ABUIABA9GAAgl6Po2wUo9qiR9gU PDF

OPERATION and
MAINTENANCE MANUAL
AWILCO/ PPL 2012
RIG #3
D3000AC Drawworks
Project: E2189
Job: C22584
S/N: 307
P.O.: 4500035653
ADDITIONAL INFORMATION
This document contains proprietary and National Oilwell Varco

confidential information of National Oilwell 6415-75 Street
Varco. Reproduction or use of this design or
distribute information by others is permissible Edmonton, AB
only if expressly authorized in writing by Canada,
National Oilwell Varco. ©Copyrights National T6E 0T3
Oilwell Varco
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
4. PRESERVATION & INSTALLATION 15

4.1 PRESERVATION ............................................................................................................... 15
4.2 PRE- INSTALLATION PROCEDURE .................................................................................... 16
4.3 INSTALLATION PROCEDURE ............................................................................................. 17
4.3.1 Lifting Instructions ..................................................................................................... 17
4.3.2 Transportation Instructions........................................................................................ 17
4.3.3 Installation Instructions.............................................................................................. 18
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
Page 2
6.1 PARTS FIT – GENERAL .................................................................................................... 27

6.2 SHAFTS .......................................................................................................................... 27
6.3 BEARINGS ...................................................................................................................... 27
6.4 SPACERS ........................................................................................................................ 28
6.5 HYDRAULIC SYSTEM ....................................................................................................... 28
6.5.1 Hydraulic Pump – Pressure Compensator Adjustment Procedure ........................... 29
6.5.2 Hydraulic Pump – Volume Adjustment Procedure .................................................... 30
6.6 SPROCKETS & CLUTCH HUBS ......................................................................................... 31
6.7 HUB & SHAFT FITS.......................................................................................................... 33
7. MAJOR REPAIRS AND MODIFICATIONS 35

7.1 GENERAL DRAWWORKS REPAIR INSTRUCTIONS .............................................................. 35
7.2 INPUT SHAFT REMOVAL .................................................................................................. 36
7.2.1 Replacement of Bearings, Input Shaft Removed ...................................................... 36
7.3 JACK SHAFT REMOVAL ................................................................................................... 37
7.3.1 Jack Shaft Bearing Removal ..................................................................................... 37
7.4 DRUMSHAFT REMOVAL ................................................................................................... 38
7.4.1 Drumshaft – Bearing Replacement from ODS .......................................................... 38
7.4.2 Drumshaft – Bearing Replacement from DS ............................................................. 38
8. LUBRICATION & MAINTENANCE 41

8.1 LUBRICATION .................................................................................................................. 41
8.1.1 Recommended Greases ........................................................................................... 41
8.1.2 Special Lubricants ..................................................................................................... 42
8.1.3 D3000AC Drawworks Lubrication ............................................................................. 42
8.2 MAINTENANCE ................................................................................................................ 44
8.2.1 Routine Inspection..................................................................................................... 45
9. GENERAL ROLLER CHAIN 53

9.1 CHAIN AND CONNECTING LINK INSTALLATION .................................................................. 53
9.2 RETAINING DEVICES........................................................................................................ 54
9.3 METHODS OF LUBRICATION ............................................................................................. 57
9.4 DRIVE GUARDING............................................................................................................ 58
10. TROUBLESHOOTING 61
10.1 EQUIPMENT FAULT SYMPTOMS & CAUSES....................................................................... 61
11. TORQUE GUIDE FOR BOLTS 63

11.1 BOLT TORQUE CHART..................................................................................................... 63
11.2 SOCKET HEAD CAPSCREW TENSILE REQUIREMENTS ....................................................... 65
11.3 TURN-OF-NUT TIGHTENING ............................................................................................. 66
12. RECOMMENDED SPARES 67

12.1 DRIVE ASSEMBLY ........................................................................................................... 67
12.2 DRUMSHAFT ASSEMBLY .................................................................................................. 67
12.3 LUBE PUMP ASSEMBLY ................................................................................................... 67
www.nov.com
Page 3
12.4 INPUT SHAFT ASSEMBLY ................................................................................................. 68

12.5 JACKSHAFT ASSEMBLY................................................................................................... 68
12.6 AC HYDRAULIC AND AIR SCHEMATIC .............................................................................. 69
12.7 LUBRICATION SCHEMATIC ............................................................................................... 69
12.8 AC DRAWWORKS EQUIPMENT ASSEMBLY ....................................................................... 70
12.9 BRAKE CALIPER ............................................................................................................. 71
13. CERTIFICATES 75
14. DRAWINGS 77
15. VENDOR INFORMATION 79
www.nov.com
Page 4
This page left intentionally blank.
www.nov.com
Page 5
1. INTRODUCTION
1.1 Manual Overview & Scope
1.2 Warranty Information
1.3 Warranty Limitations
1.4 Equipment Service Life
1.1 Manual Overview & Scope
This operation and maintenance manual provides instruction on the D3000AC

drawworks. The mechanical components discussed here are engineered and selected
for the most reliable and cost-effective operation. However, correct preventive
maintenance should be considered an investment, as it minimizes equipment wear,
failures, and downtime. New parts can be installed at less expense when the equipment
is in the shop for repairs or strip-down than when emergency servicing is required.
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.
Photo: D3000AC Drawworks
www.nov.com
Page 6
1.2 Warranty Information
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
Page 7
1.3 Warranty Limitations
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.
Improvements in design, engineering, materials, production methods, etc. may

necessitate changes in this product over time. National Oilwell Varco reserves the right
to make these design changes without incurring any obligation for the equipment
previously delivered.
1.4 Equipment Service Life
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
Page 8
www.nov.com
Page 9
2. SAFETY SUMMARY
2.1 Safety Terms & Conventions
2.1 Safety Terms & Conventions
This manual uses the following standard safety terms and conventions that span all
areas of the industry:
WARNING: A Warning is used when an operating procedure, practice, etc., that,

if not correctly implemented, could result in personnel injury and/or
equipment damage.
CAUTION: A Caution is used when an operating procedure, practice, etc., that, if

not correctly implemented, could result in equipment damage.
NOTE: A Note provides information necessary to complete the procedure properly

or information that will make the procedure easier to understand.
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.
Before performing maintenance on or disconnecting any high-pressure piping or hoses,

ensure the unit has been bled to zero pressure. Observe a similar procedure for
electrical connections and ensure the electrical power is locked out before attempting
maintenance.
www.nov.com
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.
WARNING: Use adequate hoisting equipment. Observe all safety precautions.

Ensure that hydraulic systems are depressurized and controls are
tagged “DANGER – DO NOT OPERATE – EQUIPMENT BEING
REPAIRED” before attempting adjustment and repair procedures on
the equipment.
WARNING: Determine if equipment has preloaded components such as springs

before disassembly. Remove preload prior to disassembly by
approved format.
WARNING: When working on a system, disconnect electrical power supply and

tag controls to prevent accidental operation. Serious injury or death
could result. Use mechanical shutoff when available.
www.nov.com
Page 11
3. D3000AC DRAWWORKS
3.1 General Description
3.2 Technical Specifications
3.3 Power Flow Chart
3.1 General Description
3.1.1 Construction
The D3000AC is a two-speed, chain

driven drawworks. Braking is
achieved by the use of three AC
motors, which are also the prime
movers for the drawworks.
The housing is fabricated from a high
strength plate and also heavy
structural members to provide a
sturdy, oil tight and weatherproof
enclosure for the shafts and chain
drives. Structural support plates are
provided for the main shaft bearings.
Photo: D3000AC Drawworks, Driller’s Side
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.
3.1.2 Chains and Sprockets
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.
(For more information, refer to Section 9 of manual.)
www.nov.com
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
The drawworks is equipped with a disc type braking

system. The primary function of the disc brake system is
the parking and emergency capabilities in the event of a
power failure.
The disc brake system employs two discs, one disc on

each side of the drum. The brake’s hydraulic calipers are
spring-applied and hydraulically released, providing a fail-
safe braking capability for both the park and the
emergency braking.
Photo: The D3000AC uses an air cooled brake caliper system.
3.1.5 Clutches
Plate type air actuated friction clutches are used for high/low gear changes.
3.1.6 Drum Design
The D3000AC Drawworks is equipped with a

fabricated drum, 35" bare drum diameter x
72” long with 1-5/8” Lebus grooving.
Photo: The D3000AC drawworks drum.
www.nov.com
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.
3.2 Technical Specifications
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)
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
Page 14
3.3 Power Flow Chart
14 LINES 14 LINES 14 LINES 14 LINES

MOTOR MOTOR GEAR DRUM DRUM 1ST LAYER 2ND LAYER 3RD LAYER 4TH LAYER
SPEED TORQUE BOX SPEED TORQUE FAST LINE FAST LINE BLOCK HOOK FAST BLOCK HOOK FAST FAST BLOCK HOOK FAST BLOCK HOOK
FAST LINE FAST LINE
(RPM) (FT*LBS) RATIO (RPM) (FT*LBS) SPEED PULL SPEED LOAD LINE SPEED LOAD LINE LINE SPEED LOAD LINE SPEED LOAD
PULL (LBS) PULL (LBS)
(FPM) (LBS) (FPM) (LBS) SPEED (FPM) (LBS) SPEED PULL (FPM) (LBS) SPEED (FPM) (LBS)
LOW GEAR
0 31,697 11.80 0 373,998 0 236,989 0 2,869,048 0 220,596 0 2,670,595 0 206,325 0 2,497,820 0 193,788 0 2,346,043
800 31,697 11.80 68 352,004 672 223,052 48 2,700,325 722 207,624 52 2,513,543 772 194,191 55 2,350,929 822 182,391 59 2,208,077
800 22,641 11.80 68 251,432 672 159,323 48 1,550,000 722 148,303 52 1,550,000 772 138,708 55 1,550,000 822 130,280 59 1,550,000
1,000 18,000 11.80 85 199,893 840 126,665 60 1,533,433 902 117,903 64 1,427,365 965 110,275 69 1,335,022 1,027 103,575 73 1,253,900
1,200 15,000 11.80 102 166,577 1,008 105,554 72 1,277,861 1,083 98,253 77 1,189,471 1,158 91,896 83 1,112,518 1,233 86,312 88 1,044,917
1,400 12,900 11.80 119 143,256 1,176 90,776 84 1,098,960 1,263 84,497 90 1,022,945 1,351 79,031 96 956,765 1,438 74,228 103 898,629
1,600 10,500 11.80 136 116,604 1,344 73,888 96 894,503 1,444 68,777 103 832,630 1,544 64,327 110 778,763 1,644 60,419 117 731,442
HIGH GEAR
0 31,697 4.77 0 151,058 0 95,720 0 1,158,812 0 89,099 0 1,078,657 0 83,335 0 1,008,873 0 78,271 0 947,570
800 31,697 4.77 168 142,175 1,664 90,091 119 1,090,665 1,787 83,859 128 1,015,223 1,911 78,434 136 949,543 2,035 73,668 145 891,845
800 22,641 4.77 168 101,554 1,664 64,351 119 626,047 1,787 59,900 128 626,047 1,911 56,024 136 626,047 2,035 52,620 145 626,047
1,000 18,000 4.77 210 80,737 2,080 51,160 149 619,356 2,234 47,621 160 576,515 2,389 44,540 171 539,217 2,543 41,834 182 506,452
1,200 15,000 4.77 252 67,281 2,496 42,633 178 516,130 2,681 39,684 191 480,429 2,866 37,117 205 449,347 3,052 34,862 218 422,043
1,400 12,900 4.77 294 57,861 2,911 36,665 208 443,872 3,128 34,129 223 413,169 3,344 31,921 239 386,439 3,560 29,981 254 362,957
1,600 10,500 4.77 336 47,097 3,327 29,843 238 361,291 3,575 27,779 255 336,300 3,822 25,982 273 314,543 4,069 24,403 291 295,430
Note: The shaded area is the motor's intermittent rating

THESE SHADED LOADS ARE NOT TO BE HOISTED BY THE DRAWWORKS
Maximum hookload, regardless of speed for 14 lines is: 1,550,000 lbs
Maximum Rated Single Line Pull = 125,629 lbs
www.nov.com
Page 15
4. PRESERVATION & INSTALLATION

