9108E006 - Rev. 01

OPERATION and
MAINTENANCE MANUAL
PPL AWILCO
D3000AC DC Drawworks
Project: E2142
Job: C20312
Date: March, 2005
ADDITIONAL
This document contains proprietary and National Oilwell

confidential information of National Oilwell. 6415-75 Street
Reproduction or use of this design or distribute
information by others is permissible only if Edmonton, AB
expressly authorized in writing by National Canada,
Oilwell. ©Copyrights National Oilwell T6E 0T3
DOCUMENT NO.
9108E006
Document No. 9108E006
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. PRESERVATION & INSTALLATION 11

3.1 PRESERVATION ............................................................................................................... 11
3.2 INSTALLATION ................................................................................................................. 12
4. D3000AC DRAWWORKS 13
4.1 TECHNICAL SPECIFICATIONS ........................................................................................... 13
4.2 POWER FLOW CHART ..................................................................................................... 14
4.3 GENERAL DESCRIPTION .................................................................................................. 15
4.3.1 Construction .............................................................................................................. 15
4.3.2 Chains and Sprockets ............................................................................................... 15
4.3.3 Shafting ..................................................................................................................... 15
4.3.4 Brakes ....................................................................................................................... 16
4.3.5 Clutches .................................................................................................................... 16
4.3.6 Drum Design ............................................................................................................. 16
5. PRE-STARTING 17
5.1 PRE-STARTING INSTRUCTIONS ........................................................................................ 17
6. OPERATING INSTRUCTIONS 19
6.1 BRAKE CALIPER REMOTE OPERATION ............................................................................. 19
6.2 BRAKE CALIPER MANUAL / EMERGENCY OPERATION ...................................................... 19
6.3 BRAKE CALIPER DELAY SYSTEM ..................................................................................... 21
6.4 DISC BRAKE CALIPER BURN PROCEDURE ....................................................................... 21
6.5 BRAKE TESTING PROCEDURE ......................................................................................... 21
6.6 DRILL LINE ATTACHMENT TO DRUM ................................................................................. 22
6.7 DEAD WRAPS ON THE DRUM ........................................................................................... 22
6.8 CROWN SAVER RESET PROCEDURE ................................................................................ 22
6.9 PROTECTIVE MEASURES ................................................................................................. 22
Page 2
7. MAIN OVERHAUL 23
7.1 PARTS FIT – GENERAL .................................................................................................... 23
7.2 SHAFTS .......................................................................................................................... 23
7.3 BEARINGS ...................................................................................................................... 24
7.4 SPACERS ........................................................................................................................ 24
7.5 HYDRAULIC SYSTEM ....................................................................................................... 24
7.6 SPROCKETS & CLUTCH HUBS ......................................................................................... 25
7.7 HUB & SHAFT FITS.......................................................................................................... 27
7.8 DRAWWORKS REPAIR INSTRUCTIONS .............................................................................. 28
7.9 MAJOR REPAIRS & MODIFICATIONS................................................................................. 29
7.9.1 Input Shaft Removal – 9108A002 ............................................................................. 29
7.9.2 Replacement of Bearings, Input Shaft Removed – 9108A002.................................. 29
7.9.3 Jack Shaft Removal – 9108A003 .............................................................................. 29
7.9.4 Jack Shaft Bearing Removal – 9108A019................................................................. 30
7.9.5 Drumshaft Removal – 9108A004 .............................................................................. 30
7.9.6 Drumshaft – Bearing Replacement from ODS – 9108A004...................................... 30
7.9.7 Drumshaft – Bearing Replacement from DS – 9108A004......................................... 30
8. LUBRICATION & MAINTENANCE 31

8.1 LUBRICATION .................................................................................................................. 31
8.1.1 Recommended Greases ........................................................................................... 31
8.1.2 Special Lubricants ..................................................................................................... 32
8.1.3 D3000AC Drawworks Lubrication ............................................................................. 32
8.2 MAINTENANCE ................................................................................................................ 34
8.2.1 Routine Inspection..................................................................................................... 35
9. GENERAL ROLLER CHAIN 41

9.1 CHAIN AND CONNECTING LINK INSTALLATION .................................................................. 41
9.2 RETAINING DEVICES........................................................................................................ 42
9.3 METHODS OF LUBRICATION ............................................................................................. 45
9.4 DRIVE GUARDING............................................................................................................ 46
10. TROUBLESHOOTING 49
10.1 EQUIPMENT FAULT SYMPTOMS & CAUSES....................................................................... 49
11. TORQUE GUIDE FOR BOLTS 51

11.1 BOLT CHART .................................................................................................................. 51
11.2 TURN-OF-NUT TIGHTENING ............................................................................................. 54
12. DRAWINGS 55
13. CERTIFICATES 57
Page 3
14. RECOMMENDED SPARES 59
15. VENDOR INFORMATION 61

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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 manual provides instruction on the operation and maintenance of 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 the equipment requires emergency servicing.
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

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.
Page 7
1.3 Warranty Limitations
This manual is prepared as a guide for the proper installation, care, and operation of your
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 you in
the maintenance and servicing of this equipment.
Improvements in design, engineering, materials, production methods, etc. may

necessitate changes in this product over time. We reserve the right to make these design
changes without incurring any obligation for 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
Page 8

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: This is used when an operating procedure, practice, etc., that, if not correctly
implemented, could result in personnel injury and/or equipment damage.
CAUTION: This is used when an operating procedure, practice, etc., that, if not correctly
implemented, could result in equipment damage.
NOTE: This 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, ensuring electrical power is locked out before attempting maintenance.
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.
Page 11
3. PRESERVATION & INSTALLATION

3.1 Preservation
3.2 Installation
3.1 Preservation
Proper storage and preservation measures will help ensure the maximum design life for
the drawworks. Accessory items, spare parts, etc. shall be protected in accordance with
these guidelines.
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, is 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.
The equipment should be elevated some distance from the ground or floor. Enough
beams should be provided to give normal support to the equipment and 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, moisture must be prevented from contacting
the equipment. All equipment should be packed 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 and plastic sheet is recommended along with use of desiccant. Cable ends
are preserved with sealing tape or blanks. 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 are to be shipped with sufficient oil in order to minimize the
areas that may become exposed to condensation or corrosion.
Page 12
3.2 Installation
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.
• Areas covered with corrosion preventative and surface protection coatings should be
steam-cleaned to remove the coating.
• Steam cleaning may wash away lubricants from pivot points and other moving
mechanical parts, so it is important to re-lubricate these areas.
• Also, painted areas 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
9108A017) and a power module (drawing 9108A012) 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 this manual for the torque guide.
¾ Torque down the skid connection bolts. Bolt item ‘E’ – refer to drawing
9108A017 (1462 ft-lbs).
¾ Install jackshaft to the drumshaft chain (item ‘B,’ drawing 9108A012) with the
master link.
¾ Re-install the drum sprocket guard.
Particular attention should be paid to the installation of the drum sprocket guard. Ensure that all
sealing surfaces are clean and dry prior to applying silicone sealant. Follow manufacturer’s
directions for silicone sealant application and curing times. Upon initial startup, ensure there are
no leaks from this area.
WARNING: If there is any oil leakage from this area, check the brake pads for oil
contamination. Contaminated bake 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.
Page 13
4. D3000AC DRAWWORKS
4.1 Technical Specifications
4.2 Power Flow Chart
4.3 General Description
4.1 Technical Specifications
Maximum Horse Power Rating 3000 hp @ 1,600 rpm

Wire Line Size 1 5/8"
Main Drum Size 35" x 72” with 1 5/8" Lebus Grooving
Hoisting Capacity-14 Lines Low – 1,550,000#
High– 719,124#
Chains
Motor 1 to Input Shaft 1 ¼” P RC, 100-4 Quadruple (114 P)
Input Shaft to Jackshaft (DS) 1 ½” P 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 13’- 4” (4,058 mm)
Overall Length of Drawworks 18’ – 2 ½” (5547 mm)
Overall Width of Drawworks 15’ – 8” (4774 mm)
Capacities
Oil Sump Capacity 100 US Gal. (379 L)
Hydraulic Tank Capacity 20 US Gal. (76 L)
Equipment Weights
Input Shaft Assembly 6,310 lbs. (2,862 kg)
Jackshaft Assembly 10,156 lbs. (4,607 kg)
Drumshaft Assembly 22,414 lbs. (10,166 kg)
GE Motor (each) 6,500 lbs. (2,948 kg)
Total Weight of Assembly (est.) 112,451 lbs. (51,007 kg)

Page 14
4.2 Power Flow Chart
AWILCO D3000AC Drawworks
14 LINES 14 LINES 14 LINES 14 LINES

MOTOR MOTOR DRUM DRUM 1ST LAYER 2ND LAYER 3RD LAYER 4TH LAYER
GEAR BOX
SPEED TORQUE SPEED TORQUE FAST LINE FAST LINE FAST FAST BLOCK HOOK FAST FAST BLOCK HOOK
RATIO FAST LINE BLOCK HOOK FAST LINE BLOCK HOOK LOAD
(RPM) (FT*LBS) (RPM) (FT*LBS) SPEED SPEED LINE LINE SPEED LOAD LINE LINE SPEED LOAD
PULL (LBS) SPEED (FPM) LOAD (LBS) PULL (LBS) SPEED (FPM) (LBS)
(FPM) (FPM) SPEED PULL (FPM) (LBS) SPEED PULL (FPM) (LBS)
LOW GEAR
0 31,697 11.80 0 373,998 0 236,209 0 2,859,610 0 218,760 0 2,648,368 0 203,712 0 2,466,188 0 190,601 0 2,307,459
800 31,697 11.80 68 352,004 674 222,318 48 2,691,442 728 205,896 52 2,492,623 782 191,732 56 2,321,156 836 179,392 60 2,171,762
800 22,641 11.80 68 251,432 674 158,799 48 1,550,000 728 147,068 52 1,550,000 782 136,951 56 1,550,000 836 128,137 60 1,550,000
1,000 18,000 11.80 85 199,893 843 126,248 60 1,528,389 910 116,922 65 1,415,485 977 108,879 70 1,318,115 1,044 101,871 75 1,233,278
1,200 15,000 11.80 102 166,577 1,011 105,207 72 1,273,657 1,092 97,435 78 1,179,571 1,173 90,732 84 1,098,429 1,253 84,893 90 1,027,732
1,400 12,900 11.80 119 143,256 1,180 90,478 84 1,095,345 1,274 83,794 91 1,014,431 1,368 78,030 98 944,649 1,462 73,008 104 883,850
1,600 10,500 11.80 136 116,604 1,348 73,645 96 891,560 1,456 68,204 104 825,700 1,563 63,513 112 768,900 1,671 59,425 119 719,412
1,800 8,100 11.80 153 89,952 1,517 56,812 108 687,775 1,638 52,615 117 636,968 1,759 48,996 126 593,152 1,880 45,842 134 554,975
HIGH GEAR
0 31,697 4.77 0 151,058 0 95,405 0 1,155,000 0 88,358 0 1,069,679 0 82,280 0 996,097 0 76,984 0 931,986
800 31,697 4.77 168 142,175 1,669 89,795 119 1,087,077 1,802 83,161 129 1,006,774 1,935 77,441 138 937,518 2,069 72,457 148 877,178
800 22,641 4.77 168 101,554 1,669 64,139 119 626,047 1,802 59,401 129 626,047 1,935 55,315 138 626,047 2,069 51,755 148 626,047
1,000 18,000 4.77 210 80,737 2,086 50,992 149 617,318 2,253 47,225 161 571,716 2,419 43,976 173 532,388 2,586 41,146 185 498,123
1,200 15,000 4.77 252 67,281 2,504 42,493 179 514,432 2,703 39,354 193 476,430 2,903 36,647 207 443,657 3,103 34,288 222 415,102
1,400 12,900 4.77 294 57,861 2,921 36,544 209 442,411 3,154 33,845 225 409,730 3,387 31,516 242 381,545 3,620 29,488 259 356,988
1,600 10,500 4.77 336 47,097 3,338 29,745 238 360,102 3,605 27,548 257 333,501 3,871 25,653 276 310,560 4,137 24,002 296 290,572
1,800 8,100 4.77 378 36,332 3,756 22,946 268 277,793 4,055 21,251 290 257,272 4,355 19,789 311 239,575 4,654 18,516 332 224,155
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
Page 15
4.3 General Description
4.3.1 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 of a high
strength plate and 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. 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.
Photo: D3000AC Drawworks, View from Driller’s Side
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.
4.3.2 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 10 of manual.)
4.3.3 Shafting
All 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.
Page 16
4.3.4 Brakes
The drawworks is equipped with a disc type braking

system. The primary function of the disc brake system
is parking and emergency capabilities in the event of
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 park
and emergency braking.
Photo: The D3000AC uses an air cooled brake caliper system.
4.3.5 Clutches
Plate type air actuated friction clutches are used for high/low gear changes.
4.3.6 Drum Design
The D3000AC Drawworks is equipped with a

fabricated drum, 35" bare drum diameter x 72”
long balanced with 1-5/8” Lebus grooving.
Photo: The D3000AC Drawworks drum.

