ABUIABA9GAAgl6Po2wUo9qiR9gU PDF
ABUIABA9GAAgl6Po2wUo9qiR9gU PDF
ABUIABA9GAAgl6Po2wUo9qiR9gU PDF
MAINTENANCE MANUAL
AWILCO/ PPL 2012
RIG #3
D3000AC Drawworks
Project: E2189
Job: C22584
S/N: 307
P.O.: 4500035653
ADDITIONAL INFORMATION
DOCUMENT NO.
9108E029
W W W .N O V .C O M
Document No. 9108E029
Page 1
TABLE OF CONTENTS
1. INTRODUCTION 5
1.1 MANUAL OVERVIEW & SCOPE ........................................................................................... 5
1.2 WARRANTY INFORMATION ................................................................................................. 6
1.3 WARRANTY LIMITATIONS ................................................................................................... 7
1.4 EQUIPMENT SERVICE LIFE ................................................................................................. 7
2. SAFETY SUMMARY 9
2.1 SAFETY TERMS & CONVENTIONS....................................................................................... 9
3. D3000AC DRAWWORKS 11
3.1 GENERAL DESCRIPTION .................................................................................................. 11
3.1.1 Construction .............................................................................................................. 11
3.1.2 Chains and Sprockets ............................................................................................... 11
3.1.3 Shafting ..................................................................................................................... 12
3.1.4 Brakes ....................................................................................................................... 12
3.1.5 Clutches .................................................................................................................... 12
3.1.6 Drum Design ............................................................................................................. 12
3.1.7 Lubrication................................................................................................................. 13
3.2 TECHNICAL SPECIFICATIONS ........................................................................................... 13
3.3 POWER FLOW CHART ..................................................................................................... 14
5. OPERATING INSTRUCTIONS 21
5.1 PRE-STARTING INSTRUCTIONS ........................................................................................ 21
5.2 MANUAL AND EMERGENCY OPERATION ........................................................................... 21
5.3 BRAKE CALIPER REMOTE OPERATION ............................................................................. 22
5.4 BRAKE CALIPER MANUAL / EMERGENCY OPERATION ...................................................... 22
5.4.1 Manual / Emergency Operation (Hydraulic Pumps Operating) ................................. 22
5.4.2 Manual / Emergency Operation (Hydraulic Pumps Not Operating)........................... 23
5.5 BRAKE CALIPER DELAY SYSTEM ..................................................................................... 24
5.6 DISC BRAKE CALIPER BURN PROCEDURE ....................................................................... 24
5.7 BRAKE TESTING PROCEDURE ......................................................................................... 24
5.8 CROWN SAVER RESET PROCEDURE ................................................................................ 24
5.9 DRILL LINE ATTACHMENT TO DRUM ................................................................................. 25
5.10 DEAD WRAPS ON THE DRUM ........................................................................................... 25
5.11 PROTECTIVE MEASURES ................................................................................................. 25
6. MAIN OVERHAUL 27
www.nov.com
Document No. 9108E029
Page 2
10. TROUBLESHOOTING 61
10.1 EQUIPMENT FAULT SYMPTOMS & CAUSES....................................................................... 61
www.nov.com
Document No. 9108E029
Page 3
13. CERTIFICATES 75
14. DRAWINGS 77
www.nov.com
Document No. 9108E029
Page 4
www.nov.com
Document No. 9108E029
Page 5
1. INTRODUCTION
1.1 Manual Overview & Scope
1.2 Warranty Information
1.3 Warranty Limitations
1.4 Equipment Service Life
The scope of this manual includes only equipment supplied by National Oilwell Varco
and does not pertain to equipment supplied by the Customer or others. In the Vendor
Information section you can find information that pertains to equipment that is supplied,
but not manufactured, by National Oilwell Varco. If there is any overlapping information
between this manual and a manual from a vendor, the vendor’s manual shall take
precedence unless otherwise noted.
www.nov.com
Document No. 9108E029
Page 6
1. All National Oilwell Varco equipment built in our plant is guaranteed to be free from
defects in workmanship for a period of 12 months from the date of delivery to the
original customer or as specified in the contract.
2. In the event of any failure on which a warranty claim may be presented the owner
must notify us and follow our instructions relative to the inspection or disposition of
the defective part or parts and to the repairing and/or replacement thereof.
3. The foregoing warranty is contingent on the proper application of equipment and
products by the owner in accordance with the recommendations of the manufacturer
National Oilwell Varco, and shall not apply to any products which shall have been
repaired or altered in any way so as in the judgment of National Oilwell Varco to
affect adversely their performance and reliability nor which have been subject to
misuse, negligence or accident or equipment that has been repaired to the
customer's specifications rather than to National Oilwell Varco’s specifications.
4. Our obligations under this warranty is limited to supplying parts and labour to correct
defective workmanship to an amount not exceeding the charges for the original
repair and shall not include any transportation charges, loss of revenue, or any direct
or indirect consequential damages.
5. Travel time and travel expenses will be charged to customer's account at cost.
6. All warranty work will be done on a straight time basis and the customer will be
charged for the difference between straight time and overtime.
7. The warranty does not cover any hoisting, trucking or transportation charges.
8. Products furnished by National Oilwell Varco but not manufactured by National
Oilwell Varco will carry only the warranty of the manufacturer of such products.
9. The entire liability and obligation of National Oilwell Varco with respect to
workmanship is defined by this warranty and is given in lieu of any and all other
warranties, expressed or implied. No oral or written statements or representations
with respect to the subject matter hereof shall be binding. Upon the expiration of this
warranty, all liability on the part of National Oilwell Varco in connection herewith shall
terminate in any event.
www.nov.com
Document No. 9108E029
Page 7
This manual is prepared as a guide for the proper installation, care, and operation of the
unit. Because of the varying methods and requirements for these functions, it is not
possible to detail all facets of these subjects; when situations encountered are outside
the scope of this publication, refer to the manufacturer's technical services department.
The manufacturer will, upon request and contract, provide trained personnel to assist in
the maintenance and servicing of this equipment.
National Oilwell Varco equipment that is properly maintained and operated within rated
loads has a long service life. The service life of the equipment is dependent on the
operator’s operating practices and the codes under which the country is regulated. The
operator will test and maintain the equipment at intervals as per his or her set program.
Operators should compile and retain accurate and clear maintenance records that
include the following information:
• Inspector/Mechanic
• Date of inspection
• Records of performance
• Preventative maintenance
• Repair/replacement history
www.nov.com
Document No. 9108E029
Page 8
www.nov.com
Document No. 9108E029
Page 9
2. SAFETY SUMMARY
2.1 Safety Terms & Conventions
This manual uses the following standard safety terms and conventions that span all
areas of the industry:
Only qualified personnel should be allowed to operate and maintain the equipment.
Personnel should not operate the unit unless they are thoroughly familiar with all unit
operating controls and functions and have read the equipment manual.
Personnel are protected from exposed mechanical dangers by guards fabricated from
expanded metal. Nevertheless, operating and maintenance personnel should wear
suitable protective clothing and equipment. Keep hands, hair, clothing, jewelry, rags,
tools, etc. away from all moving parts during operation.
Do not attempt equipment operation with inadequate visibility unless suitable lighting
provisions are available.
Promote good safety measures, including training, at all times around the equipment
throughout all operating phases. It is the equipment owner's/operator's responsibility to
establish safety measures as well as enforce them.
Equipment used in lifting and moving the unit must be sufficiently rated to handle the
weights involved.
www.nov.com
Document No. 9108E029
Page 10
WARNING: Do not breathe cleaning solvent vapors. The toxic effect of some
solvents is cumulative. Continued inhalation can lead to permanent
disability or death. When using flammable cleaning solvents, take all
appropriate fire protection precautions to prevent injury to
personnel and damage to equipment.
WARNING: Do not direct compressed air against any part of the body. High
pressure air can cause injuries. Do not rotate ball or roller bearings
with compressed air. Do not direct compressed air against a fire.
Tag controls and depressurize hydraulic system before
disconnecting or removing any part of the hydraulic piping. Ensure
all tanks, lines, and equipment are depressurized by slowly
releasing pressure through approved means.
www.nov.com
Document No. 9108E029
Page 11
3. D3000AC DRAWWORKS
3.1 General Description
3.2 Technical Specifications
3.3 Power Flow Chart
3.1.1 Construction
The drawworks frame is carefully fabricated using precision jigs and fixtures to maintain
accurate alignment and chain centres. The drawworks interior is designed so that piping
is protected in the case of chain failure. The drive assembly uses three electric motors.
The drawworks is constructed in two modules for the ease of shipping. Easily
removable guards are provided over all the clutches, affording easy access to the
clutches. Oversize service panels are located at key locations on the drawworks to
provide easy access for all routine maintenance and major service requirements,
ensuring minimum downtime.
The drawworks drive chains are basic power roller chains manufactured to ANSI B29.1.
This type of chain is known as the “standard series” roller chain. The chain dimensions,
weight, and capacity are proportional to the pitch. All sprockets are hobbed and the
wear points are flame hardened.
www.nov.com
Document No. 9108E029
Page 12
3.1.3 Shafting
All the shaft sizes are proportioned, assuring trouble-free operation with rated power
input. Also, all shafts are supported on self-aligning spherical roller bearings. All seals
used in rotating parts on the shafting are heavy duty seals, providing dirt exclusions as
well as lube retention. Non-adjustable, heavy duty straight roller bearings and self-
aligning spherical bearings are used in the clutch sprockets. No adjustment of these
bearings is necessary.
3.1.4 Brakes
3.1.5 Clutches
Plate type air actuated friction clutches are used for high/low gear changes.
www.nov.com
Document No. 9108E029
Page 13
3.1.7 Lubrication
A simple oil spray system is provided for lubrication of the drawworks chains. The spray
pipes lubricate as well as cool the drawworks chains. One of the oil pumps is mounted in
the oil sump towards the rear of the drawworks and driven by a chain from the jack shaft
of the drawworks. The other pump is driven by an electric motor and is mounted on the
rear section of the skid. A suction filter and a discharge filter are provided. Bearings in
the drawworks that are not lubricated by the drive chain oil are grease lubricated. The
greasing nipples and greasing panels are conveniently located about the drawworks.
General Specifications
Serial Number: 307
Max. Horse Power Rating: 3,000 hp @ 1,600 rpm
Wire Line Size: 1 5/8”
Main Drum Size: 35” x 72” with 1 5/8” Lebus Grooving
Oil Sump Capacity: 100 US Gal. (379 L)
Hydraulic Tank Capacity: 20 US Gal. (76 L)
Hoisting Capacity
14 Line: Low: 1,550,000 lbs
High: 626,047 lbs
Chains
Motor 1 to Input Shaft: 1 ¼” P RC, 100-4 Quadruple (114 P)
Motor 2 to Input Shaft: 1 ¼” P RC, 100-4 Quadruple (140 P)
Motor 3 to Input Shaft: 1 ¼” P RC, 100-4 Quadruple (140 P)
Input Shaft to Jackshaft (DS): 1 ½” R RC, 120-8 Octuple (106 P)
Input Shaft to Jackshaft (ODS): 1 ¾” P RC, 140-6 Sextuple (114 P)
Jackshaft to Drumshaft: 1 ¾” P RC, 140-8 Octuple (138 P)
Dimensions
Length of Skid: 15’ – 7 7/8” (4,772 mm)
Width of Skid: 12’ – 2” (3,708 mm)
Overall Height of Drawworks: 15’ – 6 ½” (4,739 mm)
Overall Width of Drawworks: 16’ – 6 ¼” (5,036 mm)
Overall Length of Drawworks: 18’ – 4 ¼” (5,539 mm)
Equipment Weights
Input Shaft Assembly: 6,367 lbs. (2,888 kg)
Jackshaft Assembly: 10,171 lbs. (4,613 kg)
Drumshaft Assembly: 22,622 lbs. (10,261 kg)
Baylor CM628 Motor (each) w/o blower 6,805 lbs (3,087 kg)
assembly:
Blower Assembly: 551 lbs (250 kg)
Total Approximate Weight of Assembly: (est.) 113,721 lbs. (51,583 kg)
www.nov.com
Document No. 9108E029
Page 14
www.nov.com
Document No. 9108E029
Page 15
4.1 Preservation
Proper storage and preservation measures will help ensure the maximum design life for
the D3000AC drawworks. Accessory items, spare parts, etc. shall be protected in
accordance with these guidelines.
NOTE: The drawworks is shipped dry; however, prior to shipping a preservative is
run through the lubrication system. All applicable reservoirs have been
shipped with sufficient oil to minimize the areas that may become exposed to
condensation or corrosion.
Ensure the equipment has been cleaned of all foreign matter and thoroughly dried
before preservation.
All machined surfaces should be protected with a rust inhibitor (i.e. Denso Tape or
Tecteel spray or equivalent) where applicable.
Place rubber gaskets and metal blanks over all interface connections. Interface
surfaces, which are not corrosion resistant, are to be protected with a corrosion
inhibitor before sealing.
Ensure all grease points are well-greased.
Indoor storage is preferred for the equipment because condensation and corrosion
can be minimized in a controlled environment.
Remove mud, adhering dirt, and other foreign matter able to hold moisture. If
cleaning is done with steam or a solvent, avoid washing lubricating oil or grease
from unpainted surfaces or close-fitting elements.
Touch up the paint if necessary in areas that have suffered chipping and wear.
Elevate the equipment some distance from the ground or floor. Provide enough
beams to give normal support to the equipment. Beams must be high enough to
avoid water accumulation; a drained location is preferable. Remove any
accumulated moisture on or near equipment.
If the equipment must be stored outdoors, prevent moisture from contacting the
equipment. Pack all equipment with heat-shrunk plastic or tarpaulin of at least 0.15
mm thickness or crated. Ensure the integrity of the tarpaulin and/or crating.
Where storage temperature is not stable, sufficient sealing of the equipment with
tape, a plastic sheet, and use of desiccant is recommended.
Preserve cable ends with sealing tape or blanks.
www.nov.com
Document No. 9108E029
Page 16
Desiccant bags are used inside all enclosed areas such as instrument cabinets and
junction boxes. Renew desiccant and sealing tape as necessary.
Place packing around valve panels (if applicable) to protect against shock or impact.
All applicable reservoirs should be shipped with sufficient oil in order to minimize the
areas that may become exposed to condensation or corrosion.
Various measures have been taken or should be taken to preserve the drawworks
equipment. Note the following instructions when taking the drawworks out of storage
and preparing it for installation:
• Remove tape and plastic sheeting from unpainted machined surfaces and all
exposed shafts.
• Remove any metal or molded plastic caps from all threaded connections.
• Remove blanks from the exposed piping ends of the air and cooling systems.
• Steam-clean areas covered with corrosion preventative and surface protection
coatings to remove the coating.
• Re-lubricate areas where steam-cleaning may have washed away lubricants from
pivot points and other moving mechanical parts.
• Paint areas that may have suffered chipping and wear during preservation.
Surfaces must be cleaned of surface corrosion and thoroughly dried before being
repainted with machinery enamel.
• Use silicone sealant for all sealing surfaces.
• After rust protector is removed, clean the brake discs again using a low residue
cleaning solvent such as “Electro-Sol” or MEK. Ensure discs are free of all
residues.
• The D3000AC drawworks requires the assembly of the drum module (refer to
drawing 9108A034) and a power module (drawing 9108A046) prior to installing on
a level foundation:
¾ Install O-ring and silicon at the interface of drum and motor skid.
¾ Align the two skids and tighten the bolts at the seven dowel-pinned
connections (483 ft-lbs). Refer to Section 11 of manual for the torque guide.
