LDW1000K-104 Operating and Maintenance Manual

LDW1000K Drawworks
Operating, Maintenance,
Parts, and Accessory
Manuals
for
Rowan
LDW1000K-104
6500 Brittmoore, Houston, Texas 77041 PO Box 41343, Houston, Texas 77241-1343
832-872-6500 1-866-946-5333 FAX: 832-782-6627
www.letourneau-inc.com/drilling pumps@let-tech.com
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Table of Contents
LDW1000K Operating and Maintenance Manual
Parts Catalogue
Group Number Description Drawing
00-00 Group Number Identification (No BOM) 515-0152
01-01 Main Drum and Shaft 515-0018
01-02 Main Shaft. Drum & Brake Disc 515-0000
01-03 Turnback Roller Assembly 515-0135
03-01 Air Schematic (No BOM) 515-0147
05-07 Drawworks Lubrication 515-0261
05-08 Schematic-Lube Oil (No BOM) 515-0243
07-01 Disc Brake Assembly, Main Drum 515-0073
12-01 Drawworks Frame & Skid 515-0001
12-02 Drawworks Guards & Covers 515-0044
15-01 Gear Drive 515-0260
15-03 Electrical Interconnect Assembly 515-0352
16-01 Skid Piping 515-0088
58-01 Auxiliary Brake, Eaton 436 515-0030
58-02 Auxiliary Brake Piping 515-0059
Drawworks Tiedown 515-0084
Accessory Manuals
Lube Pump EP417
Motor EM110
Heat Exchanger EE102
Motor EM112, EM113
Disc Brakes EC271
Auxiliary Brakes EB593
Pressure Transmitter ET150
832-872-6500 1-866-946-5333 FAX: 832-782-6627
LDW1000K Drawworks
Operating and Maintenance

Manual
832-872-6500 1-866-946-5333 FAX: 832-782-6627
LTI Model K Drawworks
Table of Contents
Buyer and Operator Responsibility ......................................................................................................................1
Integration of Control System .............................................................................................................................................. 1
Introduction ............................................................................................................................................................2
Accessories and Safety Equipment....................................................................................................................................... 2
Servicing Procedures ............................................................................................................................................................ 2
Drawworks Overview.............................................................................................................................................3
Testing .....................................................................................................................................................................3
Utilities Requirements............................................................................................................................................4
Installation ..............................................................................................................................................................4
Inspection ............................................................................................................................................................................. 4
Support Structure.................................................................................................................................................................. 4
Mounting .............................................................................................................................................................................. 5
Assembly .............................................................................................................................................................................. 6
Lubrication..............................................................................................................................................................7
Oil......................................................................................................................................................................................... 7
Grease ................................................................................................................................................................................... 7
Lubrication Summary ...................................................................................................................................8
Startup.....................................................................................................................................................................9
Startup Checklist................................................................................................................................................................... 9
Startup Procedure ............................................................................................................................................................... 10
Operation ..............................................................................................................................................................11
Function Check................................................................................................................................................................... 11
Drawworks Control System................................................................................................................................................ 11
Emergency Brake System................................................................................................................................................... 11
Operating Pressures ............................................................................................................................................................ 12
Operating Temperatures ..................................................................................................................................................... 12
Emergency Operation (Loss of Air Pressure)..................................................................................................................... 14
Safe Operating Practices..................................................................................................................................................... 14
Maintenance..........................................................................................................................................................15
Brake System...................................................................................................................................................................... 16
Weekly Brake Disc Inspection and Cleaning ..................................................................................................................... 17
Auxiliary Brake Alignment ................................................................................................................................................. 18
Contamination .................................................................................................................................................................... 20
Emergency Air Storage....................................................................................................................................................... 20
Drive System ...................................................................................................................................................................... 20
Bearings.............................................................................................................................................................................. 21
Spacers................................................................................................................................................................................ 22
Hubs.................................................................................................................................................................................... 22
Preservation and Storage.....................................................................................................................................23
Location.............................................................................................................................................................................. 23
Cleaning.............................................................................................................................................................................. 23
Preservation ........................................................................................................................................................................ 23
Storage................................................................................................................................................................................ 23
Torque Specifications...........................................................................................................................................24
1
Warning
Carefully read and understand the operation and
maintenance instructions for the drawworks, drive motors,
and controls. Failure to follow these instructions may
cause serious equipment damage, severe personal injury,
or loss of life.
Buyer and Operator Responsibility

It is the buyer’s and operator’s responsibility to obtain proper instruction and to train personnel in the safe
operation and maintenance of the equipment. The buyer and operator must obtain instruction in safe
operation and maintenance of the drawworks, motors, controls, and any accessories and safety devices
required to safely operate this equipment and to complete the application of this product.
Integration of Control System

