could penetrate skin layers and cause serious lesions (in the event of
an accident, immediately request the aid of a doctor);
• Liquids are present on the machine (hydraulic fluid and cooling water) and main components
(engine, exhaust, hydraulic pump, etc.) that can reach high temperature levels during
operation; take great care while carrying out maintenance operations avoiding any direct
contact (risk of burning);
• Take care of moving parts on the machine;
• Before checking the hydraulic installation release the pressure in the system and tank that
are normally under pressure.
(Rotary Oil level) (Reduction gear oil)
Figure 28 Figure 29
MAINTENANCE 9
9.2 MAINTENANCE PROGRAM

For basic machine maintenance, follow the instructions given in the “Operation and Maintence
Manual” of the crawler excavator CAT320B (SEBU 7021-01 Feb. 98).
(Livello olio riduttori Rotary) (Snodo girevole)
Figure 31
Figure 30
MAINTENANCE 9
9.3 GREASING POINTS
Figure 32
MAINTENANCE 9
9.5 LUBRICATION
POS. LUBRICATION SPECIFICATION FIRST SUPPLY CHECKIN REPL.

S G
1 Hydraulic system See manual Cat SAE 10/20W AGIP
2 Upper Rotary bearing API GL-5 (MIL-L-21058) SAE 90 AGIP ROTRAMP 50 2000
3 Rotary gears API GL-5 (MIL-L-21058) SAE 90 AGIP ROTRAMP 50 2000
4 Rotary gear box API GL-5 (MIL-L-21058) SAE 90 AGIP ROTRAMP 250 2000
5 Winch gear box API GL-5 (MIL-L-21058) SAE 90 AGIP ROTRAMP 500 2000
6 Upper Rotary bearing DIN 5150 KPF 24-30 WHITESTAR “NILS” 50
7 Kelly bar guide bearing DIN 5150 KPF 24-30 WHITESTAR “NILS” 50
8 Swivel joint DIN 5150 KPF 24-30 WHITESTAR “NILS” 50
9 Pins DIN 5150 KPF 24-30 WHITESTAR “NILS” 50
10 Mast guide FETT AGIP GR SM 50
11 Main winch rope 26x90 DX σ≥220 DRL 508 AR 10
12 Auxiliary winch rope 18x85 σ≥140 DRL 508 10
13 Gear washing filter ≥ 10 50
MAINTENANCE 9
9.6 CABLE ROPE MAINTENANCEI

The cable rope maintenance must be carried out with variable frequency according to the type of
drilling the machine is carrying out, e.g. auger drilling, bucket drilling, continuous flight auger, etc.
Indeed every working technique accompanies particular use of the cable rope that otherwise
may lead to damage or fast wear and tear.
In the event of drilling with an auger: when operating the fast unloading of rubble, the piece of
cable rope between the swivel joint of the kelly and the pulley is subject twisting; in order to
avoid premature wear and tear, grease daily the 5 mt. piece of cable rope that leads out from
the kelly attachment and often check the good working of the swivel joint.
In the event of drilling with a bucket: when the opening of the bucket is carried out without due
care and the an excessive pull is used to open the bucket, the strain is concentrated on a
precise piece of the cable rope and therefore it is recommended that the 10 mt. of rope coming
out of the kelly attachment are greased daily.
The lifespan of a cable rope can be shortened by improper or lack of maintenance, especially
when working in corrosive environments.
During the checking and replacement of cable ropes always wear protective
gloves
9.6.1 MOUNTING THE CABLE ROPES

When the cable rope is unwound from a roller and wound onto the winch drum, great care must
be taken to avoid missing a turn, because this could lead to twisting, knotting and bending.
WRONG CORRECT
MAINTENANCE 9
9.6.2 CABLE ROPE DAMAGE

Damage to the cable rope may happen in two ways:
• breaking of wires;
• deformations.
Both of these cases must be evaluated and checked according to the following instructions in
order to establish whether the cable rope is still in safe conditions or whether it must be
replaced.
9.6.2.1 Criteria for substituting cable rope