4.1 Preservation
4.2 Pre-Installation Procedure
4.3 Installation Procedure
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
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.
4.2 Pre- Installation Procedure
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
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.
WARNING: A brake capacity test must be performed after any brake

maintenance procedure.
4.3 Installation Procedure
4.3.1 Lifting Instructions
Refer to the D3000AC Drawworks Overall Lifting Diagram, drawing 9108L022, for
detailed instructions on how to lift the drawworks.
NOTE: The lifting equipment used on drawing 9108L022 is used as a reference

only. It is a typical drawing for lifting equipment suitable for the drawworks.
Equivalent, certified equipment may be used.
NOTE: The lifting equipment is not supplied with the drawworks. The drawing for
typical lifting equipment is used as a reference drawing only.
WARNING: Extreme caution must be exercised when lifting the drawworks as

personal injury or death can result from unsafe work practices.
Please follow all local laws and regulations regarding overhead
lifting operations.
4.3.2 Transportation Instructions
Support the drawworks using the whole base of the drawworks. Refer to the Footprint
and Installation Detail, drawing 9108C026.
www.nov.com
Page 18
4.3.3 Installation Instructions
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.
NOTE: Refer to the lifting instructions for details, section 4.3.1.
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
Page 19
If level measurements are out of tolerance, shim up the drawworks.
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
Page 20
www.nov.com
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
5.1 Pre-Starting Instructions
Perform the following checks before initial starting of the drawworks:
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.
5.2 Manual and Emergency Operation
For the start, normal operation, stop, and emergency stop operations, refer to the
Operation Manual, document number S0100751-OPM-200.
www.nov.com
Page 22
5.3 Brake Caliper Remote Operation
Refer to the Hydraulic and Air Schematic,

drawing 9108X009, for these operations.
1. Ensure the brake control valve (G)

is fully retracted, fully lifted and
locked into place
2. Ensure all six manual/remote valves
(F) are in the remote position.
3. Ensure emergency bleed off valve
(H) is fully opened. Ensure
emergency lowering isolation valve
(Z) is closed.
4. Operate brakes with controls in the
driller’s cabin.
5.4 Brake Caliper Manual / Emergency Operation
5.4.1 Manual / Emergency Operation (Hydraulic Pumps Operating)
Refer to the Hydraulic and Air Schematic, drawing 9108X009, for these operations.
1. Ensure emergency bleed off valve (H)

is closed. Ensure emergency lowering
isolation valve (Z) is open.
Brake Control 2. Ensure the brake control valve handle
Valve (G) is fully extended, fully lifted and
locked into place.
3. Switch all six manual / remote valves
Emergency (F) to manual position.
Bleed Off Valve 4. To release brakes, unlock the handle
of the brake control valve (G). Slowly
pull downwards on the handle. This
will increase the pressure in the
calipers to release them. Allow the
Emergency handle to move upwards to reduce
Lowering the pressure and reapply the brake
Isolation Valve calipers.
5. If for any reason control of the load is
lost, open emergency bleed off valve
Photo: D3000AC Drawworks valves
(H) to reapply the brakes quickly.
www.nov.com
Page 23
WARNING: The disc temperature must be monitored during any

manual/emergency lowering operation. Lowering must stop when
the disc temperature reaches 100°C. Lowering the load slowly will
reduce the energy to be absorbed by the disc. Use short steps
instead of continuously lowering the load. If the disc becomes too
hot, operation must stop until the disc has cooled.
5.4.2 Manual / Emergency Operation (Hydraulic Pumps Not Operating)
1. Ensure the emergency bleed valve (H) is closed.

2. Ensure brake control valve handle (G) is fully lifted.
3. Ensure all six manual/remote valves (F) are in the remote position.
4. Open the emergency lowering valve isolation valve (N).
5. Pump system up to 3,000 psi using the hand pump.
NOTE: It may be desirable to close one accumulator bottle to allow system to be

charged faster.
6. Once 3,000 psi is achieved, flip all six remote/manual valves (F) to manual.
NOTE: Remote/manual valve should be switched as quickly as possible to limit

the pressure lost due to the switch over.
7. Brakes can now be released / engaged using the brake

control valve (G).
CAUTION: Keep track of system pressure. If system pressure

drops to 2,000 psi, stop the lowering operation
and recharge the system. Otherwise, at
approximately 1,500 psi, system pressure will
drop to zero (0) and the whole operation will have
to be repeated starting at item (1).
Photo: D3000AC Drawworks Hydraulic Hand Pump
www.nov.com
Page 24
5.5 Brake Caliper Delay System
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.
5.6 Disc Brake Caliper Burn Procedure
Refer to Drawworks Control System Operation Manual, document number:

S0100751-OPM-200
5.7 Brake Testing Procedure
Refer to Drawworks Control System Operation Manual, document number:

S0100751-OPM-200
5.8 Crown Saver Reset Procedure
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
Page 25
5.9 Drill Line Attachment to Drum
Refer to drawing 9108A046 and 9108A006 for these operations.
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
5.10 Dead Wraps on the Drum
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.
5.11 Protective Measures
• Loss of hydraulic supply or electrical power will result in brake actuation.

• Contaminated pads or misadjusted calipers may result in loss of braking.
www.nov.com
Page 26
www.nov.com
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
6.1 Parts Fit – General
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
Wherever possible, all shafting should be checked by magnaflux or other means to

detect any cracks. Cracked shafts should be replaced, as a crack indicates the shaft's
potential to fail during rig operation.
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
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, used between bearings to maintain center lines of bearings or between

bearings and other parts, are usually 0.0508 mm to 0.1524 mm loose. Spacers that are
used to hold a bearing in position, which is not adjacent to another part securely, fixed
to the shaft, are usually 0.0254 mm to 0.0762 mm tight.
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.
6.5 Hydraulic System
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
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 pump pressure compensator must be set at 3,000 psi.
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.
6.5.1 Hydraulic Pump – Pressure Compensator Adjustment Procedure
Perform the following procedure to set the pressure compensator; refer to the D3000AC
Air and Hydraulic Schematic, drawing 9108X009, item X.
1. Set the system relief valve first.

2. Turn the system relief valve in to increase the pressure setting of the valve (right
hand thread on the valve).
3. Turn the compensator pressure setting adjustment on both pumps out to reduce the
pump pressure (right hand thread on the adjustment).
4. Start one of the pumps.
5. Watch the pressure rise – when the pressure stops increasing, adjust the
compensator pressure up a little so the pressure increases again.
6. Increase the compensator pressure setting. If the pressure does not increase, check
the system relief valve and increase as required.
7. When the pressure reaches 3,400 psi, stop increasing the compensator setting.
8. With the pump running, reduce the system relief valve setting down to 3,300 psi.
9. The system relief is now set correctly.
10. Now, adjust the pump compensator pressure setting down until the system pressure
is approximately 3,050 psi.
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
Page 30
12. Adjust the second pump compensator pressure setting.

NOTE: Only the pump that is being adjusted should be running.
System Relief
Compensator
Pressure
Adjustment Maximum Volume Stop
Photo: D3000 AC Drawworks Hydraulic Pump

(Motor may not be as shown)
6.5.2 Hydraulic Pump – Volume Adjustment Procedure

The maximum volume stop on the pumps should be set at the factory so the pumps
produce 2 gpm (US). It is relatively simple to ensure if this has been done. Refer to the
Hydraulic & Air Schematic, item X, drawing 9108X009 for the following procedure.
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
Page 31
6.6 Sprockets & Clutch Hubs
The teeth of almost all sprockets are surface hardened. This

hardening is effective to a depth of approximately 3.175 mm. After
several years usage the chain may wear into the sprocket teeth.
When the sprocket teeth become worn to a depth near 3.175 mm,
the rate of wear will accelerate. The amount of wear may be
ascertained by visual inspection. If inspection shows the amount of
wear to be near 3.175 mm, the sprocket should be replaced at the
time of overhaul.
Four methods are used for mounting clutch hubs, bearing inner races and sprockets on
shaft assemblies.
A. Press fit without key

B. Press fit with key
C. Shrink fit with / without key
D. Tapered shaft with key
www.nov.com
Page 32
When removing and replacing parts mounted according to arrangement A) refer to

instructions for removing bearings (reference section 6.3). Sprockets mounted
according to arrangements B) & C) may have a straight key, which has a tapped hole in
the end of it.
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.
For arrangement D), refer to the section 6.7.
www.nov.com
Page 33
6.7 Hub & Shaft Fits
The temperature required to expand a hub enough to be assembled easily over an

interference fit can be determined by the following equation:
(E)
T= + ( TR)
( 0. 00001098 )(B)
Where:
T = Heated Temperature (°C)

E = Expansion of Bore Diameter Required (millimeters)
B = Bore Diameter (millimeters)
TR = Room Temperature (°C)
0.00001098 = Approximate coefficient of steel expansion in millimeters

per degree Celsius per millimeter of length (or diameter).
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:
Press Fit - .0005 in (0.0127 mm) x shaft diameter (inches)

Shrink Fit – 0.001 in (0.0254 mm) x shaft diameter (inches)
The actual fit will have plus or minus tolerance depending on the shaft and bore
tolerances used in manufacture.
www.nov.com
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
Page 35
7. MAJOR REPAIRS AND MODIFICATIONS

7.1 General Drawworks Repair Instructions
7.2 Input Shaft Removal
7.3 Jackshaft Removal
7.4 Drumshaft Removal
7.1 General Drawworks Repair Instructions
General Information:
• Safeguard against injury to personnel and damage to equipment by all means. In

all cases, use the proper tools and equipment, provide a safe working area, and
ensure all work pieces are adequately and correctly supported and/or blocked.
• Ensure all power to the drawworks (electricity, water, and air) is disconnected or
shut off before starting to disassemble.
• If the drawworks is to be lifted for an overhaul, use the lifting lugs that are provided
on the drawworks.
• As in any piece of machinery, all parts are machined to close tolerances. It is
imperative that the working area be as clean as possible.
• All seals are wear and tear items and therefore should be replaced whenever a
shaft is being disassembled.
• Clean all of the oil passages when working in a given area by blowing air pressure
through the oil passages.
• When repair to a shaft is completed, clean all oil passages and tubes before re-
installing the cover.
• When reassembling drawworks components, ensure all of the covers are properly
sealed before they are installed.
• Verify the proper type of lubricant is being used.
• Replace any lubricant that is contaminated or is not of the proper type.
• Check all adjustments, pressures, and fluid levels before restarting the drawworks.
www.nov.com
Page 36
7.2 Input Shaft Removal
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.
7.2.1 Replacement of Bearings, Input Shaft Removed
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.
NOTE: It is recommended to replace oil seals at this time.
www.nov.com
Page 37
7.3 Jack Shaft Removal
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.
7.3.1 Jack Shaft Bearing Removal
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
Page 38
7.4 Drumshaft Removal
Refer to the Drumshaft Assembly, drawing 9108A004, for the following procedure:
1. Remove all front covers and guards.

2. Disconnect the drive chain.
3. Disconnect all air/grease/electrical connections.
4. Remove brake calipers, brake beam (refer to drawing 9108A024) and drive chains.
5. Unbolt the bearing housing bolts (B) (both sides).
6. Rotate the bearing housings until the flat surface is on top then lift the drumshaft
assembly and slide out to the front.
7.4.1 Drumshaft – Bearing Replacement from ODS
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.
7.4.2 Drumshaft – Bearing Replacement from DS
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
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
Page 40
www.nov.com
Page 41
8. Lubrication & Maintenance

8.1 Lubrication
8.2 Maintenance
8.1 Lubrication
The D3000AC drawworks should be operated and maintained as required by API

Standards and local regulations. Where the two overlap, the stricter rules should
govern.
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.
8.1.1 Recommended Greases
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
Page 42
8.1.2 Special Lubricants
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.
8.1.3 D3000AC Drawworks Lubrication
To ensure good performance of any mechanical equipment, it is necessary to maintain

good alignment and good lubrication with clean oils and greases. Check drawworks
housing and oil sump for the presence of dirt or water. Drain and clean if necessary.
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:
D3000AC Drawworks Oil Sump Capacity: 100 US Gal. (379 L)
Ambient Temperature Recommended Lubricant

Above 12°C ISO 150 Gear Oil
-18°C to 12°C ISO 150 All Season Gear Oil
Below -18°C Pour point at least 5°C lower than minimum
ambient temperature
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
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.
Perform the following checks while the lubrication system is operating:
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.
1. If pressure is too high:

a) Check chain oil spray nozzle for blockage
b) Adjust flow control valve at inlet end of spray pipe header and open further.
c) Adjust pump bypass relief valve.
2. If gauges show no pressure:

a) Check oil level in reservoir and add oil if necessary.
b) Check the pump suction strainer and clean if necessary by washing in a
suitable cleaning solution.
c) Check bypass relief valve on oil pump. Turn adjusting screw inward to
increase bypass pressure.
d) If all spray nozzles are delivering adequate oil, check pressure gauge tubing
for damages or stoppage.
Pressure Gauges
Dip Stick
Air Tank
Oil Filter
Photo: D3000 AC Drawworks Hydraulic Filter
www.nov.com
Page 44
D3000AC Drawworks - Lubrication Schedule