The owner, operator, or buyer of this drawworks needs to know that the proper integration of the
controller system with the drawworks is critical to the safe operation of the Letourneau
Technologies™ (LTI) Model K drawworks in accordance with its specifications.
Failure to properly integrate the chosen control system with the Model K drawworks can result in
severe property damage, personal injury, or death.
Integration of the Model K drawworks with the chosen control system is the responsibility of the
manufacturer of such control system, whomever that may be, and LTI is neither responsible nor liable
for any damage or injuries that may result from use of the drawworks, where the drawworks and the
chosen controller system have not been properly integrated.
In addition, even if the drawworks is properly integrated with the control system chosen by the owner,
operator, or buyer, malfunctions of the control system can still result in unpredictable operation or
failure of the drawworks, which in turn, can result in severe property damage, personal injury, or
death. The functionality of the chosen control system is the responsibility of the manufacturer of such
control system, whomever that may be, and LTI is not responsible or liable for any damage or injuries
that may result from the drawworks because of a malfunction of the control system.
Finally, even if the drawworks is properly integrated with the control system selected by the owner,
operator, or buyer and the control system functions properly, errors in the operation of such control
system—or the people operating such controller system other than in strict conformance with the
control system manufacturer’s instructions—can result in unpredictable operation or failure of the
drawworks, which also can result in severe property damage, personal injury or death.
Training operators to properly use the chosen control system is the responsibility of the manufacturer
of such control system. The actual operation of such control system is the responsibility of the drilling
contractor or other person running drilling operations. LTI is not responsible or liable for any damage
or injuries that may result from the drawworks, either as a result of incorrect use of the control system
or as a result of the control system being used other than in strict conformance with the manufacturer’s
instructions.
1
Introduction
This manual is produced as a guide for normal operations of LTI equipment. This manual will not detail
all aspects of installation, operation, and maintenance of the drawworks because of the many factors that
contribute to its proper function and operation. When situations that are not discussed occur, they should
be referred to LTI personnel for detailed instruction.
Maintenance, beyond routine service, requires adequate space with dedicated lifting equipment and
specialized tools, and it can be more efficiently performed in a facility equipped for such service..
Improvements in purchased components, design, materials, or production methods may be made from
time to time. These changes may generate differences between this manual and the actual product. LTI
reserves the right to make these changes without incurring any liability beyond that stipulated in the
purchase contract.
A serial number is assigned to each drawworks. All inquiries concerning the drawworks must include this
serial number. The serial number is on a nameplate located on the driller’s side of the drawworks frame.
The version of the drawworks being provided can be determined by reviewing the final assembly in the
drawing reference section in the back of this manual.
Accessories and Safety Equipment

This product is supplied in accordance with the buyer’s specifications and does not necessarily include
all accessories and safety devices required to put this product into operation. Power equipment and
safety devices such as, but not limited to, motors and controls, rotating equipment guards, chains,
cables, and wrenches are available from other suppliers.
Servicing Procedures
Use proper procedures when using or servicing this machinery. Use approved methods, materials, and
tools. This product and many of its parts are heavy or difficult to handle. Plan lifts carefully and use
proper lifting gear to avoid severe personal injury. Provide safe supports for all equipment and parts.
• Shut down equipment and disconnect power during maintenance.

