MANUAL DE OPERACIÓN Y MANTENIMIENTO American Block DKS-2000

OPERATIONS AND MAINTENANCE MANUAL
www.americanblock.com
MODEL NUMBER DKS-2000A
PART NUMBER 35110000-F
DESCRIPTION DRAWWORKS RATED FOR 1000 KIPS (12 LINES)
DOCUMENT NUMBER M35110000
REVISION: REV 0
ISSUE DATE MAY, 2012
6311 Breen Road

Houston, Texas 77086
Phone: 281-820-5332
Fax: 281-820-3861
ABCO@AMERICANBLOCK.COM
Operations and Maintenance Manual
M35110000
CONTENTS
WARRANTY..............................................................................................................................III
1 GENERAL INFORMATION .................................................................................................1
1.1 CONVENTIONS .................................................................................................................. 1
1.2 WARNINGS, CAUTIONS AND NOTES .............................................................................. 1
1.2.1 WARNING ........................................................................................................................................ 1
1.2.2 CAUTION ......................................................................................................................................... 1
1.2.3 NOTE ............................................................................................................................................... 1
1.2.4 ILLUSTRATIONS ............................................................................................................................. 1
1.3 SAFETY REQUIREMENTS................................................................................................. 2
1.3.1 PERSONNEL QUALIFICATIONS .................................................................................................... 2
1.3.2 RECOMMENDED TOOLS ............................................................................................................... 2
1.3.3 GENERAL SYSTEM SAFETY PRACTICES ................................................................................... 2
1.3.4 REPLACING COMPONENTS.......................................................................................................... 5
1.3.5 ROUTINE MAINTENANCE .............................................................................................................. 5
1.3.6 PROPER USE OF EQUIPMENT ..................................................................................................... 6
2 OVERVIEW ..........................................................................................................................7
2.1 DESCRIPTION.................................................................................................................... 7
2.1.1 FEATURES ...................................................................................................................................... 7
2.1.2 A/C MOTOR ..................................................................................................................................... 7
2.1.3 GEARBOX (WET SUMP) ................................................................................................................. 7
2.1.4 WIRE ROPE DRUM ......................................................................................................................... 7
2.2 GENERAL ARRANGEMENT .............................................................................................. 8
2.2.1 MAIN COMPONENTS...................................................................................................................... 9
2.3 BRAKING MODES .............................................................................................................. 9
2.3.1 PARKING BRAKE ............................................................................................................................ 9
2.3.2 DYNAMIC BRAKE (THROUGH A/C MOTOR) ................................................................................ 9
3 SPECIFICATIONS .............................................................................................................10
3.1 PHYSICAL ........................................................................................................................ 10
3.2 COMPONENT ................................................................................................................... 10
3.3 POWER REQUIREMENTS ............................................................................................... 11
3.3.1 ELECTRICAL ................................................................................................................................. 11
3.4 HORSE POWER MODES AND HOISTING PERFORMANCE .......................................... 11
4 INSTALLATION, OPERATION AND MAINTENANCE .....................................................12
4.1 INSTALLATION................................................................................................................. 12
4.2 REPLACING DRAWWORKS COMPONENTS .................................................................. 12
4.2.1 PREPARATION.............................................................................................................................. 12
4.2.2 GEARBOX ...................................................................................................................................... 13
4.2.3 A/C MOTOR AND BLOWER .......................................................................................................... 14
CONTENTS i
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4.2.4 BRAKE ........................................................................................................................................... 15

4.2.5 WORN WIRE ROPE REPLACEMENT .......................................................................................... 15
4.3 ALIGNMENT AND ADJUSTMENT PROCEDURES .......................................................... 17
4.3.1 TURNBACK ROLLER ADJUSTMENT ........................................................................................... 17
4.3.2 BRAKE ASSEMBLY ....................................................................................................................... 17
4.3.3 A/C MOTOR / GEARBOX .............................................................................................................. 17
4.3.4 BREAK-IN PROCEDURE .............................................................................................................. 17
4.4 OPERATION ..................................................................................................................... 17
4.4.1 DRAWWORKS ............................................................................................................................... 17
4.4.2 GEARBOX ...................................................................................................................................... 17
4.5 MAINTENANCE ................................................................................................................ 18
4.5.1 GENERAL PRACTICES................................................................................................................. 18
4.5.2 INSPECTION PROCEDURES ....................................................................................................... 19
4.5.3 GEARBOX OIL CHANGING PROCEDURE .................................................................................. 20
4.5.4 CLEANING THE GEAR UNIT ........................................................................................................ 22
4.5.5 LUBRICATION PROCEDURES ..................................................................................................... 23
5 TROUBLESHOOTING .......................................................................................................25
5.1 FAULT SYMPTOMS ......................................................................................................... 25
5.2 RUNNING DIAGNOSTICS ................................................................................................ 25
5.3 HELPFUL DOCUMENTS .................................................................................................. 25
5.4 GENERAL ......................................................................................................................... 26
5.5 A/C MOTOR...................................................................................................................... 26
5.6 BRAKE PROBLEMS ......................................................................................................... 27
5.7 GEARBOX ........................................................................................................................ 28
CONTENTS ii
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WARRANTY
THERE ARE NO WARRANTIES WHICH EXTEND BEYOND THE DESCRIPTION ON THE FACE
HEREOF. THIS WARRANTY IS GIVEN EXPRESSLY AND IN PLACE OF ALL OTHER EXPRESS OR
IMPLIED WARRANTIES AND ALL IMPLIED WARRANTIES FOR MERCHANTABILITY AND FITNESS
FOR A PARTICULAR PURPOSE ARE DISCLAIMED.
Goods manufactured by others are sold “as is” except to the extent the manufacturer honors any
applicable warranty made by the manufacturer. Secondhand goods are sold “as is”. Leased goods, new
or used, are leased “as is”.
In the event any goods manufactured and sold by Seller and furnished hereunder are found to be
defective or otherwise fail to conform to the conditions of this contract, Seller will, at its sole option,
either (1) replace the goods at the delivery point specified herein, (2) repair the goods, or (3) refund the
purchase price.
Buyer’s remedies with respect to goods manufactured and sold by Seller and furnished hereunder that
are found to be defective or otherwise not in conformity with the contract shall be limited exclusively to
the right to have said good replaced, repaired, or to a refund of the purchase price, at Seller’s sale
option.
Buyer’s remedies with respect to goods manufactured and sold by other and furnished hereunder that
are found defective or otherwise not in conformity with the contract are limited to any warranties
extended and honored by the manufacturer.
Buyer’s remedies are limited as aforesaid regardless of whether Buyer’s claim is based on principles of
contract or tort. Claims must be made promptly following delivery of the goods to the Buyer, but in no
event later than one year from date of tender of delivery. Seller must be given a reasonable opportunity
to investigate.
NEITHER SELLER NOR THE MANUFACTURER SHALL HAVE ANY LIABILTY FOR SPECIAL,
INDIRECT, CONSEQUENTIAL, INCIDENTIAL, OR OTHER CLAIMS FROM ANY BREACH OF
CONTRACT OR TORT COMMITTED BY SELLER OR THE MANUFACTURER OF GOODS RESOLD
BY SELLER.
Buyer agrees that he is to be solely responsible for, and will hold Seller, and the manufacturer of any
goods resold by Seller, harmless from any claims, regardless of their basis, by Buyer or third parties
that may arise from the goods after delivery, except for the replacement, repair, or refund of the
purchase price, at Seller’s sole option, for Seller’s manufactured goods or as provided in any warranties
extended and honored by the manufacturer on goods manufactured and sold by others provided above.
Seller’s total cumulative liability in any way arising from or pertaining to any products sold or required to
be sold under this contract, shall not in any case exceed the purchase price paid by Buyer for such
product.
With respect to any work performed on goods furnished by Buyer (including but not limited to repairing,
welding, machining, fabricating, heat treating, and forging) Seller agrees to make every effort to perform
fully such work in accordance with Buyer’s specifications. Seller shall be responsible for damages to
such goods caused only by Seller’s negligence, in which case Buyer’s remedy shall be limited
exclusively to the price of the work to be performed by Seller on the article damaged.
Claims must be made promptly following delivery of the goods to Buyer, but no later than three months
from delivery date the goods are out into operation, or not more than one year after date tender of
delivery which ever time period is shorter. Seller must be given a reasonable opportunity to investigate.
Seller shall have no liability for special, indirect, consequential, incidental or other damages arising from
any breach of contract or tort.
WARRANTY iii
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1 GENERAL INFORMATION
1.1 CONVENTIONS
This Operations and Maintenance (O&M) manual provides instructions for installation, operation
and repair of American Block Manufacturing Company’s (ABCO’s) DKS-2000A Drawworks by
qualified personnel. Every effort has been made to ensure the accuracy of the information
contained herein. ABCO shall not be held liable for errors in this manual or for any
consequences arising from misuse of this manual.
1.2 WARNINGS, CAUTIONS AND NOTES

Particular notes, cautions and warnings are given throughout this manual to draw the reader’s
attention to important information regarding the safe operation and maintenance of the system.
Neglecting and/or ignoring this information may damage the equipment and/or in some cases
cause serious injury or result in death due to a lack of proper operation and maintenance. It is
strongly recommended to observe all warnings, cautions and notes as presented in this manual.
1.2.1 WARNING
A warning contains essential information related to potentially hazardous conditions, procedures
and/or practices which, if not strictly followed or observed, could result in serious injury or death
to personnel and/or catastrophic damage to equipment.
WARNING:
A warning appears in red text below the information to which it
pertains.
1.2.2 CAUTION
A caution contains essential information related to potentially hazardous conditions, procedures
and/or practices which, if not followed or observed, could result in damage to equipment or
material.
CAUTION:
A caution will appear in blue text below the information to which it
pertains.
1.2.3 NOTE
A note contains essential or useful information related to conditions, procedures, practices
and/or equipment. Such notes are intended to provide assistance in operation of equipment
sequence of tasks, or to provide clarification of a specific portion of the manual contents.
NOTE:
A note will appear in black italicized text below the information to
which it pertains.
1.2.4 ILLUSTRATIONS
Illustrations (figures) provide a graphical representation of equipment components or screen
snapshots for use in identifying parts or establishing nomenclature and may or may not be
drawn to scale.
1 GENERAL INFORMATION Page 1 of 32
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For component information specific to the rig configuration, reference the technical drawings
included with your ABCO documentation packet.
1.3 SAFETY REQUIREMENTS

ABCO equipment is installed and operated in a controlled drilling rig environment involving
hazardous situations. Proper maintenance is important for safe and reliable operation.
Procedures outlined in ABCO manuals are the recommended methods of performing operations
and maintenance.
CAUTION:
To avoid injury to personnel or equipment damage, carefully
observe requirements outlined in this section.
1.3.1 PERSONNEL QUALIFICATIONS

Only qualified, trained and experienced personnel should be allowed to operate and/or maintain
the drawworks. The following skill-set should be required (as applicable) of all personnel
operation or maintaining drawworks equipment:
• Mechanical and hydraulic equipment installation and maintenance.
• Rig up and lifting of heavy equipment involved in marine operations.
• Hydraulic control systems and troubleshooting hydraulic circuits.
• Drilling rig equipment operations; specifically, drawworks operations.
WARNING:
Operation or maintenance of the DRAWWORKS by untrained or
unqualified personnel could result in improper use, equipment
failure / damage and serious injury or death to operational or
maintenance personnel.
1.3.2 RECOMMENDED TOOLS

Service operations may require the use of tools designed specifically for the purpose described.
ABCO recommends that only those tools specified be used when stated. Using the specified
tools will allow for a safer and quicker maintenance procedure. Please ensure that personnel
and equipment safety are not jeopardized when the following service procedures or using tools
not specifically recommended by ABCO.
1.3.3 GENERAL SYSTEM SAFETY PRACTICES
Operation of the drawworks and its subsequent components may present certain hazards that
require the attention and caution of all personnel involved in the operation and/or maintenance
of the system. Normally, observing and exercising standard safety precautions avoid many
hazards.

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NOTE:
Unless specifically related to component safety, the safety
precautions put forth in this manual are recommendations and for
general guidance only. National, state and local safety laws,
statutes, guidelines, rules, as well as operating company
procedures and overall Safety Program requirements shall take
precedence over the recommended safety precautions contained
in this manual.
1.3.3.1 Cable and Hose Safety Precautions

Observing the precautions listed below and those as may be required by the Operator’s overall
Safety Program will prevent damage to equipment and injury to personnel that might result from
damage to cables and/or hoses.
• Protect all electrical cables, pneumatic hoses and hydraulic hoses from cutting, scraping,
pinching, abrasion or any physical damage.
• Route all cables and hoses outside of the crew’s traffic patterns and away from
mechanical equipment.
• Welding or acetylene cutting must not be done near unprotected cables or hoses, as this
may result in damage to cables or hoses.
• Consideration must always be given to the prescribed minimum bend radius for cables
and hoses. Twisting or bending cables or hoses beyond the minimum bend radius can
damage the insulation, conductors or reinforcing wire shield.
1.3.3.2 Welding and Cutting Safety Precautions
Observing the precautions listed below and those as may be required by the Operator’s overall
Safety Program will prevent damage to equipment and injury to personnel that might result from
improper welding or cutting procedures.
• Do not weld or operate acetylene-cutting torches near unprotected electrical cable,
hydraulic or pneumatic hose or hose bundles. Weld spatter can seriously damage the
hose or cable
• Prevent weld slag or spatter from entering the hydraulic system.
• If welding or cutting must be done near cables or hoses, be sure that the cable and/or
hose is protected with fire-resistant covering.
1.3.3.3 Work Area Safety Precautions
Work should be performed in an area free of any dangerous obstructions, chemicals or hazards
of any kind in order to prevent or reduce the severity of an injury. The precautions listed below
and those as may be required by the Operator’s overall Safety Program should be observed in
order to maintain a safe working environment.
• Personnel engaged in system operation and maintenance work should be fully informed
of the hazards involved and should receive proper instruction in accident prevention and
first aid procedures.
• Work in an area free of any dangerous obstructions, chemicals or hazards.
• If any dangerous obstruction is located overhead, to the side or on the surrounding floor
of the work area, the hazard must be removed as safely and quickly as possible by
appropriate personnel.
• If any flammable materials are located in or are spilled within or in proximity to the work
area, the hazardous materials must be removed and cleaned from the work area.

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Flammable materials include but are not limited to the following materials:
• Oily rags, paper products or any combustible solid.
• Kerosene, gasoline or any combustible liquid.
• Oxygen tanks, acetylene gas or any combustible gas.
• Should any condition, situation or circumstance occur that might pose serious hazard(s),
appropriate action must be taken to correct or remove the hazard(s) from the work area.
• Use the appropriate protective devices (gloves, safety glasses, steel toed boots, hard
hat, safety harness, etc.) required by the Operator’s overall Safety Program and normal
safe working practices.
1.3.3.4 Electric Circuit Safety Precautions
Certain safety precautions must be exercised regarding the electrical circuits of the system.
Observing the precautions listed below and those that are a part of the Operator’s overall Safety
Program will prevent damage to equipment and injury to personnel that might result from
electric power.
• An electric power source must be supplied at correct voltage, current and phase to
enable safe and correct operation of equipment.
• Exercise caution when working around exposed electrical conductors, terminals and
remotely activated equipment.
• Ensure flash-proof integrity of explosion-proof electrical junction boxes, connections and
circuit breakers. This will prevent fires or explosions that might result from a spark
during electrical switching.
• Do not override or tamper with electrical or mechanical interlocks and safety devices.
• Before attempting any corrective action or maintenance on the electrical circuit, verify
that all electric power sources have been remove from the circuit. Ensure that all
electrical switches are set to OFF and appropriates breakers set to OPEN.
• Do not service or adjust the electric circuits alone. Always verify that a qualified person
is present who can render aid in case of accident and who is familiar with emergency
shutdown procedures.
• Appropriate warning tags labeled Requiring Open Circuit Condition shall be placed on all
necessary switches and circuit breakers to prevent accidental application of power units
of the system during maintenance procedures.
• Wear suitable protective clothing while working within 4 ft of exposed electrical
equipment. Do not wear rings, wristwatches or clothing with exposed metal buttons,
zippers or fasteners.
• An approved taping, coating or sleeve method should insulate metal handles of hand-
held tools.
• Provide dry wooden (or similar non-conducting material) platforms whenever it is
necessary to work on electrical circuits or equipment in wet or damp locations. This
precaution will ensure there will be no possibility of contact between the wet floor and
the worker’s shoes.
• Do not open battery boxes or other sources of power in presence of flammable gas.
• Observe all recommended minimum bend radii of cables and hoses.
1.3.3.5 Pneumatic Circuit Safety Precautions (if applicable 1):
Pneumatic source power supplied to the equipment is of sufficiently high pressure and volumes
to present a hazard if required safety practices are not followed. Exercise the following
precautions and those as may be required by the Operator’s Safety program to aid in preventing
1
ABCO Drawworks may be equipped with either hydraulic or pneumatic circuit depending upon the type of brakes
used.
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damage to equipment and injury to the personnel that might result from mishaps with pneumatic
power.
• Ensure that the pneumatic source power is supplied at adequate pressure and volume to
enable safe and proper operation of equipment. Maximum system air pressure is 125 psi
(9 BAR).
• Ensure that the air is filtered to prevent any dirt or debris from entering the pneumatic
circuit.
• The air should be dried and lubricated before it pilots or operates any motor (pneumatic
pump); moisture can damage components and result in unit failure
• Ensure all bend radii of cables and hoses are as per manufacturer’s specification.
1.3.3.6 Hydraulic Circuit Safety Precautions (if applicable1):
Hydraulic source power is provided at pressures and volumes high enough to warrant
precautionary measures. Exercise the following precautions and those as may be mandated by
the Operator’s Safety Program to aid in preventing damage to equipment and injury to
personnel that might result from hydraulic power.
• Hydraulic fluid must be filtered to prevent any dirt or debris from entering the hydraulic
circuit. NAS Class 8 is recommended as a minimum cleanliness level. Check fluid
cleanliness at the end of each well.
• Mop up spilled hydraulic fluid immediately. Immediately investigate and correct the
cause of leakage of hydraulic fluid.
• If clothing becomes drenched with hydraulic fluid, change immediately to dry clothing.
The fluid can be very irritating to eyes and skin. Prolonged contact with hydraulic fluid
may cause dermatitis, which may progress to allergic sensitization.
• Ensure that all pressure relief valves are in working condition and that the valves are set
to relieve at their specified pressure levels.
• Should there be a rupture or break in the hydraulic circuit (when pressurized), do not
place hands, face or any part of the body over the escaping jet stream of fluid. Severe
bodily injury will result.
• Never torque leaking connections or fittings while lines are pressurized. Application of
torque to fittings or connections while lines are pressurized may cause lines to rupture
and result in injury to personnel.
• Before attempting any corrective action on the hydraulic circuit, verify that the electric
and pneumatic (if applicable) power sources are turned OFF and all hydraulic pressure
containing circuit are completely vented. Verify that all hydraulic gauges read 0 psi.
• When pre-charging accumulators, use only dry nitrogen gas. The use of another gas
may cause unit failure or explosion.
• Accumulator pre-charges greater than compressed nitrogen source may require use of a
booster pump.
• Ensure all bend radii of cables and hoses are as per manufacturer’s specification.
1.3.4 REPLACING COMPONENTS

Verify all components (such as cables, hoses, etc.) are tagged and labeled during assembly and
disassembly of equipment to ensure correct installment.
Replace failed or damaged components with ABCO certified parts. Failure to do so could result
in equipment damage or injury to personnel.
1.3.5 ROUTINE MAINTENANCE
Equipment must be maintained on a routine basis. See the service manual for maintenance
recommendations.

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WARNING:
Failure to conduct routine maintenance could result in equipment
damage or injury to personnel.
1.3.6 PROPER USE OF EQUIPMENT

ABCO equipment is designed for specific functions and applications and should be used only for
its intended purpose.

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2 OVERVIEW
2.1 DESCRIPTION
A “drawworks” is essentially a “hoisting” system on a rig that raises or lowers heavy loads by
means of a cable wound on a drum.
2.1.1 FEATURES
The DKS-2000A is a single speed, gear-driven drawworks with VFD-controlled AC motors. All
the drawworks components are mounted on a unitized skid. They consist of:
• Two 480VAC powered hoist motors rated at 1350 HP.
• A single speed dual input gearbox.
• A wire-line drum with Lebus grooving (the grooving is specified to the wire size).
• A hydraulically released, spring engaged parking/emergency brake.
Figure 2.1 and Figure 2.2 show the general arrangement for these major components on
drawworks skid. The operation of the drawworks is performed from a remote control station
using a third party control system (refer to user manual provided by control system provider for
further details).
2.1.2 AC MOTORS
The DKS-2000A uses two 480VAC motors rated at 1350 HP to drive the wire rope drum through
the gearbox. The motor is coupled to the gearbox with a splined drive coupling. The wide range
of motor speed allows the drawworks to achieve a broad range of hoisting speeds.
2.1.3 GEARBOX (WET SUMP)
Power is transmitted from the hoisting motor through a single speed gearbox. The gears and
the bearings are lubricated via a pressurized lubrication system.
The gearbox has its own oil lubrication circuit. This circuit contains a positive displacement
pump, a 10-micron oil filter (containing a 101.5 psi differential mechanical bypass with visual
indicator), a heat exchanger and various mechanical gauges and/or pressure transmitters.
2.1.4 WIRE ROPE DRUM
The wire rope drum is supported by two bearings (one on each side). The drum is fitted with
Lebus grooving as per customer-specified wire-rope diameter.
2 OVERVIEW Page 7 of 32
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2.2 GENERAL ARRANGEMENT
Figure 2.1
DKS-2000A General Arrangement
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2.2.1 MAIN COMPONENTS
Figure 2.2
DKS-2000A Major Components (Front View)
2.3 BRAKING MODES

2.3.1 PARKING BRAKE
This mode is used by the driller to support the load using the Svendborg friction brake provided
with the drawworks. This is a spring-applied, hydraulically released brake. A Svendborg
Hydraulic Power Unit (HPU) is used to control the brakes. For the operation and maintenance
procedures for this brake and corresponding HPU, please refer to the Svendborg Manual No.:
MEB-0500-060_J and MEH-3000-0139-802_B. The control system provider may also have
further instructions for operating and controlling the HPU using their system.
2.3.2 DYNAMIC BRAKING
Since the drawworks motor is controlled by the VFD, its speed can be dynamically controlled by
varying the frequency of the drive. Refer to the Control System user manual for more details
about the procedures involved in dynamic braking.
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3 SPECIFICATIONS
3.1 PHYSICAL
Table 3.1
DKS-2000A Dimensions
Height (max) 102 in (2,590 mm)
Size Width (max) 114.06 in (2,897 mm)
Length (max) 237.38 in (6,030 mm)
Weight (max) 32,190.56 lb (14,601 kg)
3.2 COMPONENT
Table 3.2
DKS-2000A Component Specifications
Model AMERIMEX 1350 HP-DOMINATOR (480 V)
A/C MOTOR Torque Rating (max) Peak Torque: 16740 ft.lb (22696 Nm)
Speed Max Speed : 2300 RPM
Type Single Speed, Dual Input
Ratio(s) 7.4461:1
GEARBOX
Lubrication Forced Lube, Filter, Cooling
Oil Capacity 30 gal (113.56 L)
Size 75 in (1905 mm)

BRAKE
Emergency and Parking Spring applied, hydraulically-released brake (Svendborg
Brake Type BSFH 520-S-501)
BRAKE
COOLING
Type Air cooled
Wire rope diameter 1.375 in (34.93 mm)
Drum pitch diameter 30 in (762 mm)

WIRE ROPE
DRUM
Drum length 60.75 in (1,534.05 mm) between the wear plates
Grooving Lebus
3 SPECIFICATIONS Page 10 of 32
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3.3 POWER REQUIREMENTS

3.3.1 ELECTRICAL
Amerimex 1350 HP (2 motors) – 480 VAC (each)
Auxiliary Equipment – 480 VAC, 60 Hz, Standard
3.4 HORSE POWER MODES AND HOISTING PERFORMANCE

DKS-2000A hoisting system performance data is based on continuous use in hazardous area.
Table 3.3
DKS-2000A Performance Parameters
Rig Power Rating 2000 HP
Hook Load Capacity – 8 lines 875,000 lbf (3,892 kN)
Hook Load Capacity – 10 lines 1,000,000 lbf (4,448 kN)
Hook Load Capacity – 12 lines 1,200,000 lbf (5,338 kN)
Figure 3.1
DKS-2000A Performance Curves
3 SPECIFICATIONS Page 11 of 32
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4 INSTALLATION, OPERATION AND MAINTENANCE

4.1 INSTALLATION
Assembly and installation must be done only by trained and qualified personnel with great care.
The manufacturer cannot be held liable for damage caused by incorrect assembly and
installation.
Sufficient space should be allowed around the equipment for subsequent care and maintenance
work. All the specified lubrication points should be easily accessible.
Sufficient lifting equipment should be available before beginning the installation and assembly
work.
CAUTION:
All the fastening points provided by the design of the equipment
should be used.
Ensure that the foundation is horizontal and level.
NOTE:
For dimensions, space requirement, arrangement of supply
connections, lifting procedures etc refer to the drawings provided
in the DKS-2000A information packet.
4.2 REPLACING DRAWWORKS COMPONENTS
WARNING:
Always verify power is removed from drawworks before removing
and replacing components. Ensure that drawworks operational
area is clear of personnel and equipment before reapplying power.
When replacing components, use the assembly drawings contained in the Technical Drawings
Packet. Use ABCO-supplied replacement parts.
4.2.1 PREPARATION
Before replacing any component do the following safety steps:
• Lock out drive motor.
• Reduce hydraulic pressure to zero.
• Isolate all electrical power from the drawworks.
The component replacement procedures are listed on the following pages. A DKS-2000A with
air-cooled gearbox oil lube system is shown for illustration purposes.
4 INSTALLATION, OPERATION AND MAINTENANCE Page 12 of 32

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4.2.2 GEARBOX
Figure 4.3
GEARBOX SECTION VIEW
4.2.2.1 GEARBOX INPUT SHAFT COUPLING HUB
Removal
o Special Tools required:
o Hydraulic Jack, small
o Strong Back Bar
o Rose Bud Torch
o Temperature Stick
NOTE:
Before inspecting brakes, refer to vendor brake manuals for
specific information on cleaning, repairing and replacing brake
components.
WARNING:
Failure to remove grease from hub may result in a grease fire
when heating the hub for removal.
• Disconnect coupling and clean hub of grease.

• Slide coupling sleeve fully toward gearbox
• Remove O-ring.
• Secure coupling sleeve to gearbox with heavy wire to prevent sleeve from falling once
the hub is removed.

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WARNING:
Use caution when handling the heated hub.
• Install pulling equipment suitable for pulling off hub.