ITEM REMARKS LUBRICANT QUANTITY SERVICE
PERIOD
Drum Shaft -- EP2 Grease 4 Shots Twice/
Main week
bearings
Wireline Apply as required Wireline Application Monthly
WARNING: Avoid use Lubricant inspection
of excess wireline
lubricant. DO NOT use
mineral oil based
wireline lubricants.
Hydraulic Located on Driller Side Exxon Univus Approx. 76 6 Months
Tank N-22 litres/ 20 gal.
Lubrication Access from Rear ISO 150 Gear Approx. 379 6 Months
Sump OIl litres/ 100 gal.
Hydraulic -- Silicone-based Lightly coat 6 Months
Valves grease moving parts
Motor -- -- Forced Oil --
Mount
Bearings
One shot of grease is approximately equal to 25 grams weight.
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
Preventive maintenance may be carried out by regular operating personnel. Other,

more complex types of maintenance should be performed by specialists. The
disassembly, mechanical inspection, and repair during equipment strip-down are to be
performed by a qualified and experienced mechanic who is familiar with the proper use
of appropriate tools.
To minimize chances of personnel injury and equipment damage, provide a safe

working area and ensure all work pieces are adequately and correctly supported and/or
blocked. When other than routine servicing is necessary, it is suggested that the unit or
major component be removed to an area where ample work space is available and a
hydraulic press, overhead crane, bearing pullers, impact tools, etc. are accessible.
www.nov.com
Page 45
8.2.1 Routine Inspection
DAILY Checked Recorded

A1 Check lube oil level
A2 Check hydraulic oil level
A3 Check lube oil pressure
A4 Check for fluid leaks (hydraulic and lube oil)
A5 Check work area for cleanliness
A6 Check hydraulic pressure for and function of all
brake calipers.
A7 Check sight glass on air line filter for moisture
content and drain if necessary; drain air tank if
needed.
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.
A2 The hydraulic oil level should be

checked with both hydraulic pumps shut
off and both accumulator bottles bled off
and all the brake calipers engaged. In
this condition the oil level in the tank
should be 1 inch from the top of the
tank.
NOTE: Both sight glasses will be filled.

Hydraulic Filter
The hydraulic oil level may be checked
while the machine is running by looking
Upper Sight Glass at the sight glass on the side of the tank.
The oil level should be within 2” inches
of the top of the lower sight glass. The
Lower Sight Glass lower sight glass will be completely full
when operating if the tank is filled to
within 1” of the top of the tank as
detailed above.
Photo: D3000AC Hydraulic Tank
www.nov.com
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).
NOTE: Pressure will drop as the temperature rises.
If pressure is too high, perform the following checks:

• Check oil spray nozzles for blockage and ensure that oil holes are open and
delivering oil. If no blockage is found, see vendor service information for
setting the relief valve and flow controls.
If gauges show no pressure, perform the following checks:

• Check oil level in reservoir and add oil if necessary.
• Check oil filter and clean or renew as necessary.
• Check bypass relief valve on oil pump, turn adjusting screw inward to
increase bypass pressure.
• If all spray nozzles are delivering adequate oil, check pressure gauge tubing
for damage or blockage.
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.
WARNING: Contaminated brake pads must be replaced immediately. Do not

operate the drawworks with contaminated brake pads.
www.nov.com
Page 47
WEEKLY Checked Recorded

B1 Check all safety controls for malfunction
B2 Check wireline clamp integrity (and bolt torques)
Refer to Section 6.6.
B3 Brake calipers: inspect shoe lining, observe brake
actuation and movements in pins and levers
B4 Check nitrogen pre-charge pressure on hydraulic
system accumulator bottles
B5 Grease drumshaft main bearings
B6 Grease brake caliper pins
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.
WARNING: Absolutely no grease or oil is allowed to contact brake pads or brake

disc. Contaminated brake pads must be replaced immediately. Do
not operate drawworks with contaminated brake pads.
www.nov.com
Page 48
MONTHLY Checked Recorded

C1 Inspect electrical wiring
C2 Inspect wireline, lubricate as necessary
C3 Check availability and condition of tools
C4 Grease fittings on brake calipers
C5 Remove and rotate all brake caliper pins
C6 Check oil nozzles spray pattern
C7 Check the adjustment of the brake shoe
assembly support
C8 Check caliper adjustment brackets and adjust
or replace as necessary
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.
WARNING: Contaminated brake pads must be replaced immediately. Do not

operate the drawworks with contaminated brake pads.
www.nov.com
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
Page 50
C8 When assembling or replacing the caliper adjustment brackets, special attention

is needed to ensure what caliper pad adjustment brackets go where. The
medium and low calipers have their correspondent brake show assembly support
(P/N 0-6212-2426-00), and the top caliper has the top caliper pad adjustment
bracket (P/N 9108D309).
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
Page 51
THREE MONTHS Checked Recorded

D1 Renew lubricating oil filter
D2 Renew hydraulic oil filters
D3 Check brake caliper fastener torques
D4 Check breather conditions
D1 Renew lubricating oil filter at three month intervals.
D2 Renew hydraulic oil filter at three month intervals.
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.

SIX MONTHS Checked Recorded

E1 Change lube oil in lube oil tank
E2 Inspect lube oil piping
E3 Check all foundation and hold down bolts
E4 Check sprockets for wear and chain tension
E5 Check oil nozzles spray pattern
E6 Check condition of hydraulic fluid
E7 Check condition of accumulators
E8 Disassemble and clean caliper assembly levers
and pins
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.
E3 Check all foundation and hold-down bolts.
www.nov.com
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
YEARLY Checked Recorded

F1 Replace all brake caliper disc springs
(every five years)
F2 Visually inspect critical components
F3 Check bolt torques
F1 Refer to the National Oilwell Varco Emergency Disc Brake Caliper manual in

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.
F3 Check torque on all fasteners as per bolt torque chart.
www.nov.com
Page 53
9. GENERAL ROLLER CHAIN

9.1 Chain and Connecting Link Installation
9.2 Retaining Devices
9.3 Methods of Lubrication
9.4 Drive Guarding
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).
9.1 Chain and Connecting Link Installation
Installing the Chain:

Fit the chain around the sprockets in the drive and bring the free ends together,
normally between the sprockets, for final connection. Look for the access cover for the
master link installation. A rope or chain tightener should be used to bring the ends of
the chain together.
Installing the Connecting Link:

The connecting link, depending upon the size and type of chain, may employ either a
slip-fit or press-fit cover plate, combined with either a spring clip or cotters as the final
retainer.
Press-fit cover plates:

Are those which have an interference fit on the pins and provide integrity equal to the
base chain itself. They do, however, present their own unique degree of difficulty at
assembly.
To assemble the press-fit cover plates:

1. Insert the “Master Link,” the portion of the link that contains the pins, and provide
support or backing to resist the forces needed to drive the cover plate on.
2. Place the press-fit cover plate over the exposed pin ends and ensure that it is
aligned properly.
3. Drive the cover plate on until it is flush with the ends of the pins.
4. Obtain a hollow punch (perhaps a small piece of pipe or a discarded chain’s roller)
and locate it over/around the flush pin end.
www.nov.com
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.
To assemble the slip-fit cover plate:

1. Insert “Master Link,” the portion of the link that contains the pins, into the chain.
2. Slide the plate over the pin ends to a location which clears either the spring clip
groove or cotter hole.
3. Install the retaining device, either spring clip or cotter.
NOTE: When a slip-fit cover plate is used, a chain’s working capacity can be reduced
as much as 30%.
9.2 Retaining Devices
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
Page 55
Proper Chain Tension:

It should be expected that new chains will elongate slightly more during the first few
days of service then in the months of subsequent operation. This is due to the “running-
in” of the chain which removes minute imperfections from the surfaces of the pins and
bushings. Because of this, it is good practice to establish and adjust centre distances or
idlers for an initially snug-fitting chain. After the initial run-in period, the drive should
always be adjusted so that there is some degree of slack in the unloaded section of
chain. This slack is very important as it allows the pin/bushing joint to lubricate itself
prior to entering the working or loaded portion of the drive.
The following represents recommended mid-span movements for a properly tensioned

drive.
Recommended Possible Mid-Span Movement, A-C, of Slack Span
Dimensions in Inches
Drive Tangent Length Between Sprockets

Centre-Line 5 10 15 20 30 40 60 80 100
Horizontal to
0.25 0.50 0.75 1.00 1.50 2.00 3.00 4.00 5.00
45
Vertical to 45 0.12 0.25 0.38 0.50 0.75 1.00 1.50 2.00 2.50
Roller chain drives suffer more harm from faulty lubrication than from years of normal service!!!
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
Page 56
Chain drives require lubrication for six primary purposes:

1. Resist wear of the pin-bushing joint.
2. Cushion impact loads.
3. Dissipate heat.
4. Flush away foreign materials.
5. Lubricate chain-sprocket contact surfaces.
6. Prevent rust or corrosion.
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:
Ambient Recommended Lubricants

Temperature SUS Viscosity SAE Engine SAE Gear
ISO AGMA
Degrees F 100 F Oil Oil
20-40 200-400 20 80W 46 or 68 1 or 2
40-100 400-650 30 85W 100 3
100-120 650-950 40 90 150 4
120-140 950-1450 50 90 220 5
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.
The elongation of roller chain is the result of wear caused

by friction between the pins and bushings and regardless
of the size or type of chain, in order for any lubricant to
reach the critical pin/bushing area it should be applied to
the upper edges of link plates in the slack span. Lubricant
applied only to the chain’s rollers will not provide an
adequate supply to the internal wearing surfaces.
However, the chain’s rollers will receive adequate
lubrication due to spillage over the link plate edges when
lubricant is properly applied.
www.nov.com
Page 57
NOTE: When applying lubricant to multiple

strand chain, it is important that
lubricant be directed to each row of
chain link plates, not just the
outermost rows; and, in conveying
applications, oil should be directed
between the rollers and bushings as
well as between the chain link plates,
as significant wear can result from
external loading.
9.3 Methods of Lubrication
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.
Manual or Drip Lubrication (Type A):

Lubricant applied manually with an oil can or brush is
acceptable for slow speed drives, generally not over 600
feet per minute. When lubrication must be accomplished
with a minimum amount of oil, it is advisable to equip the
system with either felt pads or brushes which are fed by
lubricant from a reservoir and carefully positioned to
direct oil into the clearances between each row of link
plates in the slack span of chain.
Bath Lubrication (Type B):

Lubricant is applied to the chain by allowing the oil level
within an enclosed casing to cover the chain at
approximately the pitch line at its lowest point of operation.
This is by far the most desirable method for chains
operating at up to approximately 1500 feet per minute.
www.nov.com
Page 58
Forced or Circulating Lubrication (Type C):

This is similar to bath lubrication with the
exception that the lubricant is pumped onto the
chain under pressure. The oil should be
delivered to the upper edges of each row of link
plates across the lower span of chain just prior to
the chain’s entry into one of the sprockets.
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.
Chain 35 40 50 60 80 100 120 140 160 200

No.
Type A 350 300 250 215 165 145 125 110 100 80
Type B 2650 2200 1900 1750 1475 1250 1170 1050 1000 865
Type C Use for speeds higher than Type B limits
*Chain Speed in Feet/Minute
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.
9.4 Drive Guarding
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
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.)
2. Check Chain Tensions

Refer to the installation section and check chain tension. Adjust the drive as
needed to maintain the proper sag in the slack span. If elongation exceeds the
available adjustment, remove two pitches of chain and reconnect.
3. Check Chain Wear

Roller chains should be replaced promptly when worn (elongated beyond 1.5%)
or when the chain rollers begin to “ride high” near the tips of the teeth on
relatively large sprockets. If the chain is worn excessively, replace the entire
chain. Do not connect or splice a new section to a worn chain. Do not continue
to run a chain, worn in excess of 1.5% (or less in some applications), because
the chain will not engage the sprockets properly and increased damage to the
sprockets may occur.
4. Check Sprocket Tooth Wear

Check for roughness or binding when the chain engages
or disengages from the sprocket. Inspect the sprocket
teeth for reduced tooth section and “hooked” tooth tips. If
these conditions are present, the sprocket teeth are
excessively worn and the sprocket should be replaced.
Do not run new chain on worn sprockets as it will cause
the new chain to wear rapidly. Conversely, do not run a
worn chain on new sprockets as it will cause the new
sprockets to wear rapidly. As a general rule, replace the
sprockets with every third chain replacement.
5. Check Sprocket Alignment