• In order to prevent accident and injury during maintenance or inspection, shut down the equipment
and the disconnect the power. This will include the electrical and air power. Air tanks and spring-
operated devices should be drained or released before starting service. Employ good and safe
mechanical practices when making maintenance repairs and adjustments.
• Lubricate the drawworks before starting operation.
• Prior to shipment, all lubricant is drained. Before starting operation, the drawworks must be
lubricated as outlined in the lubrication section.
2
Drawworks Overview
The version of the drawworks being provided can be determined by reviewing the final assembly in the
Parts Catalogue section of this manual
The drawworks is a single, skid-mounted unit with the following:
• A hoisting drum mounted on a heavy-duty shaft with two brake discs for the spring-and air-operated
brake calipers
• The shaft is supported by two large self-aligning roller bearings with provision for a splined hub to
connect an optional auxiliary brake...
• Wire rope
The diameter of the wire rope is determined by the end user.
• Variable frequency drive motors coupled to a constant engagement gearbox.
The motors are capable of raising and lowering the load when operated by the proper control system
and connected to sufficient power dissipation equipment.
• A transmission shaft coupling the gearbox to the drum shaft
• Spring-actuated, air-returned emergency/parking brake calipers
The spring brakes are applied by actuating the emergency stop button on the driller’s console, by loss
of electric power, or by various functions of the operating system.
• An optional auxiliary brake coupled to the drum shaft through a manually shifted splined coupling.
Testing
NOTE:
The electrical control system is not tested.
Prior to shipment, LTI personnel functionally tested the drawworks—and all related mechanical
components—for an extended period to verify that the drawworks and components operate in accordance
with the stated requirements.
• The complete drawworks is aligned and all locating pins, or chocks, are secured.
• All mechanical and air control systems are operated and functionally checked.
• The lubrication system, air system, and brakes are pressure checked and inspected.
• The brake discs and pads are burnished, and the brake torque is checked to ensure full braking
capability.
• Guards, covers, and inspection openings are checked to ensure that the proper safety measures are in
place. These components serve as enclosures for the gearbox, provide safety protection for personnel,
and prevent foreign material from entering the working parts. Guards, covers and doors should be
closed and in place when the drawworks is operating and should only be opened for drawworks
service.
3
Utilities Requirements
Air and water connections, marked with appropriate nameplates, are located in the drawworks skid.
For detailed information, see the Utility Requirements section of this manual. .
Installation
Recommendations for rig-up, operation, and maintenance of LTI drilling equipment are based on the
knowledge and experience of LTI engineers and operating personnel. Following these
recommendations will result in better overall rig performance and increased equipment operating life.
Inspection
Check the drawworks at each rig-up or rig-down.
• Inspect the drawworks to ensure that all components are in place and undamaged.
• Make sure that all attaching bolts are tight.
• Check for wear and or damage of key components and replace if necessary.
Damage (bending) of the skid can cause misalignment resulting in serious wear or damage to the
operating parts. Failure to repair damage to the skid can lead to dangerous operating conditions
unless corrected.
• Make sure that all covers are in place and secured.
• Inspect the brake system every day for any corrosion that might prevent or obstruct the
movement of any brake parts.
Support Structure
The drawworks relies on the support structure to provide the rigidity required to prevent deflection
during operation. The support structure must be flat and correctly sized to provide the necessary cross
section and rigidity. Contact LTI for assistance.
The drawworks’ weight and operating loads are distributed in the skid mounting points under the
drawworks, the gearbox, the drive motors, and the auxiliary brake. See the drawworks tie-down
information in the Parts Catalog section of this book.
4
Mounting
Caution
The drawworks cannot be aligned until it is properly
attached to the substructure. If an alignment is attempted
before it is attached to the substructure, the drawworks’
components can be pulled out of alignment, which could
cause an unsafe condition, erratic operation, and
premature wear.
Note:
On permanent installations (offshore rigs), the drawworks
beams may be welded to the substructure at the same
locations.
1. Align the drawworks with the centerline of the well in accordance with the foundation location
drawing.
2. Secure the drawworks to the substructure, either with bolts or clamp plates, using the
recommended locations on the front and rear skid beams of the drawworks frame.
i. under each drawworks side plate,
ii. under the auxiliary brake,
iii. under the gearbox,
iv. at the skid ends.
3. Use stops and location blocks to help relocate the drawworks after each move.
4. See the drawworks tie-down drawing for tie-down locations.
If substructure support beams are not flat and true, shim the contact areas between the drawworks skid
beams and the substructure beams.
Note:
Take care not to distort the drawworks frame during tie-
down. The drawworks was manufactured and aligned
while resting on a true flat surface.
5
Assembly
After stringing the block,
1. remove the brake cover from the side of the main drum containing the wireline dead end slot.
2. Slide the end of the line through the slot provided in the drum flange.
3. Slip the main drum wireline clamp over the end of the line, and secure the bolts attaching the
clamp. (See the Torque Specification table for recommended torque specification)
4. Make sure that a length of line equivalent to 2- or 3-line diameters extends beyond the clamp.
5. Slide the line back though the drum flange until the clamp is properly seated in the socket of the
drum flange.
6. Install a line clamp retainer on each side of the line clamp.
7. Replace the brake cover.
When setting the deadline anchor, be sure to leave 10- to 15-wraps (coils) of line on the drum when the
block is in the lowest operating position.
If the drawworks is installed on an offshore drilling rig with a heave compensator, leave extra line on
the drum to allow for the heave compensator requirement.
The drawworks is shipped with all the connection points for control and service lines capped or
plugged to protect them from damage, dirt, or other debris. (This should be done whenever the
drawworks is moved.)
Warning
Improper control connections can cause a serious or
deadly operating condition that could result in serious
injury to personnel or equipment
1. Remove the caps protecting the control and service line connection points.
2. Inspect the ends of the lines, and remove any debris that may have entered.
3. Make sure that that these connections are properly made up to prevent leaks and to provide proper
control.
The rig system will compensate for a moderate leakage of air or water, but the leakage will cause
an unnecessary demand on the rig supply.
4. Connect the drawworks to the driller’s console and to other rig systems as required.
5. Be sure the air and electrical connections are properly connected and sealed to ensure proper and
safe operation
6. Connect electrical service in accordance with the appropriate codes.
Loose or improperly made electrical connections could cause improper signal transmission, fire, or
explosion.
7. Verify that
all connections properly made;
the covers are in place;
all bolts are tight and properly torqued.
6
Lubrication
The lubrication system is made up of an oil pressure and cooling system for the gearbox and a manual
T
grease system for the remainder of the components. The oil filter is located on the well side (WS) of
the skid beneath a main drive motor, and it is positioned above the lube oil level for easy replacement.
The pressure pumps and motors are located under removable floor plates adjacent to the drawworks
side plates on the Driller Side (DS). See the Lubrication Summary table for more information.
Oil
After the drawworks as been assembled, fill the gearbox sump with 74 gal of ANSI/AGMA 9005-E02,
ISO VG220EP lubricating oil. The viscosity index of the oil should be 160 or greater.
1. After the sump has been filled, start the first lubrication pump..
2. Allow the pump to run for a few minutes and then check the sump oil level. The dipstick is located
at the DS end.
3. Add oil through the dipstick pipe if required to maintain the correct level.
4. Observe the pressure gage on the DS of the gear case; it should read at least 20 psi.
5. Stop the first pump, and start the second pump.
6. Repeat the pressure check for the second pump.
7. Verify that the operating pump is functioning within acceptable limits each day and that both
pumps are functioning within acceptable limits each week.
Note:
Do not run both pumps simultaneously.
Grease
On initial startup, the drum shaft bearings, auxiliary brake shaft bearings, and auxiliary brake shifter
grease points should receive three to four shots from a standard grease gun. Check the splines of the
auxiliary brake coupling. Apply EP#4 grease as necessary.
Grease all moving and exposed parts on the Johnson brakes monthly, or sooner if the parts are
corroded. Do not get any grease on the brake pads. Do not over grease. Wipe off any excess grease,
because it could contaminate the brakes.
This is particularly important in saltwater environments. In non-saltwater environments, operators

should base the lubrication schedule on usage to maintain the brakes in good working order.
7
Lubrication Summary
Lubrication
Lubrication
Point or Lubricant Remarks
Schedule
System
NLG I #2 Premium Two or three shots from

Daily Shaft Bearings
Sodium Grease a standard grease gun
Auxiliary Brake NLGI #2 Premium Two or three shots from