• Using a rose bud torch, quickly heat the hub to 350°F. Use temperature stick to verify
the temperature.
• Install jack.
• Pull hub off shaft using jack to assist removal.
Installation
• Special Tools required:
• Rose Bud Torch
• Temperature Stick
• Using a Rosebud Torch, heat the hub to 350°F. Use temperature stick to verify
temperature.
WARNING:
Use caution when handling the heated hub.
• Install key.
• Install coupling sleeve onto hub.
• Slide hub onto gearbox input shaft. Refer to the top level assembly drawing in the
technical drawing packet for more details.
• Hold in place until hub cools sufficiently to grip the shaft.
• Allow hub to cool to ambient temperature.
• Install O-ring.
• Couple the coupling halves and torque bolts to 200 ft-lb (271 N·m)
• Pack coupling with grease (refer to Lubrication Procedures).
4.2.3 A/C MOTOR AND BLOWER
4.2.3.1 A/C MOTOR
1. Disconnect electrical power.
2. Remove motor coupling cover.
3. Unbolt and separate motor coupling halves. (Remove coupling spacer if applicable)
4. Remove attaching hardware at base of AC motor. (Note the position of shims. Place in
same position when installing AC motor. Refer to alignment procedure in Motor Installation
manual)
5. Back out all adjusting bolts and lock nuts.
6. Attach lifting device to lifting points and remove A/C Motor.
4.2.3.2 BLOWER MOTOR
1. Disconnect electrical power.
2. Remove attaching hardware at A/C motor and the base of blower motor.
3. Retain gasket.
4. Attach lifting device and remove blower motor assembly.

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4.2.4 BRAKE
Please refer to the latest revision of Svendborg’s Brake & HPU Manual. A copy of these
manuals is provided in the information packet provided with the drawworks.
NOTE:
When installing the brake, make sure the required mounting
hardware are of the proper grade and quantity.
CAUTION:
Proper alignment of the brake is necessary to make sure that the
friction discs track properly. Improper alignment results in
excessive wear to the material and mating surfaces. Align the
brake to limits shown in the Adjustment and Alignment Procedure.
Excessive grease may contaminate the friction material, resulting
in erratic response or loss torque.
4.2.5 WORN WIRE ROPE REPLACEMENT
NOTE:
Wire rope should be maintained in accordance with API
Specification 9B, Recommended Practice on Application, Care
and Use of Wire Rope for Oilfield Service.
Before installing the wire rope on the drum, the driller must
operate the control system sufficiently to become familiar with the
controls, the screen displays and the response of the system to
operator input commands.

M35110000
Figure 4.4
DKS-2000A WIRE ROPE REPLACEMENT
1. Remove cover prior to replacement of wire line. See Figure 4.4 for cover removal
procedure.
2. Pull wire rope through the slot in the drum flange, from inside of the flange to outside of
flange.
3. Attach wire rope clamp to tail of wire rope. Leave approximately 3 in (76 mm) of wire rope
extending out of the clamp.
4. Apply Never Seize and tighten the six nuts to 300 ft-lb (406 N·m). Tighten the bolt in a
crisscross pattern, starting at the midpoint of the 6-bolt main section and in increments of
25%, 50% and 100% of required torque to insure uniform tightening of the clamp.
5. Wrap wire line around drum by turning the drum using the driller control station. Apply
greatest amount of pretension available when wrapping wire rope on the drum. Ensure the
number of dead wraps on the drum, when the travelling block is at its lowest possible
position in the derrick, is at least 10-12 wraps.
6. Once the drum is fully spooled, raise and lower the blocks through the full derrick travel to
seat the rope properly onto the drum. Observe that smooth, proper spooling is taking place,
with no gaps or jumping and that the rope does not climb the flange when changing layers.
7. Tighten bolts when switch is in position.
NOTE:
For further details on proper reeving and wire rope maintenance,
refer to the latest revision of the IADC manual.

M35110000
4.3 ALIGNMENT AND ADJUSTMENT PROCEDURES

4.3.1 TURNBACK ROLLER ADJUSTMENT
1. Slowly rotate the drawworks drum until the wire-line is just inside the kickback plate. The
kickback plate is welded to the side of the drum flange. It is located where the Lebus
grooving ends.
2. Move the roller out until it touches the wire-line. If the roller is moved out too far, scarring
will occur on the roller or a jump loop will occur in the wire-line. If the roller is not moved out
far enough, it will not spin when the wire-line comes to the end of the drum. A properly
adjusted roller will spin at each later change but not wear excessively.
3. Repeat above steps for the opposite roller.
4.3.2 BRAKE ASSEMBLY
For details on brake assembly and adjustment, refer to Svendborg’s Installation, Operation and
Maintenance Manuals.
4.3.3 AC MOTOR / GEARBOX
Special Tools:
Dial indicator
The following page gives details on the A/C motor / gearbox alignment procedure.
4.3.4 BREAK-IN PROCEDURE
The break-in tests are performed when the gearbox or brake pads are replaced.
4.3.4.1 GEARBOX LOW TORQUE BREAK-IN
This procedure should be performed if a new gearbox has been installed or after any internal
gears or bearings have been replaced.
1. Disengage parking brakes.
2. Hoist and lower a minimal load repeatedly for 30 min.
NOTE:
While running the motors, make sure the drawworks is running
smoothly with no binding or unusual noises.
3. Visually inspect gears for any signs of mechanical malfunction.

4.3.4.2 BURNISHING THE BRAKES
This procedure should be performed if the brake pads or disc have been replaced. Never use
old pads with a new disc.
Burnish the brake friction surfaces in accordance with the Wear-in Procedures contained in the
vendor manual.
4.4 OPERATION
4.4.1 DRAWWORKS
For detailed operation procedure for the drawworks please refer to the instructions provided in
the third party controls documentation.

M35110000
4.4.2 GEARBOX
4.4.2.1 GEAR SHIFTING PROCEDURE
Please refer to the nameplate mounted on the gearbox for manufacturer recommended gear
shifting procedure.
4.4.2.2 GENERAL OPERATING DATA

During operation, the unit must be monitored for:
• Overheating (In continuous operation, the gear unit is designed for a temperature of
90°C with mineral oil. For higher temperatures, synthetic oils must be use. The
maximum short-term operating temperature is 100°C.)
• Changes in running noise
• Possible oil leakage at the housing and shaft seals
• Correct oil level
NOTE:
To check the oil level, stop operation of gear unit. When the oil is
warm it may slightly exceed the top mark of the oil dipstick. It must
not be allowed to fall below the lower mark. If necessary, top up to
the correct level.
CAUTION:
If any irregularities are noticed during operation, switch the drive
assembly off at once. Determine the cause of the fault using the
table in Section 5.
This table contains a list of possible faults, their causes and
suggested remedies.
Should it not be possible to identify the cause, or the unit cannot
be repaired with the facilities available, you are advised to contact
our customer-service for specialist assistance.
4.5 MAINTENANCE
4.5.1 GENERAL PRACTICES
CAUTION:
All persons involved in the installation, operation, maintenance
and repair of the gear unit must have read and understood these
Operating Instructions and must comply with them at all times. We
accept no responsibility for damage or disruption caused by
disregard of these instructions.
4.5.1.1 EQUIPMENT RECORDS

A Maintenance Log detailing all maintenance procedures performed on the drawworks shall be
kept. Each maintenance procedure performed shall be dated and include a description of
activities and a list the technician(s) involved. This data is valuable for fault finding and problem
solving, should technical problems arise.
M35110000
NOTE:
Procedures within this section relate to ABCO only components.
See the vendor supplied manuals for procedures and schedules
pertaining to the vendor equipment.
4.5.1.2 SAFETY PRECAUTIONS

Avoid equipment damage or injury to personnel by closely following the important safety items
highlighted as notes, cautions and warnings used throughout this manual.
To avoid serious injury or death, read and understand the following warnings before performing
maintenance or troubleshooting procedures.
WARNING:
Unless instructed otherwise, properly lock out the main power
source before performing any maintenance procedure.
Wear protective glasses to prevent eye injuries.
Do not attempt any adjustments while the machine is moving.
Read and understand all safety precautions and warnings before
performing maintenance procedures.
The gear unit must not be cleaned using high-pressure cleaning equipment.
No welding work should be done on the gear unit. The gear unit must not be used as an
earthing point for welding operations. Delicate teeth and bearings may be irreparably damaged
by welding.
4.5.2 INSPECTION PROCEDURES
The inspection procedures assume normal operating conditions. Some conditions (excessive
loading, dusty or corrosive atmosphere, temperature extremes, etc.) may warrant more frequent
inspection intervals. Perform the maintenance procedures indicated, as warranted by
inspection.
4.5.2.1 INSPECTING LOAD – CARRYING COMPONENTS
Since the load-carrying components are critical to performance, ABCO recommends performing
visual inspections on a regular basis.
Visually inspect all load-carrying components for corrosion, fatigue or other deterioration. If you
detect any excessive wear and tear on any component, replace the component.
The criteria and interval for inspection of load-carrying components are determined by your
installation manager and by local regulatory requirements.
4.5.2.2 INSPECTING GEARBOX
CAUTION:
The periods stated in the table below depend on the conditions
under which the gear unit is operated. For this reason only the
average figures can be given which refer to:
a daily operating time of 24 hrs.
a duty factor of 100%
M35110000
an input-drive speed of 1500 min-1

and a maximum oil temperature of 90°C (mineral oil only)
100°C (synthetic oil only)
Measures Periods
Check oil Temperature Daily
Check for unusual gear unit noise Daily
Check oil level Monthly
Check gear unit for leaks Monthly
Test oil for water content After 400 service hours, once per year at least
First oil change after start-up After 400 service hours
Subsequent oil changes after start-up Every 18 months or 5000 service hours1
Clean venting screw Every 3 months
Re-grease Taconite seals Every 3000 service hours, every 6 months at least
Clean gear unit housing Simultaneously with oil change
Check tightness of fastening bolts After first oil change, thereafter every second oil change
Complete inspection of gear unit Approx. every 2 years along with oil change
4.5.3 GEARBOX MAINTENANCE

4.5.3.1 PRIOR TO START-UP
• Unscrew oil drain plug and drain the conservation agent or running-in oil residues from
the housing into a suitable container and dispose of in accordance with regulations,
making sure also to open residual oil drain plugs, if any.
WARNING:
Remove oil spillage immediately with an oil-binding agent.
• Replace the oil drain plug.

• For a detailed illustration of the gear unit, refer to the drawings in the information packet.
• Release the fastening bolts on the inspection cover and remove the cover (including
seal) from the housing. Do not discard the seal.
• Fill the gear unit with fresh oil using a filter (mesh size 25µm or less)
NOTE:
For the correct type of oil (of various brands) to be used refer to
the operation instructions BA 7300 EN supplied separately.
Information on the type, viscosity and quantity of the oil is given on
the rating plate on the gear unit.
The quantity of oil stated on the rating plate is an approximation
only. The markings on the oil dipstick must always be observed.
M35110000
• Check the oil level in the gear housing with the oil dipstick. The oil level must be at the
upper mark on the oil dipstick.
• Place the inspection cover (including seal) on the housing and replace and tighten the
fastening bolts.
4.5.3.2 REMOVAL FROM SERVICE
• Switch off the drive assembly.
WARNING:
Secure the drive assembly to prevent it from being started up
accidentally. Attach a warning notice to the start switch.
• During longer periods of disuse, start the unit up briefly at intervals of approx. 3 weeks. If it is to
remain out of service for longer than six months, fill it with conservation agent.
4.5.3.3 INTERIOR CONSERVATION DURING LONGER DISUSE

Use Cortec VpCI-322 concentrated oil based multi-metal corrosion inhibitor for storage upto 12
months.
For storage longer than 12 months contact the manufacturer.

4.5.3.4 INTERIOR CONSERVATION PROCEDURE
• Switch the gear unit off and drain the oil.
• Fog in a minimum of 2 quarts of the Cortec corrosion inhibitor through one of the breather holes
or by opening the inspection cover until you observe the fog exiting the gearbox.
• Pour approximately 1 quart of the liquid corrosion inhibitor into the gear box sump.
• Plug the breather holes and reinstall all inspection covers.
CAUTION:
Before re-starting the gear unit, replace the plug with the
breathers, and flush the lubrication system and gearbox.
4.5.3.5 EXTERIOR CONSERVATION PROCEDURE

Duration of Conservation agent Layer thickness Remarks
protection
Less than 12 months Tectyle 846 K19 Approx. 50 µm Long-term wax based
conservation agent,
resistant to sea water
and tropical conditions,
soluble in benzine.
Table 4-1 Exterior protection of shaft ends and other bare surfaces
• Clean the surfaces

• Apply grease to shaft-sealing rings to protect the sealing lips from conservation agent
• Apply conservation agent
M35110000
4.5.3.6 GEARBOX OIL CHANGING PROCEDURE
CAUTION:
When changing the oil, always re-charge the gear unit with the
same type of oil. Never mix different types of oil or oils made by
different manufacturers. Never mix synthetic oils with mineral-
based oils or with other synthetic oils. When changing from
mineral based oil to synthetic oil or from one type of synthetic oil
to another, flush the gear unit well with the new type of oil
beforehand.
When changing the oil, the housing must be flushed with oil to remove sludge, metallic particles
and oil residue. Use the same type of oil as used for normal operation. High-viscosity oils should
be heated beforehand. Ensure that all residues have been removed before filling with fresh oil.
NOTE:
Drain the oil while it is still warm, i.e. immediately after switching
the machinery off.
• Stop the gear unit by switching off the drive assembly

• Place a suitable container under the oil drain plug
• Remove the venting screw on the top of housing
• Remove the oil drain plug and allow the oil to drain into the container.
4.5.3.7 ENVIRONMENTAL PROTECTION
When changing oil, the used oil must be collected in suitable containers. Any spillage of oil must
be removed immediately.
Conservation agent should be stored separately from used oil.
Used oil, conservation agent, oil binding agents and oil-soaked cloths must be disposed of in
accordance with environmental legislation.
4.5.3.8 CLEANING THE GEAR UNIT
Stop the gear unit by switching off the drive assembly
WARNING:
Secure the drive assembly to prevent it from being started up
accidentally. Attach a warning notice to the start switch.
Remove any corrosion.
CAUTION:
Never clean the gear unit with high-pressure cleaning equipment.

M35110000
4.5.4 LUBRICATION PROCEDURES

4.5.4.1 RECOMMENDED LUBRICANTS
Use Synthetic EP 220, 5EP Gear Oil.
Maximum Impact Grease (M.I.G.) by Beta Technology is recommended as the standard Grease
for use.
NOTE:
Additional recommended greases for the motor couplings are
listed in the vendor manual.
The lubricator procedures are shown on the following pages.

4.5.4.2 GREASE LOCATIONS
The following three locations are to be greased daily as shown in Figure 4.1 and Figure 4.2:
Figure 4.1
PILLOW BLOCK GREASING

M35110000
4.5.4.3 GREASING THE DRUM COUPLING

Initial greasing of drum coupling should be done after 400 hours of operation. Thereafter,
grease every 2000 hours (of operation) or 6 months whichever is sooner.
NOTE:
Coupling lubrication is critical! The use of proper and sufficient
lubrication is part of a successful operation. Lubricants should be
checked to see that proper level is maintained and that the
lubricant is free of any contamination.

M35110000
5 TROUBLESHOOTING
5.1 FAULT SYMPTOMS
Potential component failures fall into the following categories:
• Electrical components
• Mechanical components
• Hydraulic components
To help determine the nature of the problem, use the troubleshooting tables contained in this
section. Supporting illustrations are provided to show component locations.
NOTE:
The troubleshooting procedures in this chapter do not necessarily
cover all possible symptoms. The tables provide an insight to
typical symptoms, their possible causes and which components to
check as the most likely candidates causing the fault.
5.2 RUNNING DIAGNOSTICS

Diagnostics are valuable troubleshooting tools. Use the instructions contained in the control
system provider’s User Manual to run drawworks diagnostics.
5.3 HELPFUL DOCUMENTS

The Technical Drawings Package contains assembly drawings for component locations and
electrical and hydraulic schematic diagrams for signal tracing. In addition, there are vendor
manuals available with this service manual.
The following drawings and schematics are useful in troubleshooting:
• DKS-2000A Assembly Drawing (35110000-F)
5 TROUBLESHOOTING Page 25 of 29
M35110000
5.4 GENERAL
Table 5.1
General Troubleshooting
Symptom Probable Cause Remedy
System does not respond to Command is not allowed by Check the control screen for fault
operator inputs the software. indication.
Ensure the load on the wire rope

is not jammed or interfering
Mechanical interference or with the rig structure or other
failure. pieces of equipment.
Verify the brake disengages
when activated.
Check the control system’s screen

Damaged or faulty gearbox
for an encoder fault indication.
encoder
Replace the gearbox encoder.
Check for proper motor alignment

Motor alignment
to gearbox.
5.5 AC MOTOR
Table 5.2
A/C Motor Troubleshooting
A/C motors do not rotate Check the control system’s

Command is not allowed by the
screen for warning or interlock
software
condition.
Ensure neither the drum nor

the load on the drum is
binding on rig.
Mechanical interference or
Check for obstructions in wire
failure
rope sheaves.
Verify the brake disengages
when activated.
Check the control system for an

Damaged or faulty gearbox
encoder fault. Replace encoder
encoder
if necessary.
If a fault is indicated on the

VFD fault VFD, refer to third party vendor
documentation
M35110000
Table 5.2
A/C Motor Troubleshooting
Brake does not release Troubleshoot the brake system.
Motor overheats Blower motor is not working.

Blower motor
Replace blower motor.
Verify the impeller rotates with

blower motor rotation. Air
should be entering motor
Blower impeller
through louver and exiting
motor through slits near motor
output shaft.
Check electrical connection and

settings noted in Alarm and
Main motor air temperature
Fault Response Specification.
switch
Replace faulty temperature
switch.
Check electrical connection and

Blower differential pressure settings noted in Alarm and
switch Fault Response Specification.
Replace faulty pressure switch.
5.6 BRAKE PROBLEMS

Table 5.3
Brake System Troubleshooting
Emergency / Parking brake Command is not allowed by Check the control system’s screen
does not engage / disengage the software for warning or interlock condition.
1. Ensure the brake calipers are

Mechanical interference or not jammed by mechanical
failure interference or corrosion.
Check for brake alignment.
Check the Control system’s screen

Damaged or faulty encoder for an encoder fault. Replace
encoder if necessary.
M35110000
Table 5.3
Brake System Troubleshooting
Check for hydraulic input supply to

the drawworks by checking rig
pressure displayed on the control
system screen or by checking
pressure at pressure gauges
provided.
Check the directional solenoid
valves (SOVs) on the brake control
panels:
a. Verify valve operator coils are
Inadequate hydraulic pressure
energized by confirming
magnetism.
Check downstream pressure as
valves are actuated to confirm
proper operation. Replace if
faulty.
Check the appropriate control
system circuit for proper
connectivity. Repair or
reconnect as required.
5.7 GEARBOX
Table 5.4
Gearbox Troubleshooting
Changes in gear Check teeth on all components, replace

Damage to gear teeth
noise any damaged parts.
Excessive bearing play Adjust bearing play
Defective bearing Replace defective bearing
Loud noises in area of Tighten bolts/ nuts to prescribed torque.

Fastening has worked loose
gear-unit fastening Replace damaged bolts/nuts.
Contd…
M35110000
Table 5.4
Gearbox Troubleshooting
Check oil level at room temperature, top

Oil level in housing too low
up if necessary.
Increased
temperature at Check date of last oil change, change oil if
Oil too old
bearing points necessary.
Bearing defective Check bearings and replace if necessary.
Inadequate sealing of housing cover

Gear unit is oily Seal joints
or joints
Inadequate sealing of housing cover Check seals, replace if necessary, seal

or joints joints
Oil leakage from gear
unit
Check radial shaft sealing rings, replace if
Radial shaft sealing rings defective
necessary.
Check oil state using test-tube method for

Oil froths in sump water contamination. Have oil analyzed by
laboratory.
Water in oil
Gear unit exposed to cold air from
Protect gear unit with suitable insulation.
machine-room ventilator causing
Close air outlet or alter its direction.
condensation
Oil level in housing too high Check oil level and adjust if necessary.
Operating Check date of last oil change and change

Oil too old
temperature too high oil if necessary.
Oil contaminated Change oil
8 7 6 5 4 3 2 1
F SPECIFICATIONS: F
MAX. HOOK LOAD: 1,200,000 LBS. - 12 LINES
1,000,000 LBS. - 10 LINES
875,000 LBS. - 8 LINES
GEAR RATIO: 7.466

WIRE ROPE DIAMETER: 1.38"
57 DRUM DIAMETER: 30"
DRUM LENGTH: 60"
E E
114 NOTES:
DRUM
1. COAT BEARINGS AND SEALS WITH OIL BEFORE
ASSEMBLY
57 2. USE MoS2 (Moly Paste) ON ALL FASTENERS
3. TORQUE BOLTS PER AP-25
4. PAINT AS PER CONTRACT
5. TEST PER ABCO TEST PROCEDURE AP-
6 STAMP SERIAL NUMBER ON DATA TAGS
DRUM SEE BELOW FOR DETAILS
D D
81 3/4
237 3/8
C C
35110000-F
(QC TO DETERMINE)
MM/DD/YYYY
API 7K
6 2000 HP
50,700
12 1,200,000
101 11/16 10 1,000,000
8 875,000
DRUM 30"
60"
B 42 1/8
1.5" B
DRAWN BY DATE
ASSEMBLY
TOLERANCES
UNLESS SPECIFIED PS 5/11
A 2000 HP AC DRAWWORKS A
.XX ANGLES CHECKED DATE
THIS DOCUMENT EMBODIES A CONFIDENTIAL PROPRIETARY DESIGN OF WHICH  .015  1/2 AR 5/11
AMERICAN BLOCK COMPANY RETAINS ALL PATENT AND OTHER RIGHTS, APPROVED DATE
INITIAL RELEASE
.XXX
INCLUDING EXCLUSIVE RIGHT OF MANUFACTURE AND SALE. THIS DOCUMENT 0 5/11 PS SRS SRS 5/11 MANUFACTURING CO.
 .005 125
IS SUBMITTED ONLY UNDER A CONFIDENTIAL RELATIONSHIP; AND MAY NOT
Houston, Texas
ON
35110000-F
SCALE REV
CHANGE APPROV FRACTIONS SHEET
N.T.S.
ALL DIMENSIONS ARE IN INCHES UNLESS NOTED
BE COPIED, DISCLOSED, OR MADE PUBLIC KNOWLEDGE. REV. DESCRIPTION DATE
BY BY  1/16
MACHINED
SURFACES DEBURR ALL SHARP CORNERS WITH 0.03R MAX.
DO NOT SCALE DWG.
1 OF 5 0
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
24 26 27 26
F F
57
E 114 1/16 E
57
D D
237 3/8
72
25 35 41 44 40 14
C 64
C
37
101 11/16
38
B B
69 6 46 36 45 62 63 65 16
TOLERANCES DRAWN BY DATE

UNLESS SPECIFIED SC 8/12 ASSEMBLY
A A
CHECKED DATE
2000 HP AC DRAWWORKS
.XX ANGLES
THIS DOCUMENT EMBODIES A CONFIDENTIAL PROPRIETARY DESIGN OF WHICH  .015  1/2 PS 8/12
.XXX
INCLUDING EXCLUSIVE RIGHT OF MANUFACTURE AND SALE. THIS DOCUMENT 0 INITIAL RELEASE 8/12 SC MSK
MANUFACTURING CO.
125 MSK
 .005
8/12
Houston, Texas
ON
35110000-F
SCALE REV
N.T.S.
BY BY  1/16
MACHINED
DO NOT SCALE DWG.
2 OF 5 0
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
58 59 22 23
1 GAP
F TORQUE TO BETWEEN F
682 FT-LBS. HUBS
HUB TO BE INSTALLED
FLUSH WITH END OF 61 60 19 ADVANCE .125
SHAFT FROM COLD FIT
32
E B B E
A A
18
(1 1/2" DESIGNED GAP