If there is noticeable wear on the inside surface of the chain roller link plates, the
sprockets may be misaligned. Realign the sprockets as outlined in the
Installation section to prevent further abnormal chain and sprocket wear.
www.nov.com
Page 60
6. Check for Drive Interference

Check for interference between the drive and other parts of the equipment. If
there is any, correct it immediately. Interference can cause abnormal and
potentially destructive wear on the chain or the interfering part. If the edges of
the chain link plates impact against a rigid part, link plate fatigue and chain failure
can result.
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.
7. Check for Failure

Inspect the chain for cracked, broken, or deformed parts. If any of these
conditions are found, replace the entire chain. Even though portions of the
chain may appear to be in good condition, in all likelihood, the entire chain has
been damaged.
WARNING: Roller Chains that have been damaged under excessive

loading due to an accident, or otherwise, should be
completely replaced because the chain, as well as the
damaged component, has been loaded to a degree that has
impaired its ability to transmit normal loading.
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
Page 61
10. TROUBLESHOOTING
10.1 Equipment Fault Symptoms & Causes
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:
SYMPTOM POSSIBLE CAUSE

Excessive or
unusual noise • Drawworks brakes, sprockets, or electric drive motor.
from drawworks
Excessive or
unusual noise • Check bearings, lube system, lube pump and
from drawworks clutches.
interior
Improperly
functioning brakes • Brake caliper, hydraulic supply, or controls fault.
Metallic clanking • Sprocket wear, inadequate lubrication and/or
(rotating) misalignment of sprocket.
• Worn bearing (louder upon loaded condition). Possibly
Howling (rotating)
due to inadequate lubrication.
Squealing or • Brake pads worn or faulty caliper. Check brake discs
grinding (rotating) for warping.
Rattling • Loose or worn mounts.
• Check AC motor encoders.
Vibrations
NOTE: Standard bench tests will not prove that the
encoder is functioning properly.
• Check power source to the electrical motor.
Motor will not start • Check all cables from the power source to the motor.
• Crown saver requires reset.
Refer to Section 15, Vendor Information, for maintenance and troubleshooting

instructions of vendor equipment.
www.nov.com
Page 62
www.nov.com
Page 63
11. TORQUE GUIDE FOR BOLTS

11.1 Bolt Torque Chart
11.2 Socket Head Capscrew Tensile Requirements
11.3 Turn-of-Nut Tightening
11.1 Bolt Torque Chart
Tightening Torque Guide

SAE Grade 5 - Fine Thread
Size Clamp Load (lbs.) Plain Plated
1/4 - 28 (.250) 2,325 10 ft·lbs 7 in·lbs
5/16 - 24 (.3125) 3,675 19 ft·lbs 14 ft·lbs
3/8 - 24 (.375) 6,699 35 ft·lbs 26 ft·lbs
7/16 - 20 (.4375) 7,575 55 ft·lbs 41 ft·lbs
1/2 - 20 (.500) 10,200 85 ft·lbs 64 ft·lbs
9/16 - 18 (.5625) 12,975 122 ft·lbs 91 ft·lbs
5/8 - 18 (.625) 16,350 170 ft·lbs 128 ft·lbs
3/4 - 16 (.750) 23,775 297 ft·lbs 223 ft·lbs
7/8 - 14 (.875) 32,475 474 ft·lbs 355 ft·lbs
1 - 12 (1.000) 42,300 705 ft·lbs 529 ft·lbs
1 - 14 (1.000) 32,275 721 ft·lbs 541 ft·lbs
1 1/8 - 12 (1.125) 47,475 890 ft·lbs 668 ft·lbs
1 1/4 - 12 (1.250) 59,550 1,241 ft·lbs 930 ft·lbs
1 3/8 - 12 (1.375) 72,975 1,672 ft·lbs 1,254 ft·lbs
1 1/2 - 12 (1.500) 87,750 2,194 ft·lbs 1,645 ft·lbs

SAE Grade 5 - Coarse Thread
1/4 - 20 (.250) 2,025 8 ft·lbs 7 in·lbs
5/16 - 18 (.3125) 3,338 17 ft·lbs 13 ft·lbs
3/8 - 16 (.375) 4,950 31 ft·lbs 23 ft·lbs
7/16 - 14 (.4375) 6,788 50 ft·lbs 37 ft·lbs
1/2 - 13 (.500) 9,075 76 ft·lbs 57 ft·lbs
9/16 - 12 (.5625) 11,625 109 ft·lbs 82 ft·lbs
5/8 - 11 (.625) 14,400 150 ft·lbs 112 ft·lbs
3/4 - 10 (.750) 21,300 266 ft·lbs 200 ft·lbs
7/8 - 9 (.875) 29,475 430 ft·lbs 322 ft·lbs
1 - 8 (1.000) 38,625 644 ft·lbs 483 ft·lbs
1 1/8 - 7 (1.125) 42,375 794 ft·lbs 596 ft·lbs
1 1/4 - 7 (1.250) 53,775 1,120 ft·lbs 840 ft·lbs
1 3/8 - 6 (1.375) 64,125 1,470 ft·lbs 1,102 ft·lbs
1 1/2 - 6 (1.500) 78,000 1,950 ft·lbs 1,462 ft·lbs
www.nov.com
Page 64

SAE Grade 8 - Fine Thread
1/4 - 28 (.250) 3,263 14 ft·lbs 10 ft·lbs
5/16 - 24 (.3125) 5,113 27 ft·lbs 20 ft·lbs
3/8 - 24 (.375) 7,875 49 ft·lbs 37 ft·lbs
7/16 - 20 (.4375) 10,650 78 ft·lbs 58 ft·lbs
1/2 - 20 (.500) 14,400 120 ft·lbs 90 ft·lbs
9/16 - 18 (.5625) 18,300 172 ft·lbs 129 ft·lbs
5/8 - 18 (.625) 23,025 240 ft·lbs 180 ft·lbs
3/4 - 16 (.750) 33,600 420 ft·lbs 315 ft·lbs
7/8 - 14 (.875) 45,825 668 ft·lbs 501 ft·lbs
1 - 12 (1.000) 59,700 995 ft·lbs 746 ft·lbs
1 - 14 (1.000) 61,125 1,019 ft·lbs 764 ft·lbs
1 1/8 – 12 (1.125) 77,025 1,444 ft·lbs 1,083 ft·lbs
1 1/4 - 12 (1.250) 96,600 2,012 ft·lbs 1,509 ft·lbs
1 3/8 - 12 (1.375) 118,350 2,712 ft·lbs 2,034 ft·lbs
1 1/2 - 12 (1.500) 142,275 3,557 ft·lbs 2,668 ft·lbs

SAE Grade 8 - Coarse Thread
1/4 - 20 (.250) 2,850 12 ft·lbs 9 ft·lbs
5/16 - 18 (.3125) 4,725 25 ft·lbs 18 ft·lbs
3/8 - 16 (.375) 6,975 44 ft·lbs 33 ft·lbs
7/16 - 14 (.4375) 9,600 70 ft·lbs 52 ft·lbs
1/2 - 13 (.500) 12,750 106 ft·lbs 80 ft·lbs
9/16 - 12 (.5625) 16,350 153 ft·lbs 115 ft·lbs
5/8 - 11 (.625) 20,325 212 ft·lbs 159 ft·lbs
3/4 - 10 (.750) 30,075 376 ft·lbs 282 ft·lbs
7/8 - 9 (.875) 41,550 606 ft·lbs 454 ft·lbs
1 - 8 (1.000) 54,525 909 ft·lbs 682 ft·lbs
1 1/8 - 7 (1.125) 68,700 1,288 ft·lbs 966 ft·lbs
1 1/4 - 7 (1.250) 87,225 1,817 ft·lbs 1,363 ft·lbs
1 3/8 - 6 (1.375) 103,950 2,382 ft·lbs 1,787 ft·lbs
1 1/2 - 6 (1.500) 126,450 3,161 ft·lbs 2,371 ft·lbs
www.nov.com
Page 65
11.2 Socket Head Capscrew Tensile Requirements
per ASTM A574-83

Screw Dia. (in) Threads Inches Tensile Load Min. Rec. UNC Torque in
lbs.
UNC UNF UNC UNF UNRC UNRF
0.060 - 80 - 324 - 2
0.073 64 72 473 500 4 4
0.086 56 64 666 709 6 7
0.099 48 56 877 941 10 11
0.112 40 48 1,090 1,190 15 16
0.125 40 44 1,430 1,490 20 21
0.138 32 40 1,640 1,830 28 30
0.184 32 36 2,520 2,650 49 50
0.190 24 32 3,150 3,600 64 76
¼ 20 28 5,730 6,500 150 170
5/16 18 24 9,440 10,400 305 325
3/8 16 24 13,900 15,800 545 570
7/16 14 20 19,100 21,400 840 900
½ 13 20 25,500 28,800 1,300 1,370
5/8 11 18 38,400 43,500 1,850 1,970
¾ 10 16 56,800 63,400 2,630 2,660
7/8 9 14 78,500 86,500 4,400 4,800
1 8 12 103,000 113,000 7,000 7,600
1 1/8 7 12 129,000 146,000 10,400 11,000
1¼ 7 12 165,000 182,000 14,900 15,600
1 3/8 6 12 196,000 224,000 21,000 22,600
1½ 6 12 239,000 269,000 27,800 29,300
www.nov.com
Page 66
11.3 Turn-of-Nut Tightening
(Ref. RCSC specification, AISC (8)c for more details)
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.
Equipment consistency and reliability is dependent on assuring the joint is well

compacted and that all the bolts at a joint are in a snug-tight condition prior to the
application of the final required partial turn. It is critical that the element not turned in
tightening be prevented from rotating while the required degree of turn is applied to the
turned element.
Nut-Rotation from Snug-Tight Conditiona,b

Disposition of Outer Face of Bolted Parts
One face normal to
bolt axis and other
Bolt Length Both sloped no more than Both faces sloped no more
(under side of faces 1:20 than 1:20 from normal to
head to end of normal to (beveled washer not the bolt axis
bolt) bolt axis used) (beveled washer not used)
Up to and
including 4 1/3 turn 1/2 turn 2/3 turn
diameters
Over 4
diameters but 1/2 turn 2/3 turn 5/6 turn
not exceeding
8 diameters
Over 8
diameters but 2/3 turn 5/6 turn 1 turn
not exceeding
12c diameters
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
Page 67
12. RECOMMENDED SPARES

12.1 Drive Assembly
12.2 Drumshaft Assembly
12.3 Lube Pump Assembly
12.4 Input Shaft Assembly
12.5 Jackshaft Assembly
12.6 AC Hydraulic and Air Schematic
12.7 Lubrication Schematic
12.8 AC Drawworks Equipment Assembly
12.9 Brake Caliper
12.1 Drive Assembly

Oper. Comm
Part Number Description Dwg(Item #)
Qty. .Qty.
RC140-8 Roller Chain, 1 ¾” Pitch, 8 Strand – 9108A046 – C 1
138 Pitches c/w Connecting Link
RC140-6 Roller Chain, 1 ¾” Pitch, 6 Strand - 9108A046 – D 1
RC120-8 Roller Chain 1 ½” Pitch, 8 Strand – 9108A046 – E 1
RC100-4 Roller Chain 1 ¼” Pitch, 4 Strand – 9108A046 – F 2
RC100-4 Roller Chain 1 ¼” Pitch, 4 Strand – 9108A046 – G 1
12.2 Drumshaft Assembly

Oper. Comm
Qty. .Qty.
7006B236 Spherical Roller Bearing 9108A004 – A 2
7804408 Encoder 9108A004 - B 1
7006B472 Oil Seal 9108A004 - C 4
12.3 Lube Pump Assembly

Oper. Comm
Qty. .Qty.
7020B140 Hydraulic Pump 9108A037 - A 1
RC50-1 Roller Chain, 5/8” Pitch Single 9108A037 - E 1
Strand – 174 Pitches c/w
Connecting Link
www.nov.com
Page 68
12.4 Input Shaft Assembly