Daily
Shaft and Shifter Sodium Grease a standard grease gun
If contamination is found,
Daily drain and replace.
ANSI/AGMA 9005-EO2
(Check Gear Box (If no contamination is
ISO VG220EP
level) found, drain and replace
annually.)
Auxiliary Brake
Monthly Connection EP #4 Grease Apply by hand
splines
Do not over grease. Wipe

off any excess. Excess
grease can contaminate
the brakes.
Disc Brake NLGI #2 EP Premium Warning

Monthly* Calipers Lithium Grease Do not get any grease on
the brake pads. Do not
over grease. Wipe off any
excess grease, because
it could contaminate the
brakes.
Every 6 Flexible NLGI #2 Premium Remove and replace old

months Couplings Sodium Grease grease.
*This is particularly important in saltwater environments. In non-saltwater environments, operators should base the lubrication
schedule on usage.
Table 1 Lubrication Summary
8
Startup
Startup Checklist
Spool the wire rope on the drum before completing the startup checklist.
• Verify that all covers, guards, etc. are in place and there is no loose equipment or tools around
the drawworks.
• Verify that all utility connections are properly made up, and that they are tight and leak free.
• Verify that the drawworks has been lubricated and the gearbox sump is properly filled with oil.
• Determine if the auxiliary brake will or will not be engaged for startup. Take appropriate action
with the coupling shifter. Lock shifter.
• Turn on the air to the drawworks. Verify that a minimum pressure of 110 psi is available.
• Turn on the first lube pump. Verify that the minimum pressure of 20 psi is being met. See
Lubrication Instructions section. If the drawworks has a second lube pump, then turn off the first
pump and verify the pressure for the second pump.
Warning
Do not attempt to operate the drawworks unless all brakes
are operating properly. Brakes should move smoothly and
without hesitation. Service the brakes if the brakes fail to
operate correctly. Operating the drawworks with faulty
brakes could cause serious injury to personnel and
equipment.
• Push the emergency stop.

• Verify that the brake caliper pressure drops to zero (0).
• Verify that all brake calipers are closed.
• Pull the emergency stop button out, and verify that the pressure returns to normal and that the
brakes open.
• Apply the auxiliary brake, if available, and verify that the pressure comes up smoothly to
drawworks air pressure and that the brake discs close and open smoothly and evenly.
• Verify that all brake discs move smoothly with no hesitation.
• Service the brakes if they do not operate smoothly without hesitation.
• Verify that cooling water is available for the gearbox heat exchanger and the auxiliary brake.
9
Startup Procedure
Warning
Always make sure that motor power is available before
releasing the emergency brakes. Failure to do so can cause
the loss of load control, major equipment damage, severe
personal injury, or loss of life.
Verify basic control functions as follows:
• Bring the main drive motors on line and make sure that the motor cooling system is operational.
Warning
Care should be taken when verifying the emergency stop
function. Applying the brakes will quickly generate strong
shock loads that could cause serious injury to personnel
and equipment.
• Test the emergency brake function.

• Actuate the hoisting control lever to rotate the drum very slowly.
• Push the emergency stop button. The drum should stop immediately.
• Pull the emergency stop button. The drum should start to rotate smoothly.
• Actuate the hoisting control lever and rotate the drum to raise and lower the traveling block.
• Make sure that the drum rotates smoothly when it is operating.
• Make sure that the shift from the hoist function to the lower function is smooth and
without excessive noise.
10
Operation
WARNING
Qualified and trained personnel must control this
equipment for safe operation. Insufficient training and
failure to read and understand the operation and
maintenance instructions can cause major equipment
damage, serious personal injury, or death.
Function Check
Verify that the emergency stop function and interlocks are functional both before a trip and on a
weekly basis. Use the same procedure detailed in the Startup section.
Drawworks Control System

The drawworks control system is specified by the buyer and is not manufactured by LTI. See the
control manufacturer’s operating instruction. Various pressure, temperature, and position sensors in the
drawworks provide information to the control package.
Emergency Brake System

The emergency brake is released by air pressure. A clean, dry air supply at the correct pressure is
essential to the operation of the drawworks. Monitor the drawworks air pressure gage on a regular
basis.
A reduction in the air pressure will adversely affect the emergency brake and can cause partial
engagement of the brake. Operation with the brake partially engaged will seriously overheat the brake
and can harm the calipers and the discs.
11
Operating Pressures
Air Pressure
• Drawworks Air Pressure provides the main system air pressure in the drawworks. This pressure
should range from 95 psi to 130 psi. If the pressure falls below this, the emergency brake
calipers may partially engage, overheat, and cause serious damage to the brake.
Water Pressure (Optional Equipment)

• Auxiliary Brake Water Pressure provides the cooling water pressure to the optional auxiliary
brake. This pressure should range from 30 psi to 45 psi. If the pressure falls below 30 psi, the
coolant flow through the auxiliary brake will be reduced, and the braking load must be reduced,
or the brake will overheat and cause damage to the brake discs.
• Gearbox Water Pressure provides the cooling water pressure to the gearbox heat exchangers.
This pressure should range from 30 psi to 100 psi. If the pressure falls below psi, the cooling
capability of the heat exchanger will be reduced, and the gearbox may overheat.
Oil Pressure
• Gearbox Oil Pressure gage provides the gearbox lubrication oil pressure. The pressure should
be 20 to 40 psi. If the pressure falls below 20 psi, the cooling and lubrication capabilities of the
lubrication system will be compromised. Continued use of the drawworks could damage the
gearbox.
Operating Temperatures
Water Temperature
• Inlet water temperature for the optional auxiliary brake (Eaton) should be 50°F to 70°F. If the
temperature rises above 70° F, the braking load must be reduced or the brake will overheat and
cause damage to the brake discs.
• Inlet water temperature for the gearbox oil cooler should be 90°F to 100°F. If the temperature
rises above 100°F, the cooling and lubrication capabilities of the lubrication system will be
compromised. Continued use of the drawworks could damage the gearbox.
Oil Pressure
• Gearbox oil temperature should be maintained in the 100°F to 140°F range. If the temperature
rises above 140°F, the cooling and lubrication capabilities of the lubrication system will be
compromised. Continued use of the drawworks could damage the gearbox.
The auxiliary brake inlet water temperature and the gearbox oil temperature should be monitored and a
warning issued if the temperatures exceed the levels shown above.
12
Pressure and Temperature Chart