Page 17
5. PRE-STARTING
5.1 Pre-Starting Instructions
5.1 Pre-Starting Instructions
Make 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 S.A.E. 50 chain or engine oil for temperatures of 55 degrees
Fahrenheit or higher and S.A.E. 30 for 0 - 55 degrees Fahrenheit, and below 0
degrees, use oil with a pour point at least 5 degrees 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.
10. Replace GE motors locking bolts with the supplied bolting.
CAUTION: Do not attempt to operate drawworks with less than 110 psi air
pressure. Ensure that all lines and gauges are open and controls are
active.
Page 18

Page 19
6. OPERATING INSTRUCTIONS
6.1 Brake Caliper Remote Operation
6.2 Brake Caliper Manual / Emergency Operation
6.3 Brake Caliper Delay System
6.4 Disc Brake Caliper Burn Procedure
6.5 Brake Testing Procedure
6.6 Drill Line Attachment to Drum
6.7 Dead Wraps on the Drum
6.8 Crown Saver Reset Procedure
6.9 Protective Measures
6.1 Brake Caliper Remote Operation
Refer to drawing 9108X000 for these operations.
1. Ensure 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.
6.2 Brake Caliper Manual / Emergency Operation
Refer to drawing 9108X000 for these operations:
In the event of an emergency when the hydraulic pumps are working:
1. Ensure emergency bleed off valve (H) is closed. Ensure emergency lowering isolation
valve (Z) is open.
2. Ensure brake control valve handle (G) is fully extended, fully lifted and locked into
place.
Page 20
3. Switch all six manual / remote valves

(F) to manual position. Brake Control
4. To release brakes, unlock the handle Valve
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
handle to move upwards to reduce
Emergency Bleed
the pressure and reapply the brake Off Valve Emergency
calipers. Lowering
5. If for any reason control of the load is Isolation Valve
lost, open emergency bleed off valve
(H) to reapply the brakes quickly.
Photo: D3000AC Drawworks Valves
WARNING: 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, the operation must stop until the disc has
cooled.
In the event of an emergency and power is lost to the hydraulic pump, the brakes
are released as follow:
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.
Photo: D3000AC Drawworks Hand Pump

Page 21
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).
6.3 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. To set the flow controls, do the following:
1. Release brakes.
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.
7. Repeat until a one second delay is Flow Control Valve
achieved.
Photo: D3000AC Flow Control Valve is located 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.
6.4 Disc Brake Caliper Burn Procedure
Refer to Drawworks Control System Operation Manual, document number:

S0100268-OPM-200.
6.5 Brake Testing Procedure
Refer to Drawworks Control System Operation Manual, document number:

S0100268-OPM-200.
Page 22
6.6 Drill Line Attachment to Drum
Refer to drawing 9108A012 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 Line Clamp

the drum side plate.
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
6.7 Dead Wraps on the Drum
The D3000AC drawworks is designed to have a minimum of 7 dead wraps on the drum
when the traveling block is in the lowest position.
WARNING: Operating the drawworks with less than 7 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.
6.8 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 “AP.”
6.9 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.

Page 23
7. MAIN OVERHAUL
7.1 Parts Fit – General
7.2 Shafts
7.3 Bearings
7.4 Spacers
7.5 Hydraulic System
7.6 Sprockets and Clutch Hubs
7.7 Hub & Shaft Fits
7.8 Drawworks Repair Instructions
7.9 Major Repairs & Modifications
7.1 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 assembly or removal of parts ranging from 0.00 mm to 0.101 mm tight, heat to
approximately 204°C. For parts ranging from 0.127 mm to 0.254 mm tight, heat to
approximately 343°C.
7.2 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.
Page 24
7.3 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.
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 at the same time increasing tension
on the pulling mechanism. DO NOT OVERHEAT! Maximum temperature: 125°C
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
7.4 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 on to prevent leaking. To remove a
spacer which is shrunk on a shaft, proceed in accordance with 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.
7.5 Hydraulic System
The brake hydraulic system requires that the oil cleanliness be maintained at an ISO
Level of 12/15/12 (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 32.
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.
Page 25
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.
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 is 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.
7.6 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

Page 26
When removing and replacing parts mounted according to arrangement A) refer to

instructions for removing bearings (reference section 7.3). 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 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 the 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, 7.7.

Page 27
7.7 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.
Page 28
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. Therefore, for example, if a 0.0762 mm interference 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.
7.8 Drawworks Repair Instructions
General Information:
• It is important to 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.
• Make sure 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.
• Make certain that when reassembling drawworks components, all of the covers are
properly sealed before they are installed.
• Be certain that 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.
Page 29
7.9 Major Repairs & Modifications
7.9.1 Input Shaft Removal – 9108A002

1. Remove all guards and covers.
2. Disconnect lube oil connections.
3. Disconnect drive chains.
4. Remove rotorseal (H) and adapter (22).
5. Remove clutch (5) and key (31) with drive ring (A) and clutch adaptor ring (7).
6. Remove bearing retainer (15) with oil seal (N) and spacer (29).
7. Remove bearing (G). Bearing can be replaced at this time.
8. Disassemble labyrinth outer ring (19).
9. Remove sprocket (3), labyrinth inner ring (17) and labyrinth slinger ring (20) with
spacer (23), bearing retainer (14), bearing (D) and oil seal (K) as one unit.
10. Unbolt all 16 bolts (C) on both bearing housings (8 & 9).
11. Slide remaining shaft from ODS.
7.9.2 Replacement of Bearings, Input Shaft Removed – 9108A002

1. Remove bearing retainer (14) with oil seal (K) from sprocket (3).
2. Install new bearing (D).
3. Remove bearing retainer (11) and spacer (30). Replace bearing (C).
4. On the ODS, remove endplate (35) and sprocket (2) with key (34).
5. Remove spacer (26) and bearing retainer (10),
6. Install new bearing (B).
7. Reverse the above procedures to reassemble.
NOTE: It is recommended to replace oil seals at this time.
7.9.3 Jack Shaft Removal – 9108A003

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.
7.9.4 Jack Shaft Bearing Removal – 9108A019

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).
Page 30
5. Replace bearing (H).

6. Remove bearing retainer (9) and replace bearing (A). Remove 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.
7.9.5 Drumshaft Removal – 9108A004

1. Remove all front covers and guards.
2. Disconnect the drive chain.
3. Disconnect all air/grease/electrical connections.
4. Remove the 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.
7.9.6 Drumshaft – Bearing Replacement from ODS – 9108A004

1. Block the drumshaft assembly to hold it in position so it will not roll while working on it.
2. Remove 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.
7.9.7 Drumshaft – Bearing Replacement from DS – 9108A004

1. Remove end cover (23) and encoder (B) with its bracket (22).
2. Remove the drumshaft endplate (14), spacer (18) retainer plate (9) and 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.
Particular attention should be paid to the installation of the drum sprocket guard. Ensure that all
sealing surfaces are clean and dry prior to applying silicone sealant. Follow manufacturer’s
directions for silicone sealant application and curing times. Upon initial startup, ensure there are
no leaks from this area.
WARNING: If there is any oil leakage from this area, check the brake pads for oil
contamination. Contaminated bake pads must be replaced immediately. Do
not operate the drawworks with contaminated brake pads.
procedure.
Page 31
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 a 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.
Page 32
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 a 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
In order 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 SAE 50
-18°C to 12°C SAE 30
Below -18°C Pour point at least 5°C lower than
minimum ambient temperature
Page 33
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).
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
Page 34
D3000AC Drawworks - Lubrication Schedule

ITEM REMARKS LUBRICANT QUANTITY SERVICE
PERIOD
Drum Shaft -- EP2 Grease 4 Shots Twice/
Main bearings week
Wireline Apply as required WARNING: Wireline Application Monthly
Avoid use of excess wireline Lubricant inspection
lubricant. DO NOT use mineral
oil based wireline lubricants.
Hydraulic Located on Driller Side Exxon Univus Approx. 76 6 Months
Tank N-32 litres/ 20 gal.
Lubrication Access from Rear SAE 30, for Approx. 379 6 Months
Sump chain litres/ 100 gal.
Hydraulic -- Silicone-based Lightly coat 6 Months
Valves grease moving parts
Motor Mount -- -- Forced Oil --
Bearings
One shot 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.
Page 35
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 at
Upper Sight Glass 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
Lower Sight Glass 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
Page 36
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.
Page 37
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 3 or 4 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 – National Emergency Disc Brakes Manual EPL-1424).
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 = 1500 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 (4 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.
Page 38
WARNING: Ensure that absolutely no grease or oil is allowed to contact the brake
pads or the brake disc. Contaminated brake pads must be replaced
immediately. Do not operate the drawworks with contaminated brake
pads
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
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 a 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.
Page 39
WARNING: Contaminated brake pads must be replaced immediately. Do not

operate the drawworks with contaminated brake pads.
procedure.
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.
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 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.
procedure.
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
Page 40
E1 Change drawworks oil: Open the lube oil drain valve and drain oil while the unit is
still warm. Renew air breather filter. Ensure that 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 pinion
and the motor mount. 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.
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 6 months including the bladder
and valves and piping. Replace bladder if there are leaks or cracks, etc.
E8 Refer to the National Oilwell Emergency Disc Brake Caliper manual in Vendor
YEARLY Checked Recorded

F1 Replace all brake caliper disc springs (every 5 years)
F2 Visually inspect critical components
F3 Check bolt torques
F1 Refer to the National Oilwell Emergency Disc Brake Caliper manual in Vendor
procedure.
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 chart.

Page 41
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.
Page 42
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 the “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.
Page 43
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 45 0.25 0.50 0.75 1.00 1.50 2.00 3.00 4.00 5.00
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.
Page 44
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 Oil SAE Gear Oil ISO AGMA
Degrees F 100 F
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.
Page 45
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.
Page 46
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 No. 35 40 50 60 80 100 120 140 160 200

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.
Page 47
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.
Page 48
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.
Page 49
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 that are not listed and cannot be solved, please 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
• Drawworks brakes, gears, or electric drive motor.
noise from drawworks
Excessive or unusual
noise from drawworks • Check bearings, lube system, lube pump and clutches.
interior
Improperly
functioning brakes • Brake caliper, hydraulic supply, or controls fault**.
Metallic clanking • Gear wear, inadequate lubrication and/or misalignment of
(rotating) gear.
• Worn bearing (louder upon loaded condition). Possibly due
Howling (rotating)
to inadequate lubrication.
Squealing or grinding • Brake pads worn or faulty caliper. Check brake discs for
(rotating) 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.
Please see vendor information for maintenance and trouble shooting of Vendor
Equipment.
Page 50

Page 51
11. TORQUE GUIDE FOR BOLTS

11.1 Bolt Chart
11.2 Turn-of-Nut Tightening
11.1 Bolt Chart
Tightening Torque Guide

SAE Grade 5 - Fine Thread
Size Clamp Load Plain Plated
1/4 - 28 (.250) 2,325 10 ft·lbs 87 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 87 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
Page 52

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

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
Page 53
Socket Head Capscrew Tensile Requirements
per ASTM A574-83