Oper. Comm
Qty. .Qty.
7006B400 Spherical Roller Bearing 9108A045 – B 1
7006B403 Spherical Roller Bearing 9108A045 – C 1
7006B404 Cylindrical Roller Bearing 9108A045 – D 1
7006B304 Cylindrical Roller Bearing 9108A045 – E 1
7006B164 Dual Passage Rotorseal 9108A045 – F 1
7006B471 Oil Seal 9108A045 – G 1
7006B075 Oil Seal 9108A045 – H 1
7006B162 O-Ring Static Seal Gland 9108A045 – M 1
8461C Drive Plate f/ Air Clutch 7018B258 9108A045 - 3
(Twin Disc)
A6606 Diaphragm f/ Air Clutch 7018B258 9108A045 - 1
(Twin Disc)
XB1376A Plate Separator f/ Air Clutch 9108A045 - 3
7018B258 (Twin Disc)
A2708Y Release Spring f/ Air Clutch 9108A045 - 3
12.5 Jackshaft Assembly

Oper. Comm
Qty. .Qty.
7006B414 Spherical Roller Bearing 9108A003 - A 1
7006B445 Spherical Roller Bearing 9108A003 - B 1
7006B040 Spherical Roller Bearing 9108A003 - G 1
7006B486 Cylindrical Roller Bearing 9108A003 - H 1
7006B164 Dual Passage Rotorseal 9108A003 - K 1
7006B030 Oil Seal 9108A003 - M 1
7006B415 Oil Seal 9108A003 - N 1
7006B162 O-Ring Static Seal Gland 9108A003 - P 1
9802 Drive Plate f/ Air Clutch 7018B571 3
(Twin Disc)
A6646 Diaphragm f/ Air Clutch 7018B571 1
(Twin Disc)
XB1402A Plate Separator f/ Air Clutch 3
A2708AD Release Spring f/ Air Clutch 3
www.nov.com
Page 69
12.6 AC Hydraulic and Air Schematic

Oper. Comm
Qty. .Qty.
60PN1015 Toggle Valve (Crown Saver) 9108X009 - 1 1
7030B102 Replacement High Pressure Filter 9108X009 - M 1
7030B031 Replacement Air Filter 9108X009 - AM 1
7032B262 Replacement Low Pressure Filter 9108X009 - BA 1
7040B008 Relay Valve 9108X009 - AG 1
20037340 2P/5W Solenoid Valve 9108X009 - AF 2
9130A085 Brake Control Valve 9108X009 - 4 3
7056B336 Pressure Gauge – 5,000 psi 9108X009 - D 3
7025B057 2P/3W Ball Valve 9108X009 - F 2
7026B037 Pressure Reducing Valve 9108X009 - G 2
7032B091 Accumulator 9108X009 - R 1
7032B093 Accumulator Bladder 9108X009 - 1
7032B094 Butyl Kit (Bladder Kit) 9108X009 - 1
7040B269 Pressure Gauge 9108X009 - AT 1
7026B147 Back Pressure Regulator Valve 9108X009 - AC 1
7040B009 Volume Booster 9108X009 - AH 1
20042178 Pressure Transducer 9108X009 - C 3
20032731 Temperature Sensor 9108X009 - AA 1
20029260 Level Sensor 9108X009 - AB 1
20023353 2P/3W Solenoid Valve 9108X009 - AD 4
20042179 Pressure Transmitter 9108X009 - AE 3
7026B069 Relief Valve 9108X009 - AR 1
7026B128 Air Pressure Regulator 9108X009 - BH 1
12.7 Lubrication Schematic

Oper. Comm
Qty. .Qty.
7026B040 Pressure Relief Valve 9108Y009 - B 1
7030B131 Replacement Filter 9108Y009 - C 1
7040B269 Pressure Gauge 9108Y009 - E 3
7030B083 Strainer, ¾” 9108Y009 - F 1
9108D297 Suction Strainer Modification 9108Y009 - 1 1
www.nov.com
Page 70
12.8 AC Drawworks Equipment Assembly

Oper. Comm
Qty. .Qty.
7006B381 Self Lubricating Bearings 9108A024 - A 24
2112414 Brake Caliper 9108A024 - B 1
7018B695 Flexible Drive Coupling Hub 9108A010 - D 2
7018B696 Flexible Drive Coupling Hub 9108A010 - E 2
7018B598 Flexible Drive Coupling Insert 9108A010 - F 2
7018B068 Flexible Drive Coupling Hub 9108A026 - D 1
7018B697 Flexible Drive Coupling Hub 9108A026 - E 1
7018B069 Flexible Drive Coupling Insert 9108A026 - F 1
www.nov.com
Page 71
12.9 Brake Caliper
www.nov.com
Page 72
www.nov.com
Page 73
www.nov.com
Page 74
www.nov.com
Page 75
13. CERTIFICATES
www.nov.com
Page 76
www.nov.com
Page 77
14. DRAWINGS
Drawing No. Drawing Title

Overall Assemblies
9108B008 D3000AC Drawworks General Assembly
9108A046 D3000AC Drawworks Drive Assembly
Shaft Assemblies
9108A045 D3000AC Drawworks Input Shaft Assembly
9108A003 D3000AC Drawworks Jackshaft Assembly
9108A004 D3000AC Drawworks Drum Shaft Assembly
Schematics
9108X009 D3000AC Hydraulic & Air Schematic
9108Y009 Drawworks Lubrication Schematic
Miscellaneous Drawworks Drawings
9108A001 20 Gallon Hydraulic Tank Assembly
9108A006 Wire Line Clamp (Ø 1 5/8” ) Assembly
9108A007 D3000AC Chain Case (Off Driller’s Side) Assembly
9108A008 D3000AC Chain Case (Driller’s Side) Assembly
9108A010 D3000AC Drawworks Hydraulic Pump - Motor Assembly
9108A015 D3000AC Drawworks Hydraulic Tubing Guard Assembly
9108A024 D3000AC Brake Beam Installation Details
9108A025 D3000AC Drawworks Drum Kicker Plate Assembly
9108A026 D3000AC Drawworks Lube Pump – Motor Assembly
9108A033 D3000AC Dwwks Equipment (Hydraulic, Air & Lube) Assembly
9108A034 D3000AC Drawworks Frame Assembly
9108A037 D3000AC Drawworks Lube Pump Assembly
9108C016 D3000AC Drawworks Maintenance Envelope
9108C025 D3000AC Drawworks Nameplates
9108C026 D3000AC Footprint & Installation Detail
9108C027 D3000AC Drawworks Nozzle Schedule
9108D105 D3000AC Dwwks Drum Wear Plates & Lebus Grooving Installation
9108D303 D3000AC Drawworks Brake Caliper Operations Plate
9108L022 D3000AC Drawworks Overall Lifting Diagram
9108L023 D3000AC Drawworks Rear Section Lifting Diagram
9108L024 D3000AC Drawworks Front Section Lifting Diagram
9130A085 2P-4W Pilot Operated Brake Control Valve
9130A094 Remote Brake Valve Assembly
2112414 Caliper Assembly, Emergency Brake, Dreco SSGD/AHD
www.nov.com
Page 78
www.nov.com
Page 79
15. VENDOR INFORMATION
VENDOR MANUAL DESCRIPTION / MODEL

NAME NUMBER
BEI 924-02093- Model HS35 Drawworks Optical Encoder
Technologies 001
Commercial PIB-25X 25X Service Manual: Single & Tandem Oil
Intertech 10MSR6/89 Hydraulic Pumps - Motors
Denison S1-AM010-B Axial Piston, Variable Displacement Open Loop
Hydraulics Pump, Series PV/PVT Installation & Start Up
Endress & XA 063F-E Safety Instructions – Liquiphant M/S – FTL50
Hauser (H)/51 (H), FTL 51C, FTL70/71
Enerpac L1763 Hydraulic Hand Pumps Instruction Sheet
Hydac N/A High Pressure Filters
National EPL-1825 National Emergency Disc Brakes 2112414 with
Oilwell Varco Spare Parts List
Oil Air N/A Instruction Manual for the Accumulator
SKF N/A Cylindrical Roller Bearings
SKF N/A Spherical Roller Bearings
TECO- N/A Installation & Maintenance Instructions for Three
Westinghouse Phase Induction Motors, Frames 143T-445T
Tescom Form 1886 Operation and Service Manual for Piston Sensed
Pressure Reducing Regulators.
Tescom Form 1891 Safety, Installation & Operation Precautions for
Tescom Industrial Controls
Twin Discs SM-218 Model PO-330 Air Operated Clutch
Twin Discs 1015848 Model PO-336 Air Operated Clutch
www.nov.com
Instruction Sheet
¤
Hydraulic Hand Pumps
L1763 Rev F 10/03
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
®
equipment. a damaged hose may cause it to rupture.

IMPORTANT: Do not lift hydraulic Avoid situations where loads are not
equipment by the hoses or swivel directly centered on the cylinder plunger.
couplers. Use the carrying handle or other Off-center loads produce considerable
means of safe transport. strain on cylinders and plungers. In
addition, the load may slip or fall, causing potentially
CAUTION: Keep hydraulic equipment dangerous results.
away from flames and heat. Excessive
heat will soften packings and seals, Distribute the load evenly across the entire
resulting in fluid leaks. Heat also weakens saddle surface. Always use a saddle to
hose materials and packings. For optimum protect the plunger.
performance do not expose equipment to
temperatures of 65 °C [150 °F] or higher. Protect
hoses and cylinders from weld spatter. IMPORTANT: Hydraulic equipment must
only be serviced by a qualified hydraulic
DANGER: Do not handle pressurized technician. For repair service, contact the
hoses. Escaping oil under pressure can Authorized ENERPAC Service Center in
penetrate the skin, causing serious injury. your area. To protect your warranty, use only
If oil is injected under the skin, see a doctor ENERPAC oil.
immediately. WARNING: Immediately replace worn or
WARNING: Only use hydraulic cylinders in damaged parts by genuine ENERPAC
a coupled system. Never use a cylinder parts. Standard grade parts will break
with unconnected couplers. If the cylinder causing personal injury and property
becomes extremely overloaded, damage. ENERPAC parts are designed to fit properly
components can fail catastrophically causing severe and withstand high loads.
personal injury. CAUTION: Always use the handle to carry
WARNING: BE SURE SETUP IS STABLE the pump. Carrying the pump by the hose
BEFORE LIFTING LOAD. Cylinders may damage the hose and/or the pump.
should be placed on a flat surface that can
®
support the load. Where applicable, use a

cylinder base for added stability. Do not 3.0 DESCRIPTION
weld or otherwise modify the cylinder to attach a
base or other support. 3.1 Models P-141, 1001; P-142, 1002;
P-202; P-391, 1004; P-392, 1005; P-802;
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]
Stage 1 Stage 2 Stage 1 Stage 2

P-80, 1006 2 350 [25] 10,000 [700] .99 [16.23] .15 [2.46] 140 [2295]
P-84 2 350 [25] 10,000 [700] .99 [16.23] .15 [2.46] 140 [2295]
P-142, 1002 2 200 [14] 10,000 [700] .221 [3.62] .055 [.90] 20 [328]
P-142AL 2 200 [14] 10,000 [700] .221 [3.62] .055 [.90] 9.0 [148]
P-202 2 200 [14] 10,000 [700] .221 [3.62] .055 [.90] 55 [900]
P-392, 1005 2 200 [14] 10,000 [700] .687 [11.26] .151 [2.47] 55 [900]
P-392AL 2 200 [14] 10,000 [700] .687 [11.26] .151 [2.47] 55 [900]
P-462 2 200 [14] 10,000 [700] 7.69 [126.00] .29 [4.75] 462 [7572]
P-464 2 200 [14] 10,000 [700] 7.69 [126.00] .29 [4.75] 462 [7572]
P-801 2 350 [25] 10,000 [700] .99 [16.23] .15 [2.46] 250 [4095]
P-802 2 400 [28] 10,000 [700] 2.40 [39.34] .15 [2.46] 155 [2540]
P-842 2 400 [28] 10,000 [700] 2.40 [39.34] .15 [2.46] 155 [2540]
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
WARNING: These pumps are operated

with a non-vented reservoir. If the
reservoir is subjected to high pressure,
the casing may rupture, causing
personal injury and/or equipment damage.
NEVER attempt to return more oil to the reservoir
than it is capable of holding.
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
4.1 Connecting the Pump