Category Description Pressure Temperature Comments
(psi) (°F)
Air
pressure
Drawworks The main system 95–130 NA Pressure
air pressure in the If the pressure falls below this, the
drawworks emergency brake calipers may
partially engage, overheat, and cause
serious damage to the brake
Water
Auxiliary The cooling water 30–145 50–70 Pressure
Brake pressure to the If the pressure falls below 30 psi, the
auxiliary brake coolant flow through the auxiliary
brake will be diminished, and the
braking load must be reduced, or the
brake will overheat causing damage
to the brake discs.
Temperature
If the temperature rises above 70°F,
the braking load must be reduced, or
the brake will overheat and cause
damage to the brake discs.
Gearbox The cooling water 30–100 90–100 Pressure
pressure to the If the pressure falls below 30 psi, the
gearbox heat cooling capability of the heat
exchangers exchanger will be reduced, and the
gearbox may overheat.
Temperature
If the temperature rises above 140°F,
the cooling and lubrication capabilities
of the system will be reduced, and the
gearbox could be damaged.
Oil
Gearbox The gearbox 20–140 100– 140 Pressure
lubrication oil If the pressure falls below 20 psi, the
pressure cooling and lubrication capabilities of
the lubrication system will be
compromised. Continued use of the
drawworks could damage the
gearbox
Temperature
If the temperature rises above 140° F,
the cooling / lubrication capabilities of
the lubrication system will be
compromised. Continued use of the
drawworks could damage the
gearbox.
Table 2 Pressure and Temperature Chart
13
Emergency Operation (Loss of Air Pressure)

In the event of air supply failure, the emergency brake calipers will set and lock the hoisting drum. If
the load needs to be lowered to a safe position, the emergency brakes can be released with air pressure
stored in the drawworks.
To release the emergency brakes, operate the emergency lowering valve. This operation should be
performed carefully, because the stored air volume is limited. In an extreme emergency, the brake
calipers can be released mechanically. Consult the operating instructions in the brake caliper user’s
manual for instructions.
Safe Operating Practices

• Know the load being lifted.
• Do not exceed the lifting capacity of the drawworks.
• Use the correct reeving for the load.
• Be sure that the brakes, hoist, hoisting gear, and controls are properly serviced and inspected at
the beginning of each tour and before starting each trip.
• Move loads smoothly without sudden starts or stops.
• Know the position of the traveling block in the derrick at all times.
• Do not allow personnel to ride the hoisting equipment.
• Check and service the hoist both when a load approaching the rated load is anticipated and after
the load is removed.
• Do not leave the drawworks controls unattended with a suspended load. Set the load on a firm
support (e.g., a casing spider or slips in the rotary table).
• Do not use the motor to leave, or suspend, the traveling block for an extended period. Set the
emergency brake.
• Make sure that the brake is holding the load before releasing the motor power.
14
Maintenance
WARNING
Carefully read and understand the operation and
maintenance instructions. Failure to follow these
instructions could cause serious equipment damage,
severe personal injury, or loss of life.
This manual is supplied as a guide for normal operation. Because many factors contribute to proper
operation, and because installations vary, not all situations are covered by this manual. Please contact LTI
for specific situations that are not covered by this manual.
This product and many of its parts may be heavy or difficult to handle. Plan lifts carefully and use proper
lifting gear to avoid severe personal injury. Provide safe supports for all components.
Maintenance Procedures Before Starting Operations

• Fill the gearbox sump with lubricant before starting. All fluids are drained from the equipment
prior to shipping.
• Make sure that the oil pressure, the air pressure, the cooling water pressure, and the cooling
water volume are satisfactory.
• Lubricate each grease fitting on the unit.
Warning
Shut down the equipment and disconnect air and electric
power from the unit before starting repair or maintenance.
In order to prevent personal injury during maintenance or
inspection the equipment should be shut down with the
electrical and air power disconnected. The spring-operated
brake calipers should be engaged. If the calipers must be
open (released) during maintenance, the springs must
caged before starting service. Use good safety and
mechanical practices when making maintenance repairs
and adjustments.
Maintenance After Moving

When the drawworks is moved between locations, the following maintenance procedures should be
performed. Repair or replacement of worn or damaged items will increase the life and efficiency of the
unit and improve safety for personnel.
• Check for missing or loose bolts, and tighten or replace as needed.

• Check, repair, and adjust the brake discs and pads as needed.
• Clean and replace all filters (both air and oil) as needed.
• Check, clean ,and repair the mechanical shifter on the auxiliary brake to ensure it is operating
correctly.
15
• Inspect all hoses for wear, fraying, flattening, or kinking.