BETWEEN
D MOTOR AND GEARBOX) SECTION A-A D
TORQUE TO 282 FT-LBS. 47 61 TORQUE TO 454 FT-LBS.
51 54 43 8 57 59
34 8
9 1 70 18 66 67 TORQUE TO 2371 FT-LBS.
C 29 7 C
45 53 50
11
TORQUE TO
33 FT-LBS.
5
17
56
B B
2
71 55 48 15 33 69 28 48 55
TORQUE TO
1363 FT-LBS.
DRAWN BY DATE
2 ADDED 1 1/4 WASHER ITEM #71 ECN #131 8/12 SC MSK
TOLERANCES
UNLESS SPECIFIED PS 5/11 ASSEMBLY
A 2000 HP AC DRAWWORKS A
CHECKED DATE
THIS DOCUMENT EMBODIES A CONFIDENTIAL PROPRIETARY DESIGN OF WHICH 1 CHANGED PART CALLOUT, ITEM 66&67 7/11 MJS SRS .XX
 .015
ANGLES
 1/2 AR 5/11
INITIAL RELEASE
.XXX
 .005 125
Houston, Texas
ON
35110000-F
SCALE REV
N.T.S.
BY BY  1/16
MACHINED
DO NOT SCALE DWG.
3 OF 5 2
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
F F
1
51 54 43 12 32 5 2 3 10
TORQUE TO 9 FT-LBS. 52 49 42 3
E E
4
20
D D
31
C C
TORQUE TO 33 FT-LBS. 50 53 45
31
30
B 30 4 B
SECTION B-B
DRAWN BY DATE
ASSEMBLY
TOLERANCES
UNLESS SPECIFIED PS 5/11
A A
CHECKED DATE
1 SC MSK 2000 HP AC DRAWWORKS
.XX ANGLES
THIS DOCUMENT EMBODIES A CONFIDENTIAL PROPRIETARY DESIGN OF WHICH REPLACE 126-0374 w/ 126-0005 (#32) ECN 893 5/13  .015  1/2 AR 5/11
INITIAL RELEASE
.XXX
 .005 125
Houston, Texas
ON
35110000-F
SCALE REV
N.T.S.
BY BY  1/16
MACHINED
DO NOT SCALE DWG.
4 OF 5 1
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
BILL OF MATERIALS BILL OF MATERIALS
ITEM QTY PART NUMBER DESCRIPTION WEIGHT ITEM QTY PART NUMBER DESCRIPTION WEIGHT
F 45 22 201-0302 CAPSCREW, HH, SS, 3/8-16 UNC X 1.25 LG. 1 1 1 35060000 GEARBOX 2000 HP 6546 F
46 24 200-3401 SCREW, DRIVE, RD HD, ZP, #6 X 5/16 LG. 0 2 1 35064900 DRUM SHAFT COVER 67
47 12 201-4904 CAPSCREW, DH, GR8, ZP, 1-8 UNC X 3.50 LG. 14 3 2 35065100 DRUM SHAFT SEAL RETAINER 3
48 36 201-5093 CAPSCREW, HH, GR8, ZP, 1-1/4-7 UNC X 4 LG. 74 4 2 35065300 DRUM SHAFT SPACER 12
49 20 204-0111 WASHER, FLAT, SAE, ZP, 1/4 0 5 1 35070300 BEARING CARRIER SUPPORT 617
50 10 204-0113 WASHER, FLAT, SAE, ZP, 3/8 0 6 1 35110100 SKID 8905
51 16 204-0118 WASHER, FLAT, SAE, ZP, 3/4 1 7 1 35110200 DRUM 5824
52 20 204-0323 WASHER, LOCK, ZP, 1/4 0 8 1 35110300 DISC, BRAKE, 75" 1594
53 10 204-0325 WASHER, LOCK, ZP, 3/8 0 9 1 35110400 SHAFT, DRUM DRIVE 617
E 54 16 204-0330 WASHER, LOCK, ZP, 3/4 1 10 1 35110500 SHAFT, DRUM FREE 607 E
55 36 204-0334 WASHER, LOCK, ZP, 1-1/4 6 11 2 35110600 BRAKE BRACKET 798
56 8 205-0583 PIN, DOWEL, ZP, .50 DIA. X 1.75 LG. 1 12 1 35110700 COVER, OUTER BEARING CARRIER 75
57 60 201-7705 CAPSCREW, HSH, ZP, 7/8-9 UNC X 2.75 LG. 44 13 1 35111400 LEFT COVER ASSEMBLY 1225
58 6 201-7708 CAPSCREW, HSH, ZP, 7/8-9 UNC X 3.50 LG. 5 14 1 35111600 MAIN COVER ASSEMBLY 1222
59 66 204-0631 WASHER, LOCK, HI-COLLAR, ZP, 7/8 3 15 2 35112000 BEARING CARRIER SHIM PACK 8
60 2 201-4875 CAPSCREW, HH, GR8, ZP, 1-8 UNC X 2.25 LG. 2 16 8 35112100 MOTOR SHIM PACK 3
61 14 204-0332 WASHER, LOCK, ZP, 1 1 17 4 35112200 SHIM, BRAKE CALIPER 0
62 16 123-0253 NUT, HEAVY HEX, 3/8-16 UNC 1 18 2 35095600 COUPLING, MOTOR 275
D 63 12 35098800 COVER ADJUSTMENT ANGLE 7 19 2 35094600 KEEPER PLATE, MOTOR COUPLING 6 D
64 2 35099900 COUPLING GUARD 20 20 1 35101200 READOUT SHAFT 7
65 4 35098033 ANGLE, L2X2X1/4 X 16 LG. 17 21 1 35111300 COVER, READOUT 50
66 8 201-5148 CAPSCREW, HH, GR8, ZP, 1-1/2-6 UNC X 4 LG. 25 22 1 35101900 CLAMP, INSERT SET -F 7
67 8 204-0336 WASHER, LOCK, ZP, 1-1/2 2 23 1 35102000 CLAMP, WIRE ROPE 8
68 1 35109000 HYDRAULIC FOR BRAKE 0 24 1 35103000 SYSTEM, LUBRICATION 0
1 ITEM 72 SUPPLIED BY OTHERS 69 1 155-0067 STICKER, ADD GREASE 0 25 2 35103200 TURNBACK ROLLER FRAME 32
70 1 155-0112 STICKER, ADD OIL 0 26 9 35119901 BAR, SQUARE, 1" X 3.0 LNG 8
71 12 204-0034 WASHER, FLAT, USS, ZP, 1-1/4 3 27 4 35119902 BAR, SQUARE, 1" X 2.0 LNG 2
C 1 72 2 REF MOTOR 17200 28 4 35119903 BAR, SQUARE, .5" X 3.0 LNG 1 C
TOTAL WEIGHT...50,694 LBS. 29 1 171-0007 GROOVING, LEBUS, 1 3/8 WR 1313
30 1 109-0078 BEARING, SPHERICAL 14
31 2 122-0150 RADIAL SHAFT SEAL 0
3 32 1 126-0005 FITTING, GREASE, 1/4" NPT, STRAIGHT 0
33 1 126-0672 FITTING, GREASE RELIEF, 1/4" NPT 0
34 4 128-0025 BRAKE, HYDRAULIC, DUAL SPRING 3352
35 2 134-0541 TURNBACK ROLLER 17
36 2 155-0001 NAMEPLATE, ABCO 2
37 2 155-0089 NAMEPLATE, AC DRAWWORKS, 1 SPEED 2
B B
38 15 155-0065 STICKER, CAUTION 0
39 1 155-0082 NAMEPLATE, DRAWWORKS CURVE 0
40 1 155-0083 NAMEPLATE, DKS-2600 0
41 4 200-1525 U-BOLT, 3/8-16 UNC 1
42 20 201-0227 CAPSCREW, HH, SS, 1/4-20 UNC X .75 LG. 0
43 16 201-0053 CAPSCREW, HH, GALV., 3/4-10 UNC X 2.50 LG. 8
44 4 201-0301 CAPSCREW, HH, SS, 3/8-16 UNC X 1 LG. 0
DRAWN BY DATE
3 ADDED P/N 126-0005 (ITEM 32) ECN 893 5/13 SC MSK
TOLERANCES
UNLESS SPECIFIED PS 5/11 ASSEMBLY
A A
CHECKED DATE
2 SC MSK 2000 HP AC DRAWWORKS
.XX ANGLES
THIS DOCUMENT EMBODIES A CONFIDENTIAL PROPRIETARY DESIGN OF WHICH ADDED 1 1/4 WASHER ITEM #71 ECN #131 8/12  .015  1/2 AR 5/11
.XXX
INCLUDING EXCLUSIVE RIGHT OF MANUFACTURE AND SALE. THIS DOCUMENT 1 ADDED STICKERS ECN#129 7/11 MJS SRS SRS 5/11 MANUFACTURING CO.
 .005 125
Houston, Texas
ON
35110000-F
SCALE REV
N.T.S.
BY BY  1/16
MACHINED
DO NOT SCALE DWG.
5 OF 5 3
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
BILL OF MATERIALS
ITEM QTY PART NUMBER DESCRIPTION WEIGHT
1 1 SEE PAGE 3 & 4 PARALLEL SHAFT ASSY 4122
2 1 SEE PAGE 5 PLANETARY ASSY 1802
3 1 SEE PAGE 6 CARRIER, PLANET ASSY 1350
4 1 35064400 COVER, PLANETARY 5
5 2 35064500 COVER, PARALLEL SHAFT 9
D 6 1 35064600 COVER, MAIN PARALLEL 59
D
7 1 35064700 COVER, PLANETARY SUCTION 7
8 1 137-0048 MAGNETIC SUCTION SEPARATOR 2
9 58 204-0325 WASHER, LOCK, ZP, 3/8 0
10 58 201-0301 CAPSCREW, HH, ZP, 3/8-16 X 1 0
11 32 201-4677 CAPSCREW, HH, ZP,G8, 3/4-10 X 2.5 0
12 32 204-0330 WASHER, LOCK, ZP, 3/4 0
13 32 204-0118 WASHER, FLAT, SAE, ZP, 3/4 0
15 1 126-0404 NIPPLE, HEX, 1 1/2 NPT 1
16 2 155-0001 NAMEPLATE, ABCO 0
17 1 155-0024 NAMEPLATE, OILFIELD TRANSMISSION 0
1 18 2 129-0673 O-RING, 2-020 0
ESTIMATED WEIGHT 7500 LBS
C C
6
2 SPECIFICATIONS:
1) MODEL NO. DGB-PLI-S-2-7.466
1 2) MAX INPUT SPEED: 3000 RPM
3) GEAR RATIO: 7.4661:1
4) MAX OIL CAPACITY: 30 GALLONS
5) OIL TYPE: EP 220 GEAR LUBRICANT
17 NOTES:
1) COAT BEARINGS AND SEALS WITH OIL
B BEFORE ASSEMBLY B
1 2) ITEM 18 TO BE INSTALLED BEFORE
TWO HALVES ARE PUT TOGETHER
3) USE LOC-TITE ON ALL FASTNERS
4) TORQUE 3/8" FASTENERS TO 15 FT-LBS
5) TORQUE 3/4" FASTENERS TO 280 FT-LBS
6) STAMP SERIAL NUMBER ON DATA TAGS
7) TESTING AS PER ABCO TEST PROCEDURE AP-24
8) PAINT AS PER CONTRACT
A A
7 18
16
UNLESS SPECIFIED M.Despotovic 10.02.02 PARALLEL SHAFT ASSY

CHECKED DATE
GEARBOX, 2000 HP DRAWWORKS
.XX ANGLES
THIS DOCUMENT EMBODIES A CONFIDENTIAL PROPRIETARY DESIGN OF WHICH  .015  1/2 MJS 3/11
INITIAL RELEASE
.XXX
0 3/11 MJS SRS .005 SRS 3/11 MANUFACTURING CO.
INCLUDING EXCLUSIVE RIGHT OF MANUFACTURE AND SALE. THIS DOCUMENT  125
Houston, Texas
ON
35060000
SCALE REV
CHANGE APPROV FRACTIONS ALL DIMENSIONS ARE IN INCHES UNLESS NOTED SHEET
BE COPIED, DISCLOSED, OR MADE PUBLIC KNOWLEDGE. DESCRIPTION NTS 1 12 0
MACHINED
REV. DATE
BY BY  1/16 SURFACES DEBURR ALL SHARP CORNERS WITH 0.03R MAX. DO NOT SCALE DWG. OF
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
(54.525)
(45.76)
1
D D
(44.13)
(21.875)
C C
3
B B (77.00)
A
14 9 10 7 10 9 14
4
11 13
8
10
B B
15
(7.89)
SECTION B-B
(7.89)
(1.19)
A
A (74.62) A
SECTION A-A

CHECKED DATE
.XX ANGLES
INITIAL RELEASE
.XXX
Houston, Texas
ON
35060000
SCALE REV
BE COPIED, DISCLOSED, OR MADE PUBLIC KNOWLEDGE. DESCRIPTION NTS
MACHINED
REV. DATE
BY BY  1/16 SURFACES DEBURR ALL SHARP CORNERS WITH 0.03R MAX. DO NOT SCALE DWG.
2 OF 12 0
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
BILL OF MATERIALS
1 2 SEE PAGE 8 INPUT SHAFT ASSY 324
2 2 SEE PAGE 9 IDLER ASSY 147
3 1 SEE PAGE 7 OUTPUT SHAFT ASSY 799
4 2 35060500 COVER, MOTOR SIDE 21
5 2 35060800 IDLER COVER 2
D 6 2 35092700 IDLER PIN 30 D
7 1 35061800 GEAR, ANNULUS, 84 TEETH 217
7 8 1 35062300 THRUST BEARING 9
9 1 35061700 BUSHING 7
10 1 35060200 FRAME, PARALLEL SHAFTS 2018
11 2 SEE PAGE 11 SPRAY BAR 2
36 12 2 SEE PAGE 12 SPRAY BAR 0
15 4 35094200 PLUGE 1/8" NPT, MODIFIED 0
2 16 40 201-0011 CAPSCREW, HH, 1/2-13 UNC X 1.50 LG. 0
D 17 23 201-0203 CAPSCREW, HH, SS, 1/4-20 UNC X .75 LG. 0
18 6 123-0108 WASHER, FLAT, ZP, #10 0
19 6 123-0109 SCREW, ZP, #10-24 X .5 LNG 0
4 E 20 4 129-0664 O-RING, 2-222 0
21 1 129-0665 0-RING, 2-381 0
15 23 2 123-0179 SET SCREW, HEX, EXT PT, 1/2-13 X 1 0
C E
24 1 126-0114 2" NPT PLUG 0 C
15 25 12 204-0113 WASHER, FLAT, SAE, ZP, 3/8 0
27 1 137-0037 FILLER STRAINER CAP ASSY 0
C D C
1 29 2 122-0146 RADIAL SHAFT SEAL 0
30 40 204-0327 WASHER, LOCK, ZP, 1/2 0
31 12 204-0325 WASHER, LOCK, ZP, 3/8 0
32 12 201-0301 CAPSCREW, HH, SS, 3/8-16 X 1 LNG 0
33 23 204-0323 WASHER, LOCK, ZP, 1/4 0
1 34 1 126-0405 ELBOW, 90°, 3/8 TUBE X 1/4 MNPT 0
35 24 201-7649 CAPSCREW, HSH, 3/4-10 X 2.5 LNG 0
36 2 205-0594 PIN, DOWEL, SS, .50 DIA. X 1.75 LG. 0
1 37 1 126-0449 BULKHEAD, 3/8 TUBE X 3/8 TUBE
38 1 126-0458 CAP, 3/8 TUBE 0
B 2
ESTIMATE WEIGHT 4200 LBS
B
10 5 3 24 5
NOTE:
(77.00) (28.47) 1 ITEMS 34 AND 37 MUST BE CONNECTED BY 3/8 SS TUBE BEFORE
OUTPUT SHAFT ASSY INSTALLED. SEE ENGINEERING FOR BENDING
DETAILS.
2 ITEM 38 TO BE USED TO CAP 3/8 SS TUBE CONNECTED TO ITEM 12 FOR
MAIN BEARING LUBRICATION. SEE ENGINEERING FOR BENDING
DETAILS
A A

CHECKED DATE
.XX ANGLES
INITIAL RELEASE
.XXX
Houston, Texas
ON
35060000
SCALE REV
3 12 0
MACHINED
REV. DATE
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
10 36 35 7 8 9 21
26 30 16
D D
C 1 C
3
15 5 23 29
23 3 25 31 32 6 5 2 4 1
SECTION C-C
B 16 B
17 33 28
34 30
27
26
19 18
20
DETAIL 1
DETAIL 2 30 26 16
29 SECTION E-E
4 SECTION D-D
DETAIL 3
A A

CHECKED DATE
.XX ANGLES
INITIAL RELEASE
.XXX
Houston, Texas
ON
35060000
SCALE REV
4 12 0
MACHINED
REV. DATE
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
BILL OF MATERIALS
IT QTY PART NUMBER DESCRIPTION MASS
G 1 1 35060400 FRAME, PLANETARY 848
2 1 SEE PAGE 10 DRUM SHAFT ASSY 839
3 1 35064000 SPLINE ADAPTER 103
5 1 35064200 TAB 5
D 8 8 204-0330 WASHER, LOCK, ZP, 3/4 0 D
9 8 201-0053 CAPSCREW, HH, 3/4-10 X 2.5 0
10 1 105-0089 SNAP RING, EXTERNAL 270 MM 1
12 3 201-4422 CAPSCREW, DH, GR8, ZP, 1/2-13 UNC X 1.25 LG. 0
13 1 129-0666 O-RING, 2-462 0
(42.88)
F G F
C C
(21.88)
1
(41.50)
(21.30)
B 10 9 8 7 2 1 B
A 5 12 13 SECTION G-G
A
SECTION F-F TOLERANCES DRAWN BY DATE

CHECKED DATE
.XX ANGLES
INITIAL RELEASE
.XXX
Houston, Texas
ON
35060000
SCALE REV
5 12 0
MACHINED
REV. DATE
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
BILL OF MATERIALS
ITEM QTY PART NUMBER DESCRIPTION MASS
1 1 35064300 PLANET CARRIER 534
2 10 126-0447 PLUG, 1/4 NPT, SH, BRASS 0
3 5 35062700 GEAR, PLANET, 28 TEETH 465
4 5 35062100 PIN, PLANET 150
2 5 10 109-0103 BEARING, SPHERICAL 200
D 6 20 105-0085 SNAP RING, EXTERNAL, 100 MM 0 D
H 3 7 10 105-0090 SNAP RING, INTERNAL, 180 MM 0
1
6
7
C C
(28.87)
B B
DETAIL 3
NOTE:
PLUGS DO NOT NEED TO SIT FLUSH WITH HOUSING
PLANETARY ASSEMBLY:
- Mount the bearings on the pin until they sit against the shoulder/snapring.
- Install one snapring in planet-bore and heat the planet until bearing can be installed
- Slide the planet over both bearings until snapring sits against the closer one.
- Flip-around and install the other snapring into the planet bore.
- Now install the far-outside snaprings onto the pin and install assembly into the carrier.
(10.28)
A H A
SECTION H-H
UNLESS SPECIFIED S.Petrovic

M.Despotovic 10.02.02
09.08.14 PARALLEL SHAFT ASSY
PLANET CARRIER ASSY
GEARBOX,2000
2000HPHP DRAWWORKS
CHECKED DATE
GEARBOX, DRAWWORKS
.XX ANGLES
THIS DOCUMENT EMBODIES A CONFIDENTIAL PROPRIETARY DESIGN OF WHICH  .015  1/2 MJS MJS 3/11
3/11
AMERICAN BLOCK COMPANY RETAINS ALL PATENT AND OTHER RIGHTS,
00 INITIAL
INITIAL RELEASE 3/11 MJS
3/11 SRS
APPROVED DATE
RELEASE
.XXX
MJS SRS .005 SRS SRS 3/11
3/11
MANUFACTURING CO.
Houston, Texas
ON
35060000
35060000
SCALE REV
6 12 0
NTS
MACHINED
REV. DATE
BY BY  1/16 SURFACES DEBURR ALL SHARP CORNERS WITH 0.03R MAX. DO NOT SCALE DWG. OF 0
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
BILL OF MATERIALS
K IT QTY PART NUMBER DESCRIPTION WEIGH
IDLER 1 1 35063000 OUTPUT SHAFT 183
2 1 35062500 GEAR, OUTPUT, 60 TEETH 302
3 1 35062600 GEAR, SUN, 32 TEETH 52
4 1 35062200 COVER, OUTPUT SHAFT INSPECTION 24
5 1 35063100 SPACER 6
D PLANETS 6 1 35063200 BEARING CARRIER 21 D
7 1 35063300 SPACER 1
8 1 35063600 SUN TAB 4
9 1 35063700 SPACER 4
K 10 1 35063800 KEY SPECIAL 0
J J 11 1 35062900 COVER, OUTPUT SHAFT 151
12 1 35063900 SHAFT TAB 5
13 1 35094200 PLUG, 1/8 NPT MODIFIED 0
14 1 105-0086 SNAP RING, INTERNAL, 250 MM 1
15 1 129-0670 O-RING, 2-376 0
16 6 204-0115 WASHER, FLAT, SAE, ZP, 1/2" 0
17 6 204-0327 WASHER, LOCK, ZP, 1/2" 0
18 6 201-0011 CAPSCREW, HH, 1/2-13 X 1.5 LNG 0
19 1 109-0098 ANGULAR CONTACT BALL BEARING 22
20 3 201-4422 CAPSCREW, DH, G8,ZP, 1/2-13 X 1.25 LNG 0
C 21 6 201-7371 CAPSCREW, SH, ZP, 1/2-13 X 3.5 LNG 0 C
22 6 204-0627 WASHER, LOCK, HI-COLLAR, 1/2" 0
23 1 105-0087 SNAP RING, EXTERNAL, 170 MM 0
11 9 1 2 5 3 24 5 201-7363 CAPSCREW, SH, ZP, 1/2-13 X 1.5 LNG 0
25 1 109-0097 BEARING, CYLINDRICAL ROLLER 19
18 ESTIMATED WEIGHT 821 LBS
17
16
21
6
22
B 8 B
7 10
20
4 24
SECTION K-K
13
12
14
A 15 23 A
SECTION J-J DRAWN BY DATE
TOLERANCES
CHECKED DATE
.XX ANGLES
INITIAL RELEASE
.XXX
Houston, Texas
ON
35060000
SCALE REV
BE COPIED, DISCLOSED, OR MADE PUBLIC KNOWLEDGE. DESCRIPTION NTS 7 12 0
MACHINED
REV. DATE  1/16 DO NOT SCALE DWG.
BY BY SURFACES DEBURR ALL SHARP CORNERS WITH 0.03R MAX.
OF
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
BILL OF MATERIALS
1 1 35061300 INPUT SHAFT 100
IDLER 2 1 35061400 INPUT SHAFT CARRIER 44
3 1 35062800 GEAR, INPUT SHAFT, 34 TEETH 145
4 1 35061500 PINION COVER 9
5 1 35061600 BEARING CARRIER 7
D 1 6 1 126-0398 PLUG, SOCKET HEAD, 1/8" NPT 0 D
7 1 134-0622 IR 120x130x30 1
L L 10 6 204-0327 WASHER, LOCK, ZP, 1/2 0
11 6 201-0011 CAPSCREW, HH, GALV., 1/2-13 UNC X 1.50 LG. 0
12 1 109-0075 BEARING, CYLINDRICAL 0
15 1 35065200 INPUT SHAFT KEY 1
16 1 109-0074 BEARING, SPHERICAL ROLLER 12
17 6 201-7118 CAPSCREW, HSH, ZP, 3/8-16 UNC X 3 LG. 0
18 6 204-0625 WASHER, LOCK, HI-COLLAR, ZP, 3/8 0
C VIEW14
C
NOTE:
15 7 3 1 5 2 4
2 ASSEMBLIES REQUIRED
17
18
8
B B
6
11
10
14 13 13
A A
SECTION L-L

CHECKED DATE
.XX ANGLES
INITIAL RELEASE
.XXX
Houston, Texas
ON
35060000
SCALE REV
8 12 0
MACHINED
REV. DATE
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
BILL OF MATERIALS
F ITEM QTY PART NUMBER DESCRIPTION MASS F
1 1 35062400 IDLER 84
2 1 35062000 SHAFT, IDLER 23
4 2 105-0076 SNAP RING, INTERNAL, 215 MM 2
E 5 2 109-0065 BEARING, SPHERICAL ROLLER 19 E

3 1
M NOTE:
OUTPUT SHAFT
5 TWO ASSEMBLIES
D D
2 REQUIRED
C C
B 4 B
M SECTION M-M
INPUT SHAFT

A A
.XX ANGLES CHECKED DATE
THIS DOCUMENT EMBODIES A CONFIDENTIAL PROPRIETARY DESIGN OF WHICH  .015  1/2 MJS 3/11 GEARBOX, 2000 HP DRAWWORKS
.XXX
INCLUDING EXCLUSIVE RIGHT OF MANUFACTURE AND SALE. THIS DOCUMENT 0 INITIAL RELEASE 3/11 MJS SRS SRS 3/11 MANUFACTURING CO.
 .005 125
Houston, Texas
ON
35060000
SCALE REV
NTS
BY BY  1/16
MACHINED
DO NOT SCALE DWG.
99OF 12 0
OF 12
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
BILL OF MATERIALS
1 1 35063500 DRUM SHAFT 50
2 1 35064900 DRUM SHAFT COVER 67
3 1 35065100 DRUM SHAFT SEAL RETAINER 1
4 1 35065300 DRUM SHAFT SPACER 6
D N 6 1 105-0088 SNAP RING, EXTERNAL, 280 MM 1 D
7 1 122-0150 RADIAL SHAFT SEAL 0
4 9 10 204-0323 WASHER, LOCK, ZP, 1/4 0
5 10 10 201-0203 CAPSCREW, HH, 1/4-20 UNC X 3/4 0
6
C C
NOTE:
DRUMSHAFT DESIGN DEPENDS ON DRAWWORKS PART NUMBER. REFERENCE

DRAWWORKS BOM
B B
10
8
7 3 2
N 1
SECTION N-N
A A

CHECKED DATE
.XX ANGLES
INITIAL RELEASE
.XXX
Houston, Texas
ON
35060000
SCALE REV
MACHINED
DO NOT SCALE DWG.
REV. DATE
BY BY  1/16 SURFACES DEBURR ALL SHARP CORNERS WITH 0.03R MAX. 10 OF 12 0
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
PARTS LIST
ITEM QTY PART NUMBER DESCRIPTION
1 1 126-0399 SPRAY NOZZLE, 1/8" NPT
2 1 126-0402 PLUG, SOCKET HEAD, 1/2" NPT
3 1 35096600 BODY, SPRAY BAR 1
D D
3 1 2
P
C C
(2.63)
B B
P (8.13)
SECTION P-P
NOTE:
TWO ASSEMBLIES REQUIRED
A A

CHECKED DATE
.XX ANGLES
INITIAL RELEASE
.XXX
Houston, Texas
ON
35060000
SCALE REV
MACHINED
DO NOT SCALE DWG.
REV. DATE
BY BY  1/16 SURFACES DEBURR ALL SHARP CORNERS WITH 0.03R MAX.
0
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
PARTS LIST
ITEM QTY PART NUMBER DESCRIPTION
1 2 126-0399 SPRAY NOZZLE, 1/8" NPT
2 1 126-0401 REDUCER BUSHING, 1/2" MNPT X 1/8"
FNPT
3 1 35096700
D (.38) D
Q
R
3 1 2 1
(2.63)
C C
Q 11.46
SECTION Q-Q
45°
B B
NOTE:
TWO ASSEMBLIES REQUIRED
A VIEW R-R
A

CHECKED DATE
.XX ANGLES
INITIAL RELEASE
.XXX
Houston, Texas
ON
35060000
SCALE REV
MACHINED
DO NOT SCALE DWG.
REV. DATE
BY BY  1/16 SURFACES DEBURR ALL SHARP CORNERS WITH 0.03R MAX.
0
8 7 6 5 4 3 2 1
Name: MEH-3000-0139-802
Date: 18.07.2011
Revision: B
Installation and Maintenance

Manual
HYDRAULIC
BRAKE CONTROL UNIT
3000-0139-802
(1106-0006-804)
ATEX Ex II 1G II B T3
Installation and Maintenance Manual – 3000-0139-802
Table of content
TABLE OF CONTENT ............................................................................................................................................. 1
1. GENERAL.................................................................................................................................................. 2
1.1 Who to contact ........................................................................................................................................... 2
1.2 Safety ......................................................................................................................................................... 2
1.3 Conventions used in this manual ............................................................................................................... 3
1.4 Disclaimer .................................................................................................................................................. 3
1.5 Transportation ............................................................................................................................................ 3
1.6 Lifting ......................................................................................................................................................... 3
1.7 Storage ...................................................................................................................................................... 4
1.8 How to order spare parts ........................................................................................................................... 4
2. MOUNTING AND COMMISSIONING ....................................................................................................... 5
2.1 Mounting ................................................................................................................................................... 5
2.2 Connections ............................................................................................................................................... 5
2.3 Before starting the pump unit ..................................................................................................................... 5
3. DESCRIPTION OF THE HYDRAULIC SYSTEM ....................................................................................... 6
3.1 General ...................................................................................................................................................... 6
3.3 Hydraulic diagram ...................................................................................................................................... 8
4. MAINTENANCE ......................................................................................................................................... 9
4.1 Inspection................................................................................................................................................... 9
4.2 Adjustment ................................................................................................................................................. 9
4.3 Checks ....................................................................................................................................................... 9
4.4 Function test ............................................................................................................................................ 10
4.5 Dismantling the power unit....................................................................................................................... 10
4.6 Changing the oil ....................................................................................................................................... 10
4.7 Changing the oil and cleaning the reservoir............................................................................................. 11
4.8 Changing the oil filter ............................................................................................................................... 11
4.9 Changing the air breather ........................................................................................................................ 11
4.10 Measuring the gas pressure .................................................................................................................... 11
4.11 Recharging the accumulator .................................................................................................................... 12
5. TROUBLE SHOOTING ............................................................................................................................ 14
5.1 Failure intro .............................................................................................................................................. 14
5.2 Power unit does not release pressure ..................................................................................................... 15
5.3 Power unit does not set / build pressure .................................................................................................. 16
5.4 Other failures ........................................................................................................................................... 17
APPENDIX A - DIMENSION DRAWING ............................................................................................................... 19
APPENDIX A - DIMENSION DRAWING ............................................................................................................... 19
APPENDIX B - DIMENSION DRAWING - FRAME................................................................................................ 20
APPENDIX B - SPARE PARTS LIST - FRAME .................................................................................................... 21
APPENDIX C - SPARE PART DRAWING – TANK ............................................................................................... 22
APPENDIX C - SPARE PARTS LIST – TANK ...................................................................................................... 23
APPENDIX D – SPARE PART DRAWING – MAIN BLOCK ................................................................................. 24
APPENDIX D - SPARE PARTS LIST - MAIN BLOCK .......................................................................................... 25
APPENDIX E - SPARE PART DRAWING – DRAW WORKS BLOCK.................................................................. 26
APPENDIX E - SPARE PARTS LIST - DRAW WORKS BLOCK .......................................................................... 27
APPENDIX F - HYDRAULIC SETTINGS............................................................................................................... 28
APPENDIX G - ADJUSTING ................................................................................................................................. 29
APPENDIX H - ELECTRICAL DIAGRAM.............................................................................................................. 31
APPENDIX I - RECOMMENDED FLUID ............................................................................................................... 33
APPENDIX J - RECOMMENDED SPARE PARTS................................................................................................ 34
328650-sbdk-MEH-3000-0139-802_B Page 1
• In order to maintain the guarantee always