Screw Threads Inches Tensile Load Min. Tensile Rec. UNC Torque
Dia. (in) Strength in lbs.
UNC UNF UNC UNF psi/Min UNRC UNRF
0.060 - 80 - 324 180,000 - 2
0.073 64 72 473 500 180,000 4 4
0.086 56 64 666 709 180,000 6 7
0.099 48 56 877 941 180,000 10 11
0.112 40 48 1,090 1,190 180,000 15 16
0.125 40 44 1,430 1,490 180,000 20 21
0.138 32 40 1,640 1,830 180,000 28 30
0.184 32 36 2,520 2,650 180,000 49 50
0.190 24 32 3,150 3,600 180,000 64 76
¼ 20 28 5,730 6,500 180,000 150 170
5/16 18 24 9,440 10,400 180,000 305 325
3/8 16 24 13,900 15,800 180,000 545 570
7/16 14 20 19,100 21,400 180,000 840 900
½ 13 20 25,500 28,800 180,000 1,300 1,370
5/8 11 18 38,400 43,500 170,000 1,850 1,970
¾ 10 16 56,800 63,400 170,000 2,630 2,660
7/8 9 14 78,500 86,500 170,000 4,400 4,800
1 8 12 103,000 113,000 170,000 7,000 7,600
1½ 7 12 129,000 146,000 170,000 10,400 11,000
1¼ 7 12 165,000 182,000 170,000 14,900 15,600
1 3/8 6 12 196,000 224,000 170,000 21,000 22,600
1½ 6 12 239,000 269,000 170,000 27,800 29,300
Page 54
11.2 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 depends on assuring that the joint is well
compacted and that all bolts at a joint are at a snug-tight condition prior to application of
the final required partial turn. It is critical that the element not turned in tightening must 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
Bolt Length axis and other sloped Both faces sloped no more
(under side of Both faces no more than 1:20 than 1:20 from normal to the
head to end of normal to (beveled washer not 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 not exceeding 1/2 turn 2/3 turn 5/6 turn
8 diameters
Over 8 diameters
but not exceeding 2/3 turn 5/6 turn 1 turn
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.
Page 55
12. DRAWINGS
Drawing No. Drawing Title

Overall Assemblies
9108B000 D3000AC Drawworks General Assembly
9108A012 D3000AC Drawworks Drive Assembly
Shaft Assemblies
9108A002 D3000AC Drawworks Input Shaft Assembly
9108A003 D3000AC Drawworks Jackshaft Assembly
9108A004 D3000AC Drawworks Drum Shaft Assembly
Schematics
9108X000 D3000AC Hydraulic & Air Schematic
9108Y001 Drawworks Lubrication Schematic
Miscellaneous Drawworks Drawings

9108A001 20 Gallon Hydraulic Tank Assembly
9108A005 D3000AC Brake Beam Installation Details
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
9108A009 D3000AC Drawworks Lube Pump Assembly
9108A010 D3000AC Drawworks Hydraulic Pump - Motor Assembly
9108A011 D3000AC Drawworks Lube Pump – Motor Assembly
9108A014 D3000AC Dwwks Equipment (Hydraulic, Air & Lube) Assembly
9108A015 D3000AC Drawworks Hydraulic Tubing Guard Assembly
9108A017 D3000AC Drawworks Frame Assembly
9108A025 D3000AC Drawworks Drum Kicker Plate Assembly
9108C001 D3000AC Footprint & Installation Detail
9108C003 D3000AC Drawworks Maintenance Envelope
9108C004 D3000AC Drawworks Nozzle Schedule
9108D105 D3000AC Dwwks Drum Wear Plates & Lebus Grooving Installation
9108D115 D3000AC Drawworks Hoisting Specification
9108D116 D3000AC Drawworks Name Plate
9108D149 D3000AC Drawworks Brake Caliper Operations Plate
9108L000 D3000AC Overall Lifting Diagram
9108L003 D3000AC Rear Section Lifting Diagram
9108L004 D3000AC Front Section Lifting Diagram
9130A085 2P-4W Pilot Operated Brake Control Valve
9130A094 Remote Brake Valve Assembly
9130D538 Brake Valve Plunger Assembly
Page 56

Page 57
13. CERTIFICATES
Refer to attached certificates.
Page 58

Page 59
14. RECOMMENDED SPARES

Refer to the attached document.
Page 60

Drive Assembly: 9108A012
Item DWG Item Qty Part Number Description
1 B 1 RC140-8 Roller Chain, 1 3/4" Pitch, 8 Strand - 138 Pitches c/w Connecting Link
2 C 1 RC140-6 Roller Chain, 1 3/4" Pitch, 6 Strand - 114 Pitches c/w Connecting Link
3 D 1 RC120-8 Roller Chain, 1 1/2" Pitch, 8 Strand - 106 Pitches c/w Connecting Link
4 E 2 RC100-4 Roller Chain, 1 1/4" Pitch, 4 Strand - 140 Pitches c/w Connecting Link
5 F 1 RC100-4 Roller Chain, 1 1/4" Pitch, 4 Strand - 114 Pitches c/w Connecting Link
9108A002 Inputshaft Assembly
6 B 1 7006B400 Spherical Roller Bearing
7 C 1 7006B403 Spherical Roller Bearing
8 D 1 7006B404 Cylindrical Roller Bearing
9 G 1 7006B304 Cylindrical Roller Bearing
10 H 1 7006B164 Dual Passage Rotorseal
11 K 1 7006B471 Oil Seal
12 N 1 7006B075 Oil seal
13 P 1 7006B162 O-ring Static Seal Gland
14 - 3 8461C Drive Plate f/ Air Clutch 7018B258 (Twin Disc)
15 - 1 A6606 Diaphram f/ Air Clutch 7018B258 (Twin Disc)
16 - 3 XB1376A Plate Separator f/ Air Clutch 7018B258 (Twin Disc)
17 - 3 A2708Y Release Spring f/ Air Clutch 7018B258 (Twin Disc)
9108A003 Jackshaft Assembly
18 A 1 7006B414 Spherical Roller Bearing
19 B 1 7006B445 Spherical Roller Bearing
20 G 1 7006B040 Spherical Roller Bearing
21 H 1 7006B486 Cylindrical Roller Bearing
22 K 1 7006B164 Dual Passage Rotorseal
23 M 1 7006B030 Oil Seal
24 N 1 7006B415 Oil seal
25 P 1 7006B162 O-ring Static Seal Gland
- 3 9802 Drive Plate f/ Air Clutch 7018B571 (Twin Disc)
- 1 A6646 Diaphram f/ Air Clutch 7018B571 (Twin Disc)
- 3 XB1402A Plate Separator f/ Air Clutch 7018B571 (Twin Disc)
- 3 A2708AD Release Spring f/ Air Clutch 7018B571 (Twin Disc)
9108A004 DrumShaft Assembly
A 2 7006B236 Shperical Roller Bearing
B 1 7804408 Encoder
C 4 7006B472 Oil Seal
9108A009 Lube Pump Assembly
A 1 7020B128 Hydraulic Pump
Roller Chain, 5/8" Pitch Single Strand - 174 Pitches
E 1 RC50-1 c/w Connecting link
D3000 AC Hydraulic and Air Schematic : 9108X000
1 1 1 60PN1015 Toggle Valve (Crown Saver)

2 M 4 7030B112 Replacement High Pressure Filter
3 AM 4 7040B270 Replacement Air Filter
4 BA 2 7032B263 Replacement Low Pressure Filter
5 AG 1 7040B008 Relay Valve
6 AF 2 20037340 2P/5W Solenoid Valve
7 4 3 9130A085 Brake Control Valve
8 D 3 7056B336 Pressure Gauge
9 F 2 7025B057 Ball Valve
10 G 2 7026B037 Pressure Reducing Valve
11 R 1 7032B091 Accumulator
12 - 1 7032B093 Accumulator Bladder
13 - 1 7032B094 Butyl Kit (Bladder Kit)
14 AT 1 7040B269 Pressure Gauge
15 AC 1 7026B147 Back Pressure Regulator Valve
16 AH 1 7040B009 Volume Booster
17 C 3 20042178 Pressure Transducer
18 AA 1 20032731 Temperature Sensor
19 AB 1 20029260 Level Sensor
20 AD 2 20023353 2P/3W Solenoid Valve
21 AE 2 20042179 Pressure Transmitter
22 AR 1 7026B069 Relief Valve
23 BH 1 7040B312 Air Pressure Regulator
Drawworks Lubrication Schematic : 9108Y001
1 B 1 7020B128 Pressure Relief Valve

2 C 4 7030B131 Replacement Filter
3 E 2 7040B269 Pressure Gauge
4 F 1 7026B059 Strainer, 3/4"
D3000 AC Drawworks Equipment Assembly : 9108A014
9108A005 Brake Beam Installation Details

1 A 24 7006B381 Self-Lubricating Bearings
2 B 1 2112041 Brake Caliper
9108A010 Hydraulic Pump Assembly
3 D 2 7018B695 Flexible Drive Coupling Hub
4 E 2 7018B696 Flexible Drive Coupling Hub
5 F 2 7018B598 Flexible Drive Coupling Insert
9108A011 Lube Pump Assembly
6 D 1 7018B068 Flexible Drive Coupling Hub
7 E 1 7018B697 Flexible Drive Coupling Hub
8 F 1 7018B069 Flexible Drive Coupling Insert
Disc Brake Caliper Assembly : 2112041
Page 61
15. VENDOR INFORMATION

NOTE: (*) represents manuals that are too large to include in the Vendor Binder.
These manuals are included in the vendor list and were shipped together
with the National Oilwell Varco User Manuals.
VENDOR NAME DESCRIPTION / MODEL

BEI Technologies Inc. Model HS35 Drawworks Optical Encoder
Commercial Intertech 25X Service Manual: Single & Tandem Oil Hydraulic Pumps -
Motors
Denison Hydraulics Axial Piston, Variable Displacement Open Loop Pump, Series
PV/PVT Installation & Start Up
Endress & Hauser Safety Instructions for Electrical Apparatus for Explosion –
Hazardous Areas
Enerpac Hydraulic Hand Pumps Instruction Sheet
Hydac High Pressure Filters
National Oilwell Varco Drawworks Control System Operations Manual,
S0100268-OPM-200
National Oilwell Varco National Emergency Disc Brakes 2112041 EPL-1424
Oil Air Instruction Manual for the Accumulator
SKF Cylindrical Roller Bearings
SKF Spherical Roller Bearings
TECO-Westinghouse Installation & Maintenance Instructions for Three Phase
Induction Motors
Twin Disc Model PO-330 Air Operated Clutch Service Manual
Twin Disc Model PO-336 Air Operated Clutch Service Manual
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
TECHNICAL DOCUMENT FRONT COVER
Rig / Plant PPL Hull No: P2007 Jack-up, BMC PC375

Reference S0100268
Description Drawworks Control System, PPL Hull # P2007
Sub description Engineering documentation
Document title Operation manual
Drawworks Control System
Code (X) REVIEW STATUS

1 Accepted
2 Accepted, incorporate comments at next scheduled revision Date: (dd.mm.yyyy)
2A Accepted, incorporate comments. Revise and resubmit
Sign:
3 Not accepted, revise and resubmit
4 For information only
01 10.05.2005 For Information AB TB TTL

Revision Date (dd.mm.yyyy) Reason for issue Prepared Checked Approved
This document contains proprietary and confidential information which belongs to National Oilwell Varco; it is loaned for limited purposes only and remains the property of National Oilwell
Varco. Reproduction, in whole or in part; or use of this design or distribution of this information to others is not permitted without the express written consent of National Oilwell Varco. This
document is to be returned to National Oilwell Varco upon request and in any event upon completion of the use for which it was loaned.
© Copyright National Oilwell Varco 2005
Client purchase order number Remarks
Area System Discipline Main tag number Total number of pages

35
Sub area Sub system Additional code SDRL codes Design contractor Archive binder
5.3 0060 CMDL, FDD
Client document number Document number Revision
S0100268-OPM-200 01
National Oilwell Norway AS

P.O. Box 8181
4069 Stavanger
Norway
Phone +47 51 81 81 81
Telefax +47 51 80 05 47
www.natoil.com
Document number S0100268-OPM-200
Revision 01
Page 2
CHANGE DESCRIPTION
Revision Change description