• Replace damaged hoses.
• Check the water supply system for the gearbox heat exchanger and auxiliary brake. Make sure
that sufficient water is flowing and that all connections are leak free. Repair as necessary.
• Check the main drum bearing housing bolts for loose bolts or movement. Tighten or replace.
• Check each grease line for flow and leakage. Make sure that grease is reaching the proper
bearing. Repair as necessary.
• Inspect the lube oil pumps and the motor couplings. Repair as necessary.
• Clean the gearbox breather.
Brake System
Warning
The braking system must be correctly adjusted and
maintained. Failure to perform regular maintenance and to
correctly adjust the brakes will effect the reliability of the
braking system and cause an unsafe operating condition.
The cylinders have a limited amount of travel. Lack of
proper adjustment can cause the cylinders to stroke more
than intended. Excessive air gap will reduce braking
capability and could cause complete loss of brake power
that could result in serious injury to personnel and
equipment.
Always secure the drawworks and the load before

performing maintenance on the brakes. Set the load on the
slips and support the traveling block.
The standard drawworks’ brake system consists of two drum-mounted discs with air-released, spring-
engaged emergency brake calipers and an optional air-engaged, water-cooled auxiliary brake. The
auxiliary brake is a disc brake connected to the end of the drum shaft by a manually operated splined
coupling. To operate properly the brake system must be properly adjusted and free of contamination.
Daily Maintenance
To ensure proper and safe operation, operators should inspect the brake system every day to make sure
that it is clean and free of contamination from dirt and corrosion. If the daily inspection finds any
contamination, dirt, or corrosion, the brake should be immediately cleaned to remove any
contamination or corrosion.
16
Daily Use
In addition to the daily maintenance inspection, operators should activate the Johnson brake system
several times a day. The Johnson brake functions as both an emergency brake and a parking brake. To
make sure that the brake system is functioning properly, operators should use the brake to park a load
for a short period.
Operators should also test the emergency brake function:
• Actuate the hoisting control lever to rotate the drum very slowly.
• Push the emergency stop button. The drum should stop immediately.
• Pull the emergency stop button. The drum should start to rotate smoothly.
When testing the brake system, operators must use safe operating procedures and be aware of the
Warnings and Cautions found in the LTI Drawworks Operating and Maintenance Manual.
Weekly Brake Disc Inspection and Cleaning

Emergency Brake
• Inspect and adjust the brakes on either a weekly basis, or more frequently as indicated by
experience.
• The operating clearance between each brake pad and the brake disc should be between 1/16 in.
and 3/32 in. Operating clearance should not exceed these dimensions.
• The brake pad clearance should be checked and adjusted weekly. During periods of heavy usage,
it should be checked more frequently.
17
Auxiliary Brake (Optional)

Water connections for this brake are located in the web of the main skid beam below the brake and
near the end of the skid. Operate and maintain the brake according to the manufacturer’s instructions.
See these instructions for coolant volume and pressure requirements..
Auxiliary Brake Alignment

1. Use a dial indicator to check the alignment of the auxiliary brake after installation. Make sure the
two spline hubs are concentric and axially aligned as shown below.
Fig. 1 Auxiliary Brake Alignment
2. Tighten the mounting bolts after the auxiliary brake has been aligned.
3. Verify that the splined hub shifting mechanism operates smoothly and that the locking feature
works in both the engaged and retracted position.
4. Improper operation indicates a problem with alignment. Recheck the hub-to-hub total indicator
runout (TIR) readings.
18
Adjustment Procedure
Warning
Always secure the drawworks and the load before
performing maintenance on the spring brakes. Set the load
on the slips. Support the traveling block.
See the Air Gap Adjustment Instructions in the brake service manual.
The following condensed instruction is provided for convenience and is not a replacement for the
instruction in the brake service manual.
1. Apply air pressure to release the brakes and to cage the actuators.
2. Remove the three pins that connect the actuator to the toggle link and the toggle link to the caliper.
3. Swing the caliper arms open to gain access to the actuator rod clevis.
4. Turn the actuator clevis counterclockwise to decrease the air gap.
5. The air gap can also be adjusted by turning the toggle yoke between the toggle lever and the
caliper arm after removing the toggle link pin and loosening the jam nut.
6. When the proper pad clearance is achieved, reassemble the components and tighten all nuts.
7. Apply air pressure and uncage the actuator.
8. Cycle the brake a few times and verify the air gap by pushing one shoe against the disc and
measuring the clearance on the other side of the disc.
9. Reset the centering screws to properly center the air gap. Check for adequate lateral float in the
pads.
10. Repeat these steps for each caliper.
Pad Replacement Procedure

Brake pads must be replaced when they are ¼-in. thick. Allowing further wear will result in
attachment rivets touching and scoring the disc. Loose debris packed in the grooves of the scored disc
will cause loss of brake capability.
A beveled edge indicates improper clearance between the pad and disc. Adjust the pad as needed to
maintain proper running clearance.
• Apply air pressure to release the brakes and cage the actuators.
1. Remove the pin attaching the pad holder to the caliper lever.
2. Slide the pad holder toward the center of the disc and remove the pad holder from the caliper arm.
3. Remove the rivets holding the pad to the pad holder and remove the pad.
4. Clean the pad holder with a wire brush. Do not use petroleum solvent.
5. Make sure that the pad is properly placed on the pad holder. It should not hang over the edge.
6. Rivet the pad to the pad holder. Make sure that the rivets pull up properly against the pad and the
pad holder. Do not crush the pad under the rivet head.
19
7. Follow the air gap adjustment procedure (in the brake service manual) to increase the air gap and
allow for the new caliper. Be sure that there is sufficient clearance.
8. Place the pad holder next to the caliper arm and toward the center of the disc. Slide the pad holder
outward until the pinholes in the holder align with the pinholes in the caliper arm.
9. Lubricate and replace the pins.
10. Adjust the air gap in accordance with the Pad Adjustment Procedure.
11. Burnish the pads in accordance with the Caliper Brake User’s Manual.
Holding Capability
1. Place the traveling block near the lower travel limit before starting the test.
2. Actuate the calipers on one brake disc and attempt to turn the drum with the motors.
3. Repeat this procedure for each disc.
The brake passes the test if the drum cannot be rotated at full-rated torque,.
Contamination
Oil, Grease, Line Dope
1. Clean and replace the brake pads
2. Locate and remove the cause of the contamination.
Oxidization or Corrosion
1. Burnish the discs by rotating the drums a few turns with the calipers slightly engaged.
Engage the calipers by reducing the drawworks air pressure to 80-85 psi
2. Inspect the discs and brake shoes, and check the holding capability after burnishing.
Emergency Air Storage