1. Thread hose into pump outlet. Use 1 1/2 wraps of
Teflon tape (or suitable thread sealant) on hose
fitting, leaving the first complete thread free of tape
to ensure that tape does not shed into hydraulic
system, causing damage. Trim loose ends.
2. Install a pressure gauge in-line from the pump for
added safety and better control.
3. Connect the hose(s) to your cylinder or tool.
NOTE: For single-acting cylinders, connect one
hose from the pump to the cylinder. For double-
Figure 3, Models P-462, P-464 acting cylinders, connect two hoses. Connect
one hose from the pressure port of the pump to
the pressure port of the cylinder. Connect another
Table 3 hose from the retract port of the pump to the
Fig. 3 P-462 P-464 retract port of the cylinder.
A 3-Way 2-Position Valve 4-Way 3-Position Valve
B 3/8 NPTF Outlet Port 3/8 NPTF Outlet Port 4.2 Pump Venting
C Vent/Fill Plug Vent/Fill Plug See table below to determine if your pump should be
D Handle Clip Handle Clip operated with a vented or non-vented reservoir.
Vented pumps provide slightly better performance.
For pumps with nylon reservoir, turn vent/fill cap 1/4
3.4 Models P-25, P-50, and P-51 turn counter-clockwise to vent. For other pumps, see
decal on pump. Close vent prior to transporting
Figure 4 shows hand pump models P-25 and P-50, pump to prevent oil leakage.
both of which are equipped with a handle that
operates in both directions. Figure 5 shows the P-51 VENTING OPTIONS
hand pump. The main components of these pumps
are listed in the table below. EHF-65 ..........non-vented P-142AL.........non-vented
P-18 ...............non-vented P-202 ......................either
P-25 ........................either P-391, 1004 ............either
P-39, 1003 .....non-vented P-392, 1005 ........... either
P-50 ........................either P-392AL ................vented
P-51 ......................vented P-462 ....................vented
P-80, 1006 .....non-vented P-464 ....................vented
P-84 ...............non-vented P-801 .............non-vented
P-141, 1001 ............either P-802 ......................either
P-142, 1002 ............either P-842 ......................either
4.3 Pump Position

See table below to determine the correct operating
Figure 4, Models P-25 and P-50 position for your pump, horizontal or vertical.
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 5, Model P-51

4
NOTE: When operating the pump in the vertical CAUTION: Close release valve finger
position, the hose end must be pointed down, or the tight ONLY. Using tools on release valve
pump will pick up air and will not build pressure properly. can damage it and cause the pump to
malfunction.
5.0 OPERATION
2. Operate pump handle to deliver hydraulic power
to system. Pressure will be maintained until
5.1 Before Using the Pump release valve is opened.
1. Check all system fittings and connections to be 3. Open release valve (turn counter-clockwise) to
sure they are tight and leak free. release pressure, allowing oil to flow back to the
2. Check oil level in reservoir before operating reservoir.
pump. See "Adding Oil to the Pump" on page 7.
5.4 Single-Acting Applications with 3-Way,
2 Position Manual Valve
CAUTION: NEVER add extensions to
pump handle. Extensions cause 1. Shift valve handle to position 1 as shown in Figure 7.
unstable pump operation. 2. Operate pump handle to deliver hydraulic power
to the system. Pressure will be maintained until
WARNING: In certain situations the the valve is shifted.
pump handle can "kick back". Always
3. To allow oil to return to the reservoir, shift valve
keep your body to the side of the pump,
handle to position 2.
away from the line of force of the handle.
NOTE: To reduce handle effort at high pressure, take
short strokes. Maximum leverage is obtained in the
last 5° of stroke.
5.2 Using Two-Speed Pumps

These pumps provide 2-stage flow. Under no-load,
the pump operates in the high flow first stage for
rapid advance. When the load is contacted, the pump
automatically shifts to the second stage for building
pressure. For P-462 or P-464 models, when pump
pressure reaches approximately 200 psi [14 bar], you
must momentarily stop pumping and raise the handle
to shift to the high pressure stage. For P-802 or
P-842 models, when pump pressure reaches
approximately 400 psi [28 bar], you must momentarily
stop pumping and raise the handle to shift to the high
pressure stage. After the pump shifts, pumping takes
less effort.
Figure 7
NOTE: For best performance, operate pump handle
at moderate speed during the high flow first stage.
Rapid handle speed in the first stage will prevent the 5.5 Double-Acting Applications with 4-Way,
pump from delivering full volume of oil.
3 Position Manual Valve
5.3 Single-Acting Applications with Pumps with 4-way control valves are designed to
Release Valve operate double-acting cylinders. See Figure 8 for
valve positions.
1. Close release valve by turning clockwise, as
shown in Figure 6.
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.
6.0 AIR REMOVAL

Removing air from the hydraulic system will help the
Figure 8b cylinder to advance and retract smoothly (see figure 9).
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.
WARNING: Operate double-acting 7.0 MAINTENANCE

cylinder only when both hoses are
connected to the pump. If one coupler Use only Enerpac hydraulic oil with these pumps to
is left unconnected, high pressure will promote long pump life and to protect your warranty.
build behind the coupler which could cause Viton and EPR seal kits are available for some hand
personal injury and/or equipment damage. pumps. Contact your Enerpac representative for more
information on these products and their applications.
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)
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
High Pressure Element
Filtration Rating in Microns

003 = 3 µm
005 = 5 µm ®
or High Collapse Betamicron® (BH3HC) Absolute Filtration Rating
010 = 10 µm Low Collapse Betamicron (BN3HC) (ßx ≥200)
020 = 20 µm
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
Filter Element Material

BH3HC = Betamicron® BH3HC High Collapse
(Disposable)
BN3HC = Betamicron® BN3HC Low Collapse
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
Approximate Weights Housing Volumes

MODEL WITH ELEMENT WITHOUT ELEMENT Filter type LF and DF
DF 30 4.2 lbs. 1.9 kg 4.0 lbs. 1.8 kg Size Volume
DF 60 9.0 lbs. 4.1 kg 8.6 lbs. 3.9 kg 30 0.14 qt. 0.13 liter
DF 330 49.8 lbs. 22.6 kg 47.2 lbs. 21.4 kg 280* 1.53 qts. 1.45 liters
DF 660 67.2 lbs. 30.5 kg 62.4 lbs. 28.3 kg 330 1.58 qts. 1.50 liters
DF 1320 115.5 lbs. 52.4 kg 105.8 lbs. 48.0 kg 660* 3.17 qts. 3.00 liters
LF 30 1.8 lbs. 0.8 kg 1.5 lbs. 0.7 kg 1320* 5.92 qts. 5.60 liters
LF 60 3.3 lbs. 1.5 kg 2.9 lbs. 1.3 kg
LF 110 4.0 lbs. 1.8 kg 3.3 lbs. 1.5 kg * only for DF filters
LF 160 8.2 lbs. 3.7 kg 7.0 lbs. 3.2 kg
LF 240 9.5 lbs. 4.3 kg 7.9 lbs. 3.6 kg
LF 330 18.1 lbs. 8.2 kg 15.4 lbs. 7.0 kg
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)
Above subject to Technical Modifications.
Filtration Efficiency: Multi-Pass Filtration Efficiency

Ratings to ISO 4572 for Betamicron® Elements
Absolute Filtration Rating = ßx ≥ 200
Terminal ∆P Across Element = 72 psid (5 bar)
For all micron ratings (3, 5, 10, & 20), both High and Low Collapse Betamicron® Elements
Hydraulic Symbol: INLET
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:
∆P Assembly = ∆P Housing + ∆P Element
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:
Actual Specific Gravity

∆P Housing = ∆P Curve x
0.86
DF & LF SIZE 30 HOUSING DF & LF SIZES 60 & 110 HOUSING
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
Bypass Valves Curve:

Curves shown are applicable for mineral oil with a specific gravity of 0.86. Differential pressure increases in proportion to
the specific gravity of the fluid. To adjust the bypass ∆P for the fluid being used, use the equation:
Actual Specific Gravity

∆P Valve = ∆P Curve x
0.86
DF/LF 30 DF/LF 60/110
200 DF/LF 160/240/280
12 160
10 DF/LF 330/660
∆P in bar
∆P in psi
8 120
6 80
4
40
2
0 0
0 20 40 60 80 100
Q in gpm
0 50 100 150 200 250 300 350 400

Q in l/min
5
Pressure Drop Calculations: (continued)
Element ∆P Calculations: Element Max Recommended
Wire Screen Elements: Size Flow (gpm)
To find ∆P across clean wire screen element, divide Application Flow by Maximum 30 8
Recommended Flow and find percentage; then read ∆P from graph below. 60 16
110 29
160 42
Application Flow
% of Flow = 100 x 240 63
Max. Recommended Flow 280 72*
Example: 330 87
Size 60 Wire Screen @ 10 GPM: 660 174
1320 174*
* Port Size Limited Flow
10 gpm
100 x = 63% of Flow
16 gpm 0.20 3
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:
Actual Specific Gravity Actual Viscosity

∆P Element = ∆P Curve x x
0.86 141
Betamicron® 3 Plus Elements:

Act. Spec. Gravity Act. Viscosity
∆P Element = ∆P Element from Curve x x
0.86 141
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
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
6
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
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
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
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
7
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
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
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
“V” Metal Fiber Elements:

Act. Spec. Gravity Act. Viscosity
∆P Element = K Factor x Flow (gpm) x x
0.86 141
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
G 1/2 Drain Plug

26.378
670
5.197
132
5.984
152
Dimensions are inches/mm.
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
Dimensions: LF Filters (sizes 30-660) in inches/mm
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
DF 330 & 660 Only

3.811
(96.8mm)
3/4-10UNC-2B x 1.00
(4 Places) (25mm)
1.750
(44.5mm)
Dimensions are for general information only. Due to

constant development and updating of details, we ask SAE-32 FLANGE
that all critical dimensions be verified by requesting a CODE 62 - 6000 psi (414 bar)
certified print.
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.
Request catalog # 02069743

BETAFIT® Filter Elements
HYDAC manufactures high quality filter elements that are dimensionally similar
to other manufacturer's elements and will fit interchangeably into their filter
housings. This catalog lists the interchange elements and the models which they
replace and is organized by manufacturer. Even When your hydraulic or lube oil
© 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.

Condensed Filter Catalog
This condensed catalog serves as a quick reference guide for selecting
HYDAC filters. The models are divided into high, medium, and low pressure
groups. Charts then describe each filter in the group. Each model description
includes mounting method, maximum operating pressure, maximum flow rates,
number of sizes and connection size range, flow path, clogging indicator type,
and a brief description of features and benefits. General information about
clogging indicators, element types, breathers, and filler breathers is also
included.

Filtration Technology
HYDAC Filter Technology is the result of many years of research, development
and performance evaluation both in test stands and actual applications.
HYDAC’s Filter Division produces a complete range of filters. This range
includes in-line, in-tank, inside-tank, direct mount, and manifold mount, modular
stacking filters. Also available are duplex models for systems requiring continuous
operation. This catalog provides a general overview and photos of HYDAC filter
families with information on pressure and flow ratings, and mounting types. It
serves as a handy reference to select the appropriate series of filter(s) for the
application in need of filtration. More detailed literature that includes specific
technical data and dimensioned drawings is available for all models.
HYDAC TECHNOLOGY CORPORATION

2260 City Line Road • Bethlehem, PA 18017
Phone (610) 266-0100 • Fax (610) 264-3540
www.hydacusa.com • powerup@hydacusa.com
Houston, Texas
EMERGENCY DISC BRAKE CALIPER

PART NUMBER 2112414
OPERATION AND MAINTENANCE MANUAL
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
This manual is provided for guidance to operate and maintain or

adjust the emergency disc brake caliper. This information has been
prepared with a basic viewpoint to give accurate and concise data
needed to perform minor adjustments as well as major overhauls.
This information is not elementary, as it is intended for operators

and servicemen who are familiar with drilling equipment in general.
It is not intended, nor would it be possible in such limited space,
to cover every possible condition that may be encountered. Always
use good, sound mechanical practices and safety precautions.
EXERCISE EXTREME SAFETY PRECAUTIONS AND EMPLOY

SOUND MECHANICAL PRACTICES WHEN PERFORMING
INSPECTIONS, MAINTENANCE REPAIRS, OR WHEN OPERATING
THE EQUIPMENT. IT SHOULD BE OPERATED ONLY UNDER
CONDITIONS FOR WHICH IT WAS INTENDED.
Page 2
EPL-1825
ADJUSTMENT SPECIFICATIONS
1a. EMERGENCY BRAKE (Released) 1500 PSI (103 bar)

1b. EMERGENCY BRAKE (Applied) 0 PSI (0 bar)
- EMERGENCY BRAKE PAD

2. Part Number 7602-1370-46
3. Thickness (New) 1.00 Inch (25 mm)
4. Minimum Thickness (Before Pad Replacement).50 Inch (12.7 mm)
- EMERGENCY BRAKE CYLINDER

5. Part Number 6212-1832-21
5. Maximum extension of Emergency Brake Cylinder
Adjusting Eye (Before Pad Replacement) 1.25 Inch (32 mm)
- STANDOFF (Total Gap Between Disc and Both Pads)

6. Adjusted .030 Inch (1.5 mm)
7. Maximum (Before Adjustment) .060 Inch (2.3 mm)
OPERATION
The NATIONAL OILWELL VARCO emergency caliper uses high capacity

springs inside the cylinder to generate force through the lever arms
to opposing friction pads on the disc. Hydraulic pressure is
required to release the caliper. The emergency brakes are set when
the hydraulic fluid is exhausted from them.
Operation of the emergency caliper depends on a hydraulic power unit

to provide the pressure required to release the brakes. An
intelligent system is also required to engage/disengage the
emergency calipers at the appropriate times.
Page 3
EPL-1825
MAINTENANCE
EMERGENCY BRAKE CALIPER ASSEMBLY
Inspect the Emergency Brake Caliper Assemblies as indicated in the

Maintenance Schedule. Whenever the total gap between both pads and
the disc exceeds that shown in the Adjustment Specification, the
caliper assembly should be adjusted. Refer to Figure 1, included at
the end of this manual.
THE EMERGENCY BRAKE CALIPER CYLINDERS ARE SPRING LOADED.

LOSS OF HYDRAULIC PRESSURE WILL CAUSE THE EMERGENCY
BRAKE CYLINDERS TO CLOSE RAPIDLY, AND WITH GREAT FORCE. USE
EXTREME CARE WHILE ADJUSTING THE EMERGENCY BRAKE.
PAD WEAR INSPECTION
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.
AN ADJUSTMENT EYE ON THE EMERGENCY BRAKE CYLINDER ALLOWS

FOR ADJUSTMENT OF PAD GAP. THE MAXIMUM AMOUNT THE EYE CAN
EXTEND FROM THE ADJUSTING NUT IS GIVEN IN THE ADJUSTMENT
SPECIFICATIONS. REPLACE THE PADS WHENEVER THE EYE IS
EXTENDED BEYOND THE AMOUNT GIVEN IN THE ADJUSTMENT
SPECIFICATIONS.
Page 4
EPL-1825
MAINTENANCE (continued)
PAD WEAR ADJUSTMENT
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
This procedure describes replacement of the pads for one caliper

assembly. Replace all Emergency Brake pads at the same time. Use
new hardware (screws and nuts) when a pad is replaced.
When replacing the pads, apply hydraulic pressure to the Emergency

Brake Cylinder to retract it. Use extreme care in handling the
spring-loaded cylinder. Remove the pull pins. Move the hydraulic
cylinder out of the way.
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
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.
2. Inspect pins and bushings for excessive wear and replace if

necessary.
3. Inspect all brake components for evidence of damage. Replace

any bent, cracked or damaged components.
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.
EMERGENCY BRAKE CYLINDER DISASSEMBLY
THE EMERGENCY BRAKE CYLINDER IS UNDER COMPRESSED SPRING

FORCE. THE CYLINDER MUST BE RESTRAINED DURING DISASSEMBLY.
Refer to Figure 2 included at the end of this manual.
To disassemble the emergency brake cylinder, remove the cylinder

from the caliper assembly and place it with adjusting eye facing up.
Remove the adjusting eye, adjusting nut locks and adjusting nut from
the cylinder.
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
EMERGENCY BRAKE CYLINDER REASSEMBLY
Prior to reassembly of the emergency brake cylinder the springs

should be NDE checked by a qualified Inspector. If a crack is
detected in a spring, the entire set should be replaced. Inspect the
threads on the eight tie rod studs. If the threads are damaged
replace the studs. Inspect all cylinder components and replace
those that are damaged.
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.
Reinstall the emergency brake cylinder, bleed the hydraulic lines,

and adjust the pad clearance.
LUBRICANT REQUIREMENTS
The disc springs in the Emergency Brake Cylinder should be

lubricated with molybdenum disulfide based grease prior to
reassembly whenever the cylinder has been disassembled.
Lubricate pivot shafts and bushings on caliper assembly components

with molybdenum disulfide grease. DO NOT USE A LUBRICANT CONTAINING
COPPER. Due to the dissimilar metals corrosion will occur that will
cause the shafts to be difficult to remove.
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
1. While operating the emergency brake, monitor the emergency

brake supply pressure to confirm adequate brake supply
pressure. If any system or supply pressure is not within 25
PSI of the Adjustment Specifications stop using the drawworks
brakes and determine the cause.
WEEKLY
1. Inspect Emergency Brake Caliper Assemblies for brake pad

standoff. Adjust if required. Replace pads if worn thickness
of pad is less than that given in the Adjustment
Specifications. Operate Emergency Brake to confirm smooth
operation of all components.
2. Inspect emergency brake cylinders and brake piping for any

evidence of leakage. Replace or repair if leakage exists.
3. With brakes released, adjust screw on brake shoe support to

prevent pads from dragging on the disc.
4. Apply one shot of grease to each Pivot Support Shaft. Clean

off any excess grease.
WHENEVER BRAKE PADS ARE REPLACED
1. Inspect caliper assemblies for bent, cracked or worn

components. Replace any damaged components.
2. Inspect pivot shafts on Emergency Caliper assembly components

with NDE procedures. Replace any part with crack-like
indications.
3. Lubricate pivot shafts and bushings on caliper assembly

components with molybdenum disulfide grease. DO NOT USE A
LUBRICANT CONTAINING COPPER. Due to the dissimilar metals
corrosion will occur that will cause the shafts to be difficult
to remove.
Page 8
EPL-1825
MAINTENANCE SCHEDULE (continued)
ANNUALLY
Test the Emergency Cylinders by following the procedures below:

1. Release pressure on cylinders.
2. Disconnect the hydraulic supply hose to the Emergency

cylinders.
3. Connect a hydraulic hand pump, capable of producing 2100 PSI

(145 Bar), to one cylinder with an accurate pressure gauge in
the line. The hand pump should be filled with clean fluid of
the same type used in the brake system.
4. Pump the cylinder up until the pin on the live end of the
cylinder can be removed.
5. Block up under cylinder so plunger is free to move.
6. Release the pressure on cylinder and attach a magnetic base

dial indicator to cylinder end plate with the indicator button
resting on the end of the piston rod.
7. Pressure up on the cylinder to obtain readings at the following

points.
PRESSURE CYL. TO: TRAVEL SHOULD NOT EXCEED:

a) 1000 PSI (69 Bar) .332" (8.4 mm)
b) Release Pressure
c) 1400 PSI (97 Bar) .532" (13.5 mm)
8. Repeat steps 3 through 7 on the other Emergency Cylinders.
9. If any of these tests fail, proceed with Five Year replacement

of springs.
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)
Every Five Years
1. The Emergency Cylinders should be disassembled per instructions

in the maintenance section and all springs and seals replaced
with new parts.
2. Perform pressure test per number 7 in Annual inspection above.
TROUBLE SHOOTING CHART

This chart highlights the most likely causes of problems with the
emergency brake caliper. Read this manual and refer to the assembly
drawings to understand emergency brake operation. This chart is not
exhaustive, nor does it attempt to cover those items that are
assumed to be routine for experienced maintenance personnel.
SYMPTOM PROBABLE CAUSE
1. BRAKE WON'T HOLD BRAKE SUPPLY PRESSURE NOT BEING DUMPED FROM
CYLINDER
BRAKE PAD CLEARANCE NEEDS ADJUSTING
BROKEN SPRING(S) IN CYLINDER
OIL SOAKED BRAKE PADS
2. BRAKE RESPONSE SLOW RESTRICTION IN FLOW TO/FROM EMERGENCY BRAKE

CYLINDER
BRAKE PAD CLEARANCE NEEDS ADJUSTING
AIR IN EMERGENCY BRAKE 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
1. Bushing 11. Disc Spring

2. Piston 12. Stud, Cylinder
3. Wiper Seal 13. End Plate
4. Poly-Pak 14. Nut, Stud
5. End Plate 15. Adjusting Nut
6. Plug Pipe, Sq Hd 16. Adjusting Eye
7. O-ring 17. Screw, Drilled Head
8. Poly-Pak 18. Tie Wire
9. Spacer 19. Adjusting Locknut
10. Cylinder Shell 20. Hollow Hex Plug
Page 12
EPL-1825
SALES AND SERVICE INFORMATION
EXECUTIVE OFFICES MANUFACTURING PLANTS
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
CASPER, WY LONG BEACH, CA ODESSA, TX VENTURA, CA
DALLAS, TX LOS ANGELES, CA OKLAHOMA CITY, OK WICHITA, KS
WILLISTON, ND
PHONE : 701/572-3781
UNITED STATES STORES

ANCHORAGE, AK CHEYENNE WELLS, CO GREAT BEND, KS LIBERAL, KS
ANDREWS, TX CLAY CITY, IL HARTSHORNE, OK LINDSAY, OK
BAKER, MT CORPUS CHRISTI, TX HARVEY, LA LONG BEACH, CA
BAKERSFIELD, CA CORTEZ, CO HENDERSON, KY MCALLEN, TX
BIG LAKE, TX CROSSVILLE, IL HOBBS, NM MCCOOK, NB
BIG PINEY, WY DENVER CITY, TX HOMINY, OK MOBILE, AL
BIG SPRING, TX DICKINSON, ND HOUMA, LA MOHALL, ND
BILLINGS, MT ELK CITY, OK HOUSTON, TX MONAHANS, TX
BRADFORD, PA ELLINWOOD, KS KALKASKA, MI MORGAN CITY, LA
BROOKHAVEN, MS EVANSTON, WY KENAI, AK MT. CARMEL, IL
BRYAN, TX FT LUPTON, CO KENEDY, TX MT. PLEASANT, MI
CAMERON, LA FT. SMITH, AR KILGORE, TX NESS CITY, KS
CASPER, WY FREER, TX LAREDO, TX NEW IBERIA, LA
CHARLESTON, WV GILLETTE, WY LAUREL, MS ODESSA, TX
Page 13
EPL-1825
UNITED STATES STORES
OKLAHOMA CITY, OK POWELL, WY SHIDLER, OK VERNAL, UT
PAINTSVILLE, KY PUNXSUTAWNEY, PA SHREVEPORT, LA VICTORIA, TX
PAMPA, TX RATLIFF CITY, OK SNYDER, TX WATFORD CITY, ND
PEARSALL, TX RIVERTON, WY SUNDOWN, TX WILLISTON, ND
PENNSBORO, WV ROCK SPRINGS, WY VENICE, LA WOODLAND, CA
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.
OLAER GROUP COMPANY

DISASSEMBLY
Instructions for disassembling the

accumulator.
Release all the hydraulic system pressure in a safe

manner (eg: bleed valve or automatic discharge valve
installed in the system). Remove the accumulator
from the hydraulic system and place it horizontally in
a vice or a clamping device. Protect the clamping
jaws with wood or rubber so as not to damage the
accumulator shell.
1. Remove the protective cap on the gas 2. Remove the valve sealing cap from the
valve. valve adaptor.
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
Cleaning & Inspection

Clean all the metallic parts of the accumulator with
an organic solvent. Avoid exposing the rubber parts
to the solvent to prevent any attack on the rubber.
Inspect the condition of the metallic components of
the fluid port (poppet, spring, stop nut and piston)
and replace the complete fluid port assembly if any
of the components are damaged. Push the poppet
valve head to make sure it slide freely through the
guide in the fluid port. Clean the bladder with
isopropyl alcohol or equivalent. Inspect the bladder
for any visual damages. Replace if necessary. 1. Squeeze the bladder to discharge air from it by 2. Then install the valve adaptor to a torque value of
Check that there is no corrosion inside or outside of rolling it up from the bottom. 90 in.lbs (10 Nm). (For the two piece valve stem
the shell. Replace all parts considered defective. design).
The “O” Rings and back up rings must be replaced.
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
copyright 1994 OilAir Hydraulics, Inc. Printed in USA Bulletin #MMM94