01
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TABLE OF CONTENTS
1 INTRODUCTION ................................................................................................................. 5
1.1 General ..................................................................................................................... 5
1.2 Abbreviations and definitions.................................................................................... 5
1.3 Reference documents and drawings ........................................................................ 6
1.4 Service and support.................................................................................................. 6
2 OPERATION INSTRUCTIONS ........................................................................................... 7
2.1 Preparation / configuration ....................................................................................... 7
2.1.1 Block position ................................................................................................ 8
2.1.1.1 Reset of layer shift from layer 1 to 2 .......................................................... 8
2.1.1.2 Reset of floor height................................................................................... 9
2.1.2 Limits ............................................................................................................. 9
2.1.3 Autodriller limits............................................................................................. 9
2.1.4 Hook load source .......................................................................................... 9
2.1.5 Block position / proximity switch configuration ........................................... 10
2.2 Human-Machine Interface (HMI) ............................................................................ 11
2.2.1 Cyberbase displays..................................................................................... 11
2.2.2 Operator commands from Cyberbase screen ............................................ 14
2.2.3 Operator commands from keypads and joysticks....................................... 15
2.2.3.1 Drawworks manual – left side .................................................................. 15
2.2.3.2 Drawworks manual – right side................................................................ 16
2.3 Main components of the drawworks ....................................................................... 17
2.3.1 Braking systems.......................................................................................... 17
2.3.1.1 Main braking system ................................................................................ 17
2.3.1.2 Disc brakes .............................................................................................. 17
2.4 Starting procedure .................................................................................................. 18
2.5 Normal operation .................................................................................................... 18
2.5.1 Clutch change ............................................................................................. 18
2.5.2 Weight on bit ............................................................................................... 18
2.5.3 Crown saver ................................................................................................ 19
2.5.4 Floor saver .................................................................................................. 19
2.5.5 Slow speed.................................................................................................. 19
2.6 Slip & cut................................................................................................................. 20
2.7 Brake system safety and performance testing ....................................................... 20
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2.7.1 Brake capacity test procedure .................................................................... 21

2.8 Brake burning procedure ........................................................................................ 22
2.9 Stop procedures ..................................................................................................... 25
2.10 Emergency stop procedures................................................................................... 25
2.11 Start after an emergency stop ................................................................................ 25
3 SAFETY FUNCTIONS ...................................................................................................... 25
3.1 Interlock with other machines ................................................................................. 25
3.2 Shutdown logic ....................................................................................................... 26
4 DISTURBANCE OF OPERATION.................................................................................... 27
4.1 Alarms..................................................................................................................... 27
4.1.1 Group 1 Diagnostic alarms ......................................................................... 28
4.1.2 Group 2 Communication alarms ................................................................. 28
4.1.3 Group 3 Drive / motor alarms...................................................................... 29
4.1.4 Group 4 Auxiliary alarms............................................................................. 30
4.1.5 Group 5 Not used........................................................................................ 31
4.1.6 Group 6 Brake system alarms .................................................................... 31
4.1.7 Group 7 External signal fault alarms........................................................... 32
4.1.8 Group 8 Misc. alarms.................................................................................. 32
4.2 Alarm- and operation limits ..................................................................................... 34
5 OPERATOR SKILLS AND TRAINING............................................................................. 35
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1 INTRODUCTION
1.1 General
This operation manual describes the operations in conjunction with the day-to-day
running of the drawworks.
This document describes the various control and monitoring facilities. For Cyberbase
system overview and description of standard pop-ups etc, refer to document Operation
manual for Cyberbase Control System /6/, ref chapter 1.3.
It is essential that the equipment operators have the required knowledge, education and
training before using the system.
Running the drawworks involves pinch point risk. Keep distance from working
area.
1.2 Abbreviations and definitions
BOP Blowout Preventer

CW Clockwise
CCW Counter Clock Wise
DW Drawworks
FDS Functional Design Specification
HVAC Heat, Ventilation & Air Conditioning
IR Iron Roughneck
LCP Local Control Panel
LED Light Emitting Diode
HMI Human-Machine Interface
MP Mud Pump
P&ID Piping & Instrument Diagram
PLC Programmable Logic Controller
RAM Random Access Memory
ROP Rate Of Penetration
RT Rotary Table
STEP7 Siemens PLC Programming Software
TD Topdrive
VSDS Variable Speed Drive System
WOB Weight On Bit
Operator The person assigned the responsibility of physically operating and

maintaining the equipment
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1.3 Reference documents and drawings
Please refer to documents and drawings part in Final documentation dossier.
The following documents should be studied together in order to get a good

understanding of the functions, limitations and operation of the equipment;
Ref.no Document no. Description

/1/ S0100268-OPM-201 Instruction, Operation and Service Manual
Drawworks Mechanical Parts
/2/ S0100266-SID-301-01/02 Network Topology
/3/ S0100268-IDX-201 Instrument Index, Field Instruments
/4/ S0100268-MAM-200 Maintenance Manual, Drawworks Control System
/6/ S0100266-OPM-330 Operation and Maintenance Manual For DCDA
1.4 Service and support
For assistance from National Oilwell, please contact:
Company: National Oilwell Norway AS

Address: Lagerv.8
P.B. 8181
4069 Stavanger
Contact: Service Department
E-mail: service.norway@natoil.com
Telephone: +47 51818181
Telefax: +47 51800547
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2 OPERATION INSTRUCTIONS
2.1 Preparation / configuration
The drawworks control system has to be set up before the machine is ready to be used.
Most configuration data has been set up during commissioning. Configuration data other
than those listed below has to be changed by an NOI service engineer.
Setup screen
This screen is a sub-page of the drawworks screen.
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2.1.1 Block position
This procedure can also be found by pressing the “i”-button “Block Positioning Setup”.
Before the drawworks can be used the following parameters has to be set:
- Number of lines strung
- Reset of layer shift from layer 1 to 2 on the drawworks drum
- Reference height for the topdrive
- Reset of zero block position (floor height)
In order to set any of these parameters, the park brake must be on.
These settings have to be reconfigured if the wire has been replaced or a “Slip
and Cut”-operation has been executed. It is also necessary to do this if the PLC
memory has been reset. It is important to be accurate in order to ensure that the
positioning system works and that the floor- and crown-saver functions correctly.
2.1.1.1 Reset of layer shift from layer 1 to 2
Proceed with the following procedure in order to reset the layer shift from layer 1 to 2:
1. Position the block where the wire on the drum transits from layer 1 to 2.
2. Set the park brake on.
3. Press reset “Layer Shift 1 to 2”.
4. Lower the topdrive to a wanted position. This position is normally as close to the
drill floor as possible. Set the park brake on and measure the distance from a
known reference point on the topdrive. Update the “TD Reference Height”. See
below for information when this is needed.
5. Execute procedure for reset of floor height. See chapter 2.1.1.2.
It is important that the layer shift configuration is correct. Speed and safety-
functions are based upon this.
Point 4 has only to be done if the wire has been replaced or after a “Slip & Cut”-
operation. It also has to be done if the PLC memory has been reset or lost.
Reset of layer shift defines for the control system the angle on the drum. All calculations
are based upon this angle.
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2.1.1.2 Reset of floor height
The floor height is used for calculating the floor saver activation point.
Proceed with the following procedure in order to reset the floor height:
1. Position the block where the lowest point on the top drive or elevator is right
above floor level. It is also possible to place the block at a higher position if
desired.
2. Set the park brake on.
3. Press reset “Zero Block Position”.
4. Release the park brake.
5. Hoist the block about 3 meters / 10 feet.
6. Lower the block to see that the floor saver stops the block above the level chosen
in point 1. A safety margin is added to the floor saver in order to ensure that the
block will stop.
2.1.2 Limits
Maximum speed and overpull settings are not included.
2.1.3 Autodriller limits
Autodriller is not included.
2.1.4 Hook load source
The operator can choose between using the deadline anchor- and the travelling block
transmitters.
If the deadline anchor is used, it is possible to set a filter value on the measured signal
ranging between 0 and 20 seconds. A higher filter time will make the signal more robust
against rapid fluctuations in the measured signal. The filter only affects the value
displayed in the Cyberbase operator station, not the weight used by the control system.
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2.1.5 Block position / proximity switch configuration
Block position / proximity switch information screen
The block and proximity switch information picture is only intended as information for the
operator. Only an NOI service engineer can change these settings, as they have to be
changed within the PLC program. This screen will not be described in detail in this
manual but on-screen help is available by pressing the “i”-button on this screen.
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2.2 Human-Machine Interface (HMI)
The drawworks is operated from an operator station located in the driller’s cabin with all
the necessary switches and controls to operate the machine in a safe and controlled
manner.
Commands are selected and given from keypads/buttons/switches and joysticks on left
and right hand side of the operator station. Status signals are shown on the monitor(s).
Setup and configuration inputs are made from the screen(s).
2.2.1 Cyberbase displays
Machine and operation status are shown on the screens for the drawworks and the
instrument screen for drilling (Drilling –> Instr.)
Drawworks screen
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The drawworks screen shows information about the machine. By clicking on the top
menu the operator will have access to the setup screen and test / exception screen. See
chapter 2.1 and 2.7.
Instrument screen
The instrument screen shows following data applicable to the drawworks:
ROP Average rate of penetration

WOB Weight on bit
Hookload Hookload
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Test / exception screen
The test / exception screen controls and displays the;
Brake Burning Burning of new brake pads

Brake Test Test of brake capacity
Slip & Cut Slip & Cut operation
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2.2.2 Operator commands from Cyberbase screen
Motor information
Motor information pop-up is displayed by pressing the “i”-button for one of the motors.
There is one individual screen for each motor.
Drawworks sub-page menu
By clicking on this menu found on the top of every drawworks screen, it will give the
operator access to the various sub-pages found. Please note that the “Configuration”
page only will be visible if logged in as administrator on the Cyberbase operator station.
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2.2.3 Operator commands from keypads and joysticks
2.2.3.1 Drawworks manual – left side
Index Switch text Description

1 Clutch Lo Press and confirm to choose
Drawworks low clutch.
2 Crown Saver Press and hold to override
O/R the crown saver and the
crown o matic functions.
Esc TD How this works is described
in the chapter about the
RT crownsaver and crown o
matic.
TD 3 Clutch Hi Press and confirm to choose
PH high clutch.
4 Zero WOB Press and confirm to reset
the weight on bit.
5 DW On Press and confirm to turn the
machine either on or off.
6 Act. Brk. Tst / Press and confirm to start or
Clutch Crown Clutch Burn stop the brake burn or brake
Lo Saver Hi test function.
O/R 7 DW Park Press and confirm to set the
Zero park brake either on or off.
WOB
DW Act. Brk. DW
On Tst/Burn Park
Confirm
Index Joystick text Description
Elev
Open
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2.2.3.2 Drawworks manual – right side
Index Switch text Description

MP Control
Esc
TT
Pump
On
IBOP MP
Close Stop/ Sync
Resume
MP1 MP1 MP1

- On +
MP2 MP2 MP2

- On +
MP3 MP3 MP3

- On +
Confirm
Drawworks Index Joystick text Description

1 Lower Lower the block.
Lower 2 Hoist Hoist the block.
3 Creep To achieve creep speed
move the joystick to the left
Creep at the same time as hoist or
lowering command is given.
Hoist
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2.3 Main components of the drawworks
The drawworks consist of the following main elements:

- Drawworks mechanical parts with AC-motors, low and high clutch, disc brakes
and emergency lowering system.
- Cooling blowers for the drawworks motors.
- Lubrication system for the drawworks.
- Drawworks control system
- Interface to operator stations and other PLC’s.
The drawworks is run by the VSDS system and operated from the operator station in the
driller’s cabin. It communicates to these systems through communication network links.
Please look in reference /1/ for information regarding the drawworks mechanical parts.
2.3.1 Braking systems
2.3.1.1 Main braking system
Normal braking when lowering is achieved by use of regenerative braking using the AC-
motors and the VSDS as a generator, hence feeding the energy from the braking into
the resistor system.
2.3.1.2 Disc brakes
The disc brakes are designed as park brake and emergency stop brake. The drum has
two direct mounted discs. Each disc is equipped with multiple braking calipers. The
calipers are spring applied, and are deactivated by use of hydraulic pressure, thus
making the system fail safe.
The braking capacity is 200% of maximum designed static torque. Since the disc brakes
are not designed for dynamic braking (except for an emergency situation), the discs
have to cool down to below 158 F (70ºC) after an emergency stop before the operation
can continue. The temperature should be measured using a hand instrument as a laser
temperature meter or equivalent.
The disc brake system consists of a brake system A and brake system B. Each of these
systems will set half of the calipers. Each system has a capacity of 100% of the nominal
braking capacity. Separate return lines are provided for each system to ensure fail-safe
operation of the disc brakes.
Normal park brake activation from the operator station will set either brake system A or
brake system B. These are alternated each time the park brakes are set.When the
drawworks is switched off, both system A and B will be set.
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2.4 Starting procedure
1. Select the correct operator mode on the Cyberbase.