Air storage tanks, usually located under the hoisting drum in the drawworks skid, provide auxiliary
pressure for emergency release of the spring brakes. The tanks are charged by the rig air system and
the charge is retained by a check valve in the charge line. These tanks are capable of actuating their
brake system at least one (1) time without additional air volume from the rig system.
• Make sure there is at least 110-psi rig air pressure to properly charge these tanks.
Drive System
Motors
The main drive motors are factory sealed. Consult the drive motor’s user manual for maintenance
instructions.
• Inspect the intake filters on the blowers once a month and remove any debris.
Blocked intakes will cause motor overheating under high-load conditions and possibly damage
the blower impellers.
Controls
• Inspect and maintain the drawworks controls in accordance with the manufacturer’s maintenance
instructions.
20
Shafts
Generally, the shafts require little or no maintenance other than periodic greasing of the bearings.
The exception to this rule is the auxiliary brake shaft. The splined shifter connecting the auxiliary
brake shaft to the drum shaft uses a bronze follower to move the spline sleeve. The follower will wear
over time. Difficulty in shifting or excessive clearance in the shift mechanism are good indicators of a
wear problem that must be addressed.
When possible, a shaft that has been stripped for repair should be inspected for cracks. Magnaflux, or
similar nondestructive testing, is preferred. Cracks are most likely to appear at the corners or ends of
keyways and at major changes in shaft diameter. Cracked shafts must be replaced.
A shaft must also be checked for straightness.
1. Support the shaft at the normal bearing locations.

2. Rotate the it on a steady, low-friction support
3. Use a dial indicator to check for run-out at the ends and the middle of the shaft.
The total indicator reading (TIR) should not exceed 0.010 in.. Excessive TIR will cause vibration.
Lack of straightness is an indicator of other problems, such as cracking or overstressing.
Caution
DO NOT heat flexible coupling hubs beyond a maximum
temperature of 400°F to prevent hub damage.
When replacing parts that are fitted on a shaft be sure that the new parts fit within the prescribed
tolerance. For assembly or removal of parts that fit 0.000- to 0.004-in tight, heat them to approximately
350°F. For parts that fit 0.005- to 0.010-in. tight, heat the parts to approximately 600°F.
Bearings
Always discard bearings showing rust or corrosion, pitting or spalling, excessive internal clearance
(heavy wear), or cracks.
Bearings are usually lightly tight on the shaft and slip fit in the housing.
To pull a bearing, place a U-shaped puller behind the bearing and exert a balanced pull.
If a bearing is to be reused, it must not be heated with a torch as this may damage the bearing.
If a bearing is to be discarded, it may be heated with a torch to ease the removal.
Use an oven or oil bath to heat a bearing for installation. Do not use a torch. A torch cannot be used,
because bearing material is very high-carbon steel that is subject to microcracking when a torch is
used.
Do not overheat the bearing; 400° to 450°F is sufficient. Higher temperature will damage the bearing.
21
Spacers
Spacers on the shaft are usually slightly loose. Seal races and spacers that serve a sealing function are
usually slightly tight. Tight races may be removed or installed by gently and quickly heating them over
the complete surface while maintaining a steady pull on the race.
Hubs
Caution
Do not heat flexible coupling hubs beyond a maximum
temperature of 400°F to prevent hub damage.
Keyed or unkeyed hubs are always tight on the shaft. Do not pull on the outer rim of a hub when
removing it from the shaft. If the hub has puller holes, screw the puller bolts into the tapped holes;
otherwise, use a U-shaped puller behind the part. Heat may be used to assist the removal. Apply the
heat evenly around and on, or as near, the hub as possible. Do not overheat.
Before starting installation, check the fit of the key, and remove burrs or raised metal on both the shaft
and hub. Fully seat the key in the shaft keyway. A heated hub should slide freely on a cool shaft when
heated between 550° and 650°F. Unkeyed hubs require special fitting practice.
22
Preservation and Storage
Location
• Store the drawworks in a location with good drainage to prevent the accumulation of standing
water.
• Support the drawworks in a manner similar to the working support.
• Make sure the temporary supports are high enough to allow free circulation of air below the
drawworks to prevent condensation and accumulated water.
• A drained location that prevents standing water is preferred.
Cleaning
• Clean the drawworks with a power cleaning system (steam or pressurized water is preferred).
• Make sure that dirt, grease, and other accumulated material is removed from the drawworks
before storage.
• Protect the motors and controls from water intrusion during cleaning.
• Consult the manufacturer’s instructions for cleaning motors and controls.
• Flush and drain the oil system..
Preservation
• Remove any loose paint; clean rusted surfaces to bright metal; and repaint.
• Repaint any areas where the paint is thin.
• Circulate preservative oil through the lubrication system. If preservative oil is not available,
circulate clean oil through the system to coat all parts with an oil film.
• Drain the oil sump after circulating the oil.
• Make sure that all grease-lubricated parts are completely greased (filled) with the usual
operating grease. Use preservative oil on areas where grease is not applicable.
• Cover the exposed parts (shaft, drum, etc) with a dry, film-type rust preventative. Do not coat
the braking surface of the brake discs.
• See the manufacturer’s manuals for preservation of the motors and controls.
Storage
Note:
Condensation in the gearbox is a main concern during storage.
• Plug the breather opening.