1. General use original spare parts from Svendborg
Thank you for buying a Svendborg Brakes Brakes A/S.
product.
Before using the product please read this • It is the customer’s responsibility that the
manual carefully. brake and hydraulic aggregate are always
clean, and free from dirt, grease or oil.
1.1 Who to contact • It is the customer’s responsibility that the air
gap between brake pads and brake disc
In case you have any questions to this
never exceeds the air gap recommended.
manual please contact your local
representative or nearest Svendborg Brakes • Always use a torque wrench when refitting
Office: mounting bolts or valves in order to ensure
the torque obtained is the torque described
in this manual.
Svendborg Brakes Offices:
• There should be one manual available for
Denmark: the service / maintenance crew as a
Jernbanevej 9, DK-5882 Vejstrup minimum.
Phone: +45 63 255 255
E-mail: sb@svendborg-brakes.com Hydraulic power unit:
• Do not operate the hydraulic power unit
Germany: before correctly filling the reservoir / oil tank
Kirchnerstrasse 42, DE-32257 Bünde with oil.
Phone: +49 5223 68 540 0 • Do not adjust valves or pressure switches to
E-mail: sb@svendborg-brakes.de higher operating pressure than specified in
the manual.
USA: • Do not change the size or type of
100 Fillmore Street, 5th Floor, #514, components.
Denver, CO 80206 • Do not use hydraulic fluids not
Phone: +1 303 285 1271 recommended in this manual.
E-mail: sb@svendborg-brakes.us
Brakes:
China: • Do not operate the brake before removing
T40B-5, No.1765 Chuan Qiao Road the air from the hydraulic system by bleeding
Pudong 201206 Shanghai and then re-filling with oil.
Phone: +86 21-58996031 • Do not use higher operating pressures than
E-mail: sb@svendborg-brakes.com specified on the nameplate of the brake / or
in the manual.
Australia: • Do not change the size or type of spring
118 Burswood Road, P.O. Box 48 pack.
Burswood, WA 6100 • Do not use the brake pads when they are
Phone: +61 0 8 94 160300 worn to the minimum thickness as shown in
E-mail: sb@svendborg-brakes.com the manual.
• Do not operate the brake if there is dirt or
or visit us at: corrosion protection on disc or brake pads.
www.svendborg-brakes.com
Personal safety
1.2 Safety Do not work on the brake/ system before:
The Svendborg Brakes brake line of • The manual has been read and understood.
products are designed to be mounted on a • The brake disc is locked and not able to
rotating brake disc for use in conjunction rotate before adjusting the brake and / or air
with parking brake applications, service gap.
brake applications or emergency brake • Locking / securing the brake piston by using
applications only. the air gap bolt / air gap nut if working on a
spring applied brake.
Note: • Being sure there is no pressure on the
• Always make sure that you consult hydraulic power unit or circuit.
Svendborg Brakes A/S before using tools or • Being sure the oil pressure in the
any other equipment not recommended / accumulator(s) has been relieved / removed.
specified in this manual.
328650-sbdk-MEH-3000-0139-802_B Page 2
• The control signals has been shut off and downtime costs or claims of any party such
blocked before working on the system. damages, resulting from any misspellings or
• The electrical power has been shut off inaccurate information in this users guide.
This document or parts hereof may in no

1.3 Conventions used in this manual event be copied, reproduced, changed or
To make sure that you perform certain tasks translated to other languages without explicit
properly, please take note on the following written permission from Svendborg Brakes
symbols used throughout this manual. A/S.
WARNING: Information to prevent personal

1.5 Transportation
injury when trying to complete a task. When leaving the factory the hydraulic power
unit is always packed / wrapped to ensure
maximum security for the product during
CAUTION: Information to prevent damage transport.
to the components when trying to complete
a task.
CAUTION
If the hydraulic power unit has been sent by
WARNING: Electrical shock hazard air freight - please note that the gas (N2)
pressure has been released / removed from
the accumulator(s).
IMPORTANT: Information that you MUST A label (see figure 1.1) is then attached to
follow to complete a task. the accumulator.
FIGURE 1.1
NOTE: Tips and additional information to aid
in completing a task.
Figures within brackets ( ) relate to

position number and appendix number
i.e. (15-C) refers to position number 15 in If the accumulator is not pre-charged it must
appendix C on both drawing and bill of be recharged before usage. See section
material (parts list). 4.10 – “Recharging the accumulator” for
details
1.4 Disclaimer
Normally there is no hydraulic oil in the unit.
Svendborg Brakes A/S reserves the right to A warning label is attached to it.
revise this document without prior
notification. These documents have been
proofread for errors in translation and
accuracy. Despite this, technical and
WARNING
typographical deviations can sometimes FOR TRANSPORT REASONS
occur. THE PUMP IS SHIPPED
WITHOUT OIL
This document is updated on a regular
basis; changes will be published in future FILL WITH RECOMMENDED OIL
printings. Improvements and/or changes to BEFORE STARTING
the described products or manual can be REFER TO MANUAL
implemented at any time without preceding
notice. The hydraulic power unit must be filled with
oil according to appendix I of this manual
In no event shall Svendborg Brakes A/S be before usage. If running dry the pump will be
liable for any special, incidental, destroyed.
consequential or punitive damages. This
includes, but is not limited to: damage to
other property or person, inconvenience, 1.6 Lifting
loss of goodwill, lost profits or revenue, loss The hydraulic power unit weighs app. 375 kg
of use of this product or any associated (825 lbs). If it is necessary to use a lifting
equipment, cost of substitutive equipment,
328650-sbdk-MEH-3000-0139-802_B Page 3
harness, under no circumstance place it

around valves, gauges or accumulators.
See below how to lift.
If not mounted in cabinet the hydraulic power
unit may be lifted in the motor – see figure
1.3.
1.7 Storage
FIGURE 1.3
Hydraulic power units must be stored indoor
in a clean, dry area. They must be stored in
such a way that it can’t be damaged by
passing or falling objects.
For indoor storage for up to 3 month the
hydraulic power unit does not need any
surface treatment. For longer periods you
should cover it with plastic / a canvas cover
to protect it against dirt
1.8 How to order spare parts

When ordering spare parts for your hydraulic
power unit please refer to the specific item
number in the parts list – see appendices.
CORRECT WAY TO LIFT
For full identification of the hydraulic power
CAUTION unit please note the ID-number labelled on
Do not lift the hydraulic power unit in the the manifold or on the tank.
valves etc. – see figure 1.4
FIGURE 1.4 FIGURE 1.6
PU: 1106-0006-804
ID: 1-500032588
PRECAUTION!
It is suggested that service on the PU is
WRONG WAY TO LIFT done in a work shop outside the hazardous
area.
If the hydraulic power unit is mounted in a If not it must be ensured that sparks will not
cabinet the unit can be lifted by using the be created.
lifting point in the supporting frame.
FIGURE 1.5
PRECAUTION!
Please be aware of the danger of ignition in
hazardous areas. When handling the
hydraulic unit make sure not to hit or strike
other components or drop items. This might
cause sparks.
328650-sbdk-MEH-3000-0139-802_B Page 4
2.3.2 Electrical connections

2. Mounting and
commissioning WARNING
Connect the valves (19, 20, 20.1, 20.2, 22.1,
23.1, 23.2), the motor (4A), the pressure
2.1 Mounting transmitters (40, 42, B1, B2,), the thermo
In the bottom of the frame there are 4 holes switch (5e) and the level switch (5c), as well
Ø13 for floor mounting. as the switches for valve (30.1, 31.1) to the
voltage described in Appendix F.
2.2 Connections
Hydraulic pressure ports out of the manifold CAUTION
are size ¾”-16 JIC metric male according to
SAE 070501 2.3.3 Start the electric motor.
Check that the rotation of the electric motor
is correct as indicated on the motor – i.e.
2.3 Before starting the pump unit clock wise viewed from the fan end.
Check accumulator before starting – if the
accumulator has a warning sign telling that
the accumulator has NOT been pre-charged
(in case of air freight – see section 1.5).
Charge the accumulator before usage – see

section 4.9 for details.
FIGURE 2.1
2.3.1 Fill up the tank on the pump unit with oil of

the recommended quality (see appendix I).
The oil volume is approx. 105 litres. Fill up
the tank as described in section 4.6.4 &
4.6.5
FIGURE 2.2
328650-sbdk-MEH-3000-0139-802_B Page 5
from de-energizing valve 20 to de-energizing

3. Description of the the others valves (22.1, 23.1 and 23.2)
hydraulic system
3.1.2.4 Opening one brake channel.
If a signal is given to one of the valves (20.1
3.1 General or 20.2) each brake channel may be isolated
The hydraulic unit 1106-0006-804 has been in the actual position (energized coils) the
developed to use together with failsafe brake valves are operated, also valve 22.1, 23.1,
callipers from Svendborg Brakes. The pump 23.2 are closed (energized).
can be connected to one or more brakes. Pressure at each brake channel may be
monitored by the pressure transducers (B1
3.1.2 Function (See diagram 1106-0006-604) to B2).
The following describes function of the
system. 3.1.2.5 Manuel opening of brake.
In case of power failure it is possible to open
3.1.2.1 System energy the brakes by using the hand pump. Valve
Stand by. (31) is closed. Thereafter valve (30) is
In the hydraulic system an electro motor (4) closed and held in closed position. While
and a pump (2) converts electrical power holding this valve closed the hand pump
into oil pressure and oil flow. (HP) has to be operated. The actual
The pressure transmitter (40) will indicate pressure at the brakes may be observed at
that there is no pressure in the accumulator. gauge (PO).
This should lead to that valve (19) gets When the valve (31) is left without holding
signal and goes on. The pressure rises and force it will open to tank and the brakes will
when the set value is reached valve (19) be applied.
should open again. Then the oil flows Please note that, any not fully open position
through check valve (17.1) to the filter (15) in valve (30 & 31) will lead to a signal in the
and back to tank through valve (19). control system.
Also note that it is extremely important to
Note for service people: leave the system with both valves (30 and
In case of any failure, the pressure in the 31) open.
accumulator can be released through the
accumulator dump valve (52), which during 3.1.2.6 Bedding in.
normal operation is closed, and the ACCU- When signal is given to the brakes the
dump ball valve. valves (20) and (22.1) goes off and the oil is
dropped to tank through and to the pre-set
3.1.2.2 Releasing the brakes. value of valve (24.1), valve (23.1& 23.2)
When signal to open the brakes is given, must be on when bedding in.
valve (19, 20, 22.1, 23.1 & 23.2) goes on, The achieved force will apply the brakes with
and oil will flow through valve valves (20.1 to a reduced torque that is sufficient to bed the
20.2) to the brakes. The pressure at each brake pads in – in order to get the right
brake channel can be monitored at each coefficient of friction. See separate
pressure transmitter (B1 to B2). When the information packed with the brake pads.
brakes are lifted some oil will be used from
the accumulator, and the pressure will drop. 3.2. Monitoring
This will be indicated from the transmitter Pressure transmitter (42) monitors the
(40), valve (19) will close and the pump will system pressure (see 3.2.1).
refill the accumulator. When there is need for re-boosting the
system pressure it must have the motor
3.1.2.3 Braking. started and give signal to valve (19).
When signal to braking is given the brakes Pressure transmitter (42) monitors the
will be applied by deactivating valves (20, pressure before the filter.
22.1, 23.1 and 23.2). If the measured pressure difference over the
If the brakes are controlled from a PLC filter (15) exceeds 5 bar this transmitter has
(Programmable Logic Controller) or to indicate a warning signal. The signal from
equivalent it is important that valve (20) not pressure transmitter (42) must be compared
is deactivated later than the others valves. If with the signal from pressure transmitter (40)
the application allows this a delay of max 20 when the brakes are in operation.
msec. can, with advantage, be implemented The signal from pressure transmitter (42)
must be < 5 bar when valve (19) is open and
the oil is circulated through the pump, filter
328650-sbdk-MEH-3000-0139-802_B Page 6
and valve 19. If the pressure is above 5 bar

the filter element must be replaced.
Transmitter (5c) monitors the oil level in the

tank.
Transmitter (5e) monitors the oil temperature
in the tank.
328650-sbdk-MEH-3000-0139-802_B Page 7
3.3 Hydraulic diagram
In Work
CONFIDENTIAL
328650-sbdk-MEH-3000-0139-802_B Page 8
4. Maintenance 4.3 Checks

Maintenance is important for the ability of By remaining alert and paying close
the hydraulic power unit to control the attention to detail it is possible to detect
brakes at any time. faults in their early stages and so prevent
Maintenance consists of inspection and them from developing into more serious
service. malfunctions. This is particular true during
the early stages, but also remains true
throughout the service life of the pump
4.1 Inspection unit.
At initial commissioning inspection is done
to check if adjustment of the pump unit is A constant look out should be kept for:
necessary. • External leaks
Later inspection is done on a regular • Dirt
basis. • Damage, especially to hoses and pipes
4.2 Adjustment • Unusual noises from pump, electrical
motor, valves etc.
A number of components demands the • Proper functioning of instruments
right setting or charging in order to make
the braking system work properly.
The correct setting and how to adjust it
can be found in Appendix F.
All of these components in a pump unit
are pre-set to the right pressure from the
factory. They may need adjustment during
initial commissioning.
Service intervals periods

See Initial commissioning and
Inspection plan after commissioning.
chapter installation
Whatever comes first of:
Function
Test of each valve Before first real operation 6 months / 1000 h
Hydraulic oil
Level of oil Continuous Monthly / 160 h
If not using the level and
Continuous Weekly / 40 h
termo switch (3 litre tank)
Temperature Continuous Monthly / 160 h
Oil condition (sample) 6 months / 1000 h
Oil change 2 years / 4000 h
Filters
Oil filter cleaning (change
After one week 6 months / 1000 h
if necessary)
Air filter change 6 months / 1000 h
Accumulators
Gas pressure Daily 6 months / 1000 h
According to legal
Other checks
requirements
Adjustments
Valves etc. Continuous 6 months / 1000 h
Checks
Monthly / 160 h
External leaks Daily
or if decresing oil level
Dirt Monthly / 160 h
Damage Continuous Monthly / 160 h
Noises Continuous Monthly / 160 h
Instruments / electrical
Continuous 6 months / 1000 h
connections
328650-sbdk-MEH-3000-0139-802_B Page 9
4.4 Function test
Testing component
Component Explantion
position
Before
(see hydraulic diagram) Action
action
19 4A: on Motor should start and recirculate the oil through the filter
4A: off. back to the tank.
After test stops the motor.
2A, 4A, 16, 19, 20, 4: off 4A: on Motor should start and stop at the preset pressure signal
40, 42, A1 19:on from 42.
Testpoint: P For a period of 10 minutes motor should not re-start proving
all connections and the valves 19, 20 are tight
20, 20.1, A1, B1 4A: on 20: on Opening the valve 20 should let the oil from accumulator A1
Testpoint: P0 22.1, 22.2, to the brakes through connection P2.
23.1, 23.2: on This can be monitored at transmitter B2
20.1: on CAUTION: Brake P2 will be released during this test.
Disconnect the motor 4A
4A: off Opening of valve 20.1 (off) will let the oil into the brake
20.1:off connectet to P1 from the accumulator. B1 shall change
value.
CAUTION: Brake P1 will be released during this test.
22.1 20:on 22.1:off Opening of valve 22.1 shall lower the pressure to level preset
Testpoint: P0 20.1: off by valve 24.1 oil is dumped to tank.
CAUTION: Brakes will be applied to reduced torque during
this test.
23.1 22.1: off 23.1: off Opening the valve 23.1 will dump the oil back to tank.
Testpoint: P0 23.1: on
HP 31: off, by the Operate the Motor disconnected/off with no pressure in the system and
handle handpump valves closed. By operating the handpunp and simultaneous
30: off by activating of valve 30 shall the pressure raise to preset
activating the setting of the handpunp HP.
handle After the test shall the handles be left in open position.
4.6.2 Make sure that the whole oil drains into a

4.5 Dismantling the power unit secondary container for proper disposal.
This should only be carried out in an
authorised hydraulic workshop. Ask for 4.6.3 Close the drain valve and re-fit the end nut.
separate information.
4.6.4 Refill the oil reservoir to the top level mark in
4.6 Changing the oil the sight glass located on the reservoir
sidewall.
WARNING: CAUTION
4.6.1 Disconnect all power to the hydraulic power Use only filtered oil of the right viscosity for
unit and relieve all internal oil pressure in the refilling (see appendix I).
system.
4.6.5 Connect the electrical power again and start
With the drain valve: the pump. Let the unit run 10 cycles
Remove the end nut (pressurising/de-pressurising).
Open the valve. With system pressurised bleed the brakes.
The location of the drain is on the side of the With system de-pressurised refill oil if
reservoir. necessary.
328650-sbdk-MEH-3000-0139-802_B Page 10
4.7 Changing the oil and cleaning the 4.9.2 The air breather is connected to the
reservoir by pressing it in. Remove the air
reservoir
breather along with the seals.
4.7.1 Disconnect all power to the hydraulic power
unit and relieve all internal oil pressure in the 4.9.3 Mount a new complete air breather.
system.
This procedure is recommended always to 4.10 Measuring the gas pressure

be carried out in a hydraulic workshop to
ensure clean environment. CAUTION
Empty the reservoir as described in section unit and relieve all internal oil pressure in the
4.6.1 & 4.6.2 system.
4.7.2 Remove the tank cover with the mounted Oil pressure must be zero to measure the
assembly (95 – 105 kg without oil). gas pressure correctly. When working with a
hydraulic power unit it is recommended to
4.7.3 Clean the reservoir with a flock free rag. install two pressure gauges for measuring
accumulator pressure and brake pressure.
4.7.4 Refit the tank cover with the mounted Unscrew the threaded cap on top of the
assembly onto the reservoir accumulator
4.7.5 Refit the screws and torque tightens to 20 to FIGURE 4.16

25 Nm.
4.7.6 After connecting to power and brakes fill

reservoir as described in chapter 4.6.4 &
4.6.5
4.8 Changing the oil filter

unit and relieve all internal oil pressure in the
system.
The oil filter is placed in the filter housing.
4.8.2 Using an open end spanner, turn the filter

housing counter clockwise until it is
disconnected from the filter manifold. 4.10.2 Using the 6mm Allen key turn the plug by
turning it counter clockwise (¼ turn). The
4.8.3 Remove the oil filter and clean the inside of screw is now loose without loosing gas
the filter housing and cavity. Insert a new oil
filter minding the orientation. FIGURE 4.17
4.8.4 Clean the o-ring and Teflon-ring outside the

filter housing.
Renew o-ring and Teflon-ring if necessary.
4.8.5 Refit the filter housing.
4.9 Changing the air breather

unit and relieve all internal oil pressure in the
system.
The air breather consists of two parts:

A strainer inside the reservoir and
A filter in the cap 4.10.3 Mount the gas pressure gauge and close the
side valve.
328650-sbdk-MEH-3000-0139-802_B Page 11
4.11.1 Establish a filling line between the gas

FIGURE 4.18 pressure valve and a gas tank.
The accumulator charger kit contains gas
pressure gauge and filling line.
Remember that the adaptor from the line
and to the gas tank is country specific and
may need to be ordered separately.
FIGURE 4.21
4.10.4 Open the top valve, measure the gas

pressure and close the top valve again.
4.11.2 Open the gas tank valve and the top valve to
fill gas into the accumulator.
FIGURE 4.19 Close gas tank valve and wait several
minutes for the new gas to decline to
accumulator temperature.
Measure the gas pressure.

If the pressure is too low apply more gas.
FIGURE 4.22
4.10.5 If the gas pressure does not meet the

required value (see appendix F), the
accumulator must be recharged.
4.11 Recharging the accumulator

4.11.3 If the gas pressure is too high open the side
WARNING valve to relieve gas.
Recharging must be done according to local Close the top valve when the gas pressure is
safety regulations for working with pressure correct.
tanks.
FIGURE 4.23
FIGURE 4.20
4.11.4 Open the side valve, relieve the pressure

completely and remove the gas pressure
gauge.
328650-sbdk-MEH-3000-0139-802_B Page 12
4.11.5 Tighten the plug (18 - 22Nm) using the 6mm

Allen key (hexagonal) and mount the
threaded end cap by use of hand
FIGURE 4.24
328650-sbdk-MEH-3000-0139-802_B Page 13
5. Trouble Shooting
5.1 Failure intro
Locate which part of the braking system that causes the failure and proceed to the corresponding section.
Failure
Brakes are Brakes are

failsafe active
Brakes will not Brakes will not

close open
Brakes are free

of pressure
NO
See chapter 5.2

"PU doesn't release
pressure"
Brakes will not Brakes will not

open close
Brakes and Brakes have enough pressure

PU works (according to appendix D)
but behave
unexpected NO
or unusual YES
See chapter 5.3

"PU doesn't set pressure"
See chapter 5.4

"Other PU failure PU is working OK.
Failure is caused by the
brakes.
328650-sbdk-MEH-3000-0139-802_B Page 14
5.2 Power unit does not release pressure
5.2 PU doesn't release pressure
Failure in solenoid or it's power supply

- Try manual override - if this releases the pressure failure is in the
Valve between brakes
coil or its power supply.
and tank doesn't open
- Try disconnecting the electrical plug from the coil - if this releases
pressure failure is in the power supply.
Defective or dirty (choked) valve or nozzle

- Before unscrewing a valve or other component you must make sure
that the pressure behind is released. If you have only one dump valve,
you can release through a minimess hose.
At very high viscosity an active brake cannot press back oil to tank
Oil too cold
through the system
328650-sbdk-MEH-3000-0139-802_B Page 15
5.3 Power unit does not set / build pressure
5.3 PU doesn't give (enough) pressure
If leakage point isn't obvious you must refill the tank and start the
Tank level very low
pump watching for leaking oil or bubbles.
and/or oil contamination
outside the baking
Be carefull: Oil jets can be hazardous and oil contamination is
system
harmfull to the environment
- Power supply failure or motor wrongly connected

- Defective motor
Motor isn't running
- Oil level too low or oil too hot (cut off by level/thermo switch)
- Defective pressure switch
Motor is running the

Phases in the motor junction box are wrongly connected (swapped)
wrong direction
Motor is running but

speed decreases before - Power supply has too low voltage
system has reached the - Defective motor
right pressure.
- Coupling between motor and pump is broken

Motor is running but no
- Defective pump
pressure is generated
- Defective safety releif valve
Motor is running but runs

Defective check valve
backwards after it stops
- Safety relief valve out of adjustment or defective

Pressure is generated - Pressure switch setting too low
but not sufficient - Defective pump
- Leaking valves
Pressure is generated
but isn't transferred to Valve between pump and brakes doesn't open when it should
brakes on command
Try manual override - if this solves the problem the coil or its power
supply fails. If not the valve is defective.
Pressure is generated
but is transferred to tank
Valve(s) between brakes and tank doesn't close when it should
when it should have
been to the brakes
328650-sbdk-MEH-3000-0139-802_B Page 16
5.4 Other failures
5.4 Other failures
Do you get the right signals from

- level/thermo switch
Failure in
- pressure switches or transmitters in the pump line
instrumentation
- pressure switches or transmitters in the brake line
- pressure switches or transmitters for accumulator monitoring
Failure in brake pad or brake pad not bedded in?

Brake pad or disc oiled or greased?
Air gab adjustment overdue?
Insufficient braking Failsafe brake line not fully unloaded?
torque Active brake pressure too low?
Failure in brake caliber?
Valves not operational due to too high viscosity (low oil
temperature)?
Air in the braking system?

Slow brake Valves not working correctly due to oil contamination?
Orifices too small for viscosity (low oil temperature)?
Viscosity too low due to too high oil temperature?

Too fast braking
Precharged pressure in the accumulators are wrong?
Ambient temperature too high?