2. Press “DW On” and confirm in order to turn the machine on. All auxiliary
equipment then starts and makes the machine ready for operation.
3. Ensure that all auxiliary equipment is running and that no low hydraulic pressure
or low lube oil pressure alarms are active.
4. When the “Clutch Lo” or “Clutch Hi” buttons comes available, press either one of
them and press confirm. This selects which clutch the operator desires to use.
5. When the “DW Park” button comes available, press it followed by confirm. Doing
this will torque up the motors followed by the release of the park brake. It is now
possible to hoist and lower the block.
6. Run past the reference proximity switch with the block to ensure that the
positioning system is healthy.
7. The drawworks is now ready for operation.
2.5 Normal operation
Manual operation of the drawworks is available as soon as the start procedure has been
done. The block can then be hoisted and lowered with maximum speed, only limited by
the joystick displacement and available power for acceleration and deceleration. For
safety reasons, some alarm situations will also limit the speed or inhibit running in one
of the directions.
2.5.1 Clutch change
The clutch can be changed as soon as the park brake is set. Press the desired clutch
followed by confirm, and release the brake again to run with the desired clutch.
2.5.2 Weight on bit
In order to reset the weight on bit monitoring, hold the drill string right above the bottom
of the drilled hole. Then press “Zero WOB” followed by confirm. The weight on the bit is
then calculated by subtracting actual hook load from the stored weight value. If
changing between deadline anchor and travelling block hook load monitoring, the
weight on bit should be reset.
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2.5.3 Crown saver
The purpose of the crown saver is to prevent the block from being hoisted into the
crown by an accident. If the block is hoisted above a predefined upper warning height,
the maximum speed will be reduced. If it is desired to hoist the block above the upper
stop proximity switch, it must be overridden.
By pushing the “Crown Saver O/R”-button the crownomatic function will be reset /
inhibited.
To override the crown saver:

1. Push and hold the “Crown Saver O/R”-button to activate the crown saver override
function.
2. It is now possible to run past the upper stop proximity switch in slow speed.
3. Release the “Crown Saver O/R”-button to deactivate the function again.
Be aware that using this function means that there is no automatic braking /
stopping when moving upwards.
2.5.4 Floor saver
The floor saver function works together with the power management system. The power
management system calculates the required braking distance based on block speed,
hook load, position and available braking power.
In order to lower the block below the floor saver the slow speed function has to be used.
The activation point for the floor saver is based on the calculated stop length in
reference to drill floor.
The anti collision system, if present, will at any time have control over machines which
can enter the working area for the drawworks. The floor height will then be corrected to
the top of the machine which is inside the drawworks working area.
2.5.5 Slow speed
Low block speed can be achieved by holding the joystick to the left and at the same
time give a speed command by pushing the joystick either forward or backward. The
speed will then be reduced to a maximum of 10% of the maximum allowed block speed.
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2.6 Slip & cut
In order to do a slip & cut operation the block must first be hung off. Then the machine
has to be shut down and slip & cut mode selected in the Cyberbase operator screen.
The positioning system will during slip & cut mode be inhibited. Remember therefore to
recalibrate the block position. The single line pull also has to be considerably low in
order to activate the mode.
2.7 Brake system safety and performance testing
The control system has a feature for easy brake capacity testing. This feature should be
used when new brake pads are installed, prior to handling of high loads and also at
regular intervals during the operation. The testing can be done without hanging off the
block.
The brake test is developed for quick, repeatable and accurate determination of the
brake caliper capacity. The test is initiated manually, but the sequence is PLC
controlled. During the test, the motors are gradually torqued up in steps against
activated calipers (one calliper or calliper pair at the time). If the brakes slip, the torque
is logged and a brake pad percentage capacity is presented.
A passed / failed result is given for each caliper / caliper pair. This is an indication
whether the brake capacity is in accordance with the design criteria for the brake pads.
100 % equals the minimum pass value for each test.
When all callipers are tested, the overall braking capacity is given as the equivalent
hook load for each brake set and total with both brake sets active.
IMPORTANT:
System A and B are alternated by the PLC control system each time the brakes are set.
Both system A and system B must be able to hold the load.
The actual braking force for each caliper is depending on several conditions when
mounted on the Drawworks:
1. Air gap between brake pad and disc when fully released. Increased air gap reduces
the clamping force. Refer also to brake manufacturer maintenance manual as
incorporated in “User Manual Drawworks mechanical parts”, ref. document no. /1/.
2. Coefficient of friction. This factor is strongly depending on the cleanliness of the

brake disc and the brake pads. Contamination from hydraulic oil and lubricant (wire
lube, grease etc.) will strongly reduce this coefficient and thereby reduce the braking
force. Glazing of the brake pads, i.e. the brake pad material is heated and a
hardened film of brake pad material is deposited on the pad, will also lower the
coefficient of friction and reduce the braking capacity.
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3. Brake burning. The pads delivered together with the Drawworks are burned in to
achieve a braking force equal to or better than the design criteria as described
below. Some pads might be better than other pads depending on the burning in.
When purchasing new pads, these will have to be burned in on the vessel.
2.7.1 Brake capacity test procedure
1. Secure the hook load in the slips so that it is only the weight of the top drive in the
hook.
2. Hoist the travelling block between 6.6 ft or 2 meter and 16.4 ft or 5 meter above the
drill floor.
3. Park the Drawworks. Switch to ‘Test/Exception Mode’ display.
4. Turn the mode selector switch in the Drawworks control panel to Test position.
Select “Brake Test” on the “Test / Exception” screen and start the drawworks and
release the brakes as normal.
5. Activate the “Act Test” button followed by Confirm on the keypad. (This will disable
the normal drawworks operation and start the automatic sequence). Note: The test
can be aborted by activating the Joystick to the left at any time during the automatic
sequence.
6. The control system will now check that the block is located at safe distance from
floor and crown. It will also check that there is no load in the hook except for the top
drive and that there is enough motors available to fulfil the test. The ‘Brake Test
Aborted‘ and ‘Block Too Low/High’, ‘Block Weight Too High’ or ‘Not Enough Motors
Available’ indicators will be activated if any of these parameters are outside the
preset limits in the PLC.
7. Verify that the “Brake Test On” and “Brake Test Active” indicators are activated on
the operator station. This will start the automatic test sequence as follows.
8. All brakes are released and the mean torque value representing the force from the
external load is recorded by the PLC.
9. The motors are torqued up in steps for each caliper pair until the calliper slips or
reaches a value well above the pass value. Each step will be held for approx. 2
seconds giving a test time of approx. a minute for each caliper pair. The motors are
only applying torque to simulate a down ward force. For each caliper pair, an
appurtenant lamp will indicate status of the test and an Actual Torque value will be
increased gradually.
10. If the brake calipers do not slip before the passed value is reached, the Passed
indication will be activated and the actual Brake capacity in percent will be shown on
the screen.
11. If the brake calipers slip (motor turning 1/8 revolution) before the passed value is
reached during one of the caliper tests the movement of the drum will stop. The
Failed indication will be activated and the actual Brake capacity in percent will be
shown on the screen.
12. The test continues with the remaining calipers until all calipers are tested.
13. If parts of the test are not completed or aborted by the operator, the “Brake Test
Aborted” indicator will be activated and there will not be presented a final Weight
capacity.
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14. When done, set the drawworks brakes from the keypad and turn off the drawworks.
15. Ensure that the “Brake test active” and “Test Mode On” indicators are deactivated.
16. Turn the Mode selector Switch to “operation” in the Drawworks control panel.
NOTE!
If the calipers have a capacity less than the pass value, the brake capacity is lower than
the design criterion and maintenance should be done to increase the capacity.
2.8 Brake burning procedure
Refer also to brake manufacturer maintenance manual as incorporated in “User Manual

drawworks mechanical parts”, document ref. /1/.
WARNING:
"When working in drum area with drill line attached to the drum, lock out the drawworks
AC-drives".
NOTES:
• Only one caliper or linked pair of calipers can be burnt at the same time.
• If changing pad or caliper or disassembling the caliper, ensure that an air gap check
is done before performing the brake capacity test or continuing operation.
Brake burning procedure:

1. Hang off travelling block from the hang off line.
2. Remove the drill line from the drum.
3. Clean the brake discs with white spirit and thereafter with thinner or trichloretylene
prior to inserting any new pads. Install new pads according to the procedure in the
maintenance manual.
4. Park the Drawworks.
5. Ensure that all manual / remote valves are in REMOTE position. Refer to the sign
located inside the drum area for selection of correct valves.
6. Install/extend, unlatch and pin the handle on the “EMERGENCY LOWERING” valve.
7. Close the “EMERGENCY DUMP” valve.
8. Put the two (2) MANUAL / REMOTE valves on the pair of calipers to be burned
(bedded) in the MANUAL position. Refer to the sign located inside the drum area for
selection of correct valves and further instructions.
9. Switch the Test mode switch in the Drawworks Control Panel to ON.
10. Start the Drawworks and Release the Brakes as normal, Ensure the hydraulic supply
pressure is approx 3000 psi,
11. Select the “Test Mode” display
12. Select “Brake Burning”
13. Select the caliper pair to be burned in. Ensure that this is consistent with the manual
operation on the Drawworks.
14. Activate the “Act Test” button followed by Confirm on the Keypad (this will disable
normal Drawworks operation, over-ride brake alarms and disengage the calipers not
selected). Verify that the “Test Mode On” indicator is activated.
15. Pull down on the “EMERGENCY LOWERING” valve to release the caliper pair to be
burned from the brake disc.
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16. Activate the joystick to rotate the drum (speed is adjustable and limited to 10 RPM
on the drum and motor torque limit is set to 1000 Nm (740 ftlbs)
17. Slowly raise the handle of the “EMERGENCY LOWERING” valve to reduce the
pressure on the caliper pair. The pressure should be held between 400 and 600 psi
depending on the number of callipers on the set that should be burned in (two sets
have one caliper and two sets have two calipers). If the rotation stops the pressure
needs to be adjusted to stay within the available motor torque.
18. Monitor the brake disc temperature with an infrared temperature sensor (or
equivalent. Burn the brake until the disc temperature reaches 212° F or 100°
Celsius.
19. Once the disc reaches 212° F or 100° Celsius pull down on the “EMERGENCY
LOWERING” valve to fully disengage the disc caliper from the disc.
20. Select “Disc Cooling” to disengage all calipers.
21. Raise the handle on the “EMERGENCY LOWERING” valve and ensure that the
calipers remain disengaged from the disc.
22. Continue to rotate the drum and spray clean fresh water (no soaps, detergents,
softeners, salts, oils, etc) onto both sides of the heated disc to cool it down to
approximately 77° F or 25° Celsius.
23. Deselect “Disc Cooling” to engage selected caliper and repeat steps 13 thru 22 until
the caliper pair has been burned 4 times total.
24. After the caliper pair has been burned in and the disc has been cooled down to 25
degrees Celsius, stop rotating the drum. Select next Caliper pair (REMEMBER the
Manual operation on the Drawworks) and repeat the procedure.
25. Raise the handle on the “EMERGENCY LOWERING” valve and allow the caliper
pair to engage the brake disc.
26. Deselect the “Act. Test” button to disable the test mode.
27. Select the “No Test Mode”.
28. Switch the MANUAL / REMOTE valve for the caliper pair to the REMOTE position.
29. Perform an automatic brake capacity test according to the procedure.
30. If the caliper pair capacity is insufficient burn the caliper pair 2 more times and then
retest the capacity.
31. If the caliper pair capacity is adequate remove/retract, latch and pin the handle on
the “EMERGENCY LOWERING” valve.
32. Open the “EMERGENCY DUMP” valve.
33. Release the joystick and apply the brake when the complete procedure is finished.
34. Verify that the “Brakes are set” from the MMI display.
35. Switch the Test mode switch in the Drawworks Control Panel to OFF.
36. Ensure that the “Brake burning”, “Brake Test On” and “Test Mode On” indicators are
off, that the “Act Test” button is disengaged, that the brakes are set and no alarms
are active.
37. Reattach the drill line to the drum.
38. Hoist the travelling block and disconnect from the hang off rigging.
NOTE:
It is possible to burn in one caliper by itself. To do this it is necessary to disconnect one
end of the brake cylinder from the caliper arm by removing the pin shown below
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Brake calliper sketch
Removing this pin will allow the other caliper in the pair to be burnt in by itself. Thus it is
possible, if necessary, to burn in each caliper individually.
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2.9 Stop procedures
A normal stop of the machine is done from the Cyberbase operator station.
1. Let go of the joystick if the park brake is off. Wait until the block is at standstill.
Press then “DW Park” followed by confirm in order to set the park brake.
2. When the park brake is set the machine can be turned off by pressing “DW
On” followed by confirm.
2.10 Emergency stop procedures
In addition to the common emergency stop system, an emergency stop mushroom