¾ Torque down the skid connection bolts. Bolt item ‘E’ – refer to drawing
9108A034 (1462 ft-lbs).
¾ Install jackshaft to the drumshaft chain (item ‘B,’ drawing 9108A046) with
the master link.
¾ Re-install the chain guard.
www.nov.com
Document No. 9108E029
Page 17
Pay attention to the drum sprocket guard installation. Ensure that all sealing surfaces
are clean and dry prior to applying the silicone sealant. Follow manufacturer’s directions
for silicone sealant application and curing times. Upon initial startup, ensure there are
no leaks in area.
WARNING: If there is any oil leakage from this area, check the brake pads for oil
contamination. Contaminated brake pads must be replaced
immediately. Do NOT operate the drawworks with contaminated
brake pads.
Refer to the D3000AC Drawworks Overall Lifting Diagram, drawing 9108L022, for
detailed instructions on how to lift the drawworks.
NOTE: The lifting equipment is not supplied with the drawworks. The drawing for
typical lifting equipment is used as a reference drawing only.
Support the drawworks using the whole base of the drawworks. Refer to the Footprint
and Installation Detail, drawing 9108C026.
www.nov.com
Document No. 9108E029
Page 18
WARNING: Extreme caution must be exercised when lifting the drawworks into
position as personal injury or death can result from unsafe work
practices. Follow all local laws and regulations regarding overhead
lifting operations.
The drawworks has eight mounting locations. Check each mounting location according
to the procedure below.
The drawworks requires a level, straight base for proper operation. Prior to installation
of the drawworks, check the supporting structure for level and straightness at each of
the mounting locations (refer to drawing 9108C026). The variation from level can’t
exceed 1/4” over the length of the drawworks or 1/8” over the width of the drawworks.
The structure should also be straight within 1/8”. This means that measuring from line
drawn from one end of the drawworks to the other end of the drawworks will result in a
deviation of no more than 1/16” for the two mounting locations in the centre of the
drawworks.
Install shims to bring the supporting structure within the tolerances indicated above.
Once the supporting structure is level and straight, hoist and install the drawworks on to
the structure.
Prior to installing and torquing the tie down bolts, ensure the drawworks skid is in full
contact with the supporting structure at each of the mounting points. If the drawworks
skid is not touching the supporting structure then shim up the skid at the mounting point.
CAUTION: Do not tighten down the tie down bolts to pull the drawworks skid
tight to the supporting structure. Shim first.
After completing all the shimming, torque all tie down bolts. (1120 ft-lb plain, 840 ft-lb
plated for A325 structural bolts).
Check the level and straightness of the drawworks skid using a surveyor’s level or
similar instrument to take measurements on the skid at the points indicated (8 points).
Each measurement location is marked with a centre punch indent on the top flange of
the main skid beam. The locations are directly above the tie down bolt locations.
www.nov.com
Document No. 9108E029
Page 19
Once the drawworks is attached, levelled, and straight, install the loose components.
Connect all electrical devices as per the instructions in the Installation procedure
for electrical equipment.
Connect up drip pan drain lines (2 places). Refer to drawing 9108C027.
Connect up hydraulic oil tank drain and oil sump drain. Refer to drawing
9108C027.
Connect up air receiver inlet and drain line. Refer to drawing 9108C027.
The drawworks is now ready for the pre-start up procedure.
www.nov.com
Document No. 9108E029
Page 20
www.nov.com
Document No. 9108E029
Page 21
5. OPERATING INSTRUCTIONS
5.1 Pre-Starting Instructions
5.2 Manual and Emergency Operation
5.3 Brake Caliper Remote Operation
5.4 Brake Caliper Manual / Emergency Operation
5.5 Brake Caliper Delay System
5.6 Disc Brake Caliper Burn Procedure
5.7 Brake Testing Procedure
5.8 Crown Saver Reset Procedure
5.9 Drill Line Attachment to Drum
5.10 Dead Wraps on the Drum
5.11 Protective Measures
1. Check oil sump and drawworks housing for presence of dirt or water. Drain and
clean if necessary.
2. Fill oil sump with ISO 150 All Season Gear Oil chain or engine oil for temperatures
of 55 degrees Fahrenheit or higher and ISO 150 All Season Gear Oil for 0 – 55° F,
and below 0°, use oil with a pour point at least 5° lower than the lowest ambient
temperature.
3. Grease all points equipped with alemite hydraulic grease fittings.
4. Motors - lubricate in accordance with instructions furnished by the manufacturer.
5. Check transmission oil pressure gauge on the control panel to be certain that oil
system is pressurized after the drawworks is in operation.
6. Check oil level in sump after the drawworks is in operation and add oil if
necessary.
7. Remove plugs and covers from exhaust ports in quick release valves and ensure
that all are operating properly.
8. Install all safety guards.
9. Check end functions of all controls to make sure they are operating properly.
CAUTION: Do not attempt to operate drawworks with less than 110 psi air
pressure. Ensure all the lines and the gauges are open and the
controls are active.
For the start, normal operation, stop, and emergency stop operations, refer to the
Operation Manual, document number S0100751-OPM-200.
www.nov.com
Document No. 9108E029
Page 22
Refer to the Hydraulic and Air Schematic, drawing 9108X009, for these operations.
www.nov.com
Document No. 9108E029
Page 23
6. Once 3,000 psi is achieved, flip all six remote/manual valves (F) to manual.
www.nov.com
Document No. 9108E029
Page 24
With six calipers activated at the same time, light loads will be stopped quickly. Thus
two of the six calipers are equipped with a flow control valve (B) to slow the application
of the calipers. These control valves are set at the factory to have a one second delay.
In the event that these settings are changed, reset the flow control valves by doing the
following:
1. Release brakes.
Flow Control Valve
2. Close all flow controls
3. Engage brakes.
4. Open all flow controls 1/8 of a turn.
5. Release and engage brakes. Measure time
difference between non-flow control and flow
control calipers. Time difference should be
approximately one second.
6. If time is too fast, close flow controls 1/16 turn.
Photo: The flow control valve is located
7. Repeat until a one second delay is achieved. in the instrumentation box.
NOTE: Adjusting the flow control to six full turns in from full open will give a delay
of approximately one second. This is approximate only and will vary
substantially with each caliper and each valve.
If the drawworks stops functioning due to the drill line tripping the toggle valve, reset the
crown saver in its normal operating position and de-energize “AF” (reference drawing
9108X009).
www.nov.com
Document No. 9108E029
Page 25
The drill line is attached to the drum with a line clamp and socket on the Off Driller’s
Side of the drum. The line clamp is held to the drum in the socket with two half clamps.
Each half clamp has two bolts; the line clamp has six studs.
To install the drill line onto the drum, do the following:
1. Push the drill line through the opening in the drum side plate.
Line Clamp
2. Attach the line clamp to the drill line, leaving
a 3” to 4” tail past the end of the line clamp.
3. Torque the six studs to 455 ft/lbs.
4. Insert the line clamp into the drum socket
and install the two half clamps.
3” to 4” tail past the end
5. Torque the half clamp bolts to 112 ft/lbs. of the line clamp
The D3000AC drawworks is designed to have a minimum of seven dead wraps on the
drum when the traveling block is in the lowest position.
WARNING: Operating the drawworks with less than seven dead wraps may
result in the drill line being pulled from the line clamp on the drum
and consequently an uncontrolled dropping of the traveling
equipment and load.
www.nov.com
Document No. 9108E029
Page 26
www.nov.com
Document No. 9108E029
Page 27
6. MAIN OVERHAUL
6.1 Parts Fit – General
6.2 Shafts
6.3 Bearings
6.4 Spacers
6.5 Hydraulic System
6.6 Sprockets and Clutch Hubs
6.7 Hub & Shaft Fits
Economic factors enter in the normal overhaul job. When the equipment is in the shop
for repairs, new parts may be installed at far less expense than when the equipment is
in service. Should the repair shop fail to replace a partially worn bearing at the time of
overhaul, and should this old bearing fail within the first few months of new service, the
resultant costs from down time and emergency repairs would amount to many times the
cost of replacement at regular overhaul time.
When replacing parts on a shaft assembly, ensure the new part fits within the tolerance
shown. For the assembly or the removal of parts ranging from 0.00 mm to 0.101 mm
tight, heat the parts to approximately 204°C. For the parts ranging from 0.127 mm to
0.254 mm tight, heat them to approximately 343°C.
6.2 Shafts
Shafts should also be checked for straightness by supporting the shaft by any anti-
friction means placed at the position of the main bearings, and turning it. Straightness
is then checked by means of a dial indicator placed at the extreme ends of the shaft.
The total reading of the dial indicator should not exceed 0.254 mm. If a shaft shows
greater run out than 0.254 mm, a replacement should be considered. The lack of
straightness in drawworks shafting causes vibration, whipping of chains, and a generally
poor running rig.
6.3 Bearings
Roller bearings should always be discarded if they show pitting, rust or corrosion,
chipping or spalling off of small particles, excessive internal looseness which indicates
extreme wear, or cracks in rollers or races.
www.nov.com
Document No. 9108E029
Page 28
In most cases, it will be necessary to heat the bearing inner race to remove it from the
shaft. It will be necessary to heat the inner race and cool the shaft for re-assembly. To
pull the bearing and/or the inner race, place a "U" puller behind bearing or inner race.
Arrange balance of the pulling mechanism and tighten sufficiently to remove all slack.
Apply heat evenly to the bearing or inner race, while simultaneously increasing tension
on pulling mechanism. DO NOT OVERHEAT! Maximum temperature: 125°C
The fits of the outer races to the bearing housing range from 0.127 mm tight to 0.102
mm loose. If the outer race is a tight fit it will be necessary to heat the housing in order
to remove it. The bearing must be cool before it can be re-assembled. When outer race
is a tight fit, arrange the puller mechanism to apply pressure toward the open end of the
housing. Apply heat to the housing and increase pressure on the puller mechanism at
the same time. DO NOT OVERHEAT! Maximum temperature: 125°C
6.4 Spacers
Spacers that have seals on them are shrink-fitted to prevent leaking. To remove a
spacer which is shrunk on a shaft, proceed in accordance with the instructions for
removing a bearing. To replace, heat the spacer, make sure the shaft is cool, and
proceed to do the same as for bearing replacement.
The brake hydraulic system requires the oil cleanliness level maintained at an ISO Level
of 17/15/12 (NAS 6) or better. Due to the critical nature of the hydraulic system, the
viscosity of the hydraulic fluid used in this system should not exceed ISO 22.
Consequently, any repairs to the brake hydraulic system should be undertaken with
extreme diligence in the area of cleanliness. Before opening any connections, ports,
lines, etc in the hydraulic system, the work area should be thoroughly cleaned. Any
openings made in the system should be plugged or blinded immediately. Ensure the
appropriate plugs, caps and blinds are in hand prior to disassembly.
Upon completion of any major repairs, the entire system should be flushed to ensure no
contamination of hydraulic oil occurs. Oil samples should be analyzed on a regular
basis to monitor the system cleanliness.
The brake hydraulic system uses two pressure reducing relieving valves: one to reduce
the main system pressure from 3,000 psi to 1,800 psi. The second pressure reducing
relieving valve is the emergency lowering. The pressure relieving functions of the valve
must be verified before the valve is put into service.
www.nov.com
Document No. 9108E029
Page 29
The pressure compensating pump in the brake hydraulic system operates at less than
their maximum displacement. These pumps are set at the factory to have a maximum
flow of approximately 2 gpm. After overhaul or when a new pump is installed, the
volume stop setting must be verified. This is accomplished by measuring the time
required to bring the system from zero (0) pressure to pull pressure (3,000 psi). This
requires approximately 5 US gallons of oil. Therefore, the time to charge the system
with pump should be approximately 2 minutes, 30 seconds.
The main hydraulic system relief must be set to relieve at a pressure not less than 3,150
psi and not more than 3,300 psi.
Perform the following procedure to set the pressure compensator; refer to the D3000AC
Air and Hydraulic Schematic, drawing 9108X009, item X.
NOTE: The system will have to be bleed off by opening one of the bleeder valves
on the accumulator bottles to reduce the system pressure. Leave the
bleeder valve open just slightly (1/2 turn or so).
11. This pump is now set correctly. Check to ensure the pump compensator is higher
than the PLC pump pressure shut off setting. Adjust the pump or PLC to suit. The
final system pressure as controlled by the PLC should not exceed 3000 psi.
www.nov.com
Document No. 9108E029
Page 30
System Relief
Compensator
Pressure
Adjustment Maximum Volume Stop
1. Bleed all pressure from the hydraulic system by opening the bleed off valves on the
accumulator bottles.
2. Start one pump and record the time it takes for the system to reach the operating
pressure of 3,000 psi. The accumulator bottles hold 5 gallons of oil at 3,000 psi.
Therefore, the necessary time should be 2 ½ minutes to reach 3,000 psi.
3. If the time to charge is too short or too long, reduce the flow by adjusting the
maximum volume stop. Acceptable time would be between 2 minutes and 15
seconds and 2 minutes and 45 seconds. Refer to the hydraulic pump manual for
directions on adjusting the maximum volume stop.
4. Check the current draw of power by the motor to ensure it is within the operating
parameters listed on the motor name plate.
NOTE: DO NOT change the maximum volume setting or else the electric motor
could be overloaded!
www.nov.com
Document No. 9108E029
Page 31
Four methods are used for mounting clutch hubs, bearing inner races and sprockets on
shaft assemblies.
www.nov.com
Document No. 9108E029
Page 32
Screw the puller into this hole and remove the key. The sprocket may then be removed,
usually with heat application. If a tapped hole is not provided in the key, it will be
necessary to pull the sprocket without first removing the key. Insert puller studs through
openings between sprocket spokes 180° apart. Place steel plates and nuts on stud
ends extended through the openings.
Arrange balance of pulling mechanism and tighten only enough to remove any slack.
Apply heat evenly and as near to the hub as possible while increasing tension with the
puller at the same time. DO NOT OVERHEAT!
In some cases the hubs will have two tapped holes in the end so that the puller may be
screwed in. In other cases where neither spokes nor tapped holes are available for
utilization of puller studs it will be necessary to use a "strong back" or "U" plate behind
the sprocket and secure the puller studs to it.
Proceed to remove the sprocket as described above. To replace the sprocket, first
make sure the shaft is cool. Heat the sprocket to approximately 204°C. Be sure that the
keyways in the shaft and sprockets are aligned before the sprocket tightens on the
shaft. Insert key after sprocket has been installed.
CAUTION: Excess heat at the hub and attempting to pull the sprocket with a
chain attached to the outer rim (powered by a jack on the end of the
shaft), will bend the sprocket. Sprockets with shrink fits are very
difficult to remove. This should only be attempted in a shop where a
hydraulic press is available.
If the sprocket is being removed for salvaging and installing on a new shaft, cut the
shaft near the sprocket and machine part of the metal from the shaft under the sprocket.
Heat the sprocket and press out "Dutchman".
If the purpose of removal is to replace the sprocket with a new one, it is advisable to
machine or torch cut the old sprocket to remove it. Let the shaft cool, heat the new
sprocket to 204°C, and assemble on shaft.