Excessive operating
Pump running continously (due to leaky valves, external leaks or
temperature
wrong component adjustment?
328650-sbdk-MEH-3000-0139-802_B Page 17
328650-sbdk-MEH-3000-0139-802_B Page 18
Appendix A - Dimension drawing
SVENDBORG BRAKES
CONFIDENTIAL
328650-sbdk-MEH-3000-0139-802_B Page 19
Appendix B - Dimension drawing - Frame
SVENDBORG BRAKES
328650-sbdk-MEH-3000-0139-802_B Page 20
Appendix B - Spare parts list - Frame

For brake control unit 3000-0139-802
according to Spare Part Drawing and Hydraulic Diagram (section 3.3)
Adjustme
Rec. Mounting
nt
spare torque
method
Pos Qty Description SB item no parts qty. [Nm]
(see apx.
(note 1) (note 2)
C & D)
A1 1 ACCU 6,00L 330BAR 4860-0024-001 0 90
1 CABINET 9893-9000-006
COVER PLATES FOR.
1 9893-0003-801
CABINET
1 BRACKET FOR BLOCK 9806-0000-013
A1 1 CONSOL F/ACCUMULATOR 9848-1024-002
A1 1 RUBBER SUPPORT RING 9848-9024-002
A1 1 BEARING F/ACCUMULATOR 9848-0024-004
A1 1 HYDR.HOSE 1/2"X,435M 0593-0999-802
P1 1 HYDR.HOSE 3/8"X0,56M 0593-0999-808
P2 1 HYDR.HOSE 3/8"X0,65M 0593-0999-807
Notes
1) It is highly recommended to have the spare parts of the marked type in stock as this may reduce downtime in case
of failure. The quantity stated is the minimum quantity recommended.
2) Mounting torque (Nm) (lb/ft = value x 0.74) for each component or bolt fixing the component.
3) Turn in to bottom and out ¼ revolutions.
328650-sbdk-MEH-3000-0139-802_B Page 21
Appendix C - Spare part drawing – tank
SVENDBORG BRAKES
328650-sbdk-MEH-3000-0139-802_B Page 22
Appendix C - Spare parts list – tank

Adjustme
Rec. Mounting
nt
spare torque
method
(see apx.
(note 1) (note 2)
C & D)
2A 1 GEAR PUMP 3,7 CCM 0305-1117-002 17

3A 1 BELL HOUSE 9803-2070-002 65
3A 1 COUPLING 9803-1047-001 24
ATEX II 2G
4A 1 MOTOR 3X480V 60HZ 2KW IP56 5148-0999-002 65
EEXDE IIC T4
5 1 TANK 110 L 1211-1000-003
WITH
5a 1 LEVEL GLASS 1231-3024-002 1 17
TERMOMETER
5b 1 AIR BREATHER W/MOIST ABSO 2 MICRON 1712-0024-002 1
5b 1 ADAPTOR FOR AIR BREATHER 1712-9024-001
PRES TRANSMITTER 0,1BAR 4-
5c 1 ATEX(BARRIER) 4080-0999-002 1 20
20MA
5d 1 TANK COVER F/ 110 LTR 1221-1100-003
EEX IA IIB
5e 1 THERMO SENSOR 4-20 MA 1/4" 1233-0090-001 1 20
T4/T5/T6
5f 1 BALL VALVE 3/4" 9622-8999-034 1
5f 1 HYDR PLUG 3/4" BSP 9004-1010-034
30 1 HYDR BALL VALVE 12L 2280-1066-002 60
31 1 HYDR BALL VALVE 12L 2280-1066-802 60
30.1, 31.1 1 IS 1808 NC 5-25DC 10M 6901-0023-001
ACC-D 1 HYDR BALL VALVE 1/4" 2280-1999-040 1
HP 1 HANDPUMP 0350-0071-002 1
VD 4 VIBRATION DAMPER 9820-3074-009 35

P, Po 2 PRES GAUGE 5000PSI Ø63MM 4013-5999-002 1
P, Po 1 BRACKET F/FIXING 3 GAUGES 9840-0000-008
P, Po 2 TEST HOSE 1000MM 9009-3010-010
2 1 HYDR.HOSE 3/8X0,44M 0593-0999-801
T3-31 2 HYDR.HOSE 1/2"X,24M 0593-0999-805
HP 1 HYDR.HOSE 3/8X0,35M 0593-0999-806
Notes
328650-sbdk-MEH-3000-0139-802_B Page 23
Appendix D – Spare part drawing – Main block
SVENDBORG BRAKES
328650-sbdk-MEH-3000-0139-802_B Page 24
Appendix D - Spare parts list - Main block

Rec. Mounting Adjustment

spare torque method
(see apx.
(note 1) (note 2) C & D)
15 1 FILTER HOUSING HIGH PRES 1701-1024-015 180
15 1 FILTER ELEMENT HIGH PRES 1701-2024-004 1
15 1 FILTER INDICATOR VISUAL 1720-1024-003 50
16 1 RELIEFVALVE MAX 350BAR 9103-5043-002 50 2
17.1,
3 CHECK VALVE 6010-1043-005 1 50
18.1, 18.2
19 1 DIR POPPET VALVE 2/2-NO- 2222-1083-001 1 13
ATEX
20 1 DIR POPPET VALVE 2/2-NC- 2222-0083-001 1 13
ATEX
19, 20 1 MOUNTING (DISTANCE) 2290-6022-001

PRES TRANSMITTER 250BAR
40, 42 2 4080-0024-010 1 20
4-20MA
CABLE, ATEX FOR
40, 42 2 6922-0178-001 1 finger
PRES.TRANS.
41 1 TEST POINT NIPPLE 9009-1010-040 1 30
P, P0 1 TEST POINT MALE 1/4" BSP 9009-1010-040 1 30

52 1 THROTTLE VALVE ADJ 6001-2024-002 1 50
Notes
328650-sbdk-MEH-3000-0139-802_B Page 25
Appendix E - Spare part drawing – Draw works block
SVENDBORG BRAKES
328650-sbdk-MEH-3000-0139-802_B Page 26
Appendix E - Spare parts list - Draw works block

Rec. Mounting Adjustment

spare torque method
(see apx.
(note 1) (note 2) C & D)
20.1, 20.2 5 DIR POPPET VALVE 2/2-NO- 2222-1083-002 1 13
22.1, ATEX
23.1, 23.2
24.1 1 RELIEFVALVE MAX 350BAR 9102-1043-002 1 50 2
PRESSURE TRANSMITTER 12-28 VDC

B1. B2 2 4080-0024-010 1 20
ATEX 4-20 MA
M1, M2 2 TEST POINT NIPPLE 9009-1010-040 1 30
Pc 1 ORIFICE 1/8-2,0-0,0 6001-0000-846 1 30
Pc, T3 2 HYDR.HOSE 1/2"X,24M 0593-0999-805 1
Notes
328650-sbdk-MEH-3000-0139-802_B Page 27
Appendix F - Hydraulic settings

Extract from production settings report:
Order no: 328650-sbdk
POWER UNIT
Item No.: 1106-0006-804

Serial No:
Settings for brake: BSFH520
Rev. Index: A
Rev. Date: 02.05.2011
Rev. No: -
Test
Test point Setting Position Note
Setting Tolerance Unit
System relief valve 230 +/-5 bar 16 *
Accumulator 155 +/-3 bar A1 -
Burnish pressure 110 +5/0 bar 24.1 *
Hand pump 210 +/-10 bar HP -
(System pressure) (200) - bar (40)
(System pressure) (195) - bar (40)
(Brake pressure) (180) - bar (B1)
(Brake pressure) (150) - bar (B1)
No leaks at full pressure 300 sec
↑ = Raising
↓ = Falling
* = Set by Motor running
- = set by Motor stopped
# = Set by timer (two stage)
Settings approved:
FIV
Initials
05.04.2011
Date
For actual information on how to adjust the settings see Appendix B – Spare parts and
Appendix D - Adjustment
328650-sbdk-MEH-3000-0139-802_B Page 28
Appendix G - Adjusting
Choose method according to Appendix B to E “Spare parts list”
Adjustment Item drawing/Photo Description

Item type
method
The pressure switches have fixed

hysteresis.
Precise adjustment of set point to

actuate on increasing pressure
1. Lower system pressure to 0 bar.
2. Increase pressure slowly and
check if micro switch is actuated at
desired switch pressure.
3. If necessary, readjust by turning
the adjustment screw
4. Repeat step 1 - 3 until micro switch
operates at desired switch pressure.
Pressure
1 switch Precise adjustment of set point to
actuate on decreasing pressure
1. Increase pressure up to a point
clearly above the desired switch
pressure
(at least, switch pressure plus max.
hysteresis; not above max. operating
pressure).
2. Lower pressure slowly and check if
micro switch is actuated at desired
switch pressure.
3. If necessary, readjust by turning
the adjustment screw.
4. Repeat step 1 - 3 until micro switch
operates at desired switch pressure.
Tamper The system safety valve (Pos. 16 –

proof cap
relief valve) is preset at the factory to
the correct pressure / setting.
Adjustment Do not adjust this valve.
screw
If the tamper proof cap is broken or
Lock missing the power unit is no longer
Relief valve nut covered by Svendborg Brakes
or
warranty.
Counter
2
pressure valve
For other relief valves if adjustment is
(same item)
needed, remove the tamper proof
cap, loosen the lock nut and screw
out (counter-clockwise) to decrease
max. pressure setting.
Screw in (clockwise) to increase max.
pressure.
Remember to re-tighten the lock nut.
328650-sbdk-MEH-3000-0139-802_B Page 29
Adjustment Item drawing/Photo Description

Item type
method
Display and setting keys: The settings are locked from factory.
To unlock you must hold down both
Display of arrow keys for 3 sec.
measuring units
Display shows for 2 sec. “oP6” and
4 digit display then “FrEE”.
Now you can change the settings for
Pressure
upper switch point and/or hysteresis
3 switch
LED display by selecting mode. Changes are
for active made by using the arrow keys.
switching After the changes you press both
points
Setting keys arrows again for 3 sec. Display will
show “Loc” for a moment and the
new settings are saved.
Afterwards display will again show the
measured pressure.
4 Accumulator See section 4.8 & 4.9
To protect the pressure switch it is

mounted with a cover. To demount
this cover you must unplug the
electrical plug and pull the cover off.
The settings of the pressure switch
Pressure are changed like this:
5 Reset Set
switch 1) Unlock the lock ring
value value
2) Change the set and reset
values
3) Lock the lock ring
Lock 4) Remount the protection cover
ring 5) Remount the electrical plug
328650-sbdk-MEH-3000-0139-802_B Page 30
Appendix H - Electrical diagram
328650-sbdk-MEH-3000-0139-802_B Page 31
328650-sbdk-MEH-3000-0139-802_B Page 32
Appendix I - Recommended Fluid

Name: DEB-DIVE-005
DATA SHEET Date: 25.05.2011

Revision: D
RECOMMENDED FLUID FOR DISC BRAKES & HYDRAULICS

PRESSURE FLUIDS / OIL TYPES
The following oil types are recommended by Svendborg Brakes – other types corresponding to these can be used.
The general temperature range for our standard ranges of products using hydraulic oil are -20°C to +60 °C (-4°F to
+140°F) however the BSAK and BSAB brake series are generally approved for lower temperatures.
These are approved for usage at -40°C in wind turbi nes and for -30°C in other applications.
Extreme temperature applications may require special options. Please contact Svendborg Brakes.
Special option Standard Special option

-40°C - +50°C -20°C - +40°C +10°C - +60°C +30°C - +70° C
Mineral Oil
-40°F - +122°F -4°F - +104°F +50°F - +140°F +86°F - +158°F
Shell Tellus Arctic Tellus TX32 Tellus TX46 Tellus TX68
Mobil - DTE 13M DTE 15M DTE 16M
Hydro Texaco - Rando HDZ32 Rando HDZ46 Rando HDZ68
Valvoline - Ultramax HVLP32 Ultramax HVLP46 Ultramax HVLP68
-40°C - +50°C -20°C - +40°C +10°C - +60°C +30°C - +70°C
Syntethic Oil
-40°F - +122°F -4°F - +104°F +50°F - +140°F +86°F - +158°F
Mobil - SHC 524 SHC 525 SHC 526
(1) -40°C - +50°C -20°C - +30°C +10°C - +60°C +30°C - +70° C
Bio Oil
(Ester or Colza oil)
-40°F - +122°F -4°F - +86°F +50°F - +140°F +86°F - +15 8°F
Shell - Naturelle HF-E15 Naturelle HF-E32 Naturelle HF-E46
General: Mineral Pressure Fluids according to DIN 51524 Part 3
(1) There must be less than <200PPM water in the oil, due to the seals.
Viscosity
Recommended viscosity range: 20-200 cSt at working temperature. Generally Svendborg Brakes systems ared
designed to allow higher viscosity in short periods.
Filtration
The oil in a hydraulic system and the oil added to the hydraulic system must always be filtered. The level of cleanliness
in a hydraulic system is an important factor to the lifetime of the system.
When refilling the hydraulic tank, it is stipulated that the oil added to the system is filtered through a 10-micron purity off-
line filter unit to the classes listed below.
The hydraulic system, supplied by Svendborg Brakes, has a build-in oil filter with a standard 10-micron purity filter. To
maintain a reliable system it is recommend that only hydraulic oil of the following classes of purity is used: NAS 1638,
Class 8, or ISO 4406, Class 19/17/14.
It is recommended that the filter is changed at a minimum, once every six months or more often depending on the level
of exposure to contamination.
Service life of pressure fluids

Mineral oil: 8.000 Hours or at least once a year.
Other fluids: 2.000 Hours or at least once a year.
Change of pressure fluid

Note: The mixing or blending of different brands or types of pressure fluid can cause unintended chemical reactions,
such as sludging, gumming etc. The complete hydraulic system should be thoroughly flushed prior to changing from one
oil type to another.
The respective manufactures should be contacted prior to changing from one pressure fluid to another.
Seal material
Brakes from Svendborg Brakes A/S are normally supplied with PUR-seals (PolyURethane)
PTFE (PolyTetraFlourEthylene) seals can be delivered on request for most of the brake types.
Note: the BSFG 400 brake series are supplied with NBR rubber fabric seals (acrylNitrile Butadiene Rubber).
328650-sbdk-MEH-3000-0139-802_B Page 33
Appendix J - Recommended spare parts

Recommended spare parts for one brake
FILTERS
Air filter for 6 and 10 litre tank, 10 µ 1712-1024-001
Air filter for 3 litre tank, 10 µ 1712-0024-003
Pressure filter element 10 micron 1701-2024-004
ACCUMULATOR CHARGER KIT

Goes for
4899-9024-002
B, DK, D, SF, NL, N, A, PL, S, CH, CZ
With adaptor for
South-East Asia, ARG, AUS, BS, GB,
GR, IRL, JA, M, NZ, P, E, TR, CY 4899-9024-006
Africa except for Arab countries
Arab countries, BG, COI, F, RG,
4899-9024-007
Israel, MEX, RO, H
Canada, USA, Puerto Rico 4899-9024-003
Italy 4899-9024-001
Japan 4899-9024-005
Taiwan 4899-9024-008
Korea 4899-9024-009
South & Middle America except
4899-9024-010
Argentine, Venezuela and Mexico
China 4899-9024-004
FILTER FILLING STATION 1702-0024-001
328650-sbdk-MEH-3000-0139-802_B Page 34
Name: MEB-0500-060
Date: 01.05.2011
Revision: J
Installation and Maintenance

Manual
HYDRAULIC FAIL-SAFE
DUAL SPRING
DISC BRAKE
BSFH 500-S/R-501
Installation and Maintenance Manual - BSFH 500-S/R-501
Table of Contents
TABLE OF CONTENTS ............................................................................................... 1
1. GENERAL .......................................................................................................... 3
1.1 Who to contact ................................................................................................... 3
1.2 Declaration of incorporation for Partly Completed Machinery ............................ 3
1.3 Safety ................................................................................................................. 3
1.4 Notifications / symbols used in this manual ....................................................... 5
1.5 Original language ............................................................................................... 5
1.6 Disclaimer .......................................................................................................... 5
1.7 Conversion factors ............................................................................................. 5
1.8 Nameplate / Serial-numbers ............................................................................... 5
1.9 How the brake works .......................................................................................... 6
1.10 Function ............................................................................................................. 7
1.11 Operating conditions .......................................................................................... 7
1.12 Noise emissions ................................................................................................. 7
1.13 Ports & connections ........................................................................................... 8
1.14 Connecting the brake(s) ..................................................................................... 8
1.15 Lifting and handling ............................................................................................ 11
1.16 Transport ............................................................................................................ 11
1.17 Storage............................................................................................................... 11
1.18 Lubrication .......................................................................................................... 11
1.19 Disposal ............................................................................................................. 11
1.20 How to order spare parts .................................................................................... 12
2 INSTALLATION ................................................................................................. 13
2.1 Lifting and handling ............................................................................................ 13
2.2 Cleaning the brake disc ...................................................................................... 13
2.3 Cleaning of the mounting surfaces ..................................................................... 13
2.4 Handling / mounting the brake pads ................................................................... 14
2.5 Mounting the brake............................................................................................. 15
2.6 Adjusting the brake............................................................................................. 18
2.7 Inspecting the alignment of the brake................................................................ 19
2.8 Bleeding and flushing the caliper ....................................................................... 19
2.9 Installing the Indicators....................................................................................... 21
2.10 Bedding in / burnishing of the brake pads ......................................................... 21
2.11 Removing the brake ........................................................................................... 22
3. MAINTENANCE ................................................................................................. 23
3.1 Indicator ............................................................................................................. 23
3.2 Replacing the brake pads................................................................................... 23
3.3 Replacing other components .............................................................................. 25
3.4 Dismantling the active caliper ............................................................................. 26
3.5 Replacing the seals ............................................................................................ 26
3.6 Checking the clamping force .............................................................................. 29
3.7 Checking the spring pack ................................................................................... 29
3.8 Replacing the spring pack .................................................................................. 30
3.9 Lubrication of the brake ...................................................................................... 33
4. MAINTENANCE SCHEDULE ............................................................................ 34
5. TROUBLE SHOOTING ...................................................................................... 35
MEB-0500-060.docx Page 1
6. DECLARATION OF INCORPORATION FOR PCM .......................................... 36

APPENDIX A - DIMENSION DRAWING, BRAKE ....................................................... 39
APPENDIX B - ASSEMBLY DRAWING, BRAKE ........................................................ 40
APPENDIX B - ASSEMBLY PARTS LIST, BRAKE .................................................... 41
APPENDIX C - SPARE PARTS DRAWING, CALIPER HALF EXPLODED ................ 43
APPENDIX C - SPARE PARTS DRAWING, CALIPER HALF ..................................... 44
APPENDIX C - SPARE PARTS LIST, CALIPER HALF .............................................. 45
APPENDIX D - MOUNTING DRAWING ....................................................................... 46
APPENDIX E - TECHNICAL DATA ............................................................................. 47
APPENDIX F - BRAKE SWITCH / INDICATOR .......................................................... 48
APPENDIX G - RECOMMENDED FLUID .................................................................... 49
APPENDIX H - U-CUP INFORMATION ....................................................................... 50
APPENDIX I - RECOMMENDED SPARE PARTS ....................................................... 51
1. General 1.3 Safety

Thank you for buying a Svendborg Brakes The Svendborg Brakes brake line of
product. products are designed to be mounted on a
Before using the product please read this rotating brake disc for use in conjunction
manual carefully. with parking brake applications, service
brake applications or emergency brake
applications only.
1.1 Who to contact
In case you have any questions to this Note:
manual please contact your local Always make sure that you consult
representative or nearest Svendborg Brakes Svendborg Brakes A/S before using tools or
Office: any other equipment not recommended /
specified in this manual.
Svendborg Brakes offices: In order to maintain the guarantee always
use original spare parts from Svendborg
Denmark:
Brakes A/S.
Jernbanevej 9, DK-5882 Vejstrup
It is the customer‟s responsibility that the
Phone: +45 63 255 255
brake and hydraulic aggregate are always
E-mail: sb@svendborg-brakes.com
clean, and free from dirt, grease or oil.
Germany: It is the customer‟s responsibility that the air
Kirchnerstrasse 42, DE-32257 Bünde gap between brake pads and brake disc
Phone: +49 5223 68 540 0 never exceeds the air gap recommended.
E-mail: sb@svendborg-brakes.de Always use a torque wrench when refitting
mounting bolts or valves in order to ensure
USA: the torque obtained is the torque described
100 Fillmore Street, 5th Floor, #514, in this manual.
Denver, CO 80206 There should be one manual available for
Phone: +1 303 285 1271 the service / maintenance crew as a
E-mail: sb@svendborg-brakes.us minimum.
China: Hydraulic power unit:

T40B-5, No.1765 Chuan Qiao Road Do not operate the hydraulic power unit
Pudong 201206 Shanghai before correctly filling the reservoir / oil tank
Phone: +86 21-58996031 with oil.
E-mail: sb@svendborg-brakes.com Do not adjust valves or pressure switches to
higher operating pressure than specified in
Australia: the manual.
118 Burswood Road, P.O. Box 48 Do not change the size or type of
Burswood, WA 6100 components.
Phone: +61 0 8 94 160300 Do not use hydraulic fluids not
E-mail: sb@svendborg-brakes.com recommended in this manual.
or visit us at: Brakes:

www.svendborg-brakes.com Do not operate the brake before removing
the air from the hydraulic system by
bleeding and then re-filling with oil.
1.2 Declaration of incorporation for Do not use higher operating pressures than
Partly Completed Machinery specified on the nameplate of the brake / or
(PCM) in the manual.
This product is declared as a Partly Do not change the size or type of spring
Completed Machinery. pack.
The declaration of incorporation for Partly Do not use the brake pads when they are
Completed Machinery (PCM) according to worn to the minimum thickness as shown in
Machinery Directive 2006/42/EC is placed in the manual.
section 6 – „Declaration of Incorporation for Do not operate the brake if there is dirt or
PCM’ corrosion protection on disc or brake pads.
Personal safety: Heavy equipment

Do not work on the brake/system before Be careful when lifting the brake or brake
attending all the following matters: components - it is heavy equipment and is
Make sure the brake disc is locked and not not made for manually lifting.
able to rotate before adjusting the brake
and/or air gap.
Be sure to lock/secure the brake piston by
using the air gap bolt/air gap nut if working
on a spring applied brake.
Make sure there is no pressure on the
hydraulic power unit or circuit.
Make sure that the oil pressure in the
accumulator(s) has been relieved /
removed. Use proper lifting equipment in order to
prevent personal injuries.
Make sure the control signals has been shut
off and blocked before working on the
Fingers warning
system.
Never place your fingers between the brake
Make sure the electrical power has been
pad and the brake disc without having the
shut off.
brake piston properly secured.
Be sure the manual has been read and
understood
During installation, service or adjustment of
the partly completed machine the service
personnel is to handle the partly completed
machine using protective working gloves,
EN 420 / EN388 - category 2 and protective
footwear, EN345 / ISO20345 – category S3.
During work with hydraulic oil / pressure
connections it is highly recommended to use Pressure warning
eye protection. Never apply pressure to the brake before
During replacement of the spring package (if being sure that the adjusting screw turned
applicable) protective gloves – ideally sufficiently into the yoke.
disposable latex gloves or similar, EN420 /
EN374 category 3 - should be used to If the adjusting screw is too far out of the
prevent skin contact with the lubricant. yoke while pressurized - the thread may be
Avoid prolonged skin contact with hydraulic destroyed and the adjusting screw may be
fluids - read the manufacturer‟s instructions shot out of the brake.
before using hydraulic fluids and use
protective gloves – ideally disposable latex
gloves or nitrile gloves or similar, EN420 /
EN374 category 3.
If using solvent cleaners you must read the
manufacturer‟s instructions before using a
solvent cleaner, and then carefully follow
these instructions.
In order to ensure proper and safe working
conditions the working area should be To prevent any personal injuries and / or
enlightened in a way that allows for safe damages to the brake check the “dimension
working / be adequate. drawing” for the maximum dimension /
During operation dust emission from disc distance that the adjusting screw is allowed
and friction material of brake pads will occur. to be out of the yoke while pressurized - see
To protect against particles filtering half section 2.5 - Mounting the brake for details.
masks, EN 149, class FFP2S – should be
used when maintaining the brake. Avoid prolonged skin contact with hydraulic
The machinery in which the brake is to be fluids - read the manufacturer‟s instructions
installed must be designed and constructed before using hydraulic fluids.
in a way to allow access in safety for If using solvent cleaners you must read the
maintenance of the brake. manufacturer‟s instructions before using a
solvent cleaner, and then carefully follow
these instructions.
1.4 Notifications / symbols used in damages, resulting from any misspellings or

this manual inaccurate information in this users guide.
To make sure that you perform certain tasks This document or parts hereof may in no
properly, please take note on the following event be copied, reproduced, changed or
symbols used throughout this manual. translated to other languages without explicit
written permission from Svendborg Brakes
WARNING: Important information to prevent A/S.
personal injury when trying to complete a
task.
1.7 Conversion factors
CAUTION: Vital information to prevent All units in this manual are in metric units
damage to the components when trying to
complete a task. If you have needs for conversion between
metric and imperial units the following
IMPORTANT: Information that you should figures can be used.
be followed to complete a task.
Table 1.1
NOTE: Tips and additional information to aid Conversion factors
in completing a task. Length:
1 inch = 25.4 mm (millimetre)
Figures within brackets ( ) relate to position mm
number and appendix number i.e. (15-C) 1 = 0.0394 inch
(millimetre)
refers to position number 15 in appendix C Mass:
on both drawing and bill of material (parts
1 kg (kilogram) = 2.2046 lb (pound)
list).
1 lb (pound) = 0.4536 kg (kilogram)
Force:
1.5 Original language
N lbf.
The original language of this manual / 1 = 0.2248
(Newton) (pound force)
instructions is English i.e. the English kN lbf.
1 = 224.8089
version is „Original instructions‟. (kiloNewton) (pound force)
All other languages are translations and are Pressure:
„Translations of the original instructions‟. MPa
1 Bar = 0.1
(Mega Pascal)
PSI (pound per
1.6 Disclaimer 1 Bar = 14.5038
square inch)
Svendborg Brakes A/S reserves the right to MPa (Mega
1 1 N/mm²
revise this document without prior pascal)
notification. These documents have been PSI (pound per
1 N/mm² 145.038
proofread for errors in translation and square inch)
accuracy. Despite this, technical and Torque:
typographical deviations can sometimes Nm (Newton lbf.ft.
1 = 0.7376
occur. meter) (pound foot)
lbf.ft. Nm
1 = 1.3557
This document is updated on a regular (pound foot) (Newton meter)
basis; changes will be published in future
printings. Improvements and/or changes to Examples:
the described products or manual can be 115 bar = 11.5 MPa = 1667.94 PSI
implemented at any time without preceding 320 N/mm² = 46412.00 PSI
notice. 305 Nm = 224.96 lbf.ft
In no event shall Svendborg Brakes A/S be 1.8 Nameplate / Serial-numbers

liable for any special, incidental, Before contacting Svendborg Brakes A/S or
consequential or punitive damages. This your local reseller please record the serial
includes, but is not limited to: damage to number of the product.
other property or person, inconvenience, This will ease the process of identifying the
loss of goodwill, lost profits or revenue, loss actual product supplied and will help in
of use of this product or any associated locating eventual problems.
equipment, cost of substitutive equipment,
downtime costs or claims of any party such
Brakes - reading the nameplate

The nameplate looks like shown in figure 1.1 Brakes with a spring pack
and is positioned on the brake as per figure Spring applied fail safe brakes are marked
1.2. with the minimum clamping force (nominal)
provided and the operating pressure (oil
FIGURE 1.1 pressure). The lower operating pressure is
the minimum pressure needed to ensure
that the brake is lifted.
1.9 How the brake works

BSFH 520-S-501 The brake is designed to transfer a clamping
force into a braking torque from the brake
min. 200.000 20,0 - 23,0 caliper to a brake disc - either in order to
stop the rotation of the brake disc or for
1-200024812 490-3561-808 preventing it in rotating when stopped
(parking brake).
The BSFH 500 Dual Spring is designed as a

The nameplate is positioned on the brake as fail-safe spring-applied hydraulically
per figure 1.2. released disc brake.
The brake can be supplied with various
FIGURE 1.2 clamping forces.
NAMEPLATE The Dual Spring brake consists of two active
calipers each containing one spring pack
(Belleville cup springs). These springs are
located inside the active caliper.
FIGURE 1.3
Naming of the brake:

“TYPE”
The type is the description (name) of the
brake.
Serial number:
The serial number is located on the
nameplate at the label named “SERIAL
NO.”.
The serial number is a unique number,

which identifies the brake. The active calipers are mounted / joined
together onto the bracket using bolts and
Other information on the nameplate spacers (spacers only where applicable).
“ITEM NO” The assembled / bolted unit is fixed on the
This is the item number of the brake where bracket and does not move.
the first two sections “490-3561” is the main
number and the last part (-8xx) is the When braking - the piston inside both active
version. calipers (and brake pad no. 1 and no. 2) will
move towards the brake disc and will
“CLAMPING FORCE” and “OPERATING provide a braking force on both sides of the
PRESSURE” brake disc.
The performance of the brake is shown by
the clamping force provided and the Only limited movement of the brake disc is
corresponding operating pressure. allowed. The movement of the brake disc
must be within the total air gap of the brake The pad retraction springs (mounted in the
as specified. The alignment of the brake and brake pads) will then pull the pads away,
the bracket must be adjusted to match this. allowing the disc to rotate freely.
Brake disc movements exceeding the air
gap as specified for the brake will in worst The spring pack loses its force when
case result in damage to the brake / brake travelling outwards. The spring pack has
disc / hub / coupling and or mounting been set / adjusted from the factory to
structure. provide the nominal clamping force at 1mm
distance from fully lifted piston (i.e. 1mm air
Check the mounting and dimension drawing gap).
for exact dimensions, tolerances and As the brake pad wears the piston will move
allowed movement. a longer and longer distance and result in a
lower clamping force.
This Manual is valid for the brake option The brake must therefore be adjusted on a
BSFH 500-S/R-501. regular basis to compensate for the wear.
1.10 Function A pad wear indicator can be used for

indication of wear of the brake pads and
The BSFH 500 Dual Spring is designed as a when to re-adjust the brake
fail-safe spring-applied hydraulically .
released brake.
1.11 Operating conditions
The clamping force is obtained from the The BSFH 500 brake is designed for
spring pack applying the force to the piston operating at a maximum operating pressure
and passing it through the brake pad against at 23,0MPa.
the brake disc.
FIGURE 1.4 The operating temperature range for general
usage is from -20°C to +70°C.
IMPORTANT
Please ensure that the hydraulic oil is
capable of operating at the correct
temperature.
Please be aware that reaction time /
operating time may vary dramatically
depending on oil type and temperature
1.12 Noise emissions