switch is provided for installation adjacent to the drawworks. The emergency stop
system is a hardwired system. By activating the emergency stop, the disc brakes will
immediately engage, a shut down signal will be given to the VSDS system to stop the
drawworks motors and the auxiliary equipment will be shut down as normal by the
drawworks control system.
2.11 Start after an emergency stop
Pull out the activated emergency stop button and verify that the machine has no
mechanical damage as a result of the emergency stop situation. Start the machine
again by following the procedure in chapter 2.4.
3 SAFETY FUNCTIONS
The drawworks control system is designed to provide enhanced safety and integrity for
the operation, machinery, and the personnel onboard the platform. This is achieved by
an active control philosophy with equipment self-checks and monitoring, and by use of
duplicated critical equipment such as duplicated brake discs, hydraulic pumps and
encoders and by interface to other machines/systems to avoid collision or equipment
damage.
The primary safety requirement for the drawworks is that ‘one single point of failure shall
not cause any hazardous condition leading to either personnel injury or any damage to
the equipment’.
3.1 Interlock with other machines
There is an interlock against the top drive. When the top drive is in a “Make up-“ or
“Brake out”-sequence it is not possible to hoist or lower the block.
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3.2 Shutdown logic
The drawworks is equipped with many devices for monitoring of the drawworks and
related equipment conditions. A failure on simple devices that does not influence the
safety of the equipment or people on board will normally only give alarms on the
operator station screen. Other, more critical failures, will result in different actions from
the control system depending on which operational mode is active, combined with
continued warning to the driller as described below.
1) Alarms leading to reduced speed (slow speed)

2) Alarms leading to shutdown of the machine in a normal manner, i.e. speed ramped
down to zero and brakes set.
3) Alarms leading to activation of the Emergency brakes
standstill followed by
Emergency brakes
Action by control
on immediately
Deceleration to
Slow speed
brakes ON
system
Fault description
DW Brake supply pressure low-low x
DW Brake off fault x1
DW Brake on fault 2
DW Block upper warning x
DW Block upper stop x
DW Soft Floor saver active x
DW Hard Floor saver active x
DW PLC Major Fault
Comm. Loss to Ac-drives X
Comm. Loss to operator station x
3
DwM1 – 3 Drives tripped x
Remaining drives can not hold load
DwM1 – 3 Temp high-high alarm x
Creep Alarm Triggered.
(Drives not holding block at standstill when
speed ref. = zero)
Brake slip alarm Level 1
Brake slip alarm Level 2
Encoder deviation alarm from 2 encoders
1
Only used when Drawworks is at standstill and failure to release brakes.
2
Only used when Drawworks is at standstill and failure to set brakes. Motors will hold load at zero speed.
3
Coast to zero speed if moving upwards.
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4 DISTURBANCE OF OPERATION
4.1 Alarms
Alarms are shown in an alarm banner on top of the right Cyberbase screen. The last
trigged alarm will be shown in this banner.
Typical alarm banner
An alarm list is also available for the operator. This list will show the last received alarm
on the top. Unacknowledged alarms will be red, acknowledged yellow and
unacknowledged alarms which are no longer active will be green. The green alarms will
disappear from the list as soon as they are acknowledged.
Typical alarm listing
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4.1.1 Group 1 Diagnostic alarms
Alarm Description Control system action Operator action

PLC Major Diagnostic Error Combined alarm for serious Alarm only.
PLC diagnostic errors
Table 4-1
4.1.2 Group 2 Communication alarms

Communication Error DW Drive A/B/C Alarm for fault diagnostics Alarm only.
One drive must be available to operate
the drawworks.
Loss of drive will (can) limit the block
speed.
Table 4-2
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4.1.3 Group 3 Drive / motor alarms

Drive A/B/C Alarm Active Alarm for fault diagnostics Alarm only.
There is an active alarm on one of the
drives.
Drive A/B/C is Tripped Drive faulted (tripped) Alarm only. Possible drawworks stop if Check the drive information
no motors are left running or not for specific trip/alarm details.
enough torque left to hold the load.
Drive A/B/C Has Detected Motor Temperature High Motor windings high Alarm only, Check motor airflow and
temperature. blowers.
Drive A/B/C Has Detected Motor Temperature Too Motor windings high high When motor is running it will be Verify alarm by manually
High temperature. decelerated to standstill followed by checking motor temperature.
brakes on. Restart drawworks without
actual motor.
DW Release Brake Permissive Fault Release brake permissive Alarm only.
from drives timed out.
Drive A/B/C Earth Fault Diagnostic alarms. Alarm only.
Drive A/B/C Encoder Fault
Drive A/B/C External Fault
Drive A/B/C Over Current Fault
Drive A/B/C Over Voltage Fault
Drive A/B/C Under Voltage Fault
Drive A/B/C Run Disabled Fault
Table 4-3
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4.1.4 Group 4 Auxiliary alarms

DW Motor A/B/C Cooling Pressure Low The cooling pressure switch Only an alarm if the motor is running,
has faulted or cooling motor disabled if at standstill.
pressure is low.
Brake HPU Tank Level Low Low oil level in HPU tank Alarm only. Check level by reservoir dip
stick.
Brake Supply Pressure Low Low brake supply pressure Alarm. Unable to release the brake if
drawworks are at standstill.
Brake Supply Pressure Low Low Too low brake supply Speed reference is set to zero.
pressure Drawworks will decelerate at a
predefined deceleration ramp. Brakes
will be set when drawworks is at
standstill.
Brake Supply Pressure High High brake supply pressure Alarm only.
Brake HPU Filter Clogged Brake HPU filter is clogged Alarm only. Change filter element. Rake
oil sample to verify
cleanliness of hydraulic oil.
Brake HPU Tank Temperature High High temperature in HPU Alarm only.
tank
Brake HPU Excessive Running Brake HPU motors running Alarm only. Compare transmitter
for an extended time (more pressure (on screen) with
than 3 minutes). pressure on local gauges.
Shut down brake HPU to
avoid overheating.
Lube Oil Pressure Low Low lube oil pressure Alarm. Unable to release the brake if
drawworks are at standstill.
Lube Oil Pressure High High lube oil pressure Alarm only.
Lube Oil Pump Not Available Alarm only. Check MCC status.
Brake HPU A/B Not Available Alarm only. Check MCC status.
Cooling Blower A/B/C Not Available Alarm only. Check MCC status.
Table 4-4
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4.1.5 Group 5 Not used
Table 4-5
4.1.6 Group 6 Brake system alarms

DW Brake Off Fault Brakes failed to go off. Brakes will be set and motors will be Check calliper transmitters,
torqued down. callipers and valves for
faults.
DW Brake On Fault Brakes failed to be set. Motors are still holding the load. Secure the load. Check
calliper transmitters, calipers
and valves for faults.
Brake Caliper 1/2/3/4/5/6 On Fault Individual calliper on faults Alarm only.
Brake Caliper 1/2/3/4/5/6 Off Fault Individual calliper off faults. Alarm only.
Table 4-6
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4.1.7 Group 7 External signal fault alarms

Load Cell A/B Fault Fault on hook Block Hook load value locked to the value at Troubleshoot wiring or
Load Cell A/B Deviation Fault load moving last standstill. sensor failure.
Hook Load Deadline Transmitter Fault measurement, @ stand Hook load set to max.
Hook Load Top Drive Cell A/B Transmitter Fault still
Crown O Matic Transmitter Fault Analog input signal failure Alarm only. Troubleshoot wiring or
Low Clutch Transmitter Fault (Over-range, under-range sensor failure.
High Clutch Transmitter Fault or wire break)
Lube Oil Pump Pressure Transmitter Fault
Brake Supply Pressure Transmitter Fault
Brake Caliper 1&2/3/4/5&6 Pressure Transmitter
Fault
Brake HPU Oil Tank Temp. Transmitter Fault
Table 4-7
4.1.8 Group 8 Misc. alarms

Emergency Stop An emergency stop button Brakes on immediately.
is activated.
Soft Floor Saver Active The floor saver has The floor saver has activated, lowering Floor saver has to be
activated based on block is stopped, and further lowering overrided in order to do
position against hindrances. inhibited. further lowering.
Hard Floor Saver Active The floor saver has Brakes on immediately. Floor saver has to be
activated and soft floor overrided in order to do
saver did not stop the load. further lowering.
Broken Chain Alarm A broken chain has been The actual motor will be stopped. Check drawworks
detected. Continued running on the remaining mechanical chains.
motors.
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Block Upper Warning Block has passed warning Slow hoisting / lowering speed.
proximity switch or preset
warning height.
Block Upper Stop Block has passed stop Brakes on immediately. Manual hoisting in slow
proximity switch or preset speed allowed if override is
stop height. activated.
Position Check Prox. Position Error Block position calibration Alarm and slow hoisting / lowering Activate block calibration
Upper Warning Prox. Position Error routine not completed or speed. sequence. If continued fault;
Upper Stop Prox. Position Error position fault in regard to check proximity switches for
Height Not Calibrated derrick proximity switches fault.
detected.
Soft Shutdown Initiated Machine is turned off. Block is decelerated and the drawworks
turned off.
Brake On Soft Initiated Brake is set. Block is decelerated and the park brake
set.
Crown O Matic Activated The crownomatic has been Brakes on immediately. Further hoisting requires
activated. overriding of the crown saver
system.
Low Clutch On Fault Unable to set the desired Alarm only. Troubleshoot wiring,
High Clutch On Fault clutch. sensor failure, clutch and
valves.
Low Clutch Off Fault Unable to release the Alarm only. Troubleshoot wiring,
High Clutch Off Fault clutch. sensor failure, clutch and
valves.
Clutch Fault Common clutch alarm Alarm only.
Table 4-8
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4.2 Alarm- and operation limits
Alarm limit Description Limit Unit Limit Unit

DW Lube Oil Pressure low alarm 3,45 Barg 50 Psi
DW Lube Oil Pressure high alarm 15,0 Barg 220 Psi
DW Brake Supply Pressure low-low alarm 165 Barg 2400 Psi

DW Brake Supply Pressure low alarm 179 Barg 2600 Psi
DW Brake Supply Pressure high alarm 220 Barg 3200 Psi
DW Brake HPU Oil Temp. high alarm 70 °C 158 °F
DW Motor 1-3 Windings Temp high alarm 160 °C 320 °F

DW Motor 1-3 Windings Temp high-high alarm 180 °C 356 °F
Operational limit Description Limit Unit Limit Unit

DW Brake Supply Pressure low, start pump 1 196,5 Barg 2850 Psi
DW Brake Supply Pressure low, start pump 2 186,2 Barg 2700 Psi
DW Brake Supply Pressure high, stop pump 1 and 2 207 Barg 3000 Psi
DW Brake Supply Pressure OK 193 Barg 2800 Psi
(allowed to release calipers)
Brakes OFF indication pressure (speed allowed) 104 Barg 1500 Psi
Brakes ON indication pressure 4 Barg 60 Psi
Brakes start to engage (approximately) 45 Barg 650 Psi
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5 OPERATOR SKILLS AND TRAINING
The operator should be experienced and well acquainted with the type of work and
operating sequences that the equipment is performing. The operator must pay special
attention to general safety aspects and be well aware of the limitations and capabilities
of the equipment.
As a minimum requirement, the operator must carefully study the documentation listed
in chapter 1.3. Together, these documents give an overall understanding of functions,
possibilities, limitations and safety hazards related to operation of the equipment.
Further information can be obtained from National Oilwell and special training sessions
can be offered upon request.
www.natoil.com
Houston, Texas
EMERGENCY DISC BRAKE CALIPER