NOTE: When a shaft assembly is disassembled for any reason, be sure that
passages for admission of air or grease are thoroughly cleaned.
www.nov.com
Document No. 9108E029
Page 33
(E)
T= + ( TR)
( 0. 00001098 )(B)
Where:
For example, if we have a 215.9 mm (8.500") diameter bore hub which has a 0.2032
mm (0.008") interference fit with the shaft and we wish to have 0.2540 mm (0.010")
clearance while assembling the hub over the shaft - the total bore expansion needed
will be 0.4572 mm (0.018"), therefore:
E = 0.4572
B = 215.9
let TR = 21.1°C (70°F)
( 0. 4572)
then: T= + ( 211
. ) = 214° C( 420° F )
( 0. 00001098 )( 215. 9 )
CAUTION: Hardened parts such as bearing races should not be heated to over
204 - 232°C, since their hardness might be affected. Heat should be
applied carefully and evenly to prevent distortion. The general rule
for the average interference used in cylindrical fits is as follows:
The actual fit will have plus or minus tolerance depending on the shaft and bore
tolerances used in manufacture.
www.nov.com
Document No. 9108E029
Page 34
Overhung sprockets, clutch hubs, etc., are often made with tapered shaft fits for
convenience of assembly and disassembly. The tapers used on Dreco™ drawworks are
normally made to 1.250" diameter per foot of length of engagement or 10.4167 mm
diameter per 100 mm. In many cases, the hub must be shimmed against an adjacent
bearing spacer. Care must be taken to ensure the shims do not interfere with drawing
the hub up tight on the taper.
A recommended method for assembling hubs that require shimming is to assemble the
hub firmly on the shaft without shims and without heat. Measure the shim gap behind
the hub. The required thickness of the shim pack will be this measurement minus the
draw allowance to be provided for tightening the hub up on the shaft. For each 0.0254
mm of diametrical interference on a 10.4167 mm per 100 mm taper, the hub will
advance approximately 0.254 mm. For example, if an interference of 0.0762 mm is
desired in the taper fit, the shim gap must allow for a 0.762 mm advance of the hub on
the shaft. The hub may be lightly heated to facilitate the draw.
www.nov.com
Document No. 9108E029
Page 35
General Information:
www.nov.com
Document No. 9108E029
Page 36
Refer to the Input Shaft Assembly, drawing 9108A045, for the following procedure:
1. Remove all guards and covers.
2. Disconnect lube oil connections.
3. Disconnect drive chains.
4. Remove rotorseal (F) and adapter (26).
5. Remove clutch (1) and key (25) with drive ring (A) and clutch adaptor ring (2).
6. Remove bearing retainer (12) with oil seal (H) and spacer (20).
7. Remove bearing (E). Bearing can be replaced at this time.
8. Disassemble labyrinth outer ring (14).
9. Remove sprocket (5), labyrinth inner ring (13) and labyrinth slinger ring (15) with
spacer (16), bearing retainer (11), bearing (D) and oil seal (G) as one unit.
10. Unbolt all 16 bolts (C) on both bearing housings (7 & 8).
11. Slide remaining shaft from ODS.
Refer to the Input Shaft Assembly, drawing 9108A045, for the following procedure:
1. Remove bearing retainer (11) with oil seal (G) from sprocket (5).
2. Install new bearing (D).
3. Remove bearing retainer (10) and spacer (21). Replace bearing (C).
4. On the ODS, remove endplate (27) and sprocket (4) with key (24).
5. Remove spacer (17) and bearing retainer (9),
6. Install new bearing (B).
7. Reverse the above procedures to reassemble.
www.nov.com
Document No. 9108E029
Page 37
Refer to the Jackshaft Assembly, drawing 9108A003, for the following procedure:
1. Remove all necessary covers and guards. From the ODS, remove the clutch
guard.
2. Disconnect lube oil connections.
3. Disconnect drive chains.
4. Remove rotorseal (K), rotorseal adapter (11) and clutch (18) with key (17).
5. Take off the drive ring (F) with adapter ring (19).
6. Remove spacer (26) and labyrinth outer ring (23).
7. Remove labyrinth ring (22) from the ODS chain case.
8. Unbolt all 16 bolts (B) on both bearing housings (7 & 8).
9. Slide the remaining shaft assembly out from the ODS.
Refer to the Jackshaft Assembly, drawing 9108A003, for the following procedure:
1. Remove bearing retainer (21) with oil seal (M) from sprocket hub (6).
2. Remove bearing (G).
3. Remove sprocket (2) and hub (6) from shaft.
4. Remove the bearing retainer (20) with oil seal (N).
5. Replace bearing (H).
6. Remove the bearing retainer (9) and replace bearing (A). Remove the bearing
housing (7) if necessary.
7. From the DS, remove endplate (12), sprocket (4) and key (16).
8. Remove spacer (13), bearing retainer (10) and bearing housing (8).
9. Install new bearing (B).
10. Reverse the above procedure to reinstall the shaft assembly.
www.nov.com
Document No. 9108E029
Page 38
Refer to the Drumshaft Assembly, drawing 9108A004, for the following procedure:
Refer to the Drumshaft Assembly, drawing 9108A004, for the following procedure:
1. Using a block, hold the drumshaft in position to prevent any rolling while work is
being done on it.
2. Remove the end cover (24).
3. Remove the drumshaft endplate (15), spacer (18) retainer plate (7) and oil seal
(C).
4. Remove the bearing housing (6), bearing (A), retainer plate (8) and oil seal (C).
5. Install new bearing. Reverse the above procedures for reinstallation.
Refer to the Drumshaft Assembly, drawing 9108A004, for the following procedure:
1. Remove end cover (23) and encoder (B) with its bracket (22).
2. Remove the drumshaft endplate (14), the spacer (18), the retainer plate (9) and the
oil seal (C).
3. Remove the bearing housing (6), bearing (A), retainer plate (10) and oil seal (C).
4. Install new bearing. Reverse the above procedures for reinstallation.
www.nov.com
Document No. 9108E029
Page 39
Pay attention to the drum sprocket guard installation. Ensure that all sealing surfaces
are clean and dry prior to applying the silicone sealant. Follow manufacturer’s directions
for silicone sealant application and curing times. Upon initial startup, ensure there are
no leaks in area.
WARNING: If there is any oil leakage from this area, check the brake pads for oil
contamination. Contaminated brake pads must be replaced
immediately. Do NOT operate the drawworks with contaminated
brake pads.
www.nov.com
Document No. 9108E029
Page 40
www.nov.com
Document No. 9108E029
Page 41
8.1 Lubrication
Before starting any new machinery, the operator must grease all parts and fill all
reservoirs with the prescribed lubricants. New equipment should be drained and refilled
with oil after the first few weeks of service. Thereafter, it should not be necessary to
change oil more than once every six months except when:
the oil may have become contaminated by water or other foreign matter.
the temperature changes sufficiently to require a change in the viscosity of the oil
being used.
Oil levels should be checked daily and topped up if necessary and oil spray nozzles
should be checked periodically to ascertain that oil holes are open and delivering oil.
Avoid mixing lubricants of different brands, grades, and/or viscosities. Service periods
will depend on the usage of the equipment.
For many applications, the advantages of being able to use single multipurpose grease
instead of several separate grades outweigh the added product cost. Lithium complex
soap greases have been developed and are accepted for their wider operating
temperature range and good water resistance. Use a premium lithium-based
multipurpose EP 2 grease (Extreme Pressure meeting NLGI #2 or grade 2) or
equivalent for all greased components unless otherwise noted.
Apply grease regularly at fittings until the old grease starts to seep around the seal,
flushing out the used grease along with any accumulated water and debris. Maintain a
coating of grease on all sliding surfaces and unpainted machined surfaces for
lubrication and corrosion protection (e.g. scoping cylinder rod surfaces and pin/lug
contact surfaces). Grease seeping out through the seal or relief fittings during
lubrication indicates the bearing has received sufficient grease.
Where grease fittings are not present and the lubricated component must be
disassembled to replenish the grease (e.g. sealed pillow block), disassemble the
component, remove old lubricant, re-pack with new lubricant, assemble and install the
component. Re-pack all components that lack grease fittings at least once every year.
Remove any exposed grease seepage to minimize dirt accumulation.
www.nov.com
Document No. 9108E029
Page 42
There are times when a special type of lubricant is justified. Some of the super premium
greases have excellent low temperature properties. Using super premium grease during
extremely cold weather may be advantageous.
Rusting and corrosion of bearings, sprockets, etc. is normally not a problem during rig
operation, but may become serious over prolonged inactivity in a damp environment.
Ordinary oils and greases provide moderate corrosion protection, but special
compounds may provide increased corrosion protection. Applying super premium
greases to every fitting in quantities sufficient to flush out most of the old greases will go
a long way towards protecting the equipment from rust and corrosion during storage.
For maximum protection against rust and corrosion during prolonged storage, it is best
not to rely on the oil that was clinging to the parts when the rig was shut down. Instead,
use a compound that is specifically designed and formulated for this purpose and apply
it according to the manufacturer's recommendations. In selecting a special storage
lubricant, it is best to use one that does not require any special cleaning before the rig is
run again. There are compounds that will be flushed away by normal lubrication oil and
mix with it harmlessly.
All chains are lubricated by a pressure spray system to provide maximum chain and
bearing life. The guards are designed to assure return of oil to the sump and prevent
any oil from entering the clutch elements. The sump should be filled with the quantity
and viscosity of oil listed below:
Grease all points with lithium-based grease. Where toggle pins and lever bracket
bearings are lubricated directly, sufficient grease should be added at each lubrication
point until grease just begins to seep out around the hub. Self-aligning roller bearings in
weatherproof housings need only a small amount of grease at each application (three or
four grease gun shots per bearing).
www.nov.com
Document No. 9108E029
Page 43
Grease seeping out through the seal or relief fittings during lubrication indicates that the
bearing has received sufficient grease. It is not necessary to keep these housings
completely full of grease as it only expands due to heat during operation and is forced
out through the mechanical seal or relief fitting.
A. Check all spray nozzles to ascertain that oil holes are open and delivering oil. Spray
nozzles are located in all chain drive cases.
B. Check oil supply pressure gauge. It should indicate 30 - 75 psi. Pressure drop
across the filter should not exceed 20 psi.
Pressure Gauges
Dip Stick
Air Tank
Oil Filter
www.nov.com
Document No. 9108E029
Page 44
NOTE: Lubricants equivalent to those listed here may be used during the
warranty period only after consulting with and obtaining subsequent
written approval by the manufacturer to retain the warranty.
8.2 Maintenance
www.nov.com
Document No. 9108E029
Page 45
A1 Check the oil level a few minutes after the shaft has stopped rotating and the
pumps have been shut off to allow circulating oil to accumulate in the lube oil
tank. Test for and drain any condensation in the oil reservoirs at regular intervals;
especially a few hours after shutdown. If dirt or water is present in the drawworks
housing and lube tank, drain the lubricant and renew as per instruction E1.
NOTE: It is not possible to check the lube oil level with the drawworks operating.
The drawworks must be stopped and both lube pumps must be shut off
before checking the lube oil level.
www.nov.com
Document No. 9108E029
Page 46
WARNING: Do not fill the hydraulic tank while the drawworks is operating. A low
hydraulic oil level indicates a leak in the system. The operation
should be brought to a stop and the load secured in the slips. The
brakes should be checked to ensure they have not contaminated with
oil and then the drawworks should be shut off. The leak should be
found and repaired and then the hydraulic tank should be filled as
directed above before continuing operation.
A3 Lube oil pressure is indicated by a gauge in the driller’s cabin (oil pressure should
be approximately 20-75 psi or 517-1034 kPa when the rig is running).
A4 Check piping for leaks (oil and hydraulic) - a pressure drop may indicate a
substantial leak in the system. The presence of oil in the drawworks skid integral
drip pan indicates an oil leak within the drawworks.
A5 Check work area for cleanliness. A clean work area minimizes the chance of
contaminants entering the machinery, which causes premature component wear.
A6 Check the setting of the hydraulic pressure operating the brake caliper. It should
read 1800 psi. Function test the calipers from the driller’s cabin. Ensure all
calipers engage and disengage when activated.
WARNING: Brake caliper operation should be checked at the start of each shift.
www.nov.com
Document No. 9108E029
Page 47
B1 Check all safety controls for malfunction. Function test the crown saver system
and drawworks emergency lowering valve.
B2 Check wireline clamp integrity - the wireline must remain securely within the
clamp without slipping. Leave three or four inches of rope tail. After the rope has
been under load for a period of time, check the nut to ensure tightness.
WARNING: Ensure that the travelling block is secured from falling and that the
brake hydraulic system has been bled off completely. When working
on brakes, brake controls, valves, tubing, hoses, pumps, or any other
brake system component during maintenance/overhaul, inadvertent
release of the brakes may occur resulting in serious damage to
equipment and serious/fatal injuries to personnel.
B3 Inspect pad wear limit (minimum thickness = 0.50”) and inspect shoe linings
(refer to National Oilwell Varco Emergency Disc Brakes Manual EPL-1825).
B4 Ensure the accumulator bottles on the hydraulic system are pressurized. If not,
check for leaks in the system and that the system is functioning properly.
(Accumulator pre charge pressure = 1,000 psi)
NOTE: Accumulator pre charge pressure may only be checked after the entire
hydraulic system has been bled off to zero (0) pressure.
B5 Grease both main drumshaft bearings (four shots each, twice per week).
B6 Grease brake caliper main pins with molybdenum rich EP2 grease. Remove all
excess grease from the pins and brake beam.
www.nov.com
Document No. 9108E029
Page 48
C1 Inspect electrical wiring: visually inspect control system wiring in junction boxes
and instrument cabinets for cut wires, snags or other accidental damage. Unplug
any in-line disconnects, inspect for oxidation, moisture, and signs of arcing.
Clean as required and return to service.
C2 Check wire rope condition monthly. Also, check wirelines prior to use when they
have been unused for more than a few weeks. Slip and cut any wireline that
exhibits broken wires, a significant reduction in cross sectional area, or increase
in length. Pay particular attention to areas around sheaves or yokes. Breaks
often occur in the core of the line and require close inspection to locate. Replace
any rope having damage resulting in distortion of the rope structure. Wireline
corrosion reduces the metallic areas of a rope, thus weakening it. Proper wireline
lubrication will inhibit corrosion
WARNING: Mineral oil based wireline lubricants must not be used on this
drawworks. Asphalt based lubricants and plastic impregnated wire
ropes are acceptable.
C3 Check the availability and condition of tools, especially those required for regular
service. Tools should be present and in good condition.
C4 Grease all accessible fittings on the brake caliper. If fittings are not accessible,
the greasing of these fittings should be performed at the bi-annual interval
(disassemble and clean levers and pins).
C5 Remove, clean and rotate all brake caliper pins. Check for cracks and/or wear.
Apply molybdenum rich grease to all pins prior to reassembly. After reassembly
grease all pins equipped with grease zerks. Remove all excess grease from the
brake calipers and the brake beam.
www.nov.com
Document No. 9108E029
Page 49
C6 Check oil spray nozzles for blockage and ensure that oil holes are open and
delivering oil to the chains. If oil is not being distributed correctly and evenly,
adjust oil flow according to instruction A3 in this section.
C7 Check the adjustment of the brake shoe assembly support. Brake pads should
be held square to the brake disc when the brake is released. If not, apply the
brake caliper with the following procedure:
1. Adjust air gap for brake pad to 0.060”.
2. Install the brake shoe assembly support in position (items 1 and 2).
3. Install bolts A and B finger tight.
4. Tighten both bolts A and B.
5. Install bolt C into piece 1 (as shown in diagram below).
6. Install acorn nut D and tighten acorn nut onto bolt C.
7. Release any hydraulic pressure from the caliper to ensure it is applied onto
the brake disc.
8. Adjust both bolts C so the acorn nut is just touching the brake pad shoe.
9. Tighten the locking nut on bolt C.
10. Apply hydraulic pressure to release the brake caliper from the disc.
11. Ensure the pad remains parallel to the brake disc.
www.nov.com
Document No. 9108E029
Page 50
The calipers include the shoe assembly supports, but these are only to be used
on the middle and bottom calipers due to the location and inclination of the top
caliper.
Please follow the next instructions (for reference see sketches below) when
assembling or replacing the adjustment brackets located on the top caliper:
• Remove the “Brake shoe assembly support” on each side of the caliper.
• Install the “Top caliper pad adjustment bracket” on each side of the caliper.
Sketch 1
www.nov.com
Document No. 9108E029
Page 51
D3 Refer to the National Oilwell Varco Emergency Disc Brake Caliper manual in
Vendor Information section.
D4 Check breathers on the hydraulic oil and lube oil tanks. Replace if there is any
indication of dirt or oil clogging the breather. Also, check the chain case
breather.
E1 Change drawworks oil: Open the lube oil drain valve and drain oil while the unit is
still warm. Renew air breather filter. Ensure the lube tank is clean before closing
the drain valve and refilling the oil tank to the proper level. Approximate oil
requirement is 379 litres (100 US gal.). Rust and oxidation inhibitors may be
beneficial oil additives. Avoid detergent oils because of their tendency to form an
emulsion in the presence of water.
E2 Inspect lube oil piping: Inspect the lube oil distribution lines leading to each chain
and sprocket. The lines should not restrict oil distribution in any way to the
components, which require the oil.
www.nov.com
Document No. 9108E029
Page 52
E4 Check the sprockets for wear. Unevenly worn sprockets may be due to incorrect
oil distribution. Refer to instruction E5 in this section to test and adjust the oil
distribution.
E5 Check oil spray nozzles for blockage and ensure that oil holes are open and
delivering oil to the chains. If oil is not being distributed correctly and evenly,
adjust oil flow according to instruction A2 in this section.
E6 Check condition of hydraulic fluid. The fluid must remain free from foreign
contamination.
E7 Check the condition of accumulator bottles every six months including the
bladder and valves and piping. Replace bladder if there are leaks or cracks, etc.
E8 Refer to the National Oilwell Varco Emergency Disc Brake Caliper manual in
Vendor Information section.
F1 Refer to the National Oilwell Varco Emergency Disc Brake Caliper manual in
Vendor Information section.
F2 Visually inspect all critical components for signs of wear, distortion, cracks,
mechanical damage, etc. These critical components include brake calipers, brake
mount, hydraulic tubing and hose, lube piping, drum, wireline clamps, motor
mount, etc.
www.nov.com
Document No. 9108E029
Page 53
National Oilwell Varco’s Dreco series of drawworks are designed with fixed center roller
chain drives. The shaft centers are designed so a new chain will be tight on installation
but will not become “loose” after the initial run in. The chains should be inspected at
least once every three months and when it is loose enough, two pitches of chain should
be removed and a half link installed to tighten up the chain. Roller chain should be
replaced as soon as it has stretched to 1.5% of it nominal pitch length. This means a
100 pitch long piece of 1” pitch chain should be discarded as soon as the chain has
stretched to a length of 101.5”. This can be measured by checking a smaller portion of
the chain (i.e. 10 pitches of 1” chain should not be more that 10.15” long).
www.nov.com
Document No. 9108E029
Page 54
5. Alternately from one pitch hole to the other, continue to drive the ends of the link
plate onto the pins until it is clear of the spring clip groove or cotter hole. Care
should be taken not to drive the plate on so far as to squeeze against or pinch the
roller links. This will result in stiff or binding joints.
6. Install the retaining device, either spring clip or cotter.
CAUTION: Never drill out or enlarge the pitch holes of a press-fit cover plate to
make the installation easier. This will lower the integrity of the link.
Slip-fit cover plates, discussed in the General Drive Considerations section, are those,
which have a clearance fit on the pins. These connecting links are far easier to install
but reduce the working load capacity of the chain.
NOTE: When a slip-fit cover plate is used, a chain’s working capacity can be reduced
as much as 30%.
Spring clips are provided for chain models #25 - #60 and provide a quick and easy
method for securing the cover plate. Installation is performed by first determining the
direction of chain travel and locating the closed end of the clip over the leading pin’s
groove. Final installation is performed by “snapping” the clip over the trailing pin,
locking it into the groove. Care should be taken not to bend or deform the clip during
installation as this may cause it to come loose during operation.
Direction of Travel
Cotters are normally provided on #80 and larger models’ connecting links as the
method of retaining the cover plate. These cotters are specially heat treated to obtain
specific properties which are beneficial in service. After insertion, the legs should not be
spread in excess of 90° (included angle) and if removed should not be reused. It is not
recommended to use commercial cotters as they may not provide satisfactory
performance in severe applications.
www.nov.com
Document No. 9108E029
Page 55
Dimensions in Inches
A roller chain consists of a series of connected journal bearings which must be properly
lubricated to obtain the maximum service life. Although many slow speed drives
operate successfully with little or no lubrication beyond that initially applied at the time of
manufacture, continued proper lubrication will greatly extend the useful life of every
chain drive.
www.nov.com
Document No. 9108E029
Page 56
In selecting a lubricant, a good grade of clean petroleum oil without additives is most
commonly recommended. Certain additives in oil can leave a varnish or gum build-up
which will prevent additional lubricant from entering chain joints.
The viscosity of the lubricant greatly affects its ability to flow into the internal areas;
therefore, the highest viscosity oil which will flow between the chain link plates and fill
the pin-bushing areas will provide the greatest film thickness and best wear life.
Greases, applied to the exterior of the chain, serve no purpose with the exception of
protecting the external surfaces from rust or corrosion and should not be relied upon to
provide any internal lubricating benefits.
The following table provides a guideline for selecting the proper lubricant viscosity at
various ambient temperatures:
NOTE: National Oilwell Varco recommends the use of an ISO 150 gear oil for warmer
climates and an ISO all season gear oil for colder climates.
www.nov.com
Document No. 9108E029
Page 57
There are three basic methods of lubrication for roller chain drives. Close adherence to
these recommended types of lubrication is essential in obtaining the maximum service
life of a chain drive. These recommended types of lubrication, as shown in the
horsepower rating tables, are determined by the chain speed and the amount of power
transmitted.
www.nov.com
Document No. 9108E029
Page 58
The following table can be used as a guide for determining the type of lubricating
system based upon the speed of the chain in feet per minute. The final selection
should, however, be based upon the type of lubrication system recommended in the
horsepower rating tables for the specific chain, sprocket, speed and horsepower
transmitted.
All chain drives should receive regular maintenance. Each drive should be inspected
after the initial 100 hours of operation. Thereafter, most drives may be inspected at
500-hour intervals. For drawworks chains should be inspected every three months
minimum. However, drives subjected to shock loads or severe operating conditions
should be inspected at more frequent intervals. This section will provide guidance as to
what items should be evaluated during regular inspection intervals.
The strongest chain, built to the highest quality standards, still can break in normal
service due to the effects of wear, fatigue, or unexpected overloads. Therefore, a roller
chain drive should have adequate guarding to prevent personal injury or property
damage.
If a roller chain breaks on a drive while operating at speed, the chain can be thrown off
the sprockets with considerable force. The user should either provide adequate
guarding to contain a broken chain, or prevent personnel from entering an area where a
broken chain could strike them.
www.nov.com
Document No. 9108E029
Page 59
There are applications where a broken chain could release a load and cause personal
injury or property damage. Provisions for a brake or other restraining device which will
stop and hold the load in the event of a broken chain should be incorporated into the
machinery’s design.
Regular Inspections: At each inspection, the following items should be checked, the
condition corrected, or the chain replaced as necessary:
1. Check Lubrication
On slow speed drives, be sure the lubrication schedule is being followed and if
the chain is covered with dirt and debris, clean the chain with an approved
solvent and lubricate it. If drip lubrication is used, check for adequate oil flow and
be sure it is being applied at the proper location on the chain. (Refer to the
Lubrication section.)
www.nov.com
Document No. 9108E029
Page 60
Check for and eliminate any build-up of debris or foreign material between the
chain and sprockets. A relatively small amount of debris in the sprocket roll seat
can cause tensile loads great enough to break the chain if forced through the
drive.
8. Evidence of Lubrication
One of the first indications that a roller chain is not receiving adequate lubrication
is that the external areas around the joints will most likely have a reddish/brown
(rusty) colour. The inadequate lubrication can be confirmed by removing a link
(most commonly the connecting link) and examining the surface of the pins. The
colour of the pins will generally be dark brown, even blue, if the chain has been
running with inadequate lubrication. Additionally, the surface of poorly lubricated
pins will be rough, grooved, or even show evidence of galling.
Properly lubricated chains will not exhibit the rusty colour at the joints, and the
pins of the connecting links, when removed will be generally smooth, shiny and
have an obvious coating of lubricant on the surface.
www.nov.com
Document No. 9108E029
Page 61
10. TROUBLESHOOTING
10.1 Equipment Fault Symptoms & Causes
There are many variables that could play a factor in field operation; therefore, if there
are problems not listed and cannot be solved, contact National Oilwell Varco for
assistance. Assuming the drawworks equipment is properly installed and operated, and
undergoes routine maintenance and change-out, little or no trouble should be expected
from the equipment. Because the symptoms of a failed or worn component may differ
with the equipment operating conditions, observe those conditions (e.g. load/no load,
braking, etc.) which best indicate the symptoms. Understanding the schematic drawings
may be helpful for isolating faults related to the controls or lubrication systems. Where
possible, use other means to verify operation or fault conditions (e.g. pressure gauges
for hydraulics). Use the following table as a guide for fault diagnosis:
www.nov.com
Document No. 9108E029
Page 62
www.nov.com
Document No. 9108E029
Page 63
www.nov.com
Document No. 9108E029
Page 64
www.nov.com
Document No. 9108E029
Page 65
www.nov.com
Document No. 9108E029
Page 66
With any tensioning method of making connections, it is important to install bolts in all
holes of the connection and bring them to a snug-tight condition to compact the joint.
Tightening should begin at the most rigidly fixed or stiffest point and progress toward the
free edges both in the initial snugging-up and in the final tightening.
a. Nut rotation is relative to bolt regardless of the element (nut or bolt) being turned. For bolts installed
by 1/2 turn and less, tolerance is ± 30°; for bolts installed by 2/3 turn and more, tolerance is ± 45°.
b. Applicable only on connection in which all materials within the grip of the bolt are steel.
c. No research has been performed by AISC to establish the turn-of-nut values for bolt lengths
exceeding 12 diameters. Therefore, the required rotation must be established by actual test in a
suitable tension measuring device that simulates conditions of solidly fitted steel.
www.nov.com
Document No. 9108E029
Page 67
www.nov.com
Document No. 9108E029
Page 68
www.nov.com
Document No. 9108E029
Page 69
www.nov.com
Document No. 9108E029
Page 70
www.nov.com
Document No. 9108E029
Page 71
www.nov.com
Document No. 9108E029
Page 72
www.nov.com
Document No. 9108E029
Page 73
www.nov.com
Document No. 9108E029
Page 74
www.nov.com
Document No. 9108E029
Page 75
13. CERTIFICATES
www.nov.com
Document No. 9108E029
Page 76
www.nov.com
Document No. 9108E029
Page 77
14. DRAWINGS
www.nov.com
Document No. 9108E029
Page 78
www.nov.com
Document No. 9108E029
Page 79
www.nov.com
Instruction Sheet
¤
Index:
English ...................................................................1-7
Français .............................................................. 8-14
Deutsch ............................................................ 15-22
Italiano .............................................................. 23-29
Español............................................................. 30-36
Nederlands ....................................................... 37-44
Portuguese ....................................................... 45-51
........................................................... 52-58
................................................................59-64
WARNING: Stay clear of loads supported
Repair Parts Sheets for this product are available by hydraulics. A cylinder, when used as a
from the Enerpac web site at www.enerpac.com, or load lifting device, should never be used
from your nearest Authorized Enerpac Service Center as a load holding device. After the load
or Enerpac Sales office. has been raised or lowered, it must always be
blocked mechanically.
1.0 IMPORTANT RECEIVING WARNING: USE ONLY RIGID PIECES
INSTRUCTIONS TO HOLD LOADS. Carefully select steel
®
Visually inspect all components for shipping damage. or wood blocks that are capable of
®
Shipping damage is not covered by warranty. If supporting the load. Never use a hydraulic cylinder
shipping damage is found, notify carrier at once. The as a shim or spacer in any lifting or pressing
carrier is responsible for all repair and replacement application.
costs resulting from damage in shipment. DANGER: To avoid personal injury
keep hands and feet away from cylinder
SAFETY FIRST and workpiece during operation.
2.0 SAFETY ISSUES WARNING: Do not exceed equipment
ratings. Never attempt to lift a load
Read all instructions,
weighing more than the capacity of the
warnings and cautions
cylinder. Overloading causes equipment
carefully. Follow all safety
failure and possible personal injury. The cylinders are
precautions to avoid personal injury or property
designed for a max. pressure of 700 bar [10,000 psi].
damage during system operation. Enerpac cannot be
Do not connect a jack or cylinder to a pump with a
responsible for damage or injury resulting from unsafe
higher pressure rating.
product use, lack of maintenance or incorrect product
and/or system operation. Contact Enerpac when in DANGER: Never set the relief valve to a
doubt as to the safety precautions and operations. If higher pressure than the maximum rated
you have never been trained on high-pressure pressure of the pump. Higher settings
hydraulic safety, consult your distribution or service may result in equipment damage and/or
center for a free Enerpac Hydraulic safety course. personal injury. Do not remove relief valve.
Failure to comply with the following cautions and WARNING: The system operating
warnings could cause equipment damage and pressure must not exceed the pressure
personal injury. rating of the lowest rated component in
the system. Install pressure gauges in the
A CAUTION is used to indicate correct operating or
system to monitor operating pressure. It is your
maintenance procedures and practices to prevent
window to what is happening in the system.
damage to, or destruction of equipment or other
property. CAUTION: Avoid damaging hydraulic
hose. Avoid sharp bends and kinks when
A WARNING indicates a potential danger that
routing hydraulic hoses. Using a bent or
requires correct procedures or practices to avoid
kinked hose will cause severe back-
personal injury.
pressure. Sharp bends and kinks will internally
A DANGER is only used when your action or lack of damage the hose leading to premature hose failure.
action may cause serious injury or even death.
Do not drop heavy objects on hose. A
WARNING: Wear proper personal sharp impact may cause internal damage
protective gear when operating hydraulic to hose wire strands. Applying pressure to
®
SPECIFICATIONS – Use this instruction sheet for the following hand pump models.
Hand Pump Specifications
Model Type Maximum Pressure Oil Volume per Stroke Usable Oil Capacity
(Speed) Rating psi [bar] in 3 [cm 3] in3 [cm3]
EHF-65 1 6,500 [440] .16 [2.62] 22 [360]
P-18 1 2,850 [200] .16 [2.62] 22 [360]
P-25 1 2,500 [170] .58 [9.51] 231 [3786]
P-39, 1003 1 10,000 [700] .16 [2.62] 43 [705]
P-50 1 5,000 [340] .29 [4.75] 231 [3786]
P-51 1 3,000 [210] .25 [4.09] 50 [820]
P-141, 1001 1 10,000 [700] .055 [.90] 20 [328]
P-391, 1004 1 10,000 [700] .151 [2.47] 55 [900]
2
P-842 3.2 Models P-18/P-39, 1003/P-80, 1006/
Figure 1 and the corresponding table show the main P-84/P-801
components of hand pump models P-141, P-142, P- Figure 2 and the corresponding table below show the
202, P-391, P-392, P-802, and P-842. The dual- main components of these hand pump models.
purpose vent/fill cap acts as a pressure relief valve in Model P-84 is equipped with a 4-way, 3-position
case of accidental reservoir pressurization. To valve for use with double-acting cylinders. To convert
provide an access port at the rear of the reservoir for models P-18 or P-39 to foot operation, order Kit PC-
remote valves, use a return-to-tank kit. See the Table 10.
1 for kit model numbers.
Figure 1 Figure 2
Table 1
Fig. 1 P-141, 1001 P-142, 1002 P-202 P-391, 1004 P-392, 1005 P-802 P-842
A Release Valve Release Valve Release Valve Release Valve Release Valve Release Valve 4-Way Valve
B 1 /4 NPTF 1 /4 NPTF 1 /4 NPTF 3/8 NPTF 3/8 NPTF 3/8 NPTF 3/8 NPTF
Outlet Port Outlet Port Outlet Port Outlet Port Outlet Port Outlet Port Outlet Port
C Vent/Fill Vent/Fill Vent/Fill Vent/Fill Vent/Fill Vent/Fill Vent/Fill
Cap Cap Cap Cap Cap Cap Cap
D Mounting Mounting — — — Mounting Mounting
Slots Slots Slots
E — — — — — Return-to-Tank Port —
Return-to PC-20 PC-20 PC-25 PC-25 PC-25 — —
-Tank Kit
Table 2
Fig. 2 P-18 P-39, 1003 P-80, 1006 P-84 P-801
A Release Valve Release Valve Release Valve Release Valve Release Valve
B 3/8 NPTF 3/8 NPTF 3/8 NPTF 3/8 NPTF 3/8 NPTF
Outlet Port Outlet Port Outlet Port Outlet Port Outlet Port
C Fill Plug Fill Plug Fill Plug Fill Plug Fill Plug
D — — 1/4 NPTF — 1/4 NPTF
Return-to-Tank Port Return-to-Tank Port
3
3.3 Models P-462 and P-464 Table 4 and 5
Figure 3 and the table below show the main features Fig. 4 & 5 P-25 P-50 P-51
of hand pump models P-462, for use with single- A Release Valve Release Valve Release Valve
acting cylinders, and P-464, for use with double- B 1/4 NPTF 1/4 NPTF 1/4 NPTF
Outlet Port Outlet Port Outlet Port
acting cylinders.
C Vent/Fill Cap Vent/Fill Cap Vent/Fill Cap
4.0 INSTALLATION
OPERATING POSITION
EHF-65. . . . . . . . . either P-142AL . . . . . . . either
P-18 . . . . . . . . . . . either P-202 . . . . . . . . . either
P-25 . . . . horizontal only P-391, 1004 . . . . . either
P-39, 1003 . . . . . . either P-392, 1005 . . . . . either
P-50 . . . . horizontal only P-392AL . . . . . . . . either
P-51 . . . . horizontal only P-462. . . horizontal only
P-80, 1006 . . . . . . either P-464 . . . horizontal only
P-84 . . . . . . . . . . . either P-801 . . . . . . . . . either
P-141, 1001 . . . . . either P-802 . . . . . . . . . . either
P-142, 1002 . . . . . either P-842 . . . . . . . . . either
Figure 6 Figure 8a
5
5.6 Relief Valve Adjustment
All pumps contain a factory set relief valve to prevent
over-pressurization of the system. Lower pressure
settings can be obtained. Contact your Authorized
Enerpac Service Center.
1. Position lever on 4-way valve to select function as 6.1 Pump With Single-Acting Cylinder (A)
follows: 1. Vent pump reservoir (for vented pumps only) and
(A) Flow to Port "A"; port "B" returns flow to the close release valve.
reservoir 2. Position pump at higher elevation than cylinder.
(N) Neutral; ports "A" and "B" are blocked 3. Position cylinder with the plunger end down (up if
(B) Flow to port "B"; port "A" returns flow to the using pull cylinder). See Figure 9 below.
reservoir 4. Operate pump to fully extend the cylinder (retract
if using pull cylinder).
5. Open release valve to retract cylinder (extend if a
pull cylinder). This will force the trapped air to
move up to the pump reservoir.
6. Repeat the above steps as necessary.
7. Add oil if necessary. See page 7.
8. Return vent/fill cap to operating position.
6.2 Pump With Double-Acting Cylinder (B)
1. Vent pump reservoir (for vented pumps only).
2. Position pump at higher elevation than cylinder.
3. Put cylinder in horizontal position with ports up.
See Figure 9.
Figure 8c 4. Fully advance and retract the cylinder 2 to 3 times.
5. Repeat the above steps as necessary.
2. Operate pump to perform work. 6. Add oil if necessary. See page 7.
3. Change valve positions as needed. 7. Return vent/fill cap to operating position.
air
air
Figure 9
6
7.1 Adding Oil to the Pump
Check oil level regularly.
WARNING: Always add oil with
cylinders fully retracted (extended if
pull cylinders) or the system will contain
more oil than the reservoir can hold.
1. Remove vent/fill cap from reservoir.
2. Fill reservoir only to level mark shown on pump.
3. Remove air from system if necessary. See page 6.
Recheck oil level after removing air.
4. Return vent/fill cap to proper position. Figure 10
NOTE: Non-vented hand pumps require air in the
reservoir to function properly. If the reservoir is 7.4 Changing the Oil
completely filled, a vacuum will form preventing 1. Drain all oil and refill with clean Enerpac oil every
oil from flowing out of the pump. 12 months. If pump is used in dirty environments,
change the oil more often.
7.2 Keeping Oil Lines Clean
2. Remove vent/fill cap or plug from reservoir.
When coupler halves are disconnected, always screw 3. Tilt pump to drain out old oil.
on dust caps. Use every precaution to guard unit
against entrance of dirt because foreign matter may 4. Fill reservoir only to level mark shown on pump.
cause pump, cylinder, or valve failure. 5. Replace the vent/fill cap or plug.
6. Dispose of used oil properly.
7.3 Lubricating the Pump
To extend pump life and improve performance,
8.0 TROUBLESHOOTING GUIDE
lubricate the beam pin (A), cross pin (B), and piston
head (C) regularly, using roller bearing grease. See The following information is intended as an aid in
Figure 10. determining if a problem exists. For repair service,
contact the Authorized Enerpac Service Center in
your area.
TROUBLESHOOTING
Problem Possible Cause Solution
Cylinder does not 1. Oil level in pump reservoir is 1. Add oil according to the Maintenance instructions on
advance, advances low. page 6.
slowly, or advances in 2. Release valve open. 2. Close the release valve.
spurts.
3. Loose hydraulic coupler. 3. Check that all couplers are fully tightened.
4. Load is too heavy. 4. Do not attempt to lift more than rated tonnage.
5. Air trapped in system. 5. Remove air according to the instructions on page 6.
6. Cylinder plunger binding. 6. Check for damage to cylinder. Have cylinder serviced by
a qualified hydraulic technician.
Cylinder advances, but 1. Leaking connection. 1. Check that all connections are tight and leak free.
does not hold pressure. 2. Leaking seals. 2. Locate leak(s) and have equipment serviced by a
3. Internal leakage in pump. qualified hydraulic technician.
3. Have pump serviced by a qualified hydraulic technician.
Cylinder does not retract, 1. Release valve closed. 1. Open release valve.
retracts part way, or 2. Pump reservoir is over-filled. 2. Drain oil level to full mark. See page 7 instructions for
retracts more slowly than adding oil.
3. Loose hydraulic coupler.
normal.
4. Air trapped in system. 3. Check that all couplers are fully tightened.
5. Hose I.D. too narrow. 4. Remove air according to the instructions on page 6.
6. Cylinder retraction spring 5. Use larger diameter hydraulic hose.
broken or other cylinder 6. Have cylinder serviced by a qualified hydraulic
damage. technician.
7
Enerpac Worldwide Locations ✦ e-mail: info@enerpac.com ✦ internet: www.enerpac.com
Australia Germany, Austria Singapore
ENERPAC, Applied Power Australia Ltd. ENERPAC Applied Power GmbH Actuant Asia Pte. Ltd.
Block V Unit 3, Regents Park Estate P.O. Box 300113, D-40401 Düsseldorf 25 Serangoon North Ave. 5
391 Park Road, Regents Park NSW 2143 Germany #03-01 Keppel Digihub
(P.O. Box 261) Australia Tel: +49 211 471 490 Singapore 554914
Tel: +61 297 438 988 Fax: +49 211 471 49 28 Thomson Road, P.O. Box 114
Fax: +61 297 438 648 India Singapore 915704
Brazil ENERPAC Hydraulics (India) Pvt. Ltd. Tel: +65 64 84 5108, +65 64 84 3737
Power Packer do Brasil Ltda. Plot No. A/571, MIDC, TTC Industrial Area Fax: +65 64 84 5669
Rua dos Inocentes, 587 Mahape-400 701 South Korea
04764-050 - Sao Paulo (SP) Navi Mumbai, India ENERPAC , Applied Power Korea Ltd.
Tel: +55 11 5687 2211 Tel: +91 22 778 1779 163-12 Dodang-Dong
Fax: +55 11 5686 5583 Fax: +91 22 778 1473 Wonmi-Ku, Buchun-shi
Toll Free in Brazil: Italy Kyunggi-Do Republic of Korea
Tel: 000 817 200 6718 ENERPAC , Applied Power Italiana S.p.A. Tel: +82 32 675 08 36
vendasbrasil@enerpac.com Via Canova 4 Fax: +82 32 675 30 02/73
Canada 20094 Corsico (Milano) Spain, Portugal
Actuant Canada Corporation Tel: +39 02 4861 111 ENERPAC , C/San José Artesano 8 Pol. Ind.
6615 Ordan Drive, Unit 14-15 Fax: +39 02 4860 1288 28108 Alcobendas
Mississauga, Ontario L5T 1X2 Japan (Madrid) Spain
Tel: +1 905 564 5749 Applied Power Japan Ltd. Tel: +34 91 661 11 25
Fax: +1 905 564 0305 1-1-11, Shimomae, Toda-shi Fax: +34 91 661 47 89
Toll Free: Saitama Pref. Middle East, Turkey and Caspian Sea
Tel: +1 800 268 4987 Japan 335-0016 ENERPAC Middle East FZE
Fax: +1 800 461 2456 Tel: +81 48 430 2311 P.O. Box 18004
Technical Inquiries: Fax: +81 48 430 1117 Jebel Ali, Dubai
techservices@enerpac.com Mexico United Arab Emirates
China ENERPAC Applied Power Tel: +971 (0)4 8872686
Actuant China Ltd. Mexico S. de R.L. de C.V. Fax: +971 (0)4 8872687
1F, 269 Fute N. Road Avenida Principal, La Paz #100 United Kingdom, Ireland
Waigaoqiao Free Trade Zone Fracc. Industrial La Paz ENERPAC Ltd., P.O. Box 33
Pudong New District 42092 Pachuca, Hidalgo New Romney, TN28 8QF
Shanghai, 200 131 China Tel: +52 771 71851 60 United Kingdom
Tel: +86 21 5866 9099 +52 771 71870 22 Tel: +44 01527 598 900
Fax: +86 21 5866 7156 Fax: +52 771 71352 32 Fax: +44 01527 585 900
Toll Free in Mexico: USA, Latin America
Actuant China Ltd. (Beijing)
Tel: 001 800 590 0130 and Caribbean
709A Xin No. 2 , Diyang Building
The Netherlands, Belgium, Luxembourg, ENERPAC
Dong San Huan North Rd.
Sweden, Denmark, Norway, Finland P.O. Box 3241
Beijing City, 100028 China
ENERPAC B.V., Storkstraat 25 6100 N. Baker Road
Tel: +86 10 845 36166
P.O. Box 269, 3900 AG Veenendaal Milwaukee, WI 53209 USA
Fax: +86 10 845 36220
The Netherlands Tel: +1 262 781 6600
Eastern Europe
Tel: +31 318 535 911 Fax: +1 262 783 9562
Applied Power International S.A.
Fax: +31 318 525 613, +31 318 535 848
Case postale 130, CH-1213 Onex-Genéva User inquiries:
Switzerland Russia and CIS +1 800 433 2766
Tel: +49 (211) 47149 44 (excl. Caspian Sea Countries) Distributor inquiries/orders:
Fax: +49 (211) 47149 40 ENERPAC +1 800 558 0530
France, Greece, Africa Leninsky Prospect 95A Technical Inquiries:
ENERPAC S.A. 117313, Moscow, Russia. techservices@enerpac.com
B.P. 200 Tel/Fax: +7(095) 936-2005
Parc d’Activités Tel/Fax: +7(095) 198-3094
du Moulin de Massy Tel/Fax: +7(095) 938-4655
F-91882 Massy CEDEX (Paris) France Mobil: +7(903) 731-9558
Tel: +33 1 601 368 68 All Enerpac products are guaranteed against defects in workmanship and materials for as long as you own them.
Fax: +33 1 692 037 50 For your nearest authorized Enerpac Service Center, visit us at www.enerpac.com 10/30/02
HIGH PRESSURE FILTERS
Series DF & LF • Pressures to 6000 PSI • Flows to 180 GPM
APPLICATION
• HYDAC DF & LF In-line High
Pressure Filters are designed for
use on hydraulic power units,
machine tools, plastics machinery,
mobile equipment, and hydraulic
test equipment.
• These filters can be installed on
the high-pressure side of the
pump to protect control valves
and actuators from contamination.
• These filters can also be used as
In-line Return Filters.
DF Filters LF Filters
PRODUCT FEATURES
• DF Filters are manufactured with • HYDAC indicators have no external • For non-bypass applications,
a ductile iron head and cold dynamic seal. This results in a high Betamicron® BH3HC or Metal Fiber
formed steel bowl. system reliability due to magnetic (V) elements must be installed. If a
actuation, thus eliminating a potential bypass valve is used, Betamicron®
• LF Filters are manufactured with a
(BN3HC) or Wire Screen (W/HC)
leak point.
cast aluminum head and
elements can be installed.
aluminum extruded bowl. • A poppet-type bypass valve (optional)
is mounted in-line between the inlet • All filter media is supported to
• For special finishes and coatings
achieve flow fatigue resistance.
and outlet ports to provide positive
– consult HYDAC for minimum
sealing during normal operation and • Proper support of the filter media
quantities, availability and pricing.
fast opening during cold starts and also provides high Beta Ratio values
• Non-welded housing design flow surges. (particle removal efficiency) even at
reduces stress concentrations and
high differential pressures. The
prevents fatigue failure.
FILTER ELEMENTS efficiency of many competitive
• Inlet/outlet port options include elements drastically deteriorates as
NPT port, SAE straight thread O- • HYDAC DF & LF Filters are available the element clogs and differential
ring boss, and SAE 4-bolt flange with disposable Betamicron® BN3HC pressure increases.
to allow easy installation without elements having 250 psid and
costly adapters. Betamicron® BH3HC elements • High quality epoxy adhesive is used
to bond the end caps to the media
having 3000 psid collapse pressure
• O-ring seals are used to provide and to bond the seam of the media.
and absolute ratings of 3, 5, 10, and
positive, reliable sealing. Choice
20 micron.
of O-ring materials (Nitrile, Fluoro
Rubber, EPDM) provides • HYDAC DF & LF Filters are also
compatibility with petroleum oils, available with cleanable elements.
synthetic fluids, water-glycols, Metal Fiber (V) stainless steel fleece
oil/water emulsions, and high elements have a 3000 psid collapse
water base fluids. pressure and nominal ratings of 3, 5,
10, and 20 microns. Wire screen
• Screw-in bowl mounted below the
(W/HC) elements have a 250 psid
filter head requires minimal
collapse pressure and nominal
clearance to remove the element
ratings of 25, 74, and 149 microns.
for replacement, and
contaminated fluid cannot be
washed downstream when
element is serviced.
Model Code: Filter Assembly DF & LF Filters
DF BH3HC 30 G 3 A 1 .0/3
Filter Type
DF = 6000 PSI (420 bar)
LF = 1500 PSI (100 bar) (not available in sizes 280, 660, or 1320)
Filter Media
BH3HC = Betamicron® BH3HC High Collapse
(Disposable)
BN3HC = Betamicron® BN3HC Low Collapse
V = Metal Fiber
(Cleanable)
W/HC = Wire Screen
Size and Nominal Connection
30 = 1/2" BSPP / NPT / SAE 8
60 = 3/4" BSPP / NPT / SAE 12
110 = 3/4" BSPP / NPT / SAE 12
160 = 1-1/4" BSPP / NPT / SAE 20
240 = 1-1/4" BSPP / NPT / SAE 20
280 = 1-1/4" BSPP / NPT / SAE 20
330 = 1-1/2" BSPP / NPT / SAE 24 (or 2” Flange on DF model only)
660 = 1-1/2" BSPP / NPT / SAE 24 (or 2” Flange on DF model only)
1320 = 1-1/2" BSPP / NPT / SAE 24 (or 2” Flange on DF model only)
Type of Connection
G = Threaded
F = Flange (only available on DF sizes 330, 660, & 1320)
Filtration Rating in Microns
3
5
BH3HC or BN3HC Absolute Filtration Rating (ßx ≥ 200)
10
20
3
5
V
10
20 Nominal Filtration Rating
25
74 W/HC
149
Type of ∆P Clogging Indicator
A = no clogging indicator LF DF
B = visual (pop-up) clogging indicator (Automatic reset) VM5B.1 VD5B.1
BM = visual (pop-up) clogging indicator (manual reset) VM5BM.1 VD5BM.1
C = electrical clogging indicator (electric switch) VM5C.0 VD5C.0
D = electrical/visual (lamp) clogging indicator (electric switch & light) VM5D.0/L... VD5D.0/L...
J = electric switch (Brad Harrison, 5 pin mini) VMH5J.0 VDH5J.0
J4 = electric switch (Brad Harrison, 4 pin micro) VMH5J4.0 VDH5J4.0
Type Number
1
Modification Number
0 = DF 30 & all LF sizes
1 = DF 60 to 1320
Port Configuration
0 = BSPP
3 = NPT Ports
12 = SAE Straight Thread O-Ring Boss Ports
16 = SAE Flange Ports (DF 330, 660, & 1320 only)
Seals
(omit) = Nitrile (NBR) (standard)
V = Fluoro Rubber (FKM)
EPR = Ethylene Propylene (EPDM)
Bypass Valve
(omit) = Without Bypass (BH3HC or V elements recommended)
B3 = 43PSID Bypass (optional)
B6 = 87PSID Bypass (standard)
Supplementary Details
SO103H = Modification of BN3HC (Low Collapse) Element For Phosphate Esters
SO155H = Modification of BH3HC (High Collapse) Element For Phosphate Esters
SO184 = G-1/2 Drain in Bowl Option For Sizes 60 - 280 (standard for sizes 330, 660, & 1320)
SO150H = Anodize Aluminum (LF Filter components for water based fluids) Consult HYDAC for minimums, availability & pricing
SO110 = Indicator with brass piston (for use with water based fluids)
(Consult factory on B
L24 = Lamp for 24 Volts T70 - Indicator Thermal Lockout, 70°F
& BM Indicators for
L48 = Lamp for 48 Volts (D-type clogging T100 - Indicator Thermal Lockout, 100°F
thermal lockout)
L115 = Lamp for 115 Volts indicator only)
L230 = Lamp for 230 Volts
Model Codes Containing Red are non-stock items — Minimum quantities may apply – Contact HYDAC for information and availability
2
Model Code: High Pressure Filter Elements
0030 D 003 BH3HC
Element Size
Housing Size
DF/LF
0030 30
0060 60
0110 110
0160 160
0240 240
0280 280
0330 330
0660 660
1320 1320
003 = 3 µm
005 = 5 µm
Metal Fiber (V)
010 = 10 µm
020 = 20 µm
Nominal Filtration Rating
025 = 25 µm
074 = 74 µm Wire Screen (W/HC)
149 = 149 µm
V = Metal Fiber
(Cleanable)
W/HC = Wire Screen
Seals
(omit) = Nitrile (NBR) (standard)
V = Fluoro Rubber (FKM)
EPR = Ethylene Propylene (EPDM)
Supplementary Details
SO103H = Modification of BN3HC Element for Phosphate Ester Fluids
SO155H = Modification of BH3HC Element for Phosphate Ester Fluids
Model Codes Containing Red are non-stock items — Contact HYDAC for availability
3
Engineering Data: DF & LF Filters
Design: Inline Pressure Filter
Mounting Method: 4 Mounting holes in Filter Head
Connections:
Size 30 1/2" NPT or SAE- 8 port (3/4-16UNF-2B)
Size 60/110 3/4" N PT or SAE-12 port (1 -1/16-12UN-2B)
Size 160/240/280 1-1/4"NPT or SAE-20 port (1-5/8-12UN-2B)
Size 330 1-1/2"NPT or SAE-24 port (1-7/8-12UN-2B)
SAE-32 Flange, Code 62 (DF only)
Size 660/1320 1-1/2"NPT, SAE-24 port (1-7/8-12UN-2B),
or SAE-32 Flange, Code 62 (DF only)
Direction of Flow: Inlet: Side Outlet: Side (opposite inlet)
Housing Pressure Ratings: DF (iron head & steel bowl) LF (aluminum)
Operating: 6000 psid/420 bar 1500 psid/103 bar
Proof: 9000 psid/620 bar 2250 psid/155 bar
Fatigue: Contact HYDAC office
Burst: Contact HYDAC office
Element Collapse Standard Elements: BN3HC: 250 psid/17 bar
Pressure Ratings: W/HC: 250 psid/17 bar
(ISO 2941) High Collapse Elements: BH3HC: 3000 psid/207 bar
V: 3000 psid/207 bar
Fluid Temperature Range: (All seal types) -22°F to 250°F (-30°C to 121°C)
Based on Nitrile Seals under maximum continuous operating pressure.
Please contact HYDAC for information on extreme low
temperature applications (below -15°F.)
Fluid Compatibility: Compatible with all petroleum oils, water glycols, oil/water
(ISO 2948) emulsions, high water base fluids, and synthetic fluids
compatible with Fluoro Rubber or EPR seals.
Flow Fatigue Resistance: Filter medium is supported to achieve flow fatigue resistance.
(ISO 3724) Contact HYDAC office for information.
Trip Pressure of Differential Pressure Indicator: DP = 72 psid/5 bar - 10%(Standard)
DP = 29 psid/2 bar - 10% (Optional)
Cracking Pressure of DP = 87 psid/6 bar + 10% (Standard)
Bypass Valve: DP = 43 psid/3 bar + 10% (Optional)
DF & LF
Filter
Bypass
Element
Valve
Pop-up
Indicator
OUTLET
4
Pressure Drop Calculations:
Assembly:
To calculate the pressure drop of the filter assembly use the equation:
Housing:
The housing curve is based on test results using mineral oil with a specific gravity of 0.86. Differential pressure increases
in proportion to specific gravity of applicable fluid. To adjust the housing ∆P for the fluid being used, use the equation:
20 2.0 25
1.2
1.0 15 1.5 20
∆P in bar
∆P in bar
∆P in psi
∆P in psi
0.8
10 1.5 10
0.6
0.4 5 0.5 5
0.2
0 0 0 0
0 1 2 3 4 5 6 7 8 0 5 10 15 20 25 30
Q in gpm Q in gpm
0 5 10 15 20 25 30 0 15 30 45 60 75 90 105120
Q in l/min Q in l/min
DF & LF SIZES 160, 240, & 280 HOUSING DF & LF SIZES 330, 660, & DF 1320 HOUSING
20
1.2 25
3.2
1.0 15 20
∆P in bar
∆P in psi
∆P in bar
2.4
∆P in psi
0.8
10 20
0.6 1.6
0.4 10
5
0.2 0.8 5
0 0 0 0
0 10 20 30 40 50 60 0 30 60 90 120 150 180
Q in gpm Q in gpm
0 40 80 120 160 200 240 0 120 240 360 480 600 720
Q in l/min Q in l/min
∆P in psi
8 120
6 80
4
40
2
0 0
0 20 40 60 80 100
Q in gpm
63% = 1 psi ∆P for 0060D...W element (using graph to the right) 0.15
2
∆P in bar
∆P in psi
...W/HC
0.10
1
0.05
All element curves are based on test results using mineral oil
with a kinematic viscosity of 141 SSU and a specific gravity 0 0
of 0.86. The differential pressure across the element changes 0 20 40 60 80 100 120
proportionally to the viscosity and specific gravity. To adjust figures Q in gpm as % of
Max. Recommended Flow
for a different fluid use the equation:
0030D..BN3HC 0030D..BH3HC
3µm 3µm
35 60
5µm
30 50
10µm
25 5µm
40
∆P in psid
∆P in psid
20
10µm 30
15 20µm
20µm 20
10
5 10
0 0
0 2 4 6 8 10 0 2 4 6 8 10
Flow in gpm Flow in gpm
0060D..BN3HC 0060D..BH3HC
3µm 3µm
40 60
35 50
30 5µm
40
∆P in psid
∆P in psid
25 5µm
10µm
20 30
10µm
15 20
20µm
10 20µm
10
5
0 0
0 5 10 15 20 0 5 10 15 20
Flow in gpm Flow in gpm
6
Pressure Drop Calculations: (continued)
0110D..BN3HC 0110D..BH3HC
3µm 3µm
40 60
35
50
30 5µm
40
∆P in psid
∆P in psid
25 5µm
10µm
20 30 10µm
15 20µm 20
10 20µm
10
5
0 0
0 10 20 30 40 0 10 20 30 40
Flow in gpm Flow in gpm
0160D..BN3HC 0160D..BH3HC
3µm 3µm
35 45
30 40
35 5µm
25 5µm 30 10µm
∆P in psid
∆P in psid
20 10µm 25
15 20
20µm
20µm 15
10
10
5 5
0 0
0 10 20 30 40 50 0 10 20 30 40 50
Flow in gpm Flow in gpm
0240D..BN3HC 0240D..BH3HC
3µm 3µm
35 40
30 35
5µm 5µm
30
25 10µm
∆P in psid
∆P in psid
25
20
10µm 20
15 20µm
15
10 20µm
10
5 5
0 0
0 20 40 60 80 0 20 40 60 80
Flow in gpm Flow in gpm
0280D..BN3HC 0280D..BH3HC
20 3µm 30 3µm
18
16 25
14 20
∆P in psid
∆P in psid
5µm
12
5µm
10 10µm 15 10µm
8
6 10
20µm
4 20µm
5
2
0 0
0 20 40 60 80 0 20 40 60 80
Flow in gpm Flow in gpm
7
Pressure Drop Calculations: (continued)
0330D..BN3HC 0330D..BH3HC
3µm
35 3µm 50
45
30
40 5µm
5µm 10µm
25 35
∆P in psid
∆P in psid
20 30
10µm
25
15 20 20µm
10 20µm
15
10
5
5
0 0
0 20 40 60 80 100 0 20 40 60 80 100
Flow in gpm Flow in gpm
0660D..BN3HC 0660D..BH3HC
35 50 3µm
3µm
45
30
40
25 5µm 5µm
35 10µm
∆P in psid
∆P in psid
20 30
25
15 10µm
20
20µm
10 15
20µm
10
5
5
0 0
0 50 100 150 200 0 50 100 150 200
Flow in gpm Flow in gpm
1320D..BN3HC 1320D..BH3HC
12 3µm 16 3µm
14
10
5µm 12
8
∆P in psid
∆P in psid
10 5µm
10µm
6 8
20µm 10µm
6
4 20µm
4
2
2
0 0
0 50 100 150 200 0 50 100 150 200
Flow in gpm Flow in gpm
Metal Fiber
K Factors for ...D...V Elements
Size 3µm 5µm 10µm 20µm
0030 0.98784 0.71344 0.40611 0.20306
0060 0.87808 0.60368 0.35672 0.18110
0110 0.45550 0.32928 0.23050 0.11525
0160 0.24696 0.17562 0.12622 0.07683
0240 0.17561 0.13171 0.10427 0.06037
0280 0.08232 0.06586 0.05488 0.02744
0330 0.11525 0.08232 0.07134 0.04281
0660 0.06037 0.04939 0.03293 0.01701
8
Dimensons: DF Size 1320
DF 1320
1/2-20UNF x 0.67
M12 x 17
in 4 places
4.528
115
6.26 5.433
159 138
2.362
60
6.575
167
6.30
( on 1320 F)
160
DF 1320 F only
SW27
.236 3.811
6 96.8
3/4-10UNC-2B x 1.00
25
(4 Places)
1 1/2 NPT
1 7/8-12UN (SAE-24) 2.047
52
G 1 1/2 1.750
.905 deep 44.5
23
29.212
742 SAE-32 FLANGE
CODE 62 - 6000 psi (414 bar)
4.409
112
SW36
9
Dimensions: DF & LF Filters (sizes 30-660) in inches/mm
D3
SIZE B1 B2 B3 B4 B5 D1 D2 D4
NPT BSP SAE
2.72 1.34 1.772 1.181 ø2.64 ø2.05
30 — 1/2 G1/2 3/4-16UNF —
69 34 45 30 ø67 ø52
3.62 1.97 2.205 1.260 1.81 ø3.31 ø2.68 ø1.65
60/110 3/4 G3/4 1 1/16-16UN
92 50 56 32 46 ø84 ø68 ø42
5.04 2.64 3.346 1.378 2.01 ø4.57 ø3.74 ø2.28
160/240/280 1 1/4 G1 1/4 1 5/8-12UN
128 67 85 35 51 ø116 ø95 ø58
6.38 3.35 4.528 2.362 3.23 ø6.30 ø5.12 ø2.56
330/660 1 1/2 G1 1/2 1 7/8-12UN
162 85 115 60 82 ø160 ø130 ø65
SIZE D5 H1 H2 H3 H4 H5 HEX 1 HEX 2 T1 T2
10-32UNF 3.46 5.04 1.34 0.28 3.00 1 1/16 1.00 0.24
30 —
M5 88 128 34 7 75 27 24 6
1/4-28UNF 3.35 5.55 1.61 0.28 3.00 1 1/16 1 1/16 0.04 0.35
60
M6 85 141 41 7 75 27 27 1 9
1/4-28UNF 6.06 8.11 1.61 0.28 3.00 1 1/16 1 1/16 0.04 0.35
110
M6 154 206 41 7 75 27 27 1 9
3/8-24UNF 4.61 7.48 1.89 0.28 3.38 1 1/16 1 5/16 0.04 0.55
160
M10 117 190 48 7 85 27 32 1 14
3/8-24UNF 6.93 9.88 1.89 0.28 3.38 1 1/16 1 5/16 0.04 0.55
240
M10 176 251 48 7 85 27 32 1 14
3/8-24UNF 13.7 17.13 1.89 0.28 3.38 1 1/16 1 5/16 0.04 0.55
280
M10 348 435 48 7 85 27 32 1 14
1/2-20UNF 6.54 9.92 2.01 0.28 3.75 1 1/16 1 7/16 0.04 0.67
330
M12 166 252 51 7 95 27 36 1 17
1/2-20UNF 13.27 16.65 2.01 0.28 3.75 1 1/16 1 7/16 0.04 0.67
660
M12 337 423 51 7 95 27 36 1 17
D3
SIZE B1 B2 B3 B4 B5 D1 D2 D4
NPT BSP SAE
2.68 1.30 1.772 1.181 ø2.64 ø2.05
30 — 1/2 G1/2 3/4-16UNF —
68 33 45 30 ø67 ø52
3.58 1.97 2.205 1.260 1.77 ø3.27 ø2.68 ø1.65
60/110 3/4 G3/4 1 1/16-12UN
91 50 56 32 45 ø83 ø68 ø42
5.00 2.56 3.346 1.378 1.97 ø4.53 ø3.74 ø2.28
160/240/280 1 1/4 G1 1/4 1 5/8-12UN
127 65 85 35 50 ø115 ø95 ø58
6.30 3.35 4.528 2.362 3.15 ø6.18 ø5.12 ø2.56
330/660 1 1/2 G1 1/2 1 7/8-12UN
160 85 115 60 80 ø157 ø130 ø65
SIZE D5 H1 H2 H3 H4 H5 HEX 1 HEX 2 T1 T2
10-32UNF 3.39 5.00 1.34 0.28 3.00 1 1/16 1.00 0.24
30 —
M5 86 127 34 7 75 27 24 6
1/4-28UNF 3.39 5.51 1.57 0.28 3.00 1 1/16 1 1/16 0.04 0.35
60
M6 86 140 40 7 75 27 27 1 9
1/4-28UNF 6.14 8.15 1.57 0.28 3.00 1 1/16 1 1/16 0.04 0.35
110
M6 156 207 40 7 75 27 27 1 9
3/8-24UNF 4.65 7.60 1.85 0.28 3.38 1 1/16 1 5/16 0.04 0.55
160
M10 118 193 47 7 85 27 32 1 14
3/8-24UNF 6.93 9.84 1.85 0.28 3.38 1 1/16 1 5/16 0.04 0.55
240
M10 176 250 47 7 85 27 32 1 14
3/8-24UNF 14.09 17.01 1.85 0.28 3.38 1 1/16 1 5/16 0.04 0.55
280
M10 358 432 47 7 85 27 32 1 14
1/2-20UNF 6.65 10.00 2.01 0.28 3.75 1 1/16 1 7/16 0.04 0.67
330
M12 169 254 51 7 95 27 36 1 17
1/2-20UNF 13.27 16.65 2.01 0.28 3.75 1 1/16 1 7/16 0.04 0.67
660
M12 337 423 51 7 95 27 36 1 17
10
Dimensons: DF & LF Filters sizes 30-660
DF & LF 30 DF & LF 60 to 660
D5 x T2
(4 Places)
D5 x T2
(4 Places)
B3 B2 ø D1 ø D1 B2 B3
B4
B4
B1
B1
HEX 1
(Blanking Plug
in G1/2 IIndicator Port) B5
ø 1.141"
(29 mm)
HEX 1
(Blanking Plug H4 H4
in G1/2 IIndicator Port) T1
H3
H3
0.650
ø D3 (16.5 mm) D3
(2 Places)
INLET OUTLET D4 (2 Places)
(2 Places) INLET OUTLET
H2
H2
H1
H1
HEX 2 HEX 2
G 1/2 Drain
Plug (optional) G 1/2 Drain Plug
H5 (optional for sizes 30-280) H5
D2 CLEARANCE NEEDED FOR
CLEARANCE NEEDED FOR
ELEMENT REMOVAL
ø D2 ELEMENT REMOVAL
1.750
(44.5mm)
11
Other Products from HYDAC’s Filtration Line
Filtration Solutions For Mobile Equipment
Although there is great diversity in mobile equipment designs, the common demand in
the industry for improved performance has resulted in systems growing in complexity
and cost. Precision hydraulic components – variable displacement pumps and motors,
load control valves, and proportional controls – are increasingly applied to enhance
machine power, speed and versatility. Higher operating pressures – in excess of 6,000
psi – are increasing in usage in order to generate higher force and torque from a smaller
and lighter package. As fluid power systems are built to function more precisely at
higher pressures, protection against wear and malfunction becomes vital. HYDAC’s
range of filtration products are designed to provide the necessary level of protection to
maintain the efficiency, useful life and safety of high performance fluid power systems.
© Copyright 2001 HYDAC TECHNOLOGY CORPORATION - Brochure - High Pressure Filters DF & LF #02073475 / 4.01
system doesn’t have a HYDAC filter assembly, it doesn’t mean that you cannot
benefit from our Betamicron® Element technology. The high beta ratios and leading
dirt holding capacities of these elements extend service life and provide a greater
price to maintenance cost ratio than elements from other manufacturers.
EPL-1825
Jan 2006
INDEX
PREFACE ......................................................... 2
ADJUSTMENT SPECIFICATIONS ....................................... 3
OPERATION ....................................................... 3
MAINTENANCE ..................................................... 4
LUBRICANT REQUIREMENTS .......................................... 7
MAINTENANCE SCHEDULE ............................................ 8
TROUBLE SHOOTING CHART ......................................... 10
FIGURE 1 - EMERGENCY BRAKE CALIPER ASSEMBLY .................... 11
FIGURE 2 - EMERGENCY CALIPER CYLINDER ASSEMBLY ................. 12
SALES AND SERVICE INFORMATION .................................. 13
Page 1
EPL-1825
PREFACE
Page 2
EPL-1825
ADJUSTMENT SPECIFICATIONS
OPERATION
Page 3
EPL-1825
MAINTENANCE
Inspect the pad gap with the emergency brake released. The total
gap can be measured by pushing one shoe of the caliper assembly
against the disc. The total gap can be measured between the
opposite shoe and the disc. Adjust the caliper assembly whenever
the total gap is greater than the maximum gap given in the
Adjustment Specifications.
Inspect the thickness of each brake pad when inspecting the Service
Brake Caliper Assemblies. Replace the pads when any portion of the
pad is thinner than the minimum thickness given in the Adjustment
Specification.
Page 4
EPL-1825
MAINTENANCE (continued)
Adjust the caliper assembly whenever the total gap exceeds the
maximum given in the Adjustment Specifications. Adjust pad gap
while the brakes are released and the Emergency Brake Cylinder is
fully retracted (pressurized). Remove the lockwire from the four
1/2 inch capscrews in the end plate of the cylinder. Remove the
capscrews and the two adjusting nut locks from the cylinder. Rotate
the adjusting nut using a 1/2 inch diameter rod in any of the eight
holes on the outside of the adjusting nut. Adjust until the total
gap between both pads and the disc is as specified in the adjustment
specifications.
Check the amount that the back of the adjusting eye extends from the
face of the adjusting nut. If it exceeds the amount given in the
Adjustment Specifications the brake pads must be replaced.
If the amount the adjusting eye extends from the adjusting nut does
not exceed the adjustment specifications, then reinstall the
adjusting lock nuts. Reinstall the four 1/2 inch capscrews, tighten
and lockwire in place.
PAD REPLACEMENT
Remove the pull pins and pivot pins necessary to remove the brake
shoes from the caliper assembly. Remove the screws and nuts that
hold the pad to the shoe and dispose of them.
Use new hardware to replace the pad with one that has the same part
number shown in the Adjustment Specifications for the Service Brake
Caliper Assembly. Torque the pad nuts to 20-22 foot-pounds. After
one hour check the torque on nuts and retorque to 12 foot-pounds if
required.
Page 5
EPL-1825
MAINTENANCE (continued)
Inspect all brake components while removed for replacing the pad.
1. Pad wear should be even for all pads. If any pad or set of
pads shows excessive wear, investigate to find the cause.
Fill the two pockets in the bushings of each arm with grease. Apply
grease to all pivot pins and bushings. Reassemble the caliper
assembly. If the Emergency Brake Cylinder has been removed it must
be reinstalled with the 1/8-inch pipe plug at the top. Adjust each
caliper assembly for total pad gap as described in the Adjustment
Specifications.
Remove the eight nuts from the rod studs on the cylinder. The
cylinder springs are under a high compressive force. Back off the
eight nuts as a group, turning each one only a small amount at a
time. Back off the nuts in a criss- cross pattern so that the nuts
on one side of the cylinder are not loosened ahead of the others.
Once the nuts are removed the spring compression is released and the
end plate may be lifted off the cylinder body.
Page 6
EPL-1825
MAINTENANCE (continued)
If the studs have been removed from the end plate, lubricate the
threads, reinstall and torque to 105 ft-lbs (142 Nm)(Lub). Place
the end plate with the studs so that the studs face up. Lubricate
all seals with hydraulic fluid before installing them. Put the
cylinder shell on the end plate with the O- ring facing the end
plate. Install the piston and seal in the shell. Put both sets of
disc springs on the piston. The disc springs must be installed with
the dished sides of adjacent springs alternating as shown on the
cylinder assembly drawing. Grease the disc springs with a
molybdenum disulfide based grease prior to installation.
Place the other end plate on the cylinder body relative to the other
end plate as shown on the assembly drawing. Lubricate the threads on
the studs and install the eight nuts. Tighten the nuts as a group,
turning each one only a small amount at a time. Tighten the nuts in
a criss-cross pattern with a torque wrench and avoid tightening the
nuts more than 200 ft-lbs (270 Nm)(Lub). Torque the nuts to 200 ft-
lbs (270 Nm)(Lub) in a circular pattern after the end plate is
pulled into place. Reinstall the adjusting eye, adjusting nut, and
adjusting nut locks.
LUBRICANT REQUIREMENTS
Page 7
EPL-1825
MAINTENANCE SCHEDULE
Components should be inspected or serviced at the frequency listed
unless experience with the equipment under specific operating
conditions indicates the need for a shorter interval between
servicing. Refer to the manufacturer’s literature provided with the
equipment for a description of individual components.
DAILY
WEEKLY
Page 8
EPL-1825
MAINTENANCE SCHEDULE (continued)
ANNUALLY
4. Pump the cylinder up until the pin on the live end of the
cylinder can be removed.
10. Remove all of the “Caliper Arm and Pivot Shafts”. Inspect for
excessive wear, bending or visible cracks.
11. Inspect all shafts and caliper arms with NDE procedures for
cracks. Any part with crack like indications must be replaced.
Page 9
EPL-1825
MAINTENANCE SCHEDULE (continued)
1. BRAKE WON'T HOLD BRAKE SUPPLY PRESSURE NOT BEING DUMPED FROM
CYLINDER
Page 10
EPL-1825
FIGURE 1 - EMERGENCY BRAKE CALIPER ASSEMBLY
1. Support, Brake Shoe 12. Bushing, Brake Pad
2. Cylinder Assy, Emergency Brake 13. Arm, Caliper
3. Shaft, Arm Support 14. Pad, Brake Shoe
4. Shaft, Caliper Support 15. Bushing, Machine
5. Shaft, Pivot Arm 16. Bushing, Machine
6. Shaft, Brake Pad 17. Clamp Assembly
7. Shoe, Brake 18. Locknut
8. Bushing, Caliper Support 19. Fillister Head Screw
9. Bushing, Pivot Arm 20. Cotter Ring Pin
10. Bushing, Pivot Arm 21. Cotter Ring Pin
11. Bushing, Brake Pad
Page 11
EPL-1825
FIGURE 2 - EMERGENCY CALIPER CYLINDER ASSEMBLY
Page 12
EPL-1825
SALES AND SERVICE INFORMATION
HOUSTON CORPORATE HOUSTON PRODUCTS & TECHNOLOGY HOUSTON PLANT MCALESTER WORKS
HEADQUARTERS 5225 Hollister Street 11919 FM 529 Road 501 N George Nigh Exp
10000 Richmond Avenue Houston, TX 77040 Houston, TX 77041 (Hwy 69 Bypass North)
Houston, TX 77042 P.O. Box 4638 PHONE: 713/849-8000 McAlester, OK 74501
P.O. Box 4888 Houston, TX 77210-4638 PHONE: 918/423-8000
Houston, TX 77210-4888 PHONE: 713/935-8100
PHONE: 713/346-7500
SALES OFFICES
ANCHORAGE, AK DENVER, CO MIDLAND, TX RIO VISTA, CA
PHONE: 907/522-3727 PHONE: 303/298-8112 PHONE: 915/684-5576 PHONE: 707/374-2580
BAKERSFIELD, CA HOUSTON, TX NEW ORLEANS, LA TULSA, OK
PHONE: 805/589-5750 PHONE: 713/960-5100 PHONE: 504/586-1301 PHONE: 918/492-5580
CASPER, WY LONG BEACH, CA ODESSA, TX VENTURA, CA
PHONE: 307/235-2751 PHONE: 310/998-4900 PHONE: 915/332-9472 PHONE: 805/653-6670
DALLAS, TX LOS ANGELES, CA OKLAHOMA CITY, OK WICHITA, KS
PHONE: 214/265-8840 PHONE: 310/802-2638 PHONE: 405/632-7600 PHONE: 316/262-4557
WILLISTON, ND
PHONE : 701/572-3781
Page 13
EPL-1825
UNITED STATES STORES
OKLAHOMA CITY, OK POWELL, WY SHIDLER, OK VERNAL, UT
PHONE: 405/632-7600 PHONE: 307/754-2294 PHONE: 918/793-2781 PHONE: 801/789-1104
PAINTSVILLE, KY PUNXSUTAWNEY, PA SHREVEPORT, LA VICTORIA, TX
PHONE: 606/789-3791 PHONE: 814/938-3060 PHONE: 318/221-5214 PHONE: 512/575-2345
PAMPA, TX RATLIFF CITY, OK SNYDER, TX WATFORD CITY, ND
PHONE: 806/669-7321 PHONE: 405/856-3264 PHONE: 915/573-2663 PHONE: 701/842-2902
PEARSALL, TX RIVERTON, WY SUNDOWN, TX WILLISTON, ND
PHONE: 210/334-8961 PHONE: 307/856-6533 PHONE: 806/229-3701 PHONE: 701/572-3781
PENNSBORO, WV ROCK SPRINGS, WY VENICE, LA WOODLAND, CA
PHONE: 304/659-2993 PHONE: 307/362-3745 PHONE: 504/534-9671 PHONE: 916/662-1034
PLAINVILLE, KS SABINE PASS, TX VENTURA, CA
PHONE: 913/434-4624 PHONE: 409/971-2449 PHONE: 805/653-6666
INTERNATIONAL DISTRIBUTORS
NATIONAL OILWELL CANADA LTD. NATIONAL OILWELL NATIONAL OILWELL, INT'L
CANADA DE VENEZUELA, C.A. UNITED STATES
MAIN SALES OFFICE: HEADQUARTERS: MAIN SALES OFFICE:
2300 BOW VALLEY SQUARE III APARTADO 1146, 4001-A 1530 W SAM HOUSTON PKWY N
255 - 5TH AVENUE S.W. CALLE 158 CON AVENIDA 68 HOUSTON, TX 77043
CALGARY, ALBERTA AMPLIACION ZONA INDUSTRIAL P.O. BOX 4638
CANADA T2P 3G6 MARACAIBO, EDO. ZULIA, HOUSTON, TX 77210-4638
PHONE: 403/294-4500 VENEZUELA PHONE: 713/935-8000
FAX: 403/262-9166 PHONE: (011-58-61) 361850 FAX: 713/935-8351
FAX: (011-58-61) 362561
NATIONAL OILWELL (U.K.) LTD. NATIONAL OILWELL PTE. LTD. NATIONAL OILWELL (UAE) LTD.
MACHINERY CENTRE: SOUTHEAST ASIA SALES OFFICE: MIDDLE EAST SALES OFFICE:
Badentoy Road Machinery and Service Centre SALES AND SERVICE CENTRE
Badentoy Industrial Park 30 Tuas Basin Link P.O. BOX 61490
Portlethen, Aberdeen SINGAPORE 638786 RA/08-TA06
SCOTLAND abi 4ya PHONE: (011-65) 861-1566 JEBEL ALI, UAE
PHONE: (011-44-1224) 783-060 Fax: (011-65) 861-0796 PHONE: 971 4 8838776
Fax: (011-44-1224) 783-266 FAX: 971 4 8838795
Page 14
EPL-1825
Instruction
Manual
for the
INSPECTING THE CONDITION OF Accumulator
DELIVERY
After unpacking the accumulator, inspect it for possible
damage caused during transit. 3 2
1 4
1. Inspect the Locknut and the Jamnut and bleeder plug
for tightness.
2. Check the precharge tag. The accumulator is either
precharged to 25psi (1.7 bar) for shipping purpose or
charged to a pressure specified on the purchase order.
3. Check that the working pressure stamped on the 9
accumulator shell is equal to, or greater than, the
maximum pressure of the system.
7
PROTECTION & PRECAUTIONS
1. Protective Gloves: 10 6
Use chemical resistant gloves, if needed, to avoid
prolonged or repeated skin contact from the clean- 14 13
11 12 8 5
ing solutions or solvents.
2. Eye protection:
Use safety glasses before performing any maintenance SPARE PARTS
on the accumulator.
1. Shell
OTHER PRECAUTIONS: 2. Bladder 8. Spacer
3. Plug & Poppet Assembly 9. Locknut
DO NOT operate the accumulator beyond the allowable
4. Anti Extrusion Ring 10. Name Plate
working pressure and temperature limitations stamped or
5. Metal Back Up Ring 11. Valve Cap
attached to the product.
6. "O" Ring 12. Hex Jamnut
Use only the tools recommended in this manual to perform
7. Rubber Back Up (Not available for 1 quart and 13. Protective Cap
the maintenance procedures.
1 gallon sizes) 14. Bleeder Plug
Use only DRY NITROGEN for charging accumulator.
NEVER USE OXYGEN OR AIR, due to risk of explosion.
Use only valve cores approved for accumulator service and
NEVER USE AN AUTOMOTIVE TYPE VALVE CORE.
PRECHARGING: 9
1. Use DRY NITROGEN ONLY to precharge the
accumulator.
8
2. Use the charging assembly recommended in this
manual to charge the accumulator to the required 5
precharge if it is not already charged at the factory.
3. Check the charging valve for leaks using snoop or soap
water. 4
4. Tighten the jamnut at the gas valve stem and also
the locknut on the fluid port with a wrench.
5. Tighten the protective cap on the gas valve stem to
hand tight.
6. Check the gas precharge pressure periodically. This
must be done after all the hydraulic system pressure is 3 6
released. The precharge must be checked once in the
first week of operation, and then every six months dur- 7 2 1
ing normal working or every month during high cycling
or high temperature condition.
TOOLS
INSTALLATION:
The accumulator should be mounted vertically with fluid 1. Charging & Gauging Assy - P.N. CG-3000 6. Ratchet Wrench (Corresponds to elastic
port on bottom and gas valve on top with supporting brack- 2. Valve Core Tool - P.N. 11-501 stop nut and bleeder plug size)
ets and saddles specifically designed for accumulator 3. Spanner Wrench - P.N. 11-502 7. Bladder Pull Rod - P.N. 11-503
mounting. For other type of mounting, consult factory. 4. Open End Box Wrench (Corresponds to 8. Rubber Mallet
Fluid port must not be used to support the accumulator. valve stem wrench flats width) 9. Tool Box
Do not weld any support to the accumulator. For ease of 5. Open End Box Wrench (Corresponds to
maintenance and periodic checking of the precharge, an hex jamnut size)
automatic discharge valve fitted between the accumulator
and the system pressure line is recommended.
3. Connect a suitable charging & gauging assem- 4. Remove the valve adaptor from the gas valve body. 5. Remove the valve core if the gas valve body has a
bly to the valve adaptor and release all the nitrogen (2 piece valve stem design) core inside. (1 piece valve stem design)
precharge pressure from the accumulator until the
gauge reads zero.
6. Remove the jamnut and the name plate from the 7. Remove the bleeder plug from the fluid port. 8. Remove the locknut and then remove the spacer.
gas valve body. While removing the jamnut hold the Loosen locknut with a spanner wrench by turning
gas valve body with a wrench so that the bladder will 2 or 3 threads, then push the fluid port body into the
not rotate. accumulator shell if there is no hydraulic pressure. *
9. Push the fluid port body into the shell and remove 10. Slide the anti-extrusion ring off of the fluid port. 11 . By squeezing the bladder discharge as much air
the back-up ring , “O” ring and the metal back-up ring. Carefully fold the anti-extrusion ring until it's suffi- as possible by hand, then pull the bladder out slowly
ciently folded to allow removal from the shell and re- through the fluid port opening of the shell.
move fluid port from the shell.
* If the fluid port body does not go inside, then there is some hydraulic pressure left inside the accumulator. If this happens, do not attempt to do any maintenance. Consult the factory.
ASSEMBLY
3. Then install the valve core to a torque value of 4. Lubricate the accumulator shell and the bladder 5. Reinstall the name plate and the jamnut. Do not
4 in.lbs. (.45 Nm). (For the one piece valve stem either with the medium used in the system or a simi- tighten the jamnut.
design). lar product. Attach the bladder pull rod to the valve
and fold the bladder and pull into the shell. Avoid
twisting the bladder while pulling it into the shell.
6. Insert the fluid port and the anti-extrusion ring into 7. Slide the anti-extrusion ring over the fluid port. 8. Install a charging and gauging assembly on the
the shell. Pull the fluid port through the port opening. gas valve and put a low precharge of 30 psig (2 bar)
to seat the fluid port and the anti-extrusion ring in
place.
9. Hammer slightly the fluid port body at various 10. Install the metal back up, O-ring, rubber back up 11. Tighten the locknut .
angles using plastic hammer. and spacer in that order.
12. Install the bleeder plug and tighten it. 13. Rotate the accumulator shell around its axis to
lubricate its inner wall evenly all around.
14. Using a charging and gauging assembly, 15. Remove charging and gauging assembly, install
precharge to the desired pressure at a moderate rate, valve cap and protective cap. Retighten the
using DRY NITROGEN only. Check the valve for Assembly locknut & jamnut.
leaks with snoop or soap water.
STORAGE:
Accumulator storage instructions OILAIR ORIGINAL EQUIPMENT LIMITED
If after reassembly, the accumulators are stored, they must be charged with a low nitrogen pressure of 25 psi (1.5 bar)
and store in a cool and dry area. The fluid port must be sealed. The accumulator can be stored in any position. WARRANTY
The protective cap on the gas charging valve must be securely tightened to protect it from any shock.
OILAIR warrants each of its products against original
Attach a label to the accumulator stating that they must be precharged before installing in the system. defects in materials and/or workmanship and will repair
or replace any product which is determined by OILAIR,
within one (1) year of its installation, to be defective or
If the accumulator is stored for longer than 6 years, all the elastomeric components (bladder, seals etc.) must be below the manufacturing standards of OILAIR, including
replaced. warranty of merchantability, fitness for the purpose intended,
consequential and incidental damage of liability.
This Original Equipment Warranty which anticipates instal-
lation by third parties, expressly excludes warranty of
BLADDER STORAGE INSTRUCTIONS: merchantability, fitness for the purpose and consequential
or incidental damage liability.
DO NOT OPEN PLASTIC BAG UNTIL READY FOR INSTALLATION.
DO NOT USE RAZOR OR SHARP OBJECTS TO OPEN THE PLASTIC BAG. OPERATION OF ANY OILAIR ACCUMULATOR OR
COMPONENT BEYOND THE MANUFACTURER'S
Bladder in the plastic bag must be stored in a cool (preferably below 720 F), dry and dark place out of direct sunlight, WORKING PRESSURE LIMITATIONS, OR IN VIOLATION
fluorescent light, ultraviolet light and away from electrical and welding equipment. OF ANY OPERATING OR SERVICE INSTRUCTION
STAMPED OR ATTACHED TO THE PRODUCT,
Direct sunlight or fluorescent light may cause the bladder to weather check and/or dry rot, which appears on the bladder EXPRESSLY VOIDS THIS WARRANTY AND MAY BE
surface as cracks. DANGEROUS TO LIFE AND PROPERTY.
11505 West Little York Houston, Texas 77041 Tel: (713) 937-8900 Fax: (713) 937-0438/937-1516
5 6 7
Form No. 1886 Rev. 4/04 Printed 4/04 30M
SAFETY PRECAUTIONS: SAFETY PRECAUTIONS (Continued):
Safety, Installation, & WARNING WARNING
1. Inspect the regulator, valve, and 10. Regulators are not shut-off devices.
Operation Precautions accessories before each use. Install a pressure relief device
2. Never connect regulators, valves, or downstream of the regulator to protect
accessories to a supply source having a the process equipment from operating
pressure greater than the maximum pressure increases. Shut off the supply
rated pressure of the regulator, valve, or pressure when the regulator is not in use.
INDUSTRIAL CONTROLS DIVISION accessory. 11. Periodic inspection and scheduled
3. Refer to product label (modification maintenance of your equipment is
DO NOT ATTEMPT TO SELECT, INSTALL, specific) for maximum inlet pressures. If required for continued safe operation.
USE, OR MAINTAIN THIS REGULATOR, this rated pressure cannot be found, 12. The frequency of servicing is the
VALVE, OR ACCESSORY UNTIL YOU responsibility of the user based on the
HAVE READ AND FULLY UNDERSTAND contact your local Tescom
representative for the rated pressure application.
THESE INSTRUCTIONS.
prior to installation and use. Verify the 13. Never allow problems or lack of
BE SURE THIS INFORMATION REACHES designed pressure rating of all maintenance to go unreported.
THE OPERATOR AND STAYS WITH THE equipment (e.g., supply lines, fittings,
PRODUCT AFTER INSTALLATION. 14. Read and follow precautions on
connections, filters, valves, gauges, etc.)
compressed gas cylinder labels.
in your system. All must be capable of
DO NOT PERMIT UNTRAINED PERSONS handling the supply and operating 15. It is important that you analyze all
TO INSTALL, USE, OR MAINTAIN THIS pressure. aspects of your application and review
REGULATOR, VALVE, OR ACCESSORY.
all available information concerning the
4. Clearly establish flow direction of the
product or system. Obtain, read, and
IMPROPER SELECTION, fluid before installation of regulators,
understand the Material Safety Data
IMPROPER INSTALLATION, valves, and accessories. It is the
Sheet (MSDS) for each fluid used in
IMPROPER MAINTENANCE, responsibility of the user to install the
WARNING your system.
MISUSE, OR ABUSE OF equipment in the correct direction.
REGULATORS, VALVES, OR 16. Oxygen service requires special
5. Do not tighten fittings, gages, or
RELATED ACCESSORIES CAN expertise and knowledge of system
components in pressurized systems.
design and material compatibility in
CAUSE DEATH, SERIOUS 6. Never turn regulator or valve body. order to minimize the potential for death,
INJURY, AND/OR PROPERTY Instead hold regulator or valve body and serious injury, and/or property damage.
DAMAGE. turn fitting nut.
17. Never use materials for regulators,
Possible consequences include but are 7. If a regulator or valve leaks or valves, or accessories that are not
not limited to: malfunctions, take it out of service compatible with the fluids being used.
• High velocity fluid (gas or liquid) discharge immediately.
18. Users must test under normal operating
• Parts ejected at high speed 8. Do not modify equipment or add conditions to determine suitability of
• Contact with fluids that may be hot, cold, attachments not approved by the materials in an application.
toxic, or otherwise injurious manufacturer.
• Explosion or burning of the fluid 19. Vent fluids to a safe environment, and in
• Lines/hoses whipping dangerously 9. Apply pressure to the system gradually, an area away from employees. Be sure
• Damage or destruction to other avoiding a sudden surge of fluid or that venting and disposal methods are
components or equipment in the system pressure shock to the equipment in the in accordance with Federal, State, and
system. Local requirements. Locate and
2 3
WARNING SAFETY PRECAUTIONS (Continued): INSTALLATION WARNING Safe Component Selection (continued)
construct vent lines to prevent conden- Inspect the regulator, valve, and 3. Tescom may suggest material for use
sation or gas accumulation. Make sure accessories for physical damage and with specific media upon request.
the vent outlet is not obstructed by rain, contamination. Do not connect the Suggestions are based on technical
snow, ice, vegetation, insects, birds, etc. regulator, valve, or accessory if you detect compatibility resources through
Do not interconnect vent lines; use oil, grease, or damaged parts. If the associations and manufacturers.
separate lines if more than one vent is regulator, valve, or accessory is damaged, Tescom does NOT guarantee materials
needed. contact your local Tescom representative to to be compatible with specific media --
have the regulator cleaned or repaired. THIS IS THE RESPONSIBILITY OF
20. Do not locate regulators, valves, or THE USER!
accessories using flammable fluids near Make sure that the components
open flames or any other source of and materials used in the fluid 4. Component function, adequate ratings,
ignition. handling system are compatible proper installation, operation, and
WARNING with the fluid and have the maintenance are the responsibilities of
21. Some fluids when burning do not exhibit proper pressure rating. the system user.
a visible flame. Use extreme caution
REPAIR SERVICE Do not modify equipment or
when inspecting and/or servicing add attachments not approved
systems using flammable fluids to avoid If a regulator or valve leaks or malfunctions, by the manufacturer.
WARNING
death or serious injury to employees. take it out of service immediately. You must
Provide a device to warn employees of have instructions before doing any
these dangerous conditions. maintenance. Do not make any repairs you ASSEMBLY/INSTALLATION DRAWINGS
do not understand. Have qualified & BILLS OF MATERIAL Drawings and
22. Many gases can cause suffocation. personnel make repairs. Return any parts lists for your product may be
Make certain the area is well ventilated. equipment in need of service to your obtained by calling the number below.
Provide a device to warn employees of equipment supplier for evaluation and Tescom will provide these by fax or mail.
lack of oxygen. prompt service. Equipment is restored to Your local Tescom representative can
23. Never use oil or grease on these the original factory performance provide additional assistance.
specifications, if repairable. There are flat
regulators, valves, or accessories. Oil fee repair charges for each standard model. Call (800) 447 - 1250
and grease are easily ignited and may The original equipment warranty applies for assembly/installation drawings &
combine violently with some fluids under after a complete overhaul. bills of material. Be sure to have your
pressure. complete model number ready.
24. Have emergency equipment in the area
if toxic or flammable fluids are used. WARNING Safe Component Selection
25. Upstream filters are recommended for 1. Consider the total system design when
use with all fluids. selecting a component to ensure safe,
26. Do not bleed system by loosening trouble-free performance.
fittings. 2. The user is responsible for assuring all INDUSTRIAL CONTROLS DIVISION
safety and warning requirements of the 12616 Industrial Boulevard
27. Prevent icing of the equipment by application are met through his/her own Elk River, MN 55330
removing excess moisture from the gas. analysis and testing.
28. Always use proper thread lubricants and
sealants on tapered pipe threads.