The brake itself does not generate any
The reaction force is transferred via the significant noise emissions.
adjusting screw to the yoke. The A-weighted emission sound pressure
level at workstations does not exceed 70
When hydraulic pressure is applied and dB(A).
released to the pressure ports the brake is in
operation.
IMPORTANT
The brake applies the clamping force when Attention must be made towards the
the hydraulic oil pressure is released / complete application as a brake disc / motor
removed from the hydraulic chamber / unit / gear box running at high speed may
causing the piston to execute movement generate noise levels above 80 dB(A)
towards the brake disc.
During a braking cycle – especially if used in
When hydraulic oil pressure is applied to the an emergency braking cycle the noise
hydraulic chamber / unit the braking force generated by the brake pad and brake disc
decreases causing the piston to execute may generate noise levels above 80 dB(A).
movement away from the brake disc The appropriate safety precautions must be
(towards the adjusting screw). made with respect to wearing hearing
protection / not being in the area during
operation.
1.13 Ports & connections

The brake is as standard provided with two IMPORTANT
pressure ports “P” G3/8 (14-C), two drain The pipes, hoses and fittings used for
ports “A” (17-C and 18-C) G3/8 and two connecting the brakes must be suitable for
drain ports “R” (13-C) G1/4 on each caliper - hydraulic fluids and should be capable of
see figure 1.7. working with the pressure in the hydraulic
system.
IMPORTANT
Both calipers must be connected in order for NOTE
the brake to operate correctly. It is not necessary to use flexible hoses
when connecting the brake / calipers and
FIGURE 1.5 they can be connected with pipes.
For installation and maintenances issues it
may provide some advantages using flexible
PRESSURE
PORT G3/8 (2x) hydraulic hoses as a final part / section of
the connection when connecting the
pressure ports on the brake to the hydraulic
power unit.
The brake is as standard supplied with an

air breather and a plastic plug in the drain
ports “A” (17-C and 18-C) and steel plugs in
the drain ports “R” (13-C). The pressure
ports “P” are plugged with steel plugs (14-
DRAIN PORT
G3/8 (2x) C).
DRAIN PORT NOTE

G1/4 (2x) This is valid for each brake caliper i.e. both
sides of the brake.
Pressure ports
The pressure ports are used to release the
brake. The port at the lowest position shall Drain connection
always be used as a pressure connection
when connecting the brake to the hydraulic CAUTION
system. Never apply any pressure to the drain ports
The brake should always be bled from the (13-C, also called R).
highest port when mounted. If hydraulic pressure is applied to these
The highest pressure connection can be drain ports, the oil/pressure enters the
used if flushing is required. chamber between the seal and the wiper.
Flushing is depending on the design of the The pressure then blows off the wiper and
hydraulic system and may not be an option. most likely destroys the seals.
Drain ports
The drain port “R” (13-C) provides access to
the chamber between the wiper (8-C) and IMPORTANT
the outer seal (6-C) in the yoke. Beware that oil on the brake disc reduces
The drain ports “A” (17-C and 18-C) the braking force remarkably.
provides access to the chamber behind the
piston. It is highly recommended to connect the
This can be used for detecting leakage and drain ports to a (preferably clear) tube
preventing leaking oil from reaching the leading to a drain bottle. This prevents damp
brake disc. air from entering the brake and leaking oil
from reaching the brake disc.
1.14 Connecting the brake(s)
The brake(s) can be connected in several Remove the filter (17-C) or the plastic plug
different ways depending on the actual (18-C) from the drain port called “A” and the
application / needs. plug (13-C) from “R” and connect the clear
tube and the bottle to the lowest of each FIGURE 1.8

type of drain port “R” and “A”.
BLEEDING POINT (P)
The upper drain port (of each type) should
be plugged with steel plugs. If the drain PLUGGED (A) + (R)
bottle is connected to the drain port (18-C),
then plug the opposite port (17-C) with one
of the metal plugs from the pressure ports.
This is to prevent the finest dust to enter the
hydraulic system. DRAIN /
BREATHING
CONNECTION
FIGURE 1.6
(A) + (R)
PRESSURE
CONNECTION (P)
SIDE VIEW
The drain hoses from the drain ports “R” and

drain ports “A” (if to be connected to drain)
can be connected with a T-connector before
being connected to the drain bottle. FIGURE 1.9
(A)
G1/4 ”R” FIGURE 1.7
(P)
G3/8 ”A”
T-connector G1/4
Drain ports Drain port ”R”only

”R” and ”A”
(P)
Using drain bottles that are clear and one
(A)
bottle for each brake caliper makes
detection of potential leakages easier.
TOP VIEW
The drain connection could also be
connected directly to the tank of the
hydraulic power unit, but it makes it more Pressure connection (multiple brakes)
difficult to detect leakage. For multiple brake connections, it is
recommended to use parallel connection i.e.
individual pipes and hoses to each brake as
IMPORTANT this ensures simultaneous operation of all
This should be done for both brake calipers brakes.
i.e. both sides of the brake.
NOTE
Pressure connection (single brake)
Parallel connection makes bleeding and
Connect the pressure to the lowest port “P”
thereby maintenance easier
and bleed from the highest port.
Bleeding can be done by using a test point
male (G3/8) (mini-mess) and hose - see The piping line can be a common line
recommended spare parts for item numbers. separated just before each brake caliper.
Each brake caliper should be bled from the
highest point.
IMPORTANT
This should be done for both brake calipers
i.e. both sides of the brake.
Bleeding can be done by using a test point NOTE

male (G3/8) (mini-mess) and a hose - see Using serial connection may cause the last
recommended spare parts for item numbers. brakes to open / close slightly later than the
first brake (pressure in).
IMPORTANT
This should be done for both brake calliper
halves i.e. both sides of the brake(s). NOTE
Serial connection is more difficult to bleed
FIGURE 1.10 and makes maintenance more complicated
BLEEDING POINT (P)
PLUGGED (A) + (R) Bleeding can be done by using a test point

male (G3/8) (mini-mess) and hose - see
recommended spare parts for item numbers.
DRAIN/BREATHING
CONNECTION IMPORTANT
(R) + (A)
Bleeding should be done in the correct order
to ensure proper removal of residual air.
BLEEDING
POINT (P)
PLUGGED IMPORTANT
(A) + (R)
Bleeding should be done for all calliper
halves i.e. on both sides of the brake(s).
DRAIN/ FIGURE 1.12

BREATING BLEEDING POINT (P)
CONNECTION
(R) + (A)
PLUGGED (A) + (R)
PRESSURE DRAIN/BREATHING
CONNECTION (P) CONNECTION
(R) + (A)
PARALLEL CONNECTION - SIDE VIEW
PRESSURE
CONNECTION (P)
(A) FIGURE 1.11
(P) PLUGGED
(A) + (R)
DRAIN/
BREATING
CONNECTION
(R) + (A)
(P)
(A) PRESSURE
CONNECTION (P)
PARALLEL CONNECTION - TOP VIEW
SERIAL CONNECTION - SIDE VIEW
The brakes can also be mounted in serial
connection where the pressure goes from
one brake to another through hoses.
(A) FIGURE 1.13 1.18 Lubrication

(P) Different types of lubrication are used in
different situations.
This can be either for lubrication of the seals
or disc springs during servicing or when
tightening bolts of a diameter above 16mm.
Some symbols are used on the drawings to

indicate where lubrication is needed during
service.
(P)
 Grease - Molykote P74
(A)  Grease - Molykote Longterm 2 Plus
 Hydraulic oil
SERIAL CONNECTION - TOP VIEW MoS2 Molybdenum Disulfide
Molykote is produced by Dow Corning

Hydraulic oil can be synthetic or mineral oil
1.15 Lifting and handling as per recommended oil types.
For safe lifting and handling please refer to Molybdenum Disulfide (MoS2) can be in
section 2.1 – Lifting and handling various forms; either spray, fluid or solid
state but for lubrication of threads we
recommend using MoS2.
1.16 Transport
When leaving the factory the brake is always
packed / wrapped to ensure maximum 1.19 Disposal
security for the product during transport. The operator and / or user are responsible
The weight of the caliper is approx. 270kg for the proper disposal of the brake and the
excluding brake pads and bracket. associated components.
If equipped with our standard bracket the If any doubts about the correct disposal
weight is approx 350kg excluding brake please do not hesitate to contact Svendborg
pads. Brakes or your local dealer or regional
disposal enterprises for further information.
1.17 Storage Brake pads
The brake / caliper is externally treated at The brake pads are made of a steel back
the factory with an anti-corrosion film which plate and brake pad material / lining. The
is sufficient for indoor storage for up to 12 brake pad material is either made of an
months. organic compound or of the sinter metal
type. Each type is asbestos free and free of
If the brake / caliper is to be stored for lead.
periods longer than 12 months the active
caliper / piston must be "worked" / operated The brake pads can be treated as steel
at full stroke, at least 20 times every 12 waste/scrap.
months to prevent the seals from sticking to
the piston. Hydraulic oil
Hydraulic oil must be treated professionally
Spare parts like brake pads pistons etc. when disposed in order to prevent pollution.
should be kept at a dry and constant The oil must be removed from the brake and
temperature. from the hydraulic system / unit and stored
Seal kits should be kept away from direct in proper containers until delivery to local
daylight and should be in the original bag disposal enterprises.
and ideally stored in a box / dark area.
Brake
The brake is in general made of cast iron or
IMPORTANT machined steel.
The anti-corrosion protection should be Once the hydraulic oil has been removed
reapplied if necessary after transporting or from the brake, and the seals have been
handling. removed the brake can be treated as steel
waste/scrap.
Seals
The seals and o-rings used in the brake are
made of either Polyurethane (PUR), PTFE
(Teflon) or rubber (NBR).
They can all be treated as normal waste.
Electronics
If equipped with any electronic
equipment as sensors,
indicators or similar - this
equipment should be treated
as electronic waste.
1.20 How to order spare parts

When ordering spare parts for your brake
please refer to the specific item number from
the recommended spare parts list or refer to
the position number and item description in
the appendices.
For contact information when ordering spare

parts please see section 1.1 – Who to
contact or www.svendborg-brakes.com
For full identification of the brake please

note the serial number and preferably the
item number and type stated on the name
plate - see Section 1.8 - Nameplate / Serial-
numbers.
To avoid serious personal injury when you

2 Installation use solvent cleaners, you must read the
2.1 Lifting and handling manufacturer‟s instructions before using a
The BSFH 500 Dual Spring brake is solvent cleaner, and then carefully follow
equipped with eyebolts on the calipers and these instructions.
should only be lifted by means of placing a
hook through them. Also follow these procedures:
If the eye bolts are mounted in brake pad
holders please remove the eyebolts again Wear protective eye protection
before use of the brake. Wear clothing that protects your skin
In order not to damage any parts on the Work in a well-ventilated areas
brake do not fit any hook or tie any rope,
chain or strap around indicators, hoses etc. Always follow local rules and regulations for
When lifting please note that the total weight / when working with solvents.
of the complete brake when mounted on the
standard bracket is approx. 350kg. The 2.3 Cleaning of the mounting surfaces
weight of the calipers excluding brake pads
and bracket is approx. 270kg. The mounting surface of the bracket or
customer post must comply with the relevant
arrangement drawings and mounting data
WARNING drawings.
In order to avoid personal injuries during
installation, service or adjustment of the It is critical that the brake is bolted to the
partly completed machine the service mounting surface in compliance with the
personnel is to handle the partly completed tolerance specified on the caliper dimension
machine using protective working gloves, drawing.
EN 420 / EN388 - category 2 and protective
footwear, EN345 / ISO20345 – category S3.
IMPORTANT
The joint between the mounting surfaces of
The machinery in which the brake is to be
the yoke and the bracket/customer post is
installed must be designed and constructed
classified as a friction joint.
in such way as to allow access in safety for
maintenance of the brake.
Therefore NO lubricant or other compound
shall be applied between the caliper and
2.2 Cleaning the brake disc mounting surfaces.
Before installing the brake calipers the brake
disc must be cleaned from any dirt or anti The mounting of the caliper does NOT rely
corrosive protection. on the shear capacity of the mounting bolts
but of the friction joint. This friction joint is
The anti corrosive protection can normally created by the clean, dry, lubricant free
easily be removed in two steps: surface machined to the correct surface
finish and of the tension created by the
1) By using petroleum or diesel fuel for the mounting bolts.
initial cleaning.
2) Using solvent cleaners to remove the The mounting surfaces for the yoke and
remaining dirt completely. bracket (if applicable) should be cleaned in
the same way as the brake disc - see
Use a cleaning solvent for the final cleaning. section 2.2 - „Cleaning the brake disc’.
Solvent cleaners could be clear methylated
or white spirits or isopropyl alcohol.
Any residual oil or anti-corrosion preparation

will reduce the coefficient of friction greatly.
WARNING
Solvent cleaners can be flammable,
poisonous and can cause burns.
WARNING WARNING
Solvent cleaners can be flammable, Solvent cleaners can be flammable,
poisonous and can cause burns. poisonous and can cause burns.
Please follow the manufacturer‟s Please follow the manufacturer‟s
instructions and see section 2.2 - Cleaning instructions and see section 2.2 - Cleaning
the brake disc. the brake disk.
2.4 Handling / mounting the brake 2.4.3 The brake pads are mounted with pad
guides.
pads FIGURE 2.1
Friction material is a very essential part of
the brake system and the brake pads should
be handled carefully to avoid damages to
the brake pads / friction material.
The brake pads should be kept as clean as
possible - be careful to protect the pads from
grease and oil. Even a small amount of oil
can reduce the friction coefficient
considerably.
PAD GUIDES
NOTE
All brake pads supplied by Svendborg FIGURE 2.2
Brakes are asbestos free and free of lead.
Brake pads can be supplied in several types

and with different brake pad materials
depending on the actual needs in the
application.
In general there are two types of brake
pads:
Brake pads with organic / resin based

linings FIGURE 2.3
Brake pads with sintered metal pucks /
material
2.4.1 Brake pads with organic brake pad material /

lining is sensitive to dirt, grease and oil and
are normally packed / sealed in plastic to
protect them from contamination - please
keep the pads in the package for as long as
possible. PAD GUIDES
The organic pad materials can normally not
be cleaned if exposed to grease and oil.
In most cases they must be discarded and It is possible, when assuming that the space
must be replaced if exposed to this. is available for the hub, to change the pads
just by removing the 4 innermost bolts
2.4.2 Brake pads with sinter metal brake pad (M10x30) and pad guides on each pad and
material is less sensitive to dirt, grease and thereafter by sliding the brake pad towards
oil and can in some cases - where not fully the centre of the main shaft.
soaked up with oil - be cleaned with solvent
and re-used. Mounting is done in reverse order.
As they are not that sensitive the brake pads
of sintered metal are not necessarily For information on the tightening torque for
wrapped in plastic. the pad guides please refer to Table 2.1 -
Bolts for brake pad guides.
Table 2.1 bracket and alignment is checked (and

Bolts for brake pad guides adjusted accordingly).
2) Mount the brakes to the bracket, mount
Torque and align the bracket to the brake disc
Bolt size
Lubricated MoS2 Dry and foundation.
M10 8.8 37 Nm 45 Nm 3) If the brake is bought with a bracket it
“Lubricated” is based on Molykote - MoS2 may already be mounted from the factory
- the brake and bracket are to be
mounted and aligned.
If there is not enough space to remove the
pads towards the centre of the brake disc,
The following instruction is based on the
the brake pad can be removed by removing
brake is to be mounted on the bracket on
the 4 bolts (M16x70) (21-C) and the pad
site.
holder (19-C).
If the brake is already mounted onto the
The brake pad can be removed by sliding
bracket please skip the corresponding
the brake pads sideways out of the brake.
sections.
Mounting is done in reverse order.
Short summary of what to do:
FIGURE 2.4
Prepare the brake (remove indicators,
checks before adding pressure)
Secure / lift the piston
Check / clean mounting surfaces
Mount the bracket (if applicable)
Mount the brake
Mount the brake pads / retraction springs
Check alignment / adjust accordingly
Tighten the brake / bracket
PREPARE THE BRAKE

2.5.1 Remove the indicator (if fitted) from the
adjusting screw to prevent it from being
damaged.
2.4.4 After mounting the pad holders the pad GENERAL FIGURE FIGURE 2.6
retraction springs should be mounted into
the brake pads.
FIGURE 2.5
Pad retraction
spring & bolt
Pad retraction
spring & bolt
2.5.2 Check that the adjusting screw is screwed

sufficiently far into the yoke before mounting
the brake pads or applying hydraulic
pressure.
2.5 Mounting the brake

Mounting can in general be done in several
ways:
1) Mount and align the bracket where after

the brake(s) are mounted onto the
GENERAL FIGURE FIGURE 2.7 FIGURE 2.9
If the adjusting screw is too far out the

thread may be destroyed or the seals may
leak or if the adjusting screw is too far in LOWEST PRESSURE CONNECTION
there may not be sufficient space for
mounting the new brake pads. 2.5.5 Apply the minimum release pressure
according the nameplate / sign or to Table
The nominal distance from the adjusting 2.2 - Minimum release pressure to ensure
screw and to the yoke is 12mm (new pads, the brake is fully lifted.
standard air gap etc.).
CAUTION
CAUTION Maximum pressure allowed on the brake is
The maximum distance allowed while 23.0MPa (230bar).
pressurized is 13,5mm from yoke to
adjusting screw
Table 2.2
FIGURE 2.8 Minimum release pressure
Brake size Min. pressure
BSFH 507 8,0 MPa
BSFH 508 8,5 MPa
BSFH 509 9,0 MPa
BSFH 510 10,0 MPa
BSFH 512 12,0 MPa
BSFH 514 14,0 MPa
BSFH 515 14,5 MPa
BSFH 516 15,0 MPa
BSFH 520 19,0 MPa
SECURE THE PISTON 2.5.6 Remove the cover (15-C) and mount the
flange nut / air gap nut (part of tool kit) on
NOTE the centre bolt (22-C) when the piston is
The brake may be delivered with lifted piston completely lifted.
/ compressed spring pack from the factory.
In this case please disregard the next
section as the nut is already mounted - FIGURE 2.10
continue at section 2.5.8.
2.5.3 Remove the threaded plugs (14-C) in the

lowest pressure connection.
2.5.4 Connect a hand pump or a hydraulic unit to

the pressure port (G3/8) (14-C).
FLANGE NUT
This will ensure that the piston is locked into Before fully tightening the nuts and bolts
lifted position when working with the brake please make a visual check to see if any
pads. interference between brake, bracket and
brake disc is present.
IMPORTANT
Only tighten the flange nut/air gap bolt (part NOTE
of tool kit) with the fingers or if use of tools - The brake calipers may need to be lifted
only use very little force. before final tightening of the bolts / nuts as
Tightening the nut too much will make it gravity will make the calipers tend to move
almost impossible to remove it again. down.
In general this should not be a problem - but
2.5.7 Release / remove the hydraulic pressure if the bracket has large mounting holes this
again and the piston is now securely locked. could cause problems.
CHECK THE MOUNTING SURFACES MOUNT THE BRAKE PADS / PAD

2.5.8 Check that the mounting surface of the RETRACTION SPRINGS
bracket or customer post complies with the 2.5.15 Prepare the brake pads for mounting. Be
relevant arrangement drawings and careful and protect the pads from grease
mounting data drawings i.e. is flat and at and oil, see section 2.4 - Handling /
right angles to the brake disc, before mounting the brake pads.
mounting the brake.
2.5.16 If not done already remove one brake pad
2.5.9 Ensure that the mounting surfaces are clean holder from each caliper half by removing
of dirt and oil - otherwise clean as per the 4 bolts (M16x70) (21-C) and the pad
section 2.3 - Cleaning of the mounting holder (19-C).
surfaces. FIGURE 2.11
MOUNT THE BRACKET (IF APPLICABLE)

2.5.10 Mount the bracket and align it to the brake
disc.
Do not tighten the mounting bolts to the full
torque as adjustment may be needed.
MOUNT THE BRAKE

2.5.11 Lift one caliper half to the bracket and align
the holes for the mounting bolts / studs.
2.5.12 Align spacers (if applicable) between the

caliper and bracket, before mounting the
bolts.
Use the tightening torque specified on the
IMPORTANT Spare parts drawing or from Table 2.3 -
If spacers are to be used, an equal amount Bolts for brake pad holders and guides.
should be used on both sides of the bracket.
Table 2.3
Mount the mounting bolts through the caliper Bolts for brake pad holders and guides
and bracket and let the caliper rest on the
Torque
bolts. Bolt size
Lubricated MoS2 Dry
2.5.13 Lift the other caliper half into place and align M10 8.8 37 Nm 45 Nm
it to the mounting bolts - remember spacers M16 10.9 220 Nm
if applicable. “Lubricated” is based on Molykote - MoS2
2.5.14 Fit and tightens the washers and nuts

2.5.17 Fit the pad retraction springs and bolts and
slightly.
mount these - tighten firmly according to
Table 2.4 - Bolts for pad retraction springs
Use the tightening torques from the spare-

Table 2.4 parts drawing or Table 2.5 - Mounting bolts
Bolts for pad retraction springs for caliper half.
Torque
Bolt size Table 2.5
Lubricated MoS2 Dry
Mounting bolts for caliper half
M10 8.8 20 Nm 27 Nm
Torque
“Lubricated” is based on Molykote - MoS2 Bolt size
Lubricated MoS2
Standard bolts
GENERAL FIGURE FIGURE 2.12 (DIN 912 / DIN 931 / ISO 4014 style)
M24 10.9 740 Nm
M33 10.9 1980 Nm
Stud bolts
M24 10.9 610 Nm

M33 10.9 1520 Nm
“Lubricated” is based on Molykote - MoS2
2.5.21 After installing / fitting the brake pads the

brake / air gap must be adjusted - see
section 2.6 - Adjusting the brake.
2.6 Adjusting the brake

The air gap is the space between the brake
FIGURE 2.13
Pad retraction pad and the brake disc. This air gap must be
spring & bolt adjusted before taking the brake caliper into
Pad retraction operation / replacement of the brake pads
spring & bolt
and when the brake pads have been worn
enough to give a pad wear signal from the
indicator.
2.6.1 If the piston is not lifted and secured by the

flange nut (part of tool kit) at this stage apply
the minimum hydraulic pressure by hand
pump or hydraulic power unit (according to
Table 2.2 - Minimum release pressure and
fit the flange nut.
GENERAL FIGURE FIGURE 2.14

CHECK ALIGNMENT
2.5.18 Check the alignment of the brake / bracket
and brake disc.
The brake pad holders should be parallel to
the brake disc and the distance between
brake pad holder and the brake disc should
be equal.
2.5.19 Check that the brake disc can rotate freely,

without touching the brake.
TIGHTEN THE BRACKET / BRAKE (Gauge indicates pressure on)

2.5.20 When aligned, tighten the mounting bolts for
the brake (4 x M30 & 2 x M27). 2.6.2 Release / remove the hydraulic pressure
again and the piston is now securely locked.
Tighten the mounting bolts for the bracket /
base plate connection to the correct torque.
GENERAL FIGURE FIGURE 2.15 2.6.7 Mount the indicator(s) in the adjusting screw
if equipped - see section see section 2.9 -
Installing the indicators.
GENERAL FIGURE
FIGURE 2.18
(Gauge indicates no pressure)
2.6.3 Use the spanner and turn the adjusting

screw (3-C) clockwise until the piston and 2.6.8 Connect the drain lines to the brake. The
the brake pads are pressed against the drain line can be of plastic.
brake disc.
GENERAL FIGURE FIGURE 2.16 IMPORTANT

Remember to bleed the brake before use -
see section 2.8 - Bleeding and flushing the
caliper.
2.7 Inspecting the alignment of the

brake
2.7.1 Apply hydraulic pressure to the brake and
make sure that the piston is completely lifted
and the brake pads are not in contact with
the brake disc.
FIGURE 2.17 2.7.2 Check that the brake pads can move freely
within the brake pad holders. The pad
retraction springs will reduce the movement
somewhat, but the brake pad must not be
stuck to the brake.
2.7.3 The brake pad holders should be parallel to

the brake disc.
The distance between brake pad holder and
the brake disc should be equal on both
(No air gap) sides.
2.6.4 Turn the adjusting screw (3-C) a third of a
turn counter-clockwise (back / out) and the IMPORTANT
air gap will automatically be 1mm (because The axial movement of the brake disc must
the pitch is 3mm therefore 1/3 is 1mm). not exceed 0.5mm - see mounting drawing
2.6.5 Apply hydraulic pressure to the caliper and

remove the flange nut. 2.8 Bleeding and flushing the caliper
Check that the air gap is correct (1mm as Each brake caliper has been individually
standard) with a feeler gauge, and release flushed before leaving the factory and all
the pressure again if ok - otherwise readjust. hydraulic power units supplied from
Svendborg Brakes A/S has also been
2.6.6 If the hydraulic power unit has not been flushed before leaving the factory.
connected to the brake yet, then connect it Despite that fact the hydraulic system must
using the lowest pressure connection (14- be flushed and bled before taking the
C). system into full usage.
Flushing of the system will remove minor

particles and potential dirt in the system and 2.8.4 Adjust the oil pressure to 3-4bar (0,3-
prevent damages to the system. 0,4MPa)
After flushing - the individual brake calipers Bleed until only oil flows through the test
should be bled in order to remove any air in point hose (no bubbles)
the system.
If the calipers are not properly bled potential 2.8.5 Remove the oil pressure from the brake(s)
damages to the seals may occur. for 5-10 sec and then pressurize the
brake(s) again.
The hydraulic system must always be bled Repeat this several times.
in conjunction with assembly, repairs or
when making changes in the system. 2.8.6 Disconnect the test point hose from the
Failure to bleed the brakes / hydraulic bleeding point.
system will allow air to remain in the brake
system. 2.8.7 Pressurize the brake with working /
This could prevent the hydraulic pressure in operating pressure. Make sure that the
the brake system from rising / increasing brake is fully lifted.
enough to lift the brakes correctly.
A possible result from this could be that the 2.8.8 With the pressure on the brake connect the
brake pads will remain on the brake disc and test point hose to the bleeding point P1 to
heating of the brake pads and brake disc release oil / air again (the pump may be
could occur. switched off in order to avoid restart).
Air in the system could also destroy the
seals (diesel effect) within the brake / WARNING
caliper. Make sure that the free / open end of the
test point hose is fixed as the oil ray can be
2.8.1 The bleeding order depends on the dangerous.
connection of the system (serial / parallel
connection, single half or multiple caliper 2.8.9 Remove the oil pressure from the brake for
halves). 5-10 sec and then pressurize the brake with
Each caliper half / hydraulic chamber must 3-4 bar again – bleed using / connecting the
be bled starting with the caliper half / test point hose.
chamber with the longest distance to the Repeat several times.
pressure-in point / splitting point in the pipe /
hose connection. When only oil flows through the test point
The process must be repeated for each half hose continue bleeding until approximate
/ chamber while working towards the 0,5 litre of oil has been emptied through the
connection point / splitting point and all the hose.
way back again to the starting point.
If air is still present in the last caliper the
procedure must be repeated. IMPORTANT
The amount of oil that must be bled through
Bleeding must be done from the highest each caliper half will increase with the
connection point on the brake. number of brakes and the distance to the
connection point
2.8.2 Connect a test point hose to the upper
bleeding point - if not equipped with a test 2.8.10 Stop the pump and remove the test point
point connection (G3/8) then mount a test hose.
point connection in the bleeding point – see
recommended spare parts for test point The brake has now been correctly bled.
male / hose – and connect the test point
hose to the test point. If the opening and closing times of the brake
system are longer than expected or if the
2.8.3 Connect the free end of the test point hose pressure does not increase smoothly there
into an empty bottle / to the tank of the PU. are most likely air in the system.
Start the hydraulic pump and activate the

relevant valves in order to allow oil running
to the brake.
2.9 Installing the Indicators series of activations with increased load or

increased speed.
The BSFH 500-S/R-501 brake can be
mounted with 2 switches for safety use. Sinter-metal pads:
This can be our tamper-proof mechanical
The bedding in process for sinter-metal pads
switch with two signals per sensor, or it can
is the same as for organic pads, but with a
be by using 2 inductive proximity switches
slightly higher clamping force when bedding
with only one signal per indicator.
in - approx. 40% of the rated clamping force
applied.
Svendborg Bakes highly recommend the
usage of the mechanical switch because this
During the process of “bedding in”, the disc
is tamper-proof and is preset from the
temperature should be monitored to ensure
factory.
that the disc does not overheat.
2.9.1 The indicator for „Brake release‟ (On/Off) &
Instruction for the bedding in process is
„Pad Wear‟ must be mounted in the
packed together with the brake pads.
adjusting screw - position 1 on figure 2.34.
2.10.1 The clamping force can be reduced by
Remove the plug(s) (G1/2) and fit the
lowering the hydraulic pressure in the active
indicator.
caliper to the correct percentage of the
balancing pressure - see Appendix E -
 Technical Data.
Reduce the hydraulic pressure on the

hydraulic power unit if possible or connect a
hand pump and a pressure gauge into one
of the pressure ports (14-C).
PRESSURE
FIGURE 2.20
GAUGE
FIGURE 2.19
HAND PUMP OR
HYDRAULIC
POWER UNIT
2.10 Bedding in / burnishing of the
brake pads
To obtain the rated coefficient of friction
between the brake pad and the brake disc, GENERAL FIGURE
and to ensure that the pad surface is aligned

to the disc, it is essential that the pads are 2.10.2 Fully lift the piston by increasing the
bedded in / burnished to the disc surface. hydraulic pressure.
The coefficient of friction may drop by 2.10.3 Start the application / rotating of the brake
approx. 20% when not bedded in. disc.
This can be done by making a series of 2.10.4 Reduce the hydraulic pressure to the correct
load-tests with increasing load or speed until pressure level. Run until bedding in is
sufficient coefficient of friction is achieved. completed.
On a new installation the time of bedding in
will be longer because the disc also has to Example:
be bedded in. 25% of clamping force needed.
Always use new pads with a new disc. The brake size / type is BSFH 520 - the
Never use used pads with a new disc. balancing pressure is 13.8MPa (138bar) -
see Appendix E - Technical Data.
Organic pads: The reduced hydraulic pressure is
Organic pads can normally be bedded in by calculated as 100%-25% = 75% of 13.8MPa.
driving the disc through the pads with a The hydraulic pressure should be reduced to
minimum of 25% of the rated clamping force 10.4MPa (104bar) during bedding in.
applied, or if that is not possible by making a
2.11 Removing the brake