The operational safety of a cable rope is guaranteed by the proper evaluation of the following:
• Nature and number of wires broken;
• Breakage of metal wires near terminal ends;
• Localized grouping of thread breakage;
• Increased rhythm of wires broken;
• Strand breakage;
• Reduction of cable rope diameter;
• Reduction in elasticity;
• External and internal wear and tear;
• External and internal corrosion;
• Deformation;
• Deterioration due to heat or voltaic arc;
• Increased rhythm of permanent stretching.
Normally cable rope deterioration is due to a combination of more than one
factor. It is essential that the examination of wear and tear is carried out by
experts
Do not hesitate to contact expert personnel in the event of serious doubts!
9.6.2.2 Damage due to wires breaking

In the event of broken wires being visible on the rope surface, chech the entire rope according
to the following procedure:
1. Take a piece of cable rope that is 6 times the diameter of the rope (e.g. cable rope with
diameter 26 mm, 6x26=156 mm.
2. Count the number of broken wires visible on the surface of the rope, taking every time a
piece of rope that is 6 times the diameter;
3. If the number of broken wires is lower than the maximum recommended limit, the rope is
alright;
4. If there is a piece of rope where the number of broken wires is greater than the maximum
limit allowed then proceed to carry out the following test:
• Take a test piece of cable rope 30 times the size of the diameter (e.g. of a cable rope of 26,
30x26=780 mm)
• Count the number of broken wires each time examining a length that is 30 times the
diameter;
• If the number of broken wires is lower than the maximum limit allowed, the rope is alright;
• If there is a piece of the cable rope in which the number of broken threads is greater than
what is recommended, then immediately replace the cable rope.
MAINTENANCE 9
Number of wires Rope type Maximum Broken Maximum Broken

N wires in the cable part wires in the cable part
6d 30 d
da 141 a 160 crociata 6 13
9.6.2.3 Damage due to deformation

Rope with a spiral type deformation
This kind of deformation is when the
longitudinal axis of the rope resembles a
spiral. Even though this kind of deformation
does not necessarity signify a lowering in the
rope resistance, when the deformation
reaches a certain body, it can transmit
vibrations that may lead to an anormal control
of the rope, and in the long run may lead to
wear and tear and damage to wires.
Substitute when d>D/3
Rope with grommet deformation

This deformation happens when the wires of
an external layer or strands are longer than
the internal ones and poke out. This condition
may happen after a sudden tear in the rope at
rest.
Immediately replace.
Strands sticking out

This kind of damage is generally associated
with grommet deformation when the
imbalance of the rope is shown by the core
strmazione a canestro quando lo sticking out.
Immediately replace.
MAINTENANCE 9
Espulsione dei fili

This damage is generally associated with the
sudden application of a load on the rope.
Top Figure: Slight damage
keep the cable rope under tight control
Bottom Figure: serious damage

Immediately replace
Localized increase of diameter

In particular conditions the core of the rope
may swell up in localized or extensive areas.
The result of this deformation is an imbalance
in the external strands that take on an
incorrect direction.
In the event of excessive swelling replace the
cable rope.
Localized reduction in the cable rope

diameter
This deformation is associated with the
breakage of the core centre. Immediately
check the points nearest to the attachments
and substitute in the event of serious
deformation (see figure on left).
Twisting and core strands on the surface

This deformation happens when the rope
remains tightened without the possibility of
rotating.
Replace immediately
Bends
The bends are corner deviations of the rope
caused by external actions.
Replace immediately
TESTS, INSPECTIONS, CHECK 10
10. TESTS - INSPECTIONS - CHECKS
MAINTENANCE SUMMARY
Frequency Intervention Description
Check that there are no oil leakages and always eliminate them
before beginning work (this means you will avoid future
and more serious damage).
At the beginning of
every work shift
Check that the screws and spacers that keep the cables on the
mast head in their seating are properly postioned.
At the end of every Grease Swivel joint

shift
Every day Check The state of pins and fixing devices and particularly the
mobile ones
Every two days Grease the greasing points, including the rotary sliding guides,
the kelly bar guides and all the slewing rings
Check the state of the kelly bars, keeping them as clean as

possible and oiling them internally to improve their
sliding ease. (in the event of using bentonite mud, clean
the kelly bar inside too, pouring water down from the
top: this operation should be done at the end of the work
shift).
Every week Check Winch ropes and replace as soon as defects are spotted
(wires sticking out, thinn wires, bends, etc.).
Pulleys (pins, bearings, grooves), replace if they are

Check defective or worn (the pulleys must turn easily by hand
any noises or vibrations during the rotation mean the
bearings are damaged; the groove of the must not be
assymetrical; a worn pulley considerably reduces the
rope’s lifespan therefore it is better to replace it as soon
as possible).
Check all the oil levels of the following reducers:

• Rotary reducer;
• Rotary box reducer (B);
MAINTENANCE SUMMARY
Frequency Intervention Description
• Main winch reducer;

• Auxiliary winch reducer.
Every week Check the play of the anti-friction shoes located on the rotary
slider guides and kelly bar guides; if the play is greater
than 2 mm, even if only on one side, regulate the play
by regulating the regulatory screws and blocking bolts
(C) (check that the operation carried out on the rotary
slider is still aligned with the pull-down cylinder).
Check and Swivel joint of the kelly bar. The two ends must be able
grease to rotate and must not have oil or grease leakages
Check Head flange of kelly bar (that, if broken at the welding

point, are to be repaired immediately).
Check all the nuts and bolts of the rig especially if the rig is
working in a corrosive environment (near the sea or
salty water) or is subject to vibrations (core drilling or
rock drilling)
Check Shock Absorbers
Every month Check Wear of kelly bar teeth
The frequency of checks mentioned above aare calculated on the basis of

one day shift of 8 hours work and in the event of a greater work load,
increase proportionally the frequency of the interventions.
10.1 MAINTENANCE SUMMARY

Fill the following form after every maintenance operation.
Machine Type: AF220 Serial Number: ***AF220.00.356***

Worked Date Type Replaceded Note Responsible Signature
hours of parts
maintenance

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MANUAL FOR USE

OF THE HYDRAULIC DRILLING RIG

Language: English REV.00-B

Carried out by: Q.P. 28/01/02

Rev. Carried out by: Date: Approved by: Date:

1. SAFETY MEASURES ____________________________________________________4

5.2 DRILLING _____________________________________________________________31

• staff safety 89/391/CEE (DL 626/94);

1.2 CERTIFICATE OF COMPLIANCE

HYDRAULIC DRILLING RIG Model AF120

----------------------------- Harmonized Norms ----------------------------

The marking of the symbol “EC” is affixed onto the machine.

1.3 IDENTIFICATION OF THE MACHINE

Machine Weight without kelly 54.000 Kg

1.4 GENERAL WARNINGS PULLBACK

The present manual relative to the drilling equipment installed by IMT

The manuals are completly read and understood before attempting to

1.5 PLANNED USE OF THE RIG

1.6 SAFETY WARNINGS

Prudence is the best safeguard against accidents.

Characteristics, protection and accessories may vary in countries destined to receive

1.7 WARNING SIGNS

Danger High voltage-electrical parts !

Danger of falling materials !

Danger, use of naked flamme or smoking forbidden !

Danger of corrosive material !

wrong interpretation of these instructions may lead to accidents with serious

Very important information

1.8 TRAINING REQUIRED OF OPERATORS

1.9 SAFETY AND CHECKING DEVICES

f) The electronic inclinometer in the cabin checks the mast slant.

h) Microswitch of auxiliary winch end stroke

i) Microswitch of boom end stroke

1.10 GENERAL SAFETY RULES

During re-fuelling and the use of inflammable substances, smoking is strictly

1.10.1 Safety rules for loading and the transporting machine

1.10.2 Safety rules during working phases

Before unloading the tool, ensure that nobody is in the vicinity.

1.10.3 Work in proximity of electrical cables

When working near suspended or underground electrical cables there is the

1.10.4 Noise emission

1.10.7 Ground pressure

1.10.8 Wind force

1.10.9 Fire extinguishers

The machine is equipped with a powder fire extinguisher situated in the

2.1 AIM OF GENERAL INFORMATION

The manufacturer declines responsibility or liability for damage caused

2.2 IDENTIFICATION DATA OF MACHINE MANUFACTURER

2.3 CONDITIONS TO MAINTAIN WARRANTY VALIDITY

2.4 INFORMATION REGARDING CUSTOMER - IMT S.P.A. RELATIONS

2.4.1 General information on technical assistance and spare parts

2.4.2 Procedure for requesting Technical Assistance

2.4.3 Procedure for spare parts request

HYDRAULIC DRILLING RIG AF120

2.4.4 Procedure for giving technical advice