• Use a small heater (100 to 200W) in the box. (This is the preferred preservation method. If a
heater is not available, use the following procedure.)
• Plug the breather opening.
• Remove the sump drain plug.
• Tilt the drawworks if necessary to ensure the maximum, long-term drainage of
accumulated condensation.
• Cover the drain with wire mesh to prevent the entrance of insects.
• Consult the manufacturer’s manuals for long-term storage of the motors and controls.
23
Torque Specifications
Steel Fastener Torque Specifications (Lubed)
SAE Grade 5 SAE Grade 8 ASTM A193 Grade B7
Fastener Size Fasteners Fasteners Fasteners
Thread
(Fractional- USA Metric USA Metric USA
Series Metric Units
Decimal) Units Units Units Units Units
(N-m)
(ft-lb) (N-m) (ft-lb) (ft-lb) (ft-lb)
1/4 20 UNC 6 9 9 12 7 10
0.250 28 UNF 7 10 10 14 8 11
5/16 18 UNC 13 18 18 25 15 20
0.3125 24 UNF 14 20 20 28 16 22
3/8 16 UNC 23 31 33 44 26 36
.375 24 UNF 26 35 37 50 30 40
7/16 14 UNC 37 50 52 71 42 57
0.4375 20 UNF 41 56 58 79 47 64
1/2 13 UNC 56 76 80 108 64 87
0.500 20 UNF 63 86 90 122 72 98
9/16 12 UNC 81 110 115 156 93 126
0.5625 18 UNF 91 123 128 174 103 140
5/8 11 UNC 112 152 158 215 128 173
0.625 18 UNF 127 172 179 243 145 196
3/4 10 UNC 199 270 281 381 227 308
0.750 16 UNF 222 301 314 425 253 343
7/8 9 UNC 321 435 453 614 366 496
0.875 14 UNF 354 480 500 678 404 547
1 8 UNC 481 652 679 921 549 744
1.000 14 UNF 539 731 762 1034 616 835
1-1/8 7 UNC 600 813 963 1305 778 1054
1.125 8 UN 621 842 997 1352 805 1092
12 UNF 673 912 1079 1463 872 1182
1-1/4 7 UNC 846 1147 1358 1842 1097 1487
1.250 8 UN 873 1184 1401 1900 1132 1534
12 UNF 937 1270 1504 2039 1215 1647
1-3/8 6 UNC 1109 1504 1781 2414 1438 1950
1.375 8 UN 1185 1607 1902 2578 1536 2083
12 UNF 1263 1712 2027 2748 1637 2220
1-1/2 6 UNC 1473 1997 2363 3204 1909 2588
1.500 8 UN 1563 2120 2509 3402 2027 2748
12 UNF 1657 2246 2659 3605 2148 2912
1-3/4
1.750 8 UN 3300 4474
2
2.000 8 UN 5018 6804
Bolt And Cap screw Markings B7 Studs
On Head
1. All torque values given are for fasteners lubricated with 30 weight motor oil.
2. All studs used on LTI pumps are Grade B7. Nuts on studs should be torqued to grade B7 specification,
even if the nut is Grade 8.
24

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LDW1000K Drawworks

LDW1000K Operating and Maintenance Manual

Operating and Maintenance

Buyer and Operator Responsibility

Integration of Control System

Accessories and Safety Equipment

• Shut down equipment and disconnect power during maintenance.

The drawworks is a single, skid-mounted unit with the following:

This is particularly important in saltwater environments. In non-saltwater environments, operators

NLG I #2 Premium Two or three shots from

Auxiliary Brake NLGI #2 Premium Two or three shots from

Do not over grease. Wipe

Disc Brake NLGI #2 EP Premium Warning

Every 6 Flexible NLGI #2 Premium Remove and replace old

Table 1 Lubrication Summary

• Push the emergency stop.

Verify basic control functions as follows:

• Test the emergency brake function.

Drawworks Control System

Emergency Brake System

Water Pressure (Optional Equipment)

Pressure and Temperature Chart

Emergency Operation (Loss of Air Pressure)

Safe Operating Practices

Maintenance Procedures Before Starting Operations

Maintenance After Moving

• Check for missing or loose bolts, and tighten or replace as needed.

• Inspect all hoses for wear, fraying, flattening, or kinking.

Always secure the drawworks and the load before

Operators should also test the emergency brake function:

Weekly Brake Disc Inspection and Cleaning

Auxiliary Brake (Optional)

Auxiliary Brake Alignment

Fig. 1 Auxiliary Brake Alignment

Pad Replacement Procedure

Emergency Air Storage

A shaft must also be checked for straightness.

1. Support the shaft at the normal bearing locations.

If a bearing is to be discarded, it may be heated with a torch to ease the removal.

Preservation and Storage

• Plug the breather opening.

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