2.11.7 Remove the brake pad holders (4-C) and
2.11.1 Remove the indicator if equipped to prevent
the brake pads (5-B) from both the active
it from being damaged.
calipers - see section 2.4 - Handling /
mounting the brake pads.
2.11.2 Check the distance on the adjusting screw
before applying hydraulic pressure.
2.11.8 Apply hydraulic pressure to the caliper and
remove the flange nut (M24).
The nominal distance from the adjusting
Release the hydraulic pressure and the
screw and to the yoke is 12mm (new pads,
piston will now move forward again.
2.11.9 Remove the hydraulic hose and pipe
CAUTION connections from the brake.
The maximum distance allowed while
pressurized is 13,5mm from yoke to 2.11.10 Repeat for both calipers.
adjusting screw
2.11.11 Connect lifting equipment to the brake i.e.
use the equipped eyebolts
FIGURE 2.21
The eyebolts mounted on the brake can be
moved to the back of the active caliper half
or they can be mounted in the brake pad
holders for lifting.
2.11.12 The brake can now be removed safely by

removing the 2 (M24) and 4 (M33) mounting
bolts going through the caliper.
2.11.3 Apply the minimum release pressure

according the nameplate / sign or to Table
2.2 - Minimum release pressure to ensure
the brake is fully lifted.
CAUTION
Maximum pressure allowed on the brake is
23.0MPa (230bar).
WARNING
Under no circumstance place your fingers
between the brake pad and the brake disc
when the brake is pressurised.
2.11.4 Fit the flange nut.
IMPORTANT
Only tighten the air gap nut (M24) with the
fingers or if use of tools - only use very little
force.
Tightening the nut too much will make it
almost impossible to remove it again.
2.11.5 Remove / relieve the hydraulic pressure.
2.11.6 Remove the pad retractions springs and

bolts from both the active calipers - see
section 2.4 - Handling / mounting the brake
pads.
The brake pad thickness can always be

3. Maintenance checked with a gauge.
WARNING The brake pad has a total thickness of

In order to avoid personal injuries during 47mm when new, i.e. all brake pads must be
installation, service or adjustment of the replaced when the thickness of friction
partly completed machine the service material + back plate is 38mm for organic
personnel is to handle the partly completed pads and 42 for sintered pads
machine using protective working gloves,
EN 420 / EN388 - category 2 and protective The brake pads should be kept as clean as
footwear, EN345 / ISO20345 – category S3 possible - be careful to protect the pads from
grease and oil. Even a small amount of oil
During operation dust emission from disc can reduce the friction coefficient
and friction material of brake pads will occur. considerably.
To protect against particles filtering half
masks, EN 149, class FFP2S – should be See section 2.4 - Handling / mounting the
used when maintaining the brake. brake pads for proper handling of the brake
pads.
3.1 Indicator
WARNING
The brake can be equipped with several
During a braking / stopping cycle heat will
indicators for different purposes. They are
normally be generated.
not mandatory but highly recommended.
Please ensure that the brake disc and brake
pads are not hot before start working on the
During usage the brake pads will wear.
application
Wearing the brake pads leads to less
clamping force.
To compensate for this loss in clamping WARNING
force the brake must be adjusted on a Always ensure there is no hydraulic
regular basis - see section 1.10 - Function pressure in the brake before starting work.
for more details. It is important that there is no pressure on
the hydraulic power unit or circuit and that
3.1.1 Pad wear signal the control signals has been shut off and
The brake can be equipped with a “Pad blocked before working on the system.
Wear” indicator which will indicate when Please also ensure the oil pressure in the
adjustment of the brake is needed. The accumulator(s) has been relieved / removed
allowed amount of wear is chosen upon (if applicable).
selection of the indicator.
3.2.1 Remove the indicator if fitted.
The standard indicator can provide two
signals: GENERAL FIGURE FIGURE 3.1
A “Brake Release” signal that indicates

when the brake is released / activated
(On/Off).
A “Pad Wear” signal that indicates that
the brake must be readjusted.
The “Pad Wear” indicator is to be mounted

in the perimeter of the adjusting screw after
removal of the hydraulic plug (16-C).
For information on how to adjust the brake - 3.2.2 Remove the cover (15-C) from the centre
see section 2.6 - Adjusting the brake. hole of the adjusting screw.
3.2 Replacing the brake pads

The maximum wear for brake pads before
they must be replaced is, 9mm for organic
pads and 5mm for sintered pads.

(Gauge indicates no pressure)
3.2.5 Apply the minimum release pressure

IMPORTANT according to the nameplate / sign or to Table
Check that the adjusting screw is screwed 2.2 - Minimum release pressure in order to
sufficiently into the yoke before mounting the ensure that the brake is fully lifted.
brake pads or applying hydraulic pressure. Maximum pressure allowed on the brake is
23.0MPa (230bar).
If the adjusting screw is too far out, the
thread may be destroyed or the seals may 3.2.6 Mount the flange nut (part of tool kit) on the
leak. If the adjusting screw is too far in there centre bolt (22-C) coming out of the
may not be sufficient space for mounting the adjusting screw when the piston is
new brake pads. completely lifted.

The nominal distance from the adjusting
screw and to the yoke is 12mm (new pads,
CAUTION
The maximum distance allowed while
pressurized is 13,5mm from yoke to
adjusting screw
FIGURE 3.3
(Gauge indicates pressure on)
This will ensure that the piston is locked into

lifted position when working with the brake
pads.
IMPORTANT
3.2.3 Remove the threaded plug (14-C) in the Only tighten the flange nut (part of tool kit)
lowest pressure connection. with the fingers or if use of tools - only use
very little force.
3.2.4 Connect a hand pump or a hydraulic unit to Tightening the nut too much will make it
the pressure port (G3/8) (14-C). almost impossible to remove it again.
3.2.7 Remove / relieve the hydraulic pressure.
3.2.8 Remove the pad retraction springs and bolts 3.2.10 Remove the brake pads by sliding them
from both the active calipers. sideways out of the brake.
WARNING 3.2.11 Replace the brake pads.

Under no circumstance place your fingers
3.2.12 Slide the brake pads into position and mount
between the brake pad and the brake disc,
the brake pad holders (19-C) and the bolts
when the brake is pressurized.
(M16x70) (21-C) again.
GENERAL FIGURE FIGURE 3.6 Use the tightening torque specified on the
Spare parts drawing or from the Table 2.3 -
Pad holders.
3.2.12 Mount the pad retraction springs and bolts -

see figure 3.7.
Use the tightening torque as specified in
Table 2.4 - Bolts for pad retractions springs -
section 2.5 - Mounting the brake.
3.2.13 After replacing the brake pads the brake

must be readjusted again - see section 2.6 -
Adjusting the brake.
3.2.14 Remember to bed in the brake pads before

taking the brake into full load situations - see
FIGURE 3.7 section 2.10 - Bedding in.
Pad retraction
spring & bolt
Pad retraction
spring & bolt 3.3 Replacing other components
Some minor components can be replaced
with the brake mounted on site, but it is
highly recommended to take the brake to a
workshop for repairs.
NOTE
Depending on the work that needs to be
done on the brake it might be worth
considering only taking the active caliper to
3.2.9 Remove the brake pad holders (19-C) and the workshop.
the 2 bolts (M16x70) (21-C) from both the
active calipers. WARNING
When lifting please note that the total weight
FIGURE 3.8 of the complete brake is approx. 350kg - the
active caliper itself weighs approx. 135kg.
FIGURE 3.9
Bolts
Caliper
Spacer
If any
Spacer
If any Caliper
Bracket
3.3.1 Either remove one brake caliper according 3.5 Replacing the seals
to section 2.11 - Removing the brake by
If the brake has been leaking it is
removing the M24 and M33 nuts from the
recommended to replace all seals - not only
mounting bolts (2+4pcs) on one side, and
single seals.
remove one caliper half or remove both
calipers by removing the stud bolts / bolts
(7-B) completely. IMPORTANT
Please note that the sealing solution /
WARNING design can vary over time. The actual seals
Always ensure there is no hydraulic of a brake can therefore vary from the
pressure in the brake before starting work. replacement seal kit supplied.
All sealing solutions used are fully
interchangeable and backwards compatible.
3.4 Dismantling the active caliper For specific details on the different seal
In order to check if replacement of the spring types and how they should be mounted -
pack is needed it is highly recommended to please see Appendix H - U-Cup Information.
check the clamping force before dismantling
the active calliper - see section 3.6 -
IMPORTANT
Checking the clamping force
Ensure that there is no pressure on the
General caliper.
The greatest possible cleanliness must be
observed when working on a hydraulic 3.5.1 Remove the O-ring (5-C) and unscrew the
system of any type. adjusting screw (3-C) by turning it counter-
Each part must be cleaned thoroughly clockwise out of the yoke with the spanner.
washed in solvent cleaners.
Solvent cleaners could be clear methylated FIGURE 3.10
or white spirits or isopropyl alcohol.
WARNING
Solvent cleaners can be flammable,
poisonous and can cause burns.
See section 2.2 - Cleaning the brake disc for
additional information.
Parts must be stored in a clean and dust

free environment. All assembly work must
also be carried out in clean and dust free 3.5.2 Remove the adjusting screw by hand or by
environment. crane - use the tool for adjusting screw
removal (see recommended spare parts).
Dirt shortens the lifetime of the seals
considerably and may also damage the FIGURE 3.11
caliper.
The surface of the internal components i.e. Tool for removal of

piston (2-C), centre-bolt (22-C) and the yoke adjusting screw
(1-C) that are in contact with the seals are M36x2 with M10
all ground or polished. eye bolt
Please check that these surfaces are not

damaged or scratched in any way and
handle them with care to avoid damaging
the surfaces.
A damaged piston will immediately ruin the
seals resulting in leakage.
GENERAL FIGURE FIGURE 3.12 FIGURE 3.14
3.5.3 If the complete brake / bracket has been

removed from site, the piston (2-C) can be
lifted / removed using some wooden blocks, Please note that one of the seals in position
cloths and for example using a pipe as a 6-C is located inside the adjusting screw (3-
lever. C).
Be careful not to damage the piston.
Use a screwdriver to lever the seals, the
3.5.4 If only the active caliper has been taken to wiper and the wear ring out of the groove.
the workshop it must be fixed and the piston
pulled out by use of a crane, or by placing a
FIGURE 3.15
wooden block and some cloths on the piston
and then push down on the yoke/caliper.
3.5.5 Remove the piston by hand or by crane -

use the tool for piston removal (see
recommended spare parts).
FIGURE 3.13
Tool for removal

of brake piston
M24 with M10
eye bolt
Be careful not to damage the edges on the
grooves.
IMPORTANT 3.5.8 Clean and dry the involved parts, see

Before removing the piston remove one of section 2.2 - Cleaning the brake disc for
the plugs from the pressure ports (14-C). details.
This will allow air entering the hydraulic
chamber preventing the making of a vacuum 3.5.9 Open the seal kit and place the seals on the
which will make it almost impossible to table in correct order.
remove the piston.
3.5.10 Mount the new seals (6-C, 7-C and 9-C) and
the wiper (8-C). The dust lip of the wiper
IMPORTANT must be facing outwards.
Handle the piston carefully. A scratched
piston can immediately destroy the new For easing the mounting of the wiper it
seals. should be squeezed into a kidney style
shape.
3.5.6 Place the piston at a safe location while
replacing the seals.
Leave the spring pack inside the piston.
3.5.7 Remove the wiper (8-C) and the seals (6-C,

7-C and 9-C).
FIGURE 3.16 FIGURE 3.18
A B
CAUTION 3.5.15 Mount / apply the new o-ring (5-C) to

prevent dirt entering the thread of the yoke
Be very careful with the edges on the piston
and adjusting screw.
rod seals as they are quite sensitive. Only
use your fingers to squeeze out any kinks.
3.5.16 Depending on how the brake / active caliper
has been brought to the workshop it is now
3.5.11 Before mounting the piston again it is highly ready for being mounted again. Refer to
recommended to check the condition of the section 2.5 - Mounting the brake.
spring pack and / or replace the spring pack
- especially when running an application with 3.5.17 If the caliper half is removed from the
many activations of the piston. complete brake the mounting bolts must be
fitted again using the tightening torques from
If potential problems with the spring pack the spare-parts drawing or from Table 3.1 -
are suspected and the condition is to be Mounting bolts for caliper half.
checked - please refer to section 3.7 -
Checking the spring pac’.
Table 3.1
If a new spring pack is to be installed - Mounting bolts for caliper half
please refer to section 3.8 - Replacing the Torque
spring pack. Bolt size
Lubricated MoS2
Standard bolts
If no problems are found with the spring (DIN 912 / DIN 931 / ISO 4014 style)
pack, move on to the next section.
M24 10.9 740 Nm
3.5.12 Lubricate the seals and yoke according to M33 10.9 1980 Nm
the lubrication note in the Appendix C - Stud bolts
Spare parts drawing. M24 10.9 610 Nm
M33 10.9 1520 Nm
3.5.13 Place the piston (2-C) in the yoke (1-C).
“Lubricated” is based on Molykote - MoS2
NOTE
Mounting must in general ALWAYS be
carried out using new bolts, nuts and
washers; otherwise the clamping force of the
bolt connection may not be present.
IMPORTANT
If the spring pack has been replaced the
clamping force should be checked by
measuring the balancing pressure at the
correct position of the piston to ensure
Push the piston down as far as possible. proper mounting of the spring before taking
the brake into production again – see
3.5.14 Mount the adjusting screw on the piston and section 3.6
yoke and turn it clockwise until the top
surface is approximately 12mm out of the
yoke.
3.6 Checking the clamping force unit, use a hand pump instead (see
recommended spare parts).
The clamping force should be checked on
.
regular basis – see section 4 - Maintenance
3.6.4 Ideally the measuring devices should be
schedules - in order to maintain the
connected to a data-logging device, as this
performance of the brake or when replacing
will make it easier to make the readings.
the spring pack
3.6.5 From the maximum operating pressure
The clamping force can be checked by
reduce the pressure slowly while reading the
measuring the hydraulic pressure at specific
distance and hydraulic pressure.
distance from fully lifted piston (outwards
travel).
Read the pressure at the piston travel
If the pressure is below the balancing
specified in Technical Data - Appendix E
pressure stated in the technical datasheet -
Appendix E – this indicates a need for
Repeat the test 2-3 times to get correct
replacement.
readings.
The value measured should not be 5%
3.6.6 Verify the measured pressure against the
lower than nominal balancing pressure (to
limits for the specific brake size from
allow for measuring errors).
Appendix E - Technical Data.
The minimum and maximum values is found

NOTE as the minimum and maximum balancing
The values for the balancing pressure can pressure from the table.
also be calculated by dividing the required The lower value should not be more than
clamping force with the piston area 5% below.
Alternatively the values can also be

calculate - example:
IMPORTANT The brake size / type is BSFH 520 - the
Before measuring the brake should be minimum balancing pressure is 13.8MPa
activated 15-20 times (138bar).
The maximum is taken from the table or is
calculated as 218kN / 145 cm² x 10 =
3.6.1 The piston travel can be measured using a 15,0MPa
dial gauge or digital indicator either
measuring on the piston though one of the The measured pressure at 1,0mm travel
G1/2 holes in the adjusting screw (16-C) should be approximately 13.8MPa and not
after removing the plug or by measuring less than 13.1MPa (balancing -5%).but not
directly on the center bolt after having higher than the 15,0MPa.
removed the cover (15-C)
FIGURE 3.19 If the measured values are incorrect
according to specified, the spring package
should be replaced.
3.7 Checking the spring pack

When service work has been performed on
the on the brake / caliper it is highly
recommended to check the condition of the
spring pack.
3.6.2 Attach a pressure transmitter or similar IMPORTANT

equipment to one of the pressure ports Be aware of the placing of the individual cup
either directly or using a test point (see springs in the spring pack when the springs
recommended spare parts). are removed.
Note the placement for future reference.
3.6.3 If the hydraulic pressure cannot be
controlled precisely by the hydraulic power
3.7.1 After removing the adjusting screw (if not FIGURE 3.21
done already) remove the piston from the
yoke.
FIGURE 3.20
Ideally place the newly lubricated individual

springs on a second rod to ensure the
stacking is still correct.
3.7.2 Remove the cup springs from the piston,
making sure the orientation is noted, 3.7.6 Fit the lubricated spring pack inside the
preferably by turning it upside down onto a piston.
fixed rod.
This will prevent the orientation of the FIGURE 3.22
springs from getting mixed up.
Remaining cup-springs and shims / spacers
can be removed from the piston / adjusting
screw using one or two strong magnets.
Please note that shims / spacers (if any) are

located inside the adjusting screw.
3.7.3 Clean and dry the involved parts (piston,

adjusting screw, shims and cup springs)
individually, see section 2.2 - Cleaning the
brake disc, for details.
3.7.4 Carefully check the condition of each cup

spring and shims / spacers (if any).
3.7.7 The spring pack and piston is now ready for

IMPORTANT reinstallation.
If any spring is broken or severely
scratched, the complete spring pack must 3.7.8 If the checking of the spring pack was done
be replaced. during replacement of the seal kit then
please return to section 3.5.12 and complete
3.7.5 Lubricate the individual cup springs and the the process from there.
adjusting screw according to Appendix C -
Spare parts drawing. 3.8 Replacing the spring pack
Every single cup spring and the inside of the
adjusting screw must be greased. During the lifetime of the brake the spring
pack will normally „wear‟ - meaning it will
become weaker and / or individual cup
springs will break.
Depending on the load / stress in the spring
pack this can happen on a regular basis
When a single cup spring breaks it will

normally lead to several broken springs
inside the brake because the small
fragments is floating around and the travel FIGURE 3.25

for the individual cup springs increases
dramatically.
An example of broken springs can be seen
in figure 3.23.
FIGURE 3.23
3.8.2 Remove the cup springs from the piston,

making sure the orientation is noted,
preferably by turning it upside down onto a
fixed rod.
This will prevent the orientation of the
springs from getting mixed up.
Remaining cup-springs and shims / spacers
can be removed from the piston / adjusting
IMPORTANT screw using one or two strong magnets.
If any spring is broken or severely
scratched, the complete spring pack must Please note that shims / spacers (if any) are
be replaced. located inside the adjusting screw. Make
sure all (if any) is removed from the
The replacement spring pack supplied from adjusting screw as remaining shims /
Svendborg Brakes is assembled (not spacers will influence the clamping force.
lubricated) in the correct stacking with the
nominal amount of shims / spacers. 3.8.3 Clean and dry the involved parts (piston and
adjusting screw) individually, see section 2.2
FIGURE 3.24 - Cleaning the brake disc for details.
3.8.4 Compare the new spring pack with the old

spring pack to check if they do match in
design.
Place the new spring pack as the old spring
pack.
FIGURE 3.26
3.8.1 After removing the adjusting screw (if not

done already) remove the piston from the
yoke.
3.8.5 Lubricate the individual cup springs and the

adjusting screw according to Appendix C -
Spare parts drawing.
Every single cup spring and the inside of the If the replacement of the spring pack is not
adjusting screw must be lubricated. carried out during replacement of the seal
kit, then proceed with lubricating the seals
FIGURE 3.27 and yoke according to the lubrication note in
the Appendix C - Spare parts drawing.
3.8.8 Place the piston (2-C) in the yoke (1-C)
Ideally place the newly lubricated individual

springs on a second rod to ensure the Push the piston down.
stacking is still correct.
3.8.9 Mount the adjusting screw on the piston and
3.8.6 Fit the lubricated spring pack inside the yoke and turn it clockwise until the top
piston. surface is approximately 12mm out of the
yoke.
FIGURE 3.28
FIGURE 3.30
3.8.10 Check the clamping force as per section 3.6

– Checking the clamping force.
If the minimum pressure is not reached
additional shims may have to be added to
3.8.7 The spring pack and piston are now ready the spring pack.
for reinstallation. If the maximum pressure is exceeded some
shims may need to be removed.
NOTE Continue checking until the pressure is
Depending on the number of activations and within limits
the reason for removing the spring pack it is
recommended to replace the seal kit while 3.8.11 Depending on how the brake / active caliper
the caliper is disassembled. has been brought to the workshop it is now
ready for being mounted again. Refer to
NOTE section 2.5 - Mounting the brake.
If the replacement of the spring pack is
carried out during replacement of the seal kit
then please return to section 3.5.12 and
complete the process from there.
3.9 Lubrication of the brake

Lubrication is only necessary after
dismantling the active caliper for internal
maintenance / replacement of the spring
pack.
When replacing the spring pack, every
single cup spring must be greased.
For details on where to lubricate internally

see appendix C - Spare parts drawing.
4. Maintenance schedule
The maintenance intervals on a brake On a spring applied brake the air gap should
system depend on the usage of the specific normally be max 2-3mm – otherwise
brake system and also the design of the readjust the brake / air gap (preferably
application in which the brake system is adjust on every maintenance interval)
used.
Brake disc
Frequent usage will result in an increased Corrosion on the disc – especially the area
need for maintenance / inspection. covered by the brake pads – must be
removed as this can have a negative impact
The listed checks are checks that should be on the brake pads and brake performance
done on a frequent basis and is suggested Check for oil and grease contamination and
to be part of normal planned maintenance / or water i.e. from condensation
tasks. Check the disc / disc thickness for wear if
excessive wear is recorded the brake disc
For a new installation / design where the must be replaced
exact conditions are unknown it is Check brake disc warping by measuring the
recommended to start with quarterly
run-out. If exceeds recommended values
maintenance / inspection of the brake
(see mounting drawing) the disc must be re-
system and once the system has proven to machined or replaced
work perfectly the interval can be increased
to twice a year, yearly or even longer. Check the spring force
Check the hydraulic pressure at the
If it turns out that the operation conditions
specified piston travel measuring going
are very good like almost no brake dust, disc
outwards (from fully lifted piston)
is perfectly clean etc. it can be considered to
If the pressure is below the balancing
increase the maintenance intervals.
pressure stated in the technical datasheet in
For detailed information on your specific
the manual (the balancing pressure can also
application please contact Svendborg
be calculated by dividing the minimum
Brakes
required clamping force with the piston area)
this indicates a need for replacement.
In order to prevent unplanned stops we
See section 3.6 for details.
recommended annual maintenance as a
minimum.
Function test
Operate the brake in order to ensure the
Visual checks
piston can operate
Check for damaged brake lines / pipes /
If equipped with On/Off indicators check that
hoses and the hydraulic connections for
the on/off signal changes during operation
leaking oil
With the brake lifted (not braking) – ensure
Check the calliper(s) for leaks
that the brake pads are loose within the
Check the drain connection(s) for leaking oil
brake pad holders.
(ideally drain bottles on every calliper)
Ensure that the pad retractions springs (if
Check the callipers and disc for oil or grease
equipped) can keep the pad against the
contamination
piston
Check the brake pads for extreme wear
Check that the positioning system (if
Use the amount of brake dust near the equipped) is properly adjusted and that it
brake for indicating if the maintenance can push the brake towards the end stop
interval is correct
Hydraulic oil
Check the brake pads for wear
If the brake is not connected to a hydraulic
When the brake is provided with pad wear power unit with flushing capabilities it is
indicator and the signal is still on during highly recommended to replace the oil that
braking no adjustment is needed. are in the brake on a regular basis. This can
Check for total pad wear (when to replace be done by bleeding the brake and pumping
the pads) by measuring the remaining new oil into the hydraulic chamber in the
thickness of the brake pad lining calliper.
Check the pads for extreme and uneven If the oil is dirty it‟s recommended to replace
brake pad wear the oil / take an oil sample for check of the
state of the oil
5. Trouble shooting
Fault Cause Action
The brake applies slowly. Bleed system at highest point and

Air in the hydraulic system
at brake
Air gap between brake pad and Adjust the air gap / brake
disc too large
Abnormal throttling in the Check that all valves are in the
hydraulic system or correct position.
valve in wrong position
Abnormal throttling in the Clean and check pipes, hoses
hydraulic system caused by dirt and valves.
The hydraulic oil in pressure lines Check that the oil is the
between brake and tank has too recommended grade and the
high viscosity (too thick) temperature is not too cold.
Long braking time or long Load too heavy or speed too high Check the load and speed values.
braking distance or
insufficient braking force. Air gap too large Adjust the air gap / brake
Oil, paint or grease on brake disc Clean the brake disc - see section
or brake pad. 2.2
Replace or clean the brake pad -

see section 2.4
Check the hydraulic system does

not leak.
Not all brakes are braking / Check valves where applicable -
connected. check that the individual brake is
working.
Damaged or worn spring pack Replace whole spring pack, not
individual cup springs.
Leakage Worn seals Replace seals
Uneven wear on pad. The brake is incorrectly aligned Check the alignment
Excessive disc throw or shaft Replace the brake disc and check
deflection the shaft deflection.
Abnormally heavy wear on Increased brake utilisation Check that the load speed and
pad. frequency do not exceed
permissible values.
Insufficient air gap. Adjust the air gap
The brake does not lift correctly Check the oil pressure
6. Declaration of incorporation for PCM