PART NUMBER 2112041
DRECO AHD-1000 DRAWWORKS
OPERATION AND MAINTENANCE MANUAL
EPL-1424
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 ........................... 12
SALES AND SERVICE INFORMATION ................................... 13
Page 1
EPL-1424
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-1424
ADJUSTMENT SPECIFICATIONS
1a. EMERGENCY BRAKE (Released) 1600 PSI (110 bars)

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

2. Part Number 0-7602-1370-46
3. Thickness (New) 1.00 Inch (25 mm)
4. Minimum Thickness (Before Pad Replacement).50 Inch (12.7 mm)
- EMERGENCY BRAKE CYLINDER

5. 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 .060 Inch (1.5 mm)
7. Maximum (Before Adjustment) .090 Inch (2.3 mm)
OPERATION
The NATIONAL OILWELL 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-1424
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.
! WARNING !
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.
! CAUTION !
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-1424
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 less than that
given 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.
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.
Page 5
EPL-1424
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
! WARNING !
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.
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.
Page 6
EPL-1424
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-1424
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.
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-1424
ANNUALLY
Test the Emergency Cylinders by following the procedures listed

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 BE;

a) 900 PSI (62.1 Bars) .256" ? .030"(6.50mm ? .76mm)
b) Release Pressure
c) 1025 PSI (70.7 Bar) .326" ? .030"(8.28mm ? .76mm)
d) Release Pressure
e) 1270 PSI (87.6 Bars) .465" ? .030"(11.81mm ? .76mm)
f) Release Pressure
g) 1400 PSI (96.5 Bars) .542" ? .030"(13.77mm ? .76mm)
8. If any of these test fail, proceed with Five Year replacement

of springs.
9. Repeat steps 3 through 7 on the other Emergency Cylinders.
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.
12. Inspect Caliper Support Arms for cracks with NDE procedures.
Check for worn holes where the caliper support shafts go
through.
Page 9
EPL-1424
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-1424
FIGURE 1 - EMERGENCY BRAKE CALIPER ASSEMBLY
1. Cotter Pin, Pivot Arm 11. Bushing, Brake Pad

2. Cylinder Assy, Emergency Brake 12. Bushing, Brake Pad
3. Shaft, Arm Support 13. Arm, Caliper
4. Shaft, Caliper Support 14. Pad, Brake Shoe
5. Shaft, Pivot Arm 15. Bushing, Machine
6. Shaft, Brake Pad 16. Bushing, Machine
7. Shoe, Brake 17. Snap Ring
8. Bushing, Caliper Support 18. Locknut
9. Bushing, Pivot Arm 19. Fillister Head Screw
10. Bushing, Pivot Arm 20. Cotter Pin
Page 11
EPL-1424
FIGURE 2 - EMERGENCY CALIPER CYLINDER
ASSEMBLY/DISASSEMBLY
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-1424
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 W ICHITA, KS
W ILLISTON, 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
UNITED STATES STORES
Page 13
EPL-1424
OKLAHOMA CITY, OK POWELL, WY SHIDLER, OK VERNAL, UT
PAINTSVILLE, KY PUNXSUTAWNEY, PA SHREVEPORT, LA VICTORIA, TX
PAMPA, TX RATLIFF CITY, OK SNYDER, TX W ATFORD CITY, ND
PEARSALL, TX RIVERTON, WY SUNDOWN, TX W ILLISTON, ND
PENNSBORO, WV ROCK SPRINGS, WY VENICE, LA W OODLAND, 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.

MACHINERY CENTRE: SOUTHEAST ASIA SALES OFFICE:
BADENTOY ROAD MACHINERY AND SERVICE CENTRE
BADENTOY INDUSTRIAL PARK 30 TUAS BASIN LINK
PORTLETHEN, ABERDEEN SINGAPORE 638786
SCOTLAND ABI 4YA PHONE: (011-65) 861-1566
PHONE: (011-44-1224) 783-060 FAX: (011-65) 861-0796
FAX: (011-44-1224) 783-266
NATIONAL OILWELL (UAE) LTD.

MIDDLE EAST SALES OFFICE:
SALES AND SERVICE CENTRE
P.O. BOX 61490
RA/08-TA06
JEBEL ALI, UAE
PHONE: 971 4 8838776
FAX: 971 4 8838795
Page 14
EPL-1424
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
INSTALLATION AND
MAINTENANCE INSTRUCTIONS
FOR THREE PHASE
INDUCTION MOTORS
Frames 143T - 449TZ
RECEIVING
1. Check nameplate data.
2. Check whether any damage has occurred during transportation.
3. After removal of shaft clamp, turn shaft by hand to check that it turns freely.
4. If motor is to be reshipped (alone or installed to another piece of equipment) the shaft must
again be clamped to prevent axial movement.
Note: Remove the bearing clamp before turning the shaft on 284T-449TZ frame motors.
WARNING
THE FOLLOWING SAFETY PRECAUTIONS MUST BE OBSERVED:
1. Electric rotating machinery and high voltage can cause serious or fatal injury if improperly
installed, operated or maintained. Responsible personnel should be familiarized with
NEMA MG2; Safety Standards for Construction and Guide Selection. Installation and Use
of Electric Motors and Generators; National Electric Code and all local safety requirements.
2. When servicing, all power sources to the motor and to the accessory devices should be de-
energized and disconnected and all rotating parts should be at standstill.
3. Lifting means, when supplied, are intended for lifting the motor only. When two lifting
devices are supplied with the motor a dual chain must be used.
4. Suitable protection must be used when working near machinery with high noise levels.
5. Safeguard or protective devices must not be by-passed or rendered inoperative.
6. The frame of this machine must be grounded in accordance with the National Electric Code
and applicable local codes.
7. A suitable enclosure should be provided to prevent access to the motor by other than
authorized personnel. Extra caution should be observed around motors that are
automatically or have automatic re-setting relays as they may restart unexpectedly.
8. Shaft key must be fully captive or removed before motor is started.
9. Provide proper safeguards for personnel against possible failure of motor-mounted brake,
particularly on applications involving overhauling loads.
10. Explosion proof motors are constructed to comply with the label service procedure manual,
repair of these motors must be made by TECO-Westinghouse Motor Company or U/L listed
service center in order to maintain U/L listing.
LOCATION
1. Drip-proof motors are intended for use where atmosphere is relatively clean, dry, well
ventilated and non-corrosive.
2. Totally enclosed motors may be installed where dirt, moisture, or dust are present and in
outdoor locations.
3. Explosion-proof motors are built for use in hazardous locations as indicated by
Underwriters label on the motor.
4. Chemical duty enclosed motors are designed for installation in high corrosion or excessive
moisture locations.
Note: in all cases, no surrounding structure should obstruct normal flow or
ventilating air through or over the motor.
MOUNTING
1. Mount motor securely on a firm, flat base. All ball bearing normal thrust motors up to and
including 256T frame size may be side-wall or ceiling mounted; all others check nearest
TECO-Westinghouse office for mounting recommendations.
2. Align motor accurately, using a flexible coupling if possible. For drive recommendations,
consult with drive or equipment manufacturer, or TECO-Westinghouse.
3. Mounting bolts must be carefully tightened to prevent changes in alignment and possible
damage to the equipment. The recommended tightening torque s for medium carbon steel
bolts, identified by three radial lines at 120 degrees on the head, are:
Recommended Torque (Ft-lb.)

Bolt Size
Minimum Maximum
2/8 25 37
1/2 60 90
5/8 120 180
3/4 210 320
4. V-belts Sheave Pitch Diameters should not be less than those shown in Table 1 (NEMA
recommended values)
5. Tighten belts only enough to prevent slippage. Belt speed should not exceed 5000 ft. per
min.
TABLE 1. V-Belt Sheave Pitch Diameters (MG1-14.42)

V-Belt Sheave
Conventional Narrow
A, B, C, D AND E 3V, 5V, AND 8V
Minimum Minimum
*Maximum **Maximum
Horsepower at Pitch Outside
Width Width
Frame Synchronous Speed, RPM Diameter Diameter
Inches Inches
Number 3600 1800 1200 900 Inches Inches
143T 1.5 1 .75 .5 2.2 4.25 2.2 2.25
145T 2-3 1.5-2 1 .75 2.4 4.25 2.4 2.25
182T 3 3 1.5 1 2.4 5.25 2.4 2.75
182T 5 2.6 5.25 2.4 2.75
184T 2 1.5 2.4 5.25 2.4 2.75
184T 5 2.6 5.25 2.4 2.75
184T 7.5 5 3.0 5.25 3.0 2.75
213T 7.5-10 7.5 3 2 3.0 6.5 3.0 3.375
215T 10 5 3 3.0 6.5 3.0 3.375
215T 15 10 3.8 6.5 3.8 3.375
254T 15 7.5 5 3.8 7.75 3.8 4
254T 20 15 4.4 7.75 4.4 4
256T 20-25 10 7.5 4.4 7.75 4.4 4
256T 20 4.6 7.75 4.4 4
284T 15 10 4.6 9 4.4 4.625
284T 25 5.0 9 4.4 4.625
286T 30 20 15 5.4 9 5.2 4.625
TABLE 1. V-Belt Sheave Pitch Diameters (MG1-14.42)
V-Belt Sheave
Conventional Narrow
A, B, C, D AND E 3V, 5V, AND 8V
Minimum Minimum
*Maximum **Maximum
Horsepower at Pitch Outside
Width Width
Frame Synchronous Speed, RPM Diameter Diameter
Inches Inches
Number 3600 1800 1200 900 Inches Inches
324T 40 25 20 6.0 10.25 6.0 5.25
326T 50 30 25 6.8 10.25 6.8 5.25
364T 40 30 6.8 11.5 6.8 5
364T 60 7.4 11.5 7.4 5.785
365T 50 40 8.2 11.5 8.2 5.785
365T 75 9.0 11.5 8.6 5.785
404T 60 9.0 14.25 8.0 7.25
404T 50 9.0 14.25 8.4 7.25
404T 100 10.0 14.25 8.6 7.25
405T 75 60 10.0 14.25 10.0 7.25
405T 100 10.0 14.25 8.6 7.25
405T 125 11.5 14.25 10.5 7.25
444T 100 11.0 16.75 10.0 8.5
444T 75 10.5 16.75 9.5 8.5
444T 125 11.0 16.75 9.5 8.5
444T 150 16.75 10.5 8.5
445T 125 12.5 16.75 12.0 8.5
445T 100 12.5 16.75 12.0 8.5
445T 150 16.75 10.5 8.5
*Max. Sheave width = 2(N-W) - .25
**Max Sheave width = N-W
***Sheave ratios grater than 5:1 and center-to-center distance less than the diameter of the
large sheave should be referred to TECO-Westinghouse.
POWER SUPPLY & CONNECTIONS

1. Wiring of motor and control, overload protection and grounding should be in accordance
with National Electrical Code and all local safety requirements.
2. Nameplate voltage and frequency should agree with power supply. Motor will operate
satisfactorily on line voltage within –10% of nameplate voltage; or frequency with –5% and
with a combined variation not to exceed –10%. 230-volt motors can be used on 208-volt
network systems, but with slightly modified performance characteristics as shown on the
nameplate.
3. Dual voltage and single voltage motors can be connected for the desired voltage by
following connection diagram shown on the nameplate or inside of the conduit box.
4. All Explosion Proof motors have Temperature Limiting Devices in the motor enclosure to
prevent excessive external surface temperature of the motor in accordance with U/L
standards. Terminals of thermal protectors (P1 & P2) should be connected to the motor
control equipment, according to the connection diagram inside of the conduit box.
5. Standard connection diagram for three phase, not thermally protected, dual rotation motors
are shown in diagrams A through E.
(Note: To change rotation, Interchange any two line leads)
A. 3 Lead, Single Voltage
B. 6 Lead, Dual Voltage & Voltage Ration 1 to 3
B-2 Wye Start & Delta Run