OLAER GROUP COMPANY
Materials of Construction Maintenance Maintenance (continued)
OPERATION AND Standard materials of construction contacting The following procedures are provided to 4. The valve parts can now be removed
the fluid media can be any of the following: enable the customer to perform all normal from the regulator body by turning the
SERVICE MANUAL maintenance and repair operations. These seat retainer and/or back cap counter-
Regulator Body: 300 Series SST, Brass, operations are more easily performed with the clockwise until it is free of the regulator
for Hastelloy®, Monel®, Aluminum regulator removed from the line. However, in body.
Seats: Teflon®, CTFE, Vespel®, Peek®, Soft some cases repair may be accomplished without TESCOM MODELS 26-1000 AND
Goods (O-rings & back-up Rings) Teflon®, removal of the regulator body as long as the 44-1100 VALVE PARTS ARE HELD
BUNA-N, Viton A® supply has been shut off and the inlet and outlet IN PLACE BY THE USE OF LEFT-
pressures have been vented. WARNING HANDED THREADS.
Trim: 300 Series SST, Brass, Hastelloy,
Piston Sensed Pressure Monel, Aluminum The following steps outline the disassembly of NOTE: If necessary, valve seat may be
pressure reducing regulators for maintenance removed from the seat retainer using a
Reducing Regulators The official material of construction and
pressure activation method for your pressure
and repair. Up-to-date assembly drawings and sharp instrument.
bills of material are available from the factory.
General reducing regulator depends on series number CAUTION: When removing valve parts
Tescom’s piston sensed pressure reducing and modification ordered. 1. Clamp the regulator in a vise by the flats from a regulator that has a back cap,
regulators are specifically engineered for on the bottom and/or side of the regulator care must be taken to insure the main
applications requiring dependable pressure Operation (Control Knob Adjustment) body. valve stem remains vertical. If the main
regulation. These regulators are especially Controlled outlet pressure settings are valve stem is not removed correctly, parts
appropriate for installations where high system obtained using Tescom pressure reducing 2. Turn control knob and/or spring may remain in the regulator.
pressures (up to 20,000 psi) must be reduced regulators by adjusting the control knob. adjustment mechanism counterclockwise
to levels suitable for actuating low pressure (0 Rotating the knob clockwise raises the outlet to insure removal of all spring force on 5. To disassemble main valve assembly
to 20,000 psi) instruments and related pressure while a counterclockwise rotation, the piston. and/or valve, clamp valve in smoothed
equipment. coupled with venting of the downstream side jaw vice or hold with pliers. Clamping
of the regulator plumbing, lowers the outlet NOTE (Dome loaded regulators): All should be done on flats.
pressure. Final adjustments should be made pressurized gas or liquid must be vented
Pressure Activation Methods
in the direction of increasing pressure to from dome before disassembly. CAUTION: Care must be used to not
Tescom uses three basic types of activation
obtain the most accurate set point. damage valve. A special fixture may be
methods. The activation method provides the
means by which the operator can set the force 3. Remove upper portion of regulator ordered from the factory to aid in the
that determines the outlet pressure of a Tescom regulators will operate with any liquid (bonnet and/or dome). Some models disassembly of the main valve assembly
regulator or gaseous media compatible with the wetted require the handknob and/or mounting found in Tescom Regulator Models 26-
materials. Some series/modifications come bracket to be removed first. 1000 and 44-1100.
with an internal filter that only are designed to
Control Knob: Delivery pressure is increased
stop random contamination resulting from the NOTE: Upper portion of regulator may NOTE: Several of Tescom’s regulators
by turning the control knob. The control knob
installation of the regulator. An auxiliary also include spring button, load spring are supplied with internal filters. They
applies a load through a spring to the piston.
upstream filter is recommended for use in all back-up plate, and piston sensor, etc. will be located either in the inlet port or
but the cleanest media. Gaseous media Review correct drawing to ensure that all in the main valve area of the regulator. In
Dome Load: Delivery pressure is increased by should be free of excessive moisture to
applying pressurized gas or liquid to the dome parts have been disassembled. each case, they should be removed and
prevent icing of the regulator at high flow replaced before reassembly.
of a regulator at a pressure equal to the outlet rates.
pressure desired. This dome pressure is NOTE: (Two-Stage Regulator) Tescom
normally provided by a second regulator called A REGULATOR IS NOT INTENDED TO Model Series BB-5 is a two-stage Reassembly
the pilot regulator. BE USED AS A SHUTOFF DEVICE. regulator that has portions on both ends The regulator is reassembled in the reverse
WHEN THE REGULATOR IS NOT IN of the regulator body that must be order of disassembly, observing the following
WARNING USE, THE INLET SUPPLY SHOULD BE removed. It is Tescom’s recommendation precautions. Please reference the Bill of
Combination Spring and Dome: Delivery
pressure is increased by applying a spring TURNED OFF. AS A SAFETY PRECAUTION, A that two-stage regulators be returned to Material and assembly drawing for the correct
PRESSURE RELIEF DEVICE SHOULD BE the factory for repair. location of replacement parts and correct
force as well as the introduction of pressurized INSTALLED DOWNSTREAM OF THE
gas or liquid. torque specifications.
REGULATOR.
2 3 4
Reassembly (continued) Reassembly (continued)
1. Inspect all parts and replace those worn 6. Dome/Spring Combination and Dome
or damaged with Tescom replacement Loaded Regulators are more easily PRODUCT WARRANTY
parts. reassembled by holding regulator firmly in Tescom Corporation ("Tescom") warrants to the party who purchases products for initial use directly from
vise and reinstalling dome. Tescom, its affiliates or authorized distributors or representatives ("Initial Purchaser") that products
2. All parts should be cleaned to the manufactured and sold by its Industrial Controls Division (“ICD”) are free from defects in materials and
cleanliness level required for safe 7. Self-Venting Regulator - If your regulator workmanship under normal use and service for a period of 365 days from the date of delivery of the products
operation with the media and system they has an adjustable relief valve ("Warranty Period"). This warranty applies only to the Initial Purchaser. This warranty is not transferable to
will be used in. All parts in the flow mechanism, it is set on final assembly at subsequent purchasers or users of the products.
stream must be free of particles which the factory and usually will not require
could prevent proper seating of the main further adjustment. If adjustment During the Warranty Period, Tescom will, in its sole discretion, repair or replace, free of charge at its factory in
valve. becomes necessary, use the following Minnesota, any product or part thereof that is found by Tescom, after reasonable notification by the Initial
procedure after regulator has been Purchaser, to have been defective in materials or workmanship. The Initial Purchaser must pay all shipping
installed: costs for warranty service and is responsible for risk of loss or damage of products during shipment. Tescom
3. Apply a thin uniform coating of
does not warrant, and will not pay for, any repairs or replacement made during the Warranty Period by anyone
fluorocarbon grease to any or all of the
other than personnel authorized by Tescom or its ICD Division to make such repairs or replacement.
following parts: indentation of spring Step 1. Remove hole plug located in
button, threaded portion of adjusting control knob. THE ABOVE WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES. TESCOM AND ITS ICD DIVISION
screw, entire threaded area of the Step 2. Using control knob, apply 10 to MAKE NO OTHER EXPRESS OR IMPLIED WARRANTY, AND IN PARTICULAR AND WITHOUT LIMITATION
bonnet, all O-rings, all threaded parts 15 psi on downstream side. MAKE NO IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE.
internal to regulator. Step 3. Turn vent adjusting screw CW The Initial Purchaser's only remedy under this warranty is repair or replacement of the products during the
(located under hole plug) until Warranty Period. This warranty does not apply to any product which has been damaged by accident, abuse,
NOTE: Do NOT apply any type of grease media can be heard escaping misuse, modification or lack of proper maintenance. NEITHER TESCOM, NOR ITS ICD DIVISION WILL BE
to the inlet or outlet connections. through relief valve. LIABLE FOR ANY CONSEQUENTIAL, SPECIAL, INCIDENTAL OR INDIRECT DAMAGES, INCLUDING
Step 4. Turn screw CCW until media flow WITHOUT LIMITATION, LOST PROFITS.
4. Valve seats must be installed with the stops, plus 1/2 turn. Replace
chamfered side towards the main valve. hole plug.
5. Standard Regulator with Control Knobs - 8. Reinstalling wire mesh inlet filter - Insert
The body and bonnet are best joined by filter into primary inlet port. It must then INDUSTRIAL CONTROLS DIVISION
holding the bonnet assembly open end be expanded to fit correctly. This can be 12616 Industrial Boulevard
up and dropping all required items into accomplished by inserting a metal tool Elk River, MN 55330
place one at a time. The last item to be the same size as the port and then lightly 1-800-447-1250
placed in the body of most all of Tescom tapping it with a hammer. Fax: (763) 241-3224
regulators is the piston sensor. Place all e-mail: icd@tescom.com
O-rings and back-up rings that are www.tescom.com
AFTER REGULATOR HAS BEEN
external to the piston sensor in the body
REASSEMBLED, IT SHOULD BE
before placing the sensor in place. O-
CONNECTED TO A PRESSURE
rings should always be installed before WARNING SOURCE WITH MEDIA
back-up rings. The bonnet and body may
COMPATIBLE WITH THE USE OF THE
now be attached. This is best done by
REGULATOR AND PRESSURIZED TO
holding the body in one hand and the
CHECK FOR INTERNAL AND EXTERNAL
bonnet in the other. Tilt the body at a 45°
LEAKAGE AND OPERATING CHARAC-
angle and then attach the bonnet by
TERISTICS.
screwing it into the body firmly, hand
tight. Regulator should then be placed in
vise and bonnet retorqued to correct Monel® is a registered trademark of Huntington AlIoys, Inc.
specifications. See print. Hastelloy® is a registered trademark of Haynes International, Inc.
Teflon®, Viton-A® and Vespel® are registered trademarks of Du Pont.
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.
Form No. 1891 Rev. 5/00 Printed 9/02 80M

4 5 6

ABUIABA9GAAgl6Po2wUo9qiR9gU PDF

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

ABUIABA9GAAgl6Po2wUo9qiR9gU PDF

Uploaded by

Copyright:

Available Formats

OPERATION and

This document contains proprietary and National Oilwell Varco

4. PRESERVATION & INSTALLATION 15

6.1 PARTS FIT – GENERAL .................................................................................................... 27

7. MAJOR REPAIRS AND MODIFICATIONS 35

8. LUBRICATION & MAINTENANCE 41

9. GENERAL ROLLER CHAIN 53

11. TORQUE GUIDE FOR BOLTS 63

12. RECOMMENDED SPARES 67

12.4 INPUT SHAFT ASSEMBLY ................................................................................................. 68

15. VENDOR INFORMATION 79

This page left intentionally blank.

1.1 Manual Overview & Scope

This operation and maintenance manual provides instruction on the D3000AC

Photo: D3000AC Drawworks

1.2 Warranty Information

1.3 Warranty Limitations

Improvements in design, engineering, materials, production methods, etc. may

1.4 Equipment Service Life

This page left intentionally blank.

2.1 Safety Terms & Conventions

WARNING: A Warning is used when an operating procedure, practice, etc., that,

CAUTION: A Caution is used when an operating procedure, practice, etc., that, if

NOTE: A Note provides information necessary to complete the procedure properly

Before performing maintenance on or disconnecting any high-pressure piping or hoses,

WARNING: Use adequate hoisting equipment. Observe all safety precautions.

WARNING: Determine if equipment has preloaded components such as springs

WARNING: When working on a system, disconnect electrical power supply and

3.1 General Description

The D3000AC is a two-speed, chain

Photo: D3000AC Drawworks, Driller’s Side

3.1.2 Chains and Sprockets

(For more information, refer to Section 9 of manual.)

The drawworks is equipped with a disc type braking

The disc brake system employs two discs, one disc on

Photo: The D3000AC uses an air cooled brake caliper system.

3.1.6 Drum Design

The D3000AC Drawworks is equipped with a

Photo: The D3000AC drawworks drum.

3.2 Technical Specifications

3.3 Power Flow Chart

14 LINES 14 LINES 14 LINES 14 LINES

Note: The shaded area is the motor's intermittent rating

4. PRESERVATION & INSTALLATION

4.2 Pre- Installation Procedure

WARNING: A brake capacity test must be performed after any brake

4.3 Installation Procedure

4.3.1 Lifting Instructions

NOTE: The lifting equipment used on drawing 9108L022 is used as a reference

WARNING: Extreme caution must be exercised when lifting the drawworks as

4.3.2 Transportation Instructions

4.3.3 Installation Instructions

NOTE: Refer to the lifting instructions for details, section 4.3.1.

If level measurements are out of tolerance, shim up the drawworks.

This page left intentionally blank.

5.1 Pre-Starting Instructions

Perform the following checks before initial starting of the drawworks:

5.2 Manual and Emergency Operation

5.3 Brake Caliper Remote Operation

Refer to the Hydraulic and Air Schematic,

1. Ensure the brake control valve (G)

5.4 Brake Caliper Manual / Emergency Operation

5.4.1 Manual / Emergency Operation (Hydraulic Pumps Operating)