(Machinery Directive 2006/42/EC, Annex II, section 1.B)
Manufacturer: Svendborg Brakes A/S

Address; Jernbanevej 9, DK-5882 Vejstrup, Denmark
Herewith declares that for the following Partly Completed Machinery
Type: BSFH 500-S/R-501
The relevant technical documentation is compiled in accordance with part B of Annex VII of the Machinery
Directive and that this documentation or parts hereof will be transmitted by post or electronically in response
to a reasoned request by the national authorities.
The person authorized to compile the relevant technical documentation:
Name: Niels Christensen

Address: Svendborg Brakes A/S, Jernbanevej 9, DK-5882 Vejstrup, Denmark
The following essential health and safety requirements according to Machinery Directive Annex I are applied
and fulfilled:
NUMBER NAME
1.1. GENERAL REMARKS
1.1.2. Principles of safety integration
1.1.3. Materials and products
1.1.4. Lighting
1.1.5. Design of machinery to facilitate its handling
1.2. CONTROL SYSTEMS
1.2.1. Safety and reliability of control systems
1.2.2. Control devices
1.2.3. Starting
1.2.4. Stopping
1.2.4.1. Normal stop
1.2.4.2. Operational stop
1.2.4.3. Emergency stop
1.2.4.4. Assembly of machinery
1.2.5. Selection of control or operating modes
1.2.6. Failure of the power supply
1.3. PROTECTION AGAINST MECHANICAL HAZARDS
1.3.1. Risk of loss of stability
1.3.2. Risk of break-up during operation
1.3.3. Risk due to falling or ejected objects
1.3.4. Risk due to surfaces, edges or angles
1.3.5. Risks related to combined machinery
1.3.7. Risks related to moving parts
1.3.8. Choice of protection against risks arising from moving parts
1.3.8.1. Moving transmission parts
1.3.8.2. Moving parts involved in the process
1.3.9. Risks of uncontrolled movements
1.4. REQUIRED CHARACTERISTICS OF GUARDS AND PROTECTIVE DEVICES

1.4.1. General requirements
1.5. RISKS DUE TO OTHER HAZARDS
1.5.1. Electricity supply
1.5.3. Energy supply other than electricity
1.5.4. Errors of fitting
1.5.5. Extreme temperatures
1.5.6. Fire
1.5.13. Emissions of hazardous materials and substances
1.5.16. Lightning
1.6. MAINTENANCE
1.6.1. Machinery maintenance
1.6.2. Access to operating positions and servicing points
1.6.3. Isolation of energy sources
1.6.4. Operator intervention
1.7. INFORMATION
1.7.1. Information and warnings on the machinery
1.7.1.1. Information and information devices
1.7.2. Warning of residual risk
1.7.4. Instructions
1.7.4.1. General principles for the drafting of instructions
1.7.4.2. Contents of the instruction
1.3.7. Risks related to moving parts
1.3.8. Choice of protection against risks arising from moving parts
1.3.8.1. Moving transmission parts
1.3.8.2. Moving parts involved in the process
1.3.9. Risks of uncontrolled movements
The following international standards has been applied:
EN ISO 12100-1, EN ISO 12100-2, EN ISO 14121-1, EN 60204-1
This partly completed machinery must not be put into service until the final machinery into which it is to be
incorporated has been declared in conformity with the provisions of Machinery Directive 2006/42/EC, where
appropriate.
Vejstrup, date: 29/12/2009
This page in intentionally blank
Appendix A - Dimension drawing, Brake

Drawing is valid for both standard (BSFH 500-S-501) and offshore finish (BSFH 500-R-501)
SVENDBORG BRAKES
Appendix B - Assembly drawing, Brake

Drawing is valid for both standard (BSFH 500-S-501) and offshore finish (BSFH 500-R-501)
SVENDBORG BRAKES
Appendix B - Assembly parts list, Brake

The list is valid for both standard (BSFH 500-S-501) and offshore finish (BSFH 500-R-501)
Please note that several of the items shown on drawing and in the parts list are optional and may not be
present on the actual brake
BSFH 500 S/R - 501
POS. QTY ITEM NAME
1 2 BSFH 500-X-501 ½
BRAKE SIZE WILL VARY ACCORDING TO CLAMPING FORCE SUPPLIED
2 1 PAD RETRACTION SPRING SET
THE FOLLOWING PARTS ARE NOT INCLUDED IN THE BRAKE AND MUST BE ORDERED
SEPERATELY
3 1 BOLT SET
SIZE WILL VARY ACCORDING TO THICKNESS OF BRAKE DISC
4 1 BRACKET
A STANDARD BRACKET IS SHOWN BUT THE TYPE MAY VARY ACCORDING TO
THE SPECIFIC ORDER
5 1 BRAKE PAD SET
THE BRAKE PAD TYPE WILL VARY ACCORDING TO BRAKE PAD SUPPLIED
6 1 INDICATOR “ON/OFF” & “PAD WEAR” XMM WITH XM CABLE

INDICATORS ARE OPTIONAL BUT HIGHLY RECOMMENDED - AVAILABLE IN 30DC
AND 125 VAC AND WITH DIFFERENT CABLE OPTIONS
This page in intentionally blank
Appendix C - Spare parts drawing, caliper half exploded

Drawing is valid for both standard (BSFH 500-S-501 ½) and offshore finish (BSFH 500-R-501 ½)
SVENDBORG BRAKES
Appendix C - Spare parts drawing, caliper half

Drawing is valid for both standard (BSFH 500-S-501 ½) and offshore finish (BSFH 500-R-501 ½)
Updated needed
SVENDBORG BRAKES
Appendix C - Spare parts list, caliper half

The list is valid for both standard (BSFH 500-S-501 ½) and offshore finish (BSFH 500-R-501 ½)
BSFH 500-X-501 ½
POS. QTY. ITEM NAME

1 1 YOKE BSFH 500-X-501/507
2 1 PISTON BSFH500
3 1 ADJUSTING SCREW
10 1 SPRING PACK BSFH 500
11 1 NAMEPLATE W/4 HOLES
12 4 BLIND RIVET Ø2,4X6 RH
13 2 HYDRAULIC PLUG G1/4 WITH SEAL
15 1 COVER WITH O-RING
17 1 AIR FILTER G3/8
18 1 PLUG G3/8 - PLASTIC
19 2 PAD HOLDER - STANDARD FINISH
20 8 WASHER Ø17X30X4 DIN6916
21 8 BOLT M16 X 70 10.9 DIN931
22 1 CENTRE BOLT - BSFH500
23 2 EYE BOLT M16 DIN580
24 1 FLANGE NUT M24 ISO4161 (NOT IN DRAWING – USED FOR LOCKING THE BRAKE)
SEAL KIT BSFH 500 ½

5 1 O-RING Ø189
6 2 ROD SEAL Ø160
7 1 ROD SEAL Ø210
8 1 WIPER Ø160
9 1 QUAD RING Ø215
Appendix D - Mounting Drawing
SVENDBORG BRAKES
Appendix E - Technical data

Name: DEB-0500-001

Revision: E
TECHNICAL DATA AND CALCULATION FUNDAMENTALS FOR

DISC BRAKE BSFH 500
Caliper Clamping force 1) Braking Loss of Operating Balancing Piston Max. Pad surface
type force 2) force per pressure pressure 1) travel airgap pressure 5)
3) 4)
1mm
Min [N] Max [N] [N] [%] [Bar] Min [Bar] Max [Bar] [mm] [mm] [N/mm²]
BSFH 507 70.000 74.000 56.000 9,0 80 48 51 1,0 3 1,17 – 1,70
BSFH 508 80.000 85.000 64.000 7,0 85 55 59 1,0 3 1,35 – 1,95
BSFH 509 90.000 95.000 72.000 6,0 90 62 66 1,0 3 1,51 – 2,18
BSFH 510 100.000 105.000 80.000 5,0 100 69 73 1,0 3 1,67 – 2,41
BSFH 511 110.000 115.000 88.000 4,5 110 76 79 1,0 3 1,83 – 2,64
BSFH 512 120.000 130.000 96.000 8,0 120 83 90 1,0 3 2,06 – 2,98
BSFH 514 140.000 153.000 112.000 7,0 140 97 106 1,0 3 2,42 – 3,51
BSFH 515 150.000 164.000 120.000 6,0 145 103 113 1,0 3 2,60 – 3,76
BSFH 516 160.000 175.000 128.000 6,0 150 110 121 1,0 3 2,78 – 4,01
BSFH 520 200.000 218.000 160.000 10,0 190 138 150 1,0 3 3,46 – 5,00
1)
The figures are based on 1mm air gap (i.e. 1mm on each side of disc on a Dual Spring and 1mm total on a Mono Spring)
2)
Braking force (FB) is based on the minimum clamping force (FC), nominal coefficient of friction of µ = 0.4 and 2 brake surfaces.
3)
The distance / piston travel from fully lifted at which the pressure limits (balancing pressure limits) is measured.
4)
Maximum permissible air gap depending on wear.
5)
Organic / sintered pads (at max. clamping force).
BRAKING TORQUE
The braking torque MB is calculated from following formula:
a is the number of calipers acting on the disc
(D0 – 0.22)
FB is the braking force according to table above [N] or
MB = a FB [Nm]
calculated from FB = FC 2 µ
2
D0 is the brake disc outer diameter [m]
The actual braking torque may vary depending on adjustment of brake and coefficient of friction.
CALCULATION FUNDAMENTALS Dual Spring Mono Spring

Weight of caliper with standard bracket Approx. 380kg Approx. 480kg
Weight of caliper without bracket Approx. 300kg
Overall dimensions 430 x 465 x 490mm 720 x 540 x 470mm
Pad width 220mm 220mm
2 2
Pad area (organic) 63.000 mm (*) 63.000 mm (*)
Max. wear of pad (organic) 11mm (*) 6 mm (*)
2 2
Pad area (sintered) 43.600 mm (*) 43.600 mm (*)
Max. wear of pad (sintered) 6mm (*) 6mm (*)
Nominal coefficient of friction = 0.4 = 0.4
2 2
Total piston area - each caliper half: 145 cm 145 cm
2 2
Total piston area - each caliper: 290 cm 145 cm
3 3
Volume for each caliper at 1 mm stroke: 30 cm 15 cm
3 3
Volume for each caliper at 3 mm stroke: 90 cm 45 cm
Actuating time (guide value for calculation): 0.4 sec. 0.4 sec.
Pressure connection/port: 3/8" BSP 3/8" BSP
Drain connection port R: 1/4" BSP 1/4" BSP
Recommended pipe size: 16/12 mm 16/12 mm
Operating temperature range from -20 to +70 C from -20 to +70 C
(For temperatures outside this range contact Svendborg Brakes)
(*) On each brake pad
Denmark: Germany:
Jernbanevej 9, DK-5882 Vejstrup Kirchnerstrasse 42, DE-32257 Bünde
Tel +45 63 255 255 Tel +49 522 368 540-0
e-mail: sb@svendborg-brakes.dk e-mail: sb@svendborg-brakes.de
Appendix F - Brake switch / Indicator

Name: DEB-INDI-014

Revision: A
BRAKE SWITCH - “Brake Released” & “Pad Wear”

Spring applied failsafe brakes
Function 30V Connections 125V Connections
Two micro-switches are mounted inside the housing of
the switch. The plunger detects the piston movement
through extender pins (if applicable) touching the brake
piston through the adjusting screw.
The “Brake Release” switch triggers when the brake is

released / activated (On/Off). The switch is closed from
fully lifted brake to approx. 0.4mm of piston movement ON/OFF PAD WEAR ON/OFF PAD WEAR
signal signal signal signal
The “Pad Wear” switch triggers when the brake pad is COLOR CODE:
worn to the allowed limit (1, 2, 3 or 4mm wear), and the BK = BLACK, BN = BROWN, WH = WHITE, GY = GREY, BU = BLUE
brake needs adjustment. INDICATOR NOT MOUNTED 30VDC 125VAC
Brake ON / OFF switch (1-4) ON / OFF
Brake ON / OFF switch is OPEN signal
The actual switch points vary according to the specific
brake type / switch and are not adjustable. PAD WEAR switch (3-2-5)
PAD WEAR switch OPEN (2-3) PAD WEAR
signal
The brake switch is available for 2 voltages: 30 VDC or
125 VAC / 30 VDC (high current) and with different cable
BRAKE "OFF", NO "PAD WEAR" **)
options. The cable is connected to the switch by a Indicator mounted & brake is OFF ON / OFF
standard M12 connector (angled). Brake "Lifted" - Contact is made signal
Brake ON / OFF switch is CLOSED (1-4)
Fail Safe operation PAD WEAR contact is made PAD WEAR

PAD WEAR switch is CLOSED (2-3) signal
For fail-safe operations the switch should be wired to
have a signal/connection when everything is ok (i.e.
closing a normally open switch (NO)). BRAKE "ON", NO "PAD WEAR" *)
Indicator mounted & brake is activated ON / OFF
The connection should disappear when switching i.e. Brake released - Contact is broken signal
applying the brake, having wear or in case of faults like Brake ON / OFF switch is OPEN (1-4)
broken cable, poor connections etc. PAD WEAR contact is made PAD WEAR
NOTE - The indication for “Pad Wear” is only active PAD WEAR switch is CLOSED (2-3) signal
during braking and disappears when the brake is lifted.

BRAKE "ON", "PAD WEAR" *)
Indicator mounted & brake is activated ON / OFF
Mounting Brake released - Contact is broken signal
1. Mount the brake and brake pads - refer to manual. Brake ON / OFF switch is OPEN (1-4)
2. Remove the plug (1/2” BSP) from the adjusting screw. PAD WEAR contact is broken PAD WEAR
signal
3. Mount the indicator (figure C) into the threaded hole or PAD WEAR switch is OPEN (2-3)
mount the adaptor (BSFI 200 / BSFH 300-S) on the
indicator before mouting (figure D). BRAKE "OFF", "PAD WEAR" **)
ON / OFF
4. Mount the M12 connector on the switch – for electrical Indicator mounted & brake is OFF
Brake "Lifted" - Contact is made signal
connection see connection diagram. Brake ON / OFF switch is CLOSED (1-4)
PAD WEAR switch is CLOSED (2-3) PAD WEAR

because NO indication for PAD WEAR signal
when brake is lifted
*) = Brake “ON” = NO hydraulic pressure / brake released / activated

**) = Brake “OFF” = MAX. hydraulic pressure = brake “lifted”
Technical data 30 VDC 125 VAC 64 Fig.C

0 0 0 0
Operating temperature : -40 C to +85 C -40 C to +85 C +min 15mm to remove plug
Max. Voltage / Current : 30 VDC / 100 mA 125 VAC / 3 A Ø40
45 (75 with adaptor)
30 VDC / 2 A
B
Switching tolerance : +/- 0.2mm +/- 0.2mm
Max. Stroke : 16mm 16mm
Protection grade : IP 65 (mounted) IP 65 (mounted)
Max. Tightening torque 1/2” BSP : 20 Nm - A) 20 Nm - A)
Max. Tightening torque M12 : finger tight - B) finger tight - B) Fig.D
Min. no. of operations : 1 million 1 million
Cable length : 5, 10 or 15meters 5, 10 or 15meters
Cable type/material : PUR PUR A
2 2
Cable dimension : 5 x 0.34mm 4 x 0.34mm
Thread size - A) : 1/2” BSP (G 1/2”) 1/2” BSP (G 1/2”)
Spanner size (SW) - A) : 36mm 36mm
Denmark: Germany:
Tel +45 63 255 255 Tel +49 522 368 540-0
Appendix G - Recommended fluid

Name: DEB-DIVE-005

Revision: C
RECOMMENDED FLUID FOR DISC BRAKES & HYDRAULICS

PRESSURE FLUIDS / OIL TYPES
The following oil types are recommended by Svendborg Brakes – other types corresponding to these can be used.
The general temperature range for our standard ranges of products using hydraulic oil are -20°C to +60°C (-4°F to
+140°F) however the BSAK and BSAB brake series are generally approved for lower temperatures.
These are approved for usage at -40°C in wind turbines and for -30°C in other applications.
Extreme temperature applications may require special options. Please contact Svendborg Brakes.
Special option Standard Special option

-40°C - +20°C -20°C - +40°C +10°C - +60°C +30°C - +70°C
Mineral Oil
-40°F - +68°F -4°F - +104°F +50°F - +140°F +86°F - +158°F
Shell Tellus Arctic Tellus TX32 Tellus TX46 Tellus TX68
Mobil - DTE 13M DTE 15M DTE 16M
Hydro Texaco - Rando HDZ32 Rando HDZ46 Rando HDZ68
Valvoline - Ultramax HVLP32 Ultramax HVLP46 Ultramax HVLP68
-40°C - +20°C -20°C - +40°C +10°C - +60°C +30°C - +70°C
Syntethic Oil
-40°F - +68°F -4°F - +104°F +50°F - +140°F +86°F - +158°F
Mobil - SHC 524 SHC 525 SHC 526
Bio Oil (1) -40°C - +20°C -20°C - +30°C +10°C - +60°C +30°C - +70°C
(Ester or Colza oil)
-40°F - +68°F -4°F - +86°F +50°F - +140°F +86°F - +158°F
Shell - Naturelle HF-E15 Naturelle HF-E32 Naturelle HF-E46
General: Mineral Pressure Fluids according to DIN 51524 Part 3
(1) There must be less than <200PPM water in the oil, due to the seals.
Viscosity
Recommended viscosity range: 20-200 cSt at working temperature.
Filtration
The oil in a hydraulic system and the oil added to the hydraulic system must always be filtered. The level of cleanliness
in a hydraulic system is an important factor to the lifetime of the system.
When refilling the hydraulic tank, it is stipulated that the oil added to the system is filtered through a 10-micron purity off-
line filter unit to the classes listed below.
The hydraulic system, supplied by Svendborg Brakes, has a build-in oil filter with a standard 10-micron purity filter. To
maintain a reliable system it is recommend that only hydraulic oil of the following classes of purity is used: NAS 1638,
Class 8, or ISO 4406, Class 19/17/14.
It is recommended that the filter be changed at a minimum, once every six months or more often depending on the level
of exposure to contamination.
Service life of pressure fluids

Mineral oil: 8.000 Hours or at least once a year.
Other fluids: 2.000 Hours or at least once a year.
Change of pressure fluid

Note: The mixing or blending of different brands or types of pressure fluid can cause unintended chemical reactions,
such as sludging, gumming etc. The complete hydraulic system should be thoroughly flushed prior to changing from one
oil type to another.
The respective manufactures should be contacted prior to changing from one pressure fluid to another.
Seal material
Brakes from Svendborg Brakes A/S are normally supplied with PUR-seals (PolyURethane)
PTFE (PolyTetraFlourEthylene) seals can be delivered on request for most of the brake types.
Note: the BSFG 400 brake series are supplied with NBR rubber fabric seals (acrylNitrile Butadiene Rubber).
Denmark: Germany:
Tel +45 63 255 255 Tel +49 522 368 540-0
Appendix H - U-cup information

Name: DEB-DIVE-008

Revision: A
U-CUP INFORMATION
Svendborg Brakes have changed the sealing system (gaskets) in the brakes.
The new seals are in general made of polyurethane (PU) and the type is called U-Cup.
The old seal were typically the Stepseal (PTFE) type.
The U-cup type and the Stepseal type of seals are fully interchangeable with the
exception of the temperature range and the allowed oil types. The U-cup type of seals are
softer and will produce less wear on the moving parts i.e. piston.
This information is only to inform how the U-Cup-seals shall be mounted when replacing
your seals.
The side with O-ring in the U-cup or the side with the groove in the U-Cup must be placed
towards the pressure side (where the hydraulic fluid is), see drawing below.
To mount the seals - gently form it into a

U–shape / kidney-shape without any
sharp bends and fit it into the groove
NOTE: A B
The U-Cup seals are only to be used
within an ambient temperature range of -30°C to +80°C. Please correspond to the ambient
temperature range of your brake.
If the temperature is outside the mentioned limits you must specify, that you need step
seals.
Products using the step seal solution are still available but only as a special order.
Please refer to the SB sales department for information.
Denmark: Germany:
Tel +45 63 255 255 Tel +49 522 368 540-0
Appendix I - Recommended spare parts

When ordering spare parts please provide the serial number of the brake – see section 1.20
Recommended spare parts
Spring pack
Spring pack BSFH 507-X-5XX 490-0928-801
Check the nameplate / sign for actual
Order 2 sets per brake (i.e. 1 set size - see section 1.8 - „Nameplate /
PER caliper half) Serial-numbers’ for details
Brake pad set

Brake pad set complete
Sinter metal MD550 490-0522-801
Brake pad set complete

Organic BE3521 complete 490-1016-801
Incl. back plate
(1 set needed per brake)
Brake shoe complete (1pcs)

(2 pcs. needed per brake) 490-0581-801
Replacement sets
Brake pad lining set – 490-2035-801
Organic BE3521
Brake pad lining set –

Organic IP160 278-0776-801
Brake pad retraction springs

Pad retraction spring set - standard 490-3605-801
finish
Pad retraction spring set - offshore 490-3605-802

finish
Seal kit
Seal kit (½ brake) 478-2914-816
Order 2 sets per brake (i.e. 1 set

PER caliper half)
Piston complete (incl. center bolt)
Standard finish 490-3808-801
Offshore finish 490-3808-802

PER caliper half)
Cover for center bolt
Cover with o-ring 490-3576-801

PER caliper half)
Bolt set
Based on special bracket

Studs
25-45mm brake disc (no spacers) 478-1297-801
45-65mm brake disc (no spacers) 478-1397-801
Indicators
Mechanical indicators are as
standard with a 5 meter cable,
other options available on request
30 VDC
Brake release & 1mm Pad Wear 490-3371-811
Brake release & 2mm Pad Wear
Brake release & 3mm Pad Wear
490-3372-81164
490-3373-811
+min 15mm to remove plug
Fig.C
5m cable w/M12 plug (angle) Ø40
5490-0109-003
45 (75 with adaptor)
10m cable w/M12 plug (angle) 5490-0109-008

15m cable w/M12 plug (angle) 5490-0109-007 B
125 VAC
Fig.D
15m cable w/M12 plug (angle) -
A
For indicator without cable –
replace 811 with 911
Tools - part 1 Used for adjusting the brake (mandatory - 1 per brake)
Tool kit standard - Dual Spring 490-0113-803

Flange nut (M24) (2pcs) (4490-0101-001)
Adjusting spanner (378-1330-801)
Tool kit with lock pin - Dual Spring 490-3331-806

Air gap nut (2pcs)
Adjusting spanner
Extension handle
Tools - part 2 Used for manually lifting the brake piston (hydraulically)
Hand pump with 800mm test point 0350-1019-801

hose
Test point connectors (Mini mess)

Test point male G1/4 (drain “R”) 9009-1010-040
Test point male G3/8 (pressure “P” 9009-1010-060

and drain “A”)
Test point hose 800mm 9009-3010-008
Tools - part 3 Used for during maintenance / overhaul (optional)
Tool for lifting the adjusting screw 490-3456-803

out of the yoke (M36)
Tool for lifting piston out of the yoke 490-3456-804

(M24)
Drain kit
Drain bottle 0,5L plastic 9640-0999-001

Drain bottle 1,0L plastic 9640-0999-002
Converters (G on brake)
Male G to male NPT

G1/4 to 1/4” NPT (drain “R”) 9040-1200-014
G3/8 to 3/8" NPT (pressure “P” and
drain “A”) 9040-1200-038

MANUAL DE OPERACIÓN Y MANTENIMIENTO American Block DKS-2000

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MANUAL DE OPERACIÓN Y MANTENIMIENTO American Block DKS-2000

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OPERATIONS AND MAINTENANCE MANUAL

6311 Breen Road

4.2.4 BRAKE ........................................................................................................................................... 15

1.2 WARNINGS, CAUTIONS AND NOTES

1.3 SAFETY REQUIREMENTS

1.3.1 PERSONNEL QUALIFICATIONS

1.3.2 RECOMMENDED TOOLS

1 GENERAL INFORMATION Page 2 of 32

1.3.3.1 Cable and Hose Safety Precautions

1 GENERAL INFORMATION Page 3 of 32

1.3.4 REPLACING COMPONENTS

1 GENERAL INFORMATION Page 5 of 32

1.3.6 PROPER USE OF EQUIPMENT

1 GENERAL INFORMATION Page 6 of 32

2.2 GENERAL ARRANGEMENT

2.2.1 MAIN COMPONENTS

2.3 BRAKING MODES

Height (max) 102 in (2,590 mm)

Size Width (max) 114.06 in (2,897 mm)

Length (max) 237.38 in (6,030 mm)

Weight (max) 32,190.56 lb (14,601 kg)

Model AMERIMEX 1350 HP-DOMINATOR (480 V)

Speed Max Speed : 2300 RPM

Type Single Speed, Dual Input

Oil Capacity 30 gal (113.56 L)

Size 75 in (1905 mm)

Wire rope diameter 1.375 in (34.93 mm)

Drum pitch diameter 30 in (762 mm)

3.3 POWER REQUIREMENTS

3.4 HORSE POWER MODES AND HOISTING PERFORMANCE

Rig Power Rating 2000 HP

Hook Load Capacity – 8 lines 875,000 lbf (3,892 kN)

Hook Load Capacity – 10 lines 1,000,000 lbf (4,448 kN)

Hook Load Capacity – 12 lines 1,200,000 lbf (5,338 kN)

4 INSTALLATION, OPERATION AND MAINTENANCE

Ensure that the foundation is horizontal and level.

4.2 REPLACING DRAWWORKS COMPONENTS

4 INSTALLATION, OPERATION AND MAINTENANCE Page 12 of 32

• Disconnect coupling and clean hub of grease.

4 INSTALLATION, OPERATION AND MAINTENANCE Page 13 of 32

• Install pulling equipment suitable for pulling off hub.

4 INSTALLATION, OPERATION AND MAINTENANCE Page 14 of 32

4.2.5 WORN WIRE ROPE REPLACEMENT

4 INSTALLATION, OPERATION AND MAINTENANCE Page 15 of 32

4 INSTALLATION, OPERATION AND MAINTENANCE Page 16 of 32

4.3 ALIGNMENT AND ADJUSTMENT PROCEDURES

3. Visually inspect gears for any signs of mechanical malfunction.

4 INSTALLATION, OPERATION AND MAINTENANCE Page 17 of 32

4.4.2.2 GENERAL OPERATING DATA

4.5.1.1 EQUIPMENT RECORDS

4.5.1.2 SAFETY PRECAUTIONS

4.5.2.2 INSPECTING GEARBOX

an input-drive speed of 1500 min-1

4.5.3 GEARBOX MAINTENANCE

• Replace the oil drain plug.

4.5.3.3 INTERIOR CONSERVATION DURING LONGER DISUSE

For storage longer than 12 months contact the manufacturer.

4.5.3.5 EXTERIOR CONSERVATION PROCEDURE

• Clean the surfaces

4.5.3.6 GEARBOX OIL CHANGING PROCEDURE

• Stop the gear unit by switching off the drive assembly

Remove any corrosion.

4 INSTALLATION, OPERATION AND MAINTENANCE Page 22 of 32

4.5.4 LUBRICATION PROCEDURES