B-1 Across the Line Start & Run
(Low Voltage only)
C. 9 Leads; Dual Voltage & Voltage Ratio 1 to 2, Wye Connected
C-2 Part Winding Start

C-1 Across the Line Start & Run
(Low Voltage only)
D. 9 Leads; Dual Voltage & Voltage Ration 1 to 2, Delta Connected
D-2 Part Winding Start

D-1 Across the Line Start & Run
(Low Voltage only)
E. 12 Leads, Dual Voltage
E-1 Across the Line Start & Run
E-2-1 Wye Start & Delta Run (Low Voltage only)
E-2-2 Wye Start & Delta Run (High Voltage only)

E-3 Part Winding Start (Low Voltage only)
*Important: For Part Winding Start, M2 contactor should be closed within two (2) seconds
after M1 contactor is closed.
Only 4 pole and above (e.g., 6P, 8P ) motors are satisfactory for Part Winding
Start at low voltage.
START UP
1. Disconnect load and start motor. Check direction of rotation. If rotation must be changed,
ALLOW THE MOTOR TO STOP COMPLETLEY. Interchange any two leads of a three-
phase motor.
2. Connect load. The motor should start quickly and run smoothly. If no, shut power off at
once. Recheck the assembly including all connections before restarting.
3. If excessive vibration is noted, check for loose mounting bolts too flexible motor support
structure or transmitted vibration from adjacent machinery. Periodic vibration checks
should be made; foundations often settle.
4. Operate under load for short period of time and check operating current against nameplate.
TESTING
If the motor has been in storage for an extensive period or has been subjected to adverse
moisture conditions, it is best to check the insulation resistance of the stator winding with a
megometer. Depending on the length and conditions of storage it may be necessary to
regrease or change rusted bearings.
If the resistance is lower than one megohm the windings should be dried in one of the following
two ways:
1. Bake in oven at temperatures not exceeding 194¡F until insulation resistance becomes
constant.
2. With rotor locked, apply low voltage and gradually increase the current through windings
until temperature measured with a thermometer reaches 194¡F. Do not exceed this
temperature.
MAINTENANCE
INSPECTION
Inspect motor at regular intervals. Keep motor clean and ventilation openings clear.
LUBRICATION
1. Frame 143T-256T: Double shielded and pre-lubricated ball-bearing motors without grease
fittings and don t need relubrication, except on MAX-E1¤ and MAX-E2¤ products which
have regreasable features.
2. Frames 280TS, 320-449TZ(TS): Motors having grease fittings and grease discharge
devices at brackets. Motors are shipped with grease for initial running. It is necessary to
relubricate anti-friction bearing motors periodically, depending on size and type of service.
See Table 2 to provide maximum bearing life. Excessive or too frequent lubrication may
damage the motor.
TABLE 2
Standard Severe Extreme

Horsepower
Conditions Conditions Conditions
1 Thru 30 Hp, 1800 rpm and below 7 years 3 years 180 days
40 Thru 75 Hp, 1800 rpm and below 210 days 70 days 30 days
100 Thru 150 Hp, 1800 rpm and below 90 days 30 days 15 days
1 Thru 20 Hp, 3600 rpm 5 years 2 years 90 days
25 Thru 75 Hp, 3600 rpm 180 days 60 days 30 days
100 Thru 150 Hp, 3600 rpm 90 days 30 days 15 days
Note:
A. Standard conditions: 8 hours operation per day, normal or light loading, clear and 40¡C
ambient conditions.
B. Severe conditions: 24-hour operation per day or light shock loading, vibration or in dirty
or dusty conditions.
C. Extreme conditions: With heavy shock loading or vibration or dusty conditions.
D. For double shielded bearings, above data (lubrication frequency) means that the
bearing must be replaced.
3. Be sure fittings are clean and free from dirt. Using a low-pressure grease gun, pump in the
recommended grease until new grease appears at grease discharge hole.
4. Use the ALVANIA R3 grease or equivalent lithium based grease unless special grease is
specified on the nameplate.
5. If relubrication is to be performed with the motor running, stay clear of rotating parts. After
regreasing, allow the motor to run for ten to thirty minutes.
RENEWAL PARTS
1. Use only genuine TECO-Westinghouse renewal parts or as recommended by TECO-
Westinghouse Motor Company.
2. When you order renewal parts please specify complete information to TECO-Westinghouse
office/agent such as type, frame no., poles, horsepower, voltage, series no., quantity, etc.
FOR FURTHER INFORMATION PLEASE CONTACT

TECO-WESTINGHOUSE MOTORS (CANAD) INC.
SALES OFFICE: Edmonton, AB (780) 444-8933

Calgary, AB (403) 640-2063
Vancouver, BC (604) 273-7202
Cambridge, ON (519) 624-1616
Lachine, PQ (514) 636-8964
STANDARD WARRANTY
STANDARD WARRANTY FOR
TECO-WESTINGHOUSE MOTORS
All TECO-Westinghouse brand stock motors sold by TECO-Westinghouse Motors (Canada) Inc.
are warranted to be free of defects in material and workmanship for a period of 36 months from
the date of sale (Advantage Plus 5 Year Warranty - IEEE 841 only).
This warranty is conditioned upon the installation, operation, and maintenance of the motors
in accordance with TECO-Westinghouse Motors (Canada) Inc. recommendations or standard
industry practice and the motors have at all times being operated or used under normal
operating conditions for which they were designed.
TECO-Westinghouse Motors (Canada) Inc. shall, at its sole option and expense, either repair
or replace, F.O.B. TWMI warehouse, any such motor or part which is defective within the
warranty period.
In the event of a warranty claim, TECO-Westinghouse Motors (Canada) Inc. must be notified
promptly following any motor failure. The motor shall be sent to a TECO-Westinghouse Motors
(Canada) Inc. authorized service center for diagnosis on the cause of failure. If the failure is due
to defective material and/or workmanship, TECO-Westinghouse Motors (Canada) Inc. will
replace or repair the defective motor or part.
The repair or replacement of defective material and workmanship shall constitute complete
fulfillment of TECO-Westinghouse Motors (Canada) Inc. warranty liability whether the warranty
claims are based on contract, tort (including negligence and strict liability), or otherwise.
THERE ARE NO OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING ANY
IMPLIED WARRANTY OF MERCHANTABILITY AND FITNESS FOR PARTICULAR
PURPOSE, AND ALL WARRANTIES ARISING FROM COURSE OF DEALING AND
USAGE OF TRADE. UNDER NO CIRCUMSTANCES, SHALL TECO-WESTINGHOUSE
MOTOR COMPANY BE LIABLE FOR ANY SPECIAL, INDIRECT, INCIDENTAL, OR
CONSEQUENTIAL DAMAGES, INCLUDING FREIGHT.
STANDARD TERMS & CONDITIONS
STANDARD TERMS AND CONDITIONS FOR
TECO-WESTINGHOUSE MOTORS
TERMS OF PAYMENT
NET 30 days.
STANDARD FREIGHT POLICY
Shipping terms are F.O.B. point of shipment with freight prepaid and allowed to the first
destination serviced by common carrier,provided order value is greater than $3,500.00 CAD.
The company reserves the right to determine the point of origin of shipment,select the method
or transportation and the routing of shipment. If the customer requests a specific carrier for a
prepaid andallowed shipment, they agree to pay the difference in transportation costs.
If the order value is less than $3,500.00 CAD, freight charges will be collect. In this case,
the customer must advise the preferred transportation company to be used for shipment.
If shipping instructions are not specified on the order, all goods will be shipped with the
carrier of our choice freight prepaid and charge with an additional administration fee.
Regardless of order value, freight is collect for all shipments other than to distributor
warehouse or local trade area. On special orders requiring “RUSH” or “AIR” shipping,
the customer agrees to pay for all transportation charges, collect or prepaid and charge
with an additional administration fee.
* Shipments to the United States of America
Unless otherwise agreed in writing, all customs clearance, brokerage charges, U.S. duty,
and Temporary Import Bonds will be the sole responsibility of the purchaser or the consignee.
Should the purchaser or the consignee not have a U.S. Customs Broker in place, we will
clear shipments on a prepaid and charge basis with an additional administration fee.
STANDARD TERMS & CONDITIONS
LOSS, DAMAGE OR DELAY
In the event a shipment arrives damaged, it is the responsibility of the consignee to make a
notation such as “POSSIBLE DAMAGE” or “FREIGHT IS DAMAGED” on the Freight Bill of
Lading at the point of delivery prior to the delivering driver’s departure. This will provide a
basis for the claim that must be filed with the transportation company. The consignee must
notify TECO-Westinghouse immediately of any said damages and provide photographs
when possible. TECO-Westinghouse will assume all responsibility for filing claims for prepaid
shipments provided all necessary steps have been followed. Claims for all collect shipments
will ultimately be the responsibility of the consignee. Please be advised if the consignee
accepts delivery of any damaged freight and fails to note this on the Freight Bill of Lading at
point of delivery, a claim will not be filed as the consignee has accepted all commodities
received in good condition with his signature on the Freight Bill of Lading.
Shipping dates are approximate and are based on prompt receipt of all necessary information
and approvals from the purchaser. TECO-Westinghouse will not be liable for delay in perform-
ance due to floods, strikes or other labour difficulties, acts of God, or acts of any governmental
authorities. In the event of delay in performance due to the above noted causes, the date of
delivery or time of completion will be postponed by such period of time as may be reasonably
necessary to compensate for the delay.
RESTOCKING POLICY
All returned goods are subject to prior approval and must be accompanied by a return material
authorization (RMA) number.
These goods must be returned within 30 days, freight prepaid, in resalable condition and in
original packaging. A restocking charge may be applied.
PRICING
Contact your TECO-Westinghouse representative for appropriate discount.
* Pricing subject to change without notice.

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OPERATION and

This document contains proprietary and National Oilwell

3. PRESERVATION & INSTALLATION 11

8. LUBRICATION & MAINTENANCE 31

9. GENERAL ROLLER CHAIN 41

11. TORQUE GUIDE FOR BOLTS 51

14. RECOMMENDED SPARES 59

15. VENDOR INFORMATION 61

This page left intentionally blank.

1.1 Manual Overview & Scope

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

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2.1 Safety Terms & Conventions

NOTE: This provides information necessary to complete the procedure properly or

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. PRESERVATION & INSTALLATION

4.1 Technical Specifications

Maximum Horse Power Rating 3000 hp @ 1,600 rpm

Total Weight of Assembly (est.) 112,451 lbs. (51,007 kg)

4.2 Power Flow Chart

AWILCO D3000AC Drawworks

14 LINES 14 LINES 14 LINES 14 LINES

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

4.3 General Description

4.3.2 Chains and Sprockets

(For more information, refer to Section 10 of manual.)

The drawworks is equipped with a disc type braking

The disc brake system employs two discs, one disc

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

4.3.6 Drum Design

The D3000AC Drawworks is equipped with a

Photo: The D3000AC Drawworks drum.

5.1 Pre-Starting Instructions

Make the following checks before initial starting of the drawworks:

3. Grease all points equipped with alemite hydraulic grease fittings.

4. Motors - lubricate in accordance with instructions furnished by the manufacturer.

8. Install all safety guards.

10. Replace GE motors locking bolts with the supplied bolting.

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6.1 Brake Caliper Remote Operation

Refer to drawing 9108X000 for these operations.

6.2 Brake Caliper Manual / Emergency Operation

Refer to drawing 9108X000 for these operations:

In the event of an emergency when the hydraulic pumps are working:

3. Switch all six manual / remote valves

Photo: D3000AC Drawworks Valves

WARNING: Disc temperature must be monitored during any

1. Ensure the emergency bleed valve (H) is closed.

NOTE: It may be desirable to close one accumulator

6. Once 3,000 psi is achieved, flip all six remote/manual

Photo: D3000AC Drawworks Hand Pump

6.3 Brake Caliper Delay System

Photo: D3000AC Flow Control Valve is located in the

6.4 Disc Brake Caliper Burn Procedure

Refer to Drawworks Control System Operation Manual, document number:

6.5 Brake Testing Procedure

Refer to Drawworks Control System Operation Manual, document number: