TABLE OF CONTENTS Industries, Ltd. 1. HRI-550 Specifications 2. Equipment Serialization 3. Mast Certifications 4. API Certifications 5. Operation 5.1 Rig Operation 5.2 Rig Starting Procedure 6. Lubrication Maintenance Information 7. Parts Book @ 7.1 Vehicle 7.2. Drawworks 7.3 Hydraulics 7.3.1. 37X Hydraulic Pump 7.3.2. Chelsea PTO 7.3.3. Braden Gearmatic Winch BG-8 7.4 Controls 7.4.1. HD-2 Controlair Valve 7.4.2, HE-2 Controlair Valve 7.4.3. PilotAir Valve 7.5 Mast Loadcraft Industries Ltd gaderaft Industries ttHERE ARE SOME OF THE REASONS WHY IT IS SO VALUABLE FOR YOU TO KEEP THIS MANUAL It contains information collected specifically for your machine, ‘There is no better reference available to you, regarding your equipment. Much effort has gone into writing this book for your machine. But it must not be assumed that, because it is supplied with the equipment at no extra charge, it does not have great value; the opposite is true, it is worth a lot to the operator. Due to changing materials, designs, specifications, and changing preferences of what customers want in their machines, the makeup of the models change with the passing of time. ‘Therefore, it is often difficult for the manufacturer to re-supply parts and instruction books for the older models. Even when supplied at actual reproduction cost, the charges some manufacturers find they must pass on are substantial amounts. Furthermore, even when books can be supplied for the older models, a considerable waiting period is often necessary for their delivery, because they must be reproduced and assembled. ‘Your book, in most cases, will be identified as belonging to your machine by naming the model and by listing the serial number of the machine; both of these are very important when ordering parts or when conferring with the manufacturer about other matters pertaining to your equipment. Using the model and serial number to identfy your machine make accurate information possible, which otherwise is guess work, When ordering parts, delays and extra expense can be avoided if the proper part numbers and descriptions obtained from the parts book are given to the supplier with the order. Without this accurate information, itis often a guessing game of “trial and error”. Keeping and using your book is ‘obviously a much better way of getting what you want. The book contains valuable maintenance, adjustment and lubrication instructions which apply to various components of your machine. This information is important to you. By following instructions, your machine will perform better and it wll cost less to keep it working on the job.| Manufacturing Plant at Brady, Texas e [oyNeYei7vae 915-597-2916 915.5 LOADCRAFT INDUSTRIES LTD. hup://www.hri-rig.com ‘The LCI 550 is a Double-Drum Drilling, Workover & Well Servicing Unit LCI 550 STANDARD RIG CAPACITY Its mast reaches 110’ above the ground and provides a 265,000LB static hook load capacity. A Cat C-15@ 540 hp with an Allison 6061RB or equal transmission & torque converter powers the unit. All components are mounted on a 5-axle carrier. BASICRIG LCLCARRIER _(5 axle) "Tandem front, tandem rear carrier with 10x4 drive Wheelbase: 340”(863cm) front center to rear tandem center Fabricated high tensile stee! beam vehicle frame Safety tread decking * Front and rear tow bars #4 Internal mast guy boomers “Tandem front steering axle, 40,000LB(18.04 Mb) total service rating with air brakes on all wheels Walking beam, spring suspension rated at 42,000LB (19.05 Mi) Hydraulic power assist on steering axles, with ample capacity to provide ease of steering 20,000LB air ride, load equalizing rear axle assembly Eaton standard tandem drive axles, 50,000LB (22.67 Mt) service rating with lock-up Air controlled spring brakes mounted on both rear axles Emergency brakes on drive axles 12V battery installed in battery box Highway equipment includes: Headlights Stop &€ taillights Front and rear tum signals License plate bracket Clearance lights Mad flaps behind rear tires Reflectors Air homs One-man cab with heater, defroster, windshield washer & wiper ‘Two - bus type rear view mirrors ‘Adjustable bucket seat with shock absorber mounts & seat belt ‘The cab instrument panel consists of the following instruments: ammeter, engine oil pressure gauge, tachometer, fuel gauge, water temperature gauge, and transmission converter oil temperature gauge Engine driven compressor System includes hoses; fittings, ar lines, regulators, and gauges 3LOADCRAFT INDUSTRIES LTD. | Manufacturing Plant at Brady, Texas e [oyNeyoi Na 915-597-2911 915.597.0781 http:/ /www.hri-rig.com © 12V electric system for all instrument lights including wiring, fittings, 8 switches PLATFORMS WITH HANDRAILS ON OPERATOR SIDE Hinged platforms run full length on operator's side of unit, at bed level. Handrails are attached to the platforms on the operator's side of the rig and a stairway, with handrails, from platform to ground is included. Platform’s are approximately 2’-0” wide. 110 GALLON FUEL TANK ‘One 110 gal (#16L) fuel tank side mounted on cartier frame ONE PLATFORM OFF-OPERATOR SIDE, ‘One folding platform, approximately 12'(37 m) long x 1"(3 m) wide, is hinged along the off-operator side of the rig drawworks at the bed level. FRONT TIRES (FOUR 445/65R / 22.5) 4 front tires ~ 445 x 65 Rx 225 L6-ply duplex highway tread eo Rated at 39,5001.B(17.69Mt) All tires are inflated to 90psi(6.2kg/ ems!) Disc wheels REAR TIRES 12 Each 12:00R x 22.5, 14 PLY Twelve 12:00R x 22.5, 14 ply, all-purpose tread tube-type rear ties Rated at 49,120Mt(22.28 Mi) All tres inflated to 80 psi (5.5 kg/em2).. Disc wheels DEADLINE ANCHOR Base for customer furnished type F anchor 50 GPM (190Lpm) HYDRAULIC SYSTEM “The hydraulic system is designed to operate at a maximum of 2,500psi and 50 gpm (190Lpm) @ 2,100 rpm. Its pump is PTO driven by the transmission, An air-activated clutch provides pump engagement and disengagement. ‘The system includes installation of a 195-gal (757L) hydraulic oil tank with filler cap, breather and a combination oil level/oil temperature gauge. Also included are manual shutoff valves in the pump suction line, in the pressure line from pump to various control valves and pressure ports, and in the eo retum line from fiker to tank,LOADCRAFT INDUSTRIES LTD. | Manufacturing Plant at Brady, Texas e OADCRAFT 915-597-29116915-597-0781 http://www. CONTROL CONSOLE The rig’ control console is located at the operator's position near the mast providing good visibility of wellhead, traveling block, and work area. Console includes: VVVVVVY Main drum control consisting of mechanical brake lever Air operated clutch control for main drum Air operated hand control for engine throttle valve Hydraulic and air pressure gauges ‘Transmission shift controls Standard engine shutdown, located in console Operator platform FOUR HYDRAULIC JACKSCRE WS. Four hydraulic leveling jacks, two mounted in the rear bumper, and two mounted at the mid-point of the rig remove weight from the truck axles and provide greater lateral stability. Each jack has an adjustable support screw with a locking nut feature to remove hydraulic pressure from the cylinder while the rig is in use. LEVELS ‘Two levels are provided for use with the leveling jacks to ensure that the rig is level. ENGINE ASSEMBLY VV VVVVVVVVVVV Cat G-15 engine 540hp@2100rpm with limiting speed governor Air throttle actuator SAE # 1 flywheel housing Exhaust diverted to off-operator side with 85db muffler & spark arrestors Permanent type anti-freeze Dry type air cleaner Lube & fuel filters 24cfm (11328 cm2/sec), air compressor driven from engine 75A/12V alternator 12V electric starting High ambient radiator & fan High water temp/low oil pressure emergency shutdown Overspeed emergency shutdown Engine oil pressure gauge and water temperature gauge 5LOADCRAFT INDUSTRIES LTD. Manufacturing Plant at Brady, Texas OADCRAFT 915-597-2916 915-597-0781 ELECTRIC STARTING SYSTEM (12 volt) Rig is equipped with a 12V electric starting system that includes a starter, wiring and 12V battery mounted in recessed battery box with above deck access. TRANSMISSION - Allison 6061RB drop box » Allison 6061RB six-speed transmission & TC-590 converter with oil cooler, including a straight through with a disconnect clutch for the drawworks > Air over hydraulic dual controls, with air indicator > Power shift from cab and rear control MODEL 42x12 MAIN DRUM WINCH ASSEMBLY Full air, clutch outside drawworks frame. Brakes are 42°(106.7cm) diameter x 12"(30.5em) wide, lined with 1-1/8"(2.9cm) x 12"(30.5em) x 12"(30.5cm) API drilled brake blocks, full wrap, dead-end e@ equalized. Brake rims are removable with rings for splash water-cooling. Brake operation shafts are mounted on ball bearings, these are self-energized type for positive application and release by operator. Drum barrel is 18"(45.7cm) diameter x 38"(96.Scm) long, mounted on double row self-aligning spherical roller bearings on a 6 1/2"(16.5cm) drum shaft, One line pocket provided in drum, For 1” wireline to assist ion spooling and to reduce line wear, lebus counter balanced sleeve is grooved (Clutch single lin pull is 37,500L,B(17006K) on bare drum and in first gear. MODEL 42x8 SANDLINE DRUM Fall air double plate 24"(60.9cm) clutch Brakes are 42"(106.6cm) diameter x 8"(20.3cm) wide lined with 1"(2.5cm) x 8"(20.3cm) x 12"(30.5cm) API dried brake blocks, full wrap, dead-end equalized. Brakes are removable with rings for splash wwater-cooling. 5 3/4"(14.6cm) drum shaft mounted on double row self-aligning spherical roller bearings, drum barrel is 16"(40.6cm) diameter x 43"(109.2cm) long. Capacity of 9/16"(1-4cm) wire line is 14,600(4450m), 11,900'(3627m) of 5/8"(1.6cm) line Dnip pan with drain under sandline drum, SANDLINE DRUM CONTROL Sandline drum controls consisting of a mechanical rake lever, combination air cutch and an engine @ throttle valve are located on the operator's side of the winch. “An engine emergency kill switch s located in the control panel along with a clutch control valve. 6LOADCRAFT INDUSTRIES LTD. Manufacturing Plant at Brady, Texas e ASAE M1897 29691 997 LUBRICATION Centralized lubrication system to all bearings and brake linkage on drawworks. For ease of servicing, all grease fittings on drawworks are located outside frame. BRAKE WATER COOLING Includes air-pressurized water system with 60gal(227L) reservoir, filler, air and water piping from reservoir to main drum brake rims, Water piping is complete with control valve at operator's position. A cutoff valve is also at reservoir to shut off all pressure to tank. RIGHT ANGLE GEAR BOX LCT heavy-duty, right angle gearbox with oikbath lubrication for gears and bearing. Includes installation on canter frame, input torque shaft from transmission to gearbox and powershaft from gearbox to drawworks drive sprocket. DRAWWORKS DRIVE ASA-140-2 (1-3/4") pitch, double-strand roller chain, e@ Chain drive from input sprocket-to-sprocket on the jackshaft ASA-140-2 (1-3/4") pitch, double-strand roller chain on the final drive to the main drum All chains are in oil-bath case outside the drawworks frame, A window in side of the chainguard provides an oil level check. HYDROTARDER Parmac 202 hydrotarder or equivalent with two plate air clutch, oil bath chain drive, chains and bearings. 325 Gal. Water tanks, lines, valves, and plumbing installed on rig. Hydrotarder includes air controlled inlet valve and piping for water. HANDLING WINCH ‘Hydraulic powered planetary winch ~ 8,000 Ib. Rated line pull @ 100 f.p.m. and 2,000 psi. Rating are for first wrap on drum. 325 ft. of 14” line provided with winch. (Failsafe brake, winch pullin and run-out is hydraulically powered,) Winch sheaves provided in crown. Winch controls are located at rear of unit near operators console.LOADCRAFT INDUSTRIES LTD. Manufacturing Plant at Brady, Texas e OADCRAFT ‘TWIN BOX MAST-LCI 110°/265K MAST: 110°/265K TWIN BOX MAST ‘The mast has a 110° clear working height with an API rated static hook load of: OPTIONAL with 8 lines strung 225,000LB with 6 lines strung Open face tubing mast is designed to withstand a wind of 75mph(120.7 km/h) from any direction provided the four jacks on the vehicle are properly deployed. Telescoping tubing. structural mast is designed and constructed to API standard 4-F (Third Revision) and Q-1 quality control (Second Revision) and will have an API monogram. e@ Constructed in two sections with the upper section telescoping into the lower section for over-the-road position. Top section of mast automatically latches to lower section, when extended, Lock control at base of mast. Ladder to crows nest on crown. ‘The mast is atached to its support frame at the pivot point near the rig's rear bumper. Itis supported during roading bya rest (headache frame) near the front of the rig. Each leg of the lower section contains an adjustable support screw. Mast has large girts and braces that do not extend inside, for extra block clearance. Mast includes installation, front rest and two intemal load lines to rig from crown. CROWN Crown arrangement for 6 or 8 line string-up with conventional block to hang flat with mast: One- 30°(76 cm) diameter fastline sheave, grooved 1” (2. One- 30°(76 cm) diameter deadline sheave, grooved 1” “Three -24"(60.8 cm) diameter sheave cross-mounted, grooved 1” (2.86cm) ‘Two- Hydraulic tong sheaves, grooved 3/8"(95 cm). One- Auxiliary winch sheave, grooved 1/2°1.3 cm). ‘One-24" diameter sandline sheave grooved 9/16” ‘Crown sheaves are steel with flame hardened grooves. Sheaves are mounted on Timken tapered roller bearings. Fitings are provided for individual greasing of bearings. Crows nest crown platforr) provided for safety when servicing crown sheaves, floor of expanded metal, handrails and toe boards around crown e with entrance at ladder. Attachments for two intemal guylines from crown to rig are provided on crown beams. 8LOADCRAFT INDUSTRIES LTD. Manufacturing Plant at Brady, Texas 915-597-2916 915-597-0781 itp: / /wow. TUBING BOARD © Tubing board, of all welded construction, is automatically lowered into working position as mast is telescoped up and is raised into folded position as mast is telescoped down for ro © Tubing board fingers are adjustable for 18,360°(5596m) of 2-7/8"(7.3 cm) wbing, or 11,520°(351: 1m) of 3-1/2"(9 cm) drill pipe for end tubing, Tubing board is mounted at 55'(16.8m) above ground for tubing doubles. A26"(.6m, 15.2 cm) wide monkey board/ walkway is included. ‘Handrails are installed around the tubing board for safety Rod basket MAST CONTROLS Raising, lowering and telescoping controls are installed at operator's position near base section of mast which are unlatched and moved at time of raising or lowering the mast. RAISING, LOWERING & TELESCOPING ‘Mast is hydraulically raised and scoped by hydraulic cylinders, and upper section is extended by unlocking e upper section from lower section and extending until the spring latches snap into operating position. Mast is retracted in like manner, When latches clear the latch seats, a control line is pulled to retract latches. With rope held tight, the latch lines can be tured loose and mast will lower to its stacked position with section re-locked together, mast is lowered to headrest. Mast locking pins shall be painted orange.LOADCRAFT INDUSTRIES LTD. Manufacturing Plant at Brady, Texas @ IOADCRAFT ‘915-597-2911¢915-597-0781 hutp:/ / wwwbari-i Il. RIG ADDITIONS CROWN-O-MATIC Stewart &¢ Stevenson crown saving device includes installation on rig drawworks. MAST GUYLINES Four 5/8 * (1.6 cm) - 6x37 IWRC wire rope guyline to ground from derrick 2 required for top-front & of crown and 2 required for top-rear of crown. Two 9/16” (1.4 cm) - 6x37 IWRC wire rope guylines from tubing board to ground. Guylines include thimbles, clips, tail chains and grab hook. Six heavy-duty walking load binders for 1/2” (1.3 cm BLOCK 150 Ton McKissick with 4-30” rolled forged sheaves grooved for 1” line Grooves— flame hardened Hook— cast alloy steel, duplex style with latches Rod hook clevis 10Loaderat Industries Lud, SSIIN Bridge Brady, Texas 76825, Phone 325-597-2911 Fax 0597-0781 RIG SERIALIZATION Rig Number | W00875 Model Number | 550 LEFT (SINGLE) ENGINE RIGHT ENGINE ‘Manufacturer | CAT Manafserorer | N7A ‘Type ‘Type Model | C-15_ Model ‘Serial Number | JREO3298 Serial Number LEFT TRANSMISSION” RIGHT TRANSMISSION” Manafsceurer | Alison “Manufacturer [ N7A ‘Model | CLT6061-5 Model Part Number | 1860-en Part Number Serial Number |'80-43768 ‘Serial Number LEFT POWER TAKE-OFF RIGHT POWER TAKE-OFF “Manufacturer | Chelsea Manufacurer | N7A Model | 852XGAKP-F4XS_ Model ‘Serial [7071 Serial HYDRAULIC PUMP ROTARY HYDRAULIC PUMPS, Manufacturer | Parker Manufacturer | N7A" Model | 305-9219.557 Model Serial [No207-6761 ‘Serial ‘LEFT AIR-COMPRESSOR_ RIGHT AIR-COMPRESSOR” “Manufacturer | Bendix ‘Manufacturer | NTA CATH Ba-922 Model BENDIX# 5011625 Serial ‘STEERING GEARBOX POWER STEERING PUMP ‘Manufacturer | Sheppard ‘Manufacturer | Eaton Part Number | MI0PCSIT “Model | MHV25-1P6P-38C30 Serial Number [ 07034138 Serial | VO74:DII4 AIRTANK Manufacturer | N7A Part Number Serial Number FRONT AXLE NUMBER T FRONT AXLE NUMBER? Manufacturer | Spicer Manulacurer | Spicer ‘Part Number | H800-80025 ‘Part Number | H800-80025 Serial Number | OMYHUO090#352 Seral Number | OMYHUD0SO4333 ‘Fabco Number Fabco Number Kato. | N7X Ratio Loaderaft Industries, Lid, DOC. NO. LC-7.5-011 REV.0 (03-05-07)FRONT AXLE NUMBERS REAR AXLE PUSHER ‘Manufacturer | NZ ‘Manufacturer | N7A ‘Part Number Model Number | Seral Number Serial Number Fabco Number REAR AXLE NUMBER 1 REAR AXLE NUMBER "Manufacturer | Spicer Manufacnuer | Spicer Model Number | DP521P° Model Number | RP521 “Housing Model Number Housing Model Number “Bale Specification Number | 0885572 “Axle Specification Number | 0871302 Serial Number | HNO2742392 Serial Number | FING2749650 Ratio | 00531 ‘Ratio | 00531 REAR AXLE NUMBER3 REAR AXLE NUMBER 4 Manufacturer | N7A ‘Manufacturer | N7A ‘Model Number Model Number “Housing Model Number Fiousing Model Number “le Specification Number ‘Aale Specification Number Serial Number Serial Number Ratio Ratio FRONT TIRES REAR TIRES Manufacturer | Goodyear Manufacturer | Kelly ‘Model Number | G286. ‘Model Number | KRM Size/Ply | 445/65R22.5-6 Size/Ply | BR/225-6 FRONT WHEELS REAR WHEFIS ‘Manufacturer | Motor Wheel Manufacturer | GPX ‘Model ‘Model Part Number | 8368 Par Number Size/ Configuration | 22.5x13.00 Size/ Configuration | 225x825 DRAWWORKS BEVEL GEARBOX. CAB Manufacturer | LCL Manufacuurer cc ‘Model Number ‘Pan Number 2A Serial Number TIRT Number 0284 ‘CLUTCH-TUBING DRUM HYDROBRARE CLUTCH Manufacturer | WPT Manufacturer | WPT Size | W25-OC206 Size | W25-O206 Par Number | W070072-12 Par Number | WO70072-11 ‘CLUTCHE-SANDLINE ‘Manufacturer | WPT Size | W25-OC31T Pat Number | WO70072-12 UTILITY WINCH MOTOR, UTILITY WINCH Manufaccurer | Bradon Manufacturer | Parker ‘Model Number | BG8B-34039-01 “Model Number | 25515 Serial Number | 0759449 Serial Number | NOS07-36 UTILITY WINGT ‘MOTOR, UTILITY WINCH, Manufaccurer | A Manufacturer | N7A Model Number “Model Number Seral Number ‘Serial Number. Loadcraft Industries, Ltd DOC. NO. LCI-7.5-011 REV.0 (03-05-07)HYDROBRAKE DRAWWORKS. Manufacturer | DT ‘Manufacturer | LCL Model Number Part Number | 42x12 Serial Number | 632077 Serial Number | O70148 MAST SCOPING CYLINDER ‘Manufacturer | CCL Manufacturer | LCE Model Number | 110-265 Part Number Serial Number | 070149 Serial Number RAISING CYLINDER (oper side)_[ HYCO. RAISING CYL (off-oper side) ‘Manufacturer Manufacturer ‘Part Number | 50069-933-147 Part Number Serial Number | 100025506 Serial Number ELEVATED CHAINCASE ROTARY CLUTCH cLurcHt Manufacturer | N7A ‘Manufacturer | NTA Part Number Model Number Size Sie COMPOUND BOX BREAK-OUT CYLINDER Manufacturer | N7R Manufacturer | N7A ‘Model Number Part Number Seral Number Serial Number LEFT MUDPUMP ENGINE RIGHT MUDPUMP ENGINE ‘Manufacturer | N7A Manufacwurer | N7A ‘Model Number Model Number Type Type Seral Number Seval Number MUDPUMP. ROTARY TABLE 10" ‘Manufacturer | N7A Manufacturer | N7A Model Number Model Number Seral Number Serial Number MAKE-UP CYLINDER ROTARY TABLE 2” ‘Manufacturer | N7A Manufacturer | N7A ‘Part Number Model Number Seral Number Serial Number BLOCK/HOOK HYDROBRAKE COOLER Manufacturer | MeRissick Manufacture | NTA “Model Number | 84-A Part Number Seral Number | 0751592 ‘Sheaves [ 4-30°-7" DEADLINE ANCHOR ROTARY DRIVE TORQUE IND. Manufacturer | CCL Manufacturer | NTA Model Number Serial number Master Control Unit Serial Number ‘Serial Number Rotating Transmitter BRAKE WATER PUMP HYDROBRAKE WATER PUMP ‘Manufacturer | N7A Manufacturer | N7A Part Number Part Number Model Number ‘Model Namber Serial Number Serial Number Loaderaft Industries, Lid, DOC. NO. LCI-7.5-011 REVO (03-05-07)PART BOOK MAST SECTION Drawing # Assembly, son Tod Board Assy liom Part Number Desripion vans 1 sons13000 Tune, Noe 2 Hemsspoa Tine Ane : 3 Hawsznoas TUBE AINE : bs Hesston MATE LG 2 3 Hpszsa0s PATE: i é Hamssboe PLATE LUG : $ fioaz aor ate Lue 2 5 Hewsetso. trate Lue 3 3 Hewseis0.0 PATE END 3 To tonsainore ATED 2 isorsaneen Tone Beace 3 i 2130013 HATE SUPPORT 3 i 2130013 PATE: SD 3 " 2130 Tl HINGE 2 ‘ 2130 TUBE HINGE ; ie sonsasoois rot ; (a fooszlors ANGLE PRAM 3 3 foosrlos ma 3 fo Heroszisano malt 2 31 esoszlsaor Peas, STRAP 3 2 Hawssoe Pare abe i 3 tewsai.3 on : 2 a on 2 sas mn 3 3 lloras eet 3 Bias ExPANDED METAL Hass ROD SOR ASSEMBLY, LEFT HAND ; 3 hisses OD FINGER ASSEMBLY, RIOT HAND 30 HS00-52130-030 PLATE, LUG e Loaderaft Industries Ltd1 NG AP IdV HLM TONVCYOOOY NIDA ALIOOTIA GNIM WAINIXVIN ‘> TTIM OL MUVIN NI LSVIN NOU FONVLSIC WOWNIXVIN SANIT | HLM ST ] if dVO CaLVY YOVELas (VOT MOOH J. 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The above policy does not cover rigs sold for purposes other than servicing, workover or drilling of oil wells; such rigs will be serviced ‘under special agreement with the purchaser of the equipment at time of purchase. [After the initial start-up is rendered, it will be the responsibility of the purchaser to maintain the rig and should the purchaser request the services of an HRI representative for additional maintenance, this will be considered as regular ficld service and charged for at the current established rates. However, should mechanical difficulties arise during the warranty period which are attributed to faulty workmanship or materials, as covered by HIRI’s warranty, the time spent by a Heartland Rig International, Inc. representative will not be charged for in making the necessary corrections. ‘Any changes in the tig, exchanges of equipment or return of equipment made after the machine has been delivered will be at the purchaser’s expense. Prior approval must be granted before any materials can be returned to Heartland Rig International, Inc. and transportation charges or other expenses involved will be at the purchaser's expense. At HRI’s option a restocking charge may be made for any materials or parts retumed. No credit will be allowed on parts notin current production or parts that have been damaged to the extent that they cannot be sold as new. Heartland Rig International, Ine. will not pay for any rig down time or for time spent by crew making repairs on rig regardless of cause for repairs, or for services of labor by others, unless written prior approval has been given that HRI will pay such charges, “Two parts books will be furnished with each rig, If additional parts books are required, there will be a charge ‘TAKE TIME TO BE SAFE Heartland Rig International, Inc. will not in any way, be responsible for any damage to mast either in raising, lowering, and telescoping or over pulling the mast. We have hundreds of these masts, which ive excellent service when properly used. The success of any mast lies with the operator in handling the mast. “The capacity as set forth in these instructions is the ultimate capacity of the pole. HRI recommends that no more than 1/3 of the ultimate pole capacity is pulled on the mast. We recommend a weight indicator be used if loads are not known, REMEMBER: The drawworks unit has sufficient capacity to pull in the mast, if the transmission is in the lower gears.‘TABLE OF CONTENTS OPERATING INSTRUCTIONS Introduction. Preparation for Roading Driving Instructions Operator's Control Operation 4.A. Air System 4B. Hydraulic System 4.C. Engine Kill Button 4.D. Main Drum Clutch/Throttle Control 4.E, Main Drum Brake Control 4.. Water Spray Brake Cooling System 4.G. Work Platform Operating Instructions 4.H. Auxiliary Hydraulic Catline Winch 4.L Drop Gear Box Selector 4J.. Drawworks Transmission Spotting Rig on Well ‘Mast Raising and Lowering Instructions G.A. General Instructions GB. Raising the Mast 6.C. Telescoping the Mast 6.D. Mast Rigging G.E. Retracting the Mast 6.F. Lowering the Mast 7. External Wind Guys 8, Ground Anchors INSPECTION AND SERVICE DATA General Recommendations Daily Inspections Weekly Inspections Monthly Inspections ‘Six Month Inspections Bolt Torque Chart Drawworks Brake Adjustment Procedures Drawworks Brake Block Replacement Procedure Servicing Raising, Scoping, and Tong Cylinders 10. Care of Wire Rope 11. Cold Weather OperationOPERATING INSTRUCTIONS Introduction All instructions should be read and fully understood by all crew members before attempting to operate this rig. It is impossible to anticipate every kind of problem or condition that may be encountered in the use of the rig, but compliance with instructions and suggestions set forth in this operating manual will assist the operator in successfully operating the rig Failure to operate and maintain the nig in accordance with this operating manual may affect the warranty covering the rig. ‘The information contained in this operating manual shall not in any way relieve the operator of the responsibility for exercising reasonable care and prudence in the operation of this equipment. Proceed slowly and carefully during all rig operations, especially during initial rig-up. Always watch for falling objects during rig-up operations (ie. tools, debris, etc.) During all operations, always watch for interference of lines, hoses, ete. with any moving equipment. Before operating any hydraulic equipment, circulate and bleed hydraulic oil as prescribed in the operating instructions. Air in hydraulic systems can cause accidents, Never open or close a control valve abruptly, this can cause severe shock loads resulting in structural damage As with any piece of heavy machinery, caution must be exercised at all times to prevent damage to equipment and/or injury to personnel Preparation for Roading ‘Move the hydraulic diverter valve to the closed position. Move the hydraulic jack control to the lower position, one at a time, to retract the hydraulic jacks. Screw the mechanical jackscrews in each hydraulic jack to the fully retracted position. ‘The hydraulic jacks should always be secured in the fully retracted position before roading. Move the hydraulic diverter to the open position. ‘With the engine at idle speed and the cartier transmission in neutral, move the drop gear box to the road position, All rig equipment and accessories are to be properly secured to prevent damage or loss during vehicle movement. All folding walkways must be folded up and secured. All loose tools should be secured in tool box doors to prevent accidental opening during transportation, All controls on the drillers console should be in the off or neutral position. All other air and hydraulic controls should be in the off or neutral position ‘The mast should be properly aligned resting on the headache rack. ‘The traveling block should be properly secured to the mast. Jack stands and wheel blocks should be properly stored,3. Driving Instructions Caution: Due to the size and high center of gravity, caution must be observed when moving the vehicle. When backing the vehicle or when moving the vehicle in a confined area, the driver should be assisted by a "spotter". The "spotter" should aide the driver by givig him directions ‘concerning turning and how far to move. The "spotter" should always be on the ground away from the vehicle, and in full view of the driver. ‘The vehicle should not be operated at high speeds while comering or while on rough terrain. This could cause severe damage to the vehicle a possible injuries to the personnel. Extreme caution must be observed when operating the vehicle near objects with low ground clearance, such as underpasses, bridges, or electrical power lines. Also, due to the high weight of the vehicle, extreme caution must be observed when operating the vehicle on soft pavement or small bridges. Whenever possible, do not drive on or near the sholder of a roadway. ‘The weight of the vehicle could cause the sholder to collapse, which in turn could cause the vehicle to overturn. WARNING: ABSOLUTELY NO PERSONNEL SHOULD BE ALLOWED ON THE RIG WHILE MOVING, EXCEPT FOR RIG OPERATOR. 4. Operator's Controls A. Air System Air to the rig is supplied from the carrier's air compressor system. An air pressure gauge is provided to indicate the rig air system operating pressure. CAUTION: Do not attempt to operate rig if the air pressure gauge indicates less than 100 psi or more than 130 psi. ‘The in-line air dryer is mounted upstream from the air control valves and supplies dry air to the operator's console. ‘The air volume tank in the rig is equipped with a drain valve located at the bottom of the tank. Condensate should be drained from the tank daily before operations begin. B. Hydraulic System ‘An hydraulic pressure gauge is provided to indicate the rig hydraulic system's operating pressure. CAUTION: The rig hydraulic system should not be operated at pressures in excess of 2,500 psi ‘The hydraulic system pump is a gear pump, driven by the tig drop gear box. One section of the pump supplies fluid to the rig hydraulic system. ‘To engage power to the hydraulic system the carrier transmission must be in neutral with the engine at idle speed. Move the control lever on the rig drop gear box to the winch position and then shift the carrier transmission to the normal gear for winch operations. Engine speed can be controlled with the main drum clutch/throttle control as described in section L.6.D. Diverter Control Valve- The diverter valve must be in the closed postion during mast aising/lowering, scoping and rig jacking operations. With the valve in this position all rig hydraulic equipment can be operated. After mast raising/lowering, scoping, and sig jacking operations are complete, the diverter valve should be returned to the cpen position. With the valve in the open position hydraulic pressure is diverted away from the hydraulic raising, scoping, and jack cylinders. Auxiliary/Catline Winch Control Valve- The auxiliary/catline winch is used for general lifting operations on and around the rig work platform. To lift, move the valve control handle to the raise position. To lower, move the valve control to the lower position,‘Tubing Break Out Control Valve- The rig is equipped with an hydraulic cylinder assembled with a wire rope running through a series of sheaves and tied off to tubing tongs. ‘The cylinder is used to break out tight tubing joint threads during pipe tripping operations. To operate the cylinder, place the break-out tongs on the tubing to be broken out and rotate tongs until all slack is out of the wire rope ‘connecting the tongs to the break-out cylinder. Move the break-out cylinder control valve handle to the break-out position. When the cylinder has traveled through its stroke, retract the cylinder by moving the valve control handle to the opposite position. Repeat this operation as many times as necessary to loosen tubing joint. Jack Control Valve- The rig is equipped with hydraulic jacks used to raise and level rig as described in operating instructions 1 5. Each hydraulic cylinder has a hydraulic valve and each valve is labeled according to the location of the cylinder it operates. The hydraulic diverter valve must be moved to the closed position before the hydraulic jacks can be operated. To operate the hydraulic jack system move individual control valve handles to the lower position until the rig is at the desired height. To lower rig move individual valve control handles to the lower position until the hydraulic jacking cylinders are completely retracted, ‘Mast Raising Control Valve- To operate the mast raising control valve, the hydraulic diverter valve ‘must be in the closed position. ‘To raise the mast, move the mast raising control to the raise position. To lower the mast, move the mast raising control valve to the lower position. See operating instructions I. 6. B. for detailed mast raising and lowering information, ‘Mast Scoping Control Valve- ‘The rig is equipped with a two-part mast that is extended to its full height by two hydraulic cylinders. ‘The hydraulic diverter valve must be moved to its closed position before the mast scoping control valve can be operated. To operate the mast scoping cylinders move the mast scoping cylinder control valve handle to the extended position. To lower the mast move the mast scoping cylinder control valve handle to the retract position. See operating instructions section 1.6.C. for detailed mast telescoping information, Remote Hydraulic Panel- ‘The mast raising and scoping cylinders can be operated remotely with the remote hydraulic panel. The panel is supplied with a 80 foot long cable. To make the panel operational, plug cable into receptacle located on the local control panel. Move the panel to a remote location from the local panel. On the remote panel select raising or scoping with the selector switch depending on the cylinder to be operated. Move the control valve handle to the up position to extend the cylinder sclected. Move the control valve handle to the down position to retract the cylinder selected. To resume local control of the raising and scoping cylinders, unplug remote panel cable from the local panel receptacle. C.— Kill Button ‘An engine kill button is provided to allow engine kill control at the operator's position. Depress the ill button to actuate the fuel shut-off solenoid, and release the button when the engine stops, CAUTION: Always place the rig transmission in "neutral" before starting or killing the rig engine. D. — Main Drum Clutch/Throttle Control To engage main drum clutch, move valve handle to “clutch” position or first valve or first valve detent. To increase engine speed continue to move handle beyond "clutch" position through the "throttle" portion of the travel. Valve handle will remain in the desired position when released. To return engine to idle and desengage clutch, move valve handle to "oft" position.‘The main drum clutch control can be disengaged by pulling the valve handle out from the valve body when the valve handle is in the "off" position. When in this position, the valve handle can be used to contol engine speed only. ‘To re-engage drum clutch control, with the valve handle in the "off" position simply push the valve control handle back into its fully engaged position in the valve body. E, Main drum Brake Control ‘The main drum brake system is actuated by this lever. ‘To set the drum brakes simply push down on the brake lever until the required braking force is achieved. A chain is supplied to lock the brake lever. CAUTION: The brakes should be applied and the brake lever chained down any time the operator's controls are left unattened. ‘To release the brake lever raise brake lever. Lever should be fully raised to its maximum height when tripping pipe to fully release brake pads from brake drum and prevent unnecessary brake-pad wear. Adjustment of the brake lever height, to accommodate varing operator heights and preferences, should be accomplished by adjusting clevis ends of brake lever mechanical linkage rod to the Grawworks brake system. CAUTION: Do not use this adjustment to compensate for drawworks brake system wear or misadjustment. F, Water Spray Brake Cooling System (When required) An air pressurized water system is provided to allow cooling of the drawworks brake systems. Foot ‘operated valves located at the operator's console for the main drum brakes controls the spray of water on the brake rims. Experience will help to determine the amount of water required to maintain brake cooling and prevent rim overheating, Use only enough water to cool the rims. Do not actuate spray when drum is stopped. Heat is removed by the formation of steam. A slight dipping from the bottom of the rig indicates maximum cooling has been achieved. CAUTION: Overheating of the brakes severely reduces load carrying capacity, shortens brake life, and causes destruction of the brake rims due to scoring. ‘The water spray brake reservoir, uses rig air pressure regulated at 30 psi to force water through the foot control valves to the nozzles which spray the water on the brake rims. To fill the reservoir with water close the air supply control valve and open the air bleeder valve. Do not attempt to remove the cap from the water fill tube until all air pressure has bled down from the reservoir. Fill the reservoir through the water fill tube with fresh water only. Never use anything but pure and clean water in the water spray brake cooling system. After filling the reservoir, re-install and tighten the filer cap in the filler tube. Close the air bleeder valve. When the water spray brake cooling system is being used, open the air supply control valve. When the water spray brake cooling system is not in use (when roading the vehicle) close the air supply control valve and open the air bleeder valve on the reservoir to release air pressure in the tank.G. Work Platform Operating Instructions (If Required) ‘The light work platform should remain attached to the mast base section in the retracted position during transportation, With the mast in the vertical position, attach catline to top end of light platform. Gently pull light work platform up and release platform restraining chains from base section legs. Lower light work platform to the horizontal position and release the catline cables. ‘The light work platform should now be in the lowest positions. If higher elevation is desired, attach catline to center of platform, remove pins, at mast leg rails, aise platform to the desited elevation, and replace pins at mast leg rails ‘To retract the light work platform, reverse the above procedure. H. Auxiliary Hydraulic Catline Winch ‘The auxiliary hydraulic catline winch is a utility winch primarily used for lifting or handling auxiliary surface equipment on the tig work platform and around well location. ‘The hydraulic valve at the ‘operator position described in operating section I. 4. B. supplies fluid to the hydraulic motor to drive hoist or winch-drum for lifting. ‘The winch has a worm gear brake for safe handling of loads. Operator caution must be exercised at all times to insure safety of crew. At no time should any crew ‘member be under the load being handled. I. _ Drop Gear Box Selector ‘The drawworks drive line connecting link is a drop gear box. ‘The gear box has a three position selector. The engine must be at idle speed and the carrier transmission in the neutral position to move the drop gear box selector. To put power to the drawworks drive line, move the selector to the winch position. To put power to the carrier, move the selector to the road position. The neutral position is the middle position on the selector and disengages power to both the drawworks and the carrier. J. Drawworks Transmission The drawworks is equipped with a five speed manual transmission. To operate the transmission move the cartier transmission to the seural position. With the engine at idle move the drop box selector to the winch position. Move the carrier transmission to the normal gear for winch operations. At the operator's console move the drive train clutch handle to the disengaged position, ‘The operator must move to the transmission, and manually select the desired gear required for the required speed and load situations. At the operator's console the drive train clutch handle can now be moved to the engaged position.5. Spotting the Rig on Well Back the rig toward well with the longitudinal centerline of the rig passing through the well center. Use the jack location plan provided in this manual to determine exact distance from well center to ‘mast legs. Secure vehicle in its normally parked configuration. Set Wheel Blocks beneath the wheels so the rig cannot move forward or backward. If manufactured Wheel Blocks are not available block ‘wheels with board matting materials Lower operator's work platform for access to hydraulic controls. Now is a good time to install all walkways, stairs, and guard railings. Lay mast foundation and rig jack footings suitable for area soil conditions (refer to API Spec 4F). Supplemental footings are required to provide a stable base for mast erection and to support the mast during the most extreme loading that will be encountered, ‘The foundation supporting a minimum of the hookload plus one-half the gross weight of the completely equipped rig. A base beam is used as part of the mast foundation and it should be placed under the jack screws at the rear of the rig before the rig jacks are extended. Extend the jack screws to the sockets on the base beam and insert pins through the jack screws to secure the jack screws to the base beam. Now extend the front jack screws down to the jack stands and the tig is ready to be hydraulically raised o jacked. With the engine at idle and the carrier transmission in neutral, move the drop gear box selector to the winch position. Shift the carrier transmission to normal gear for winching operations and control engine speed with the main drum clutch/ throttle control valve at the operator's console. With the engine at idle speed, move the hydraulic system diverter valve at the operator's console to the closed position. Using the hydraulic jack controls, raise and level the rig. The rig should only be raised enough to pick up the load off the front and rear tires. Do not lift the tires off the ground unless necessary to level the rig on uneven terrain. Use bubble kvels to determine when the rig is level. CAUTION: The hydraulic jacks have a stroke of 1 inches and the maximum screw extention of the manual levering jackscrew is 14 inches. Use additional matting under the jackscrew if the jackscrew extension is not sufficient. Once the rig is raised and leveled, tighten all hydraulic jack locknuts. 6. Mast Raising and Lowering A. General Precautions Before operating any hydraulic equipment, circulate fluid and bleed entrapped air from the hydraulic system. Air in the hydraulic system can cause accidents. Hydraulic fluid must be circulated until fluid temperature is elevated to the normal operating range (30 degrees above the pour point), Never open or close any control valve abruptly. This can cause severe impact loads resulting in structural or mechanical damageWARNING: The mast should not be raised in the vicinity of electrical power lines. Mast or guylines too close or coming in contact with electrical power lines may result in damage to Property, and/or personal injury or death. Keep all personnel off and out from under mast when raising, lowering, telescoping, or retracting mast. ‘The maximum hydraulic pressure required to raise and telescope the mast will vary with the weight of lines, traveling block, and other accessory equipment that may be installed on the mast. The hydraulic valve bank is equipped with an adjustable pressure relief valve. It is set sufficiently above the ‘maximum required pressure to raise and telescope the mast without bypassing. It will bypass in the event some obstruction imposes an excessive load in the raising or telescoping rams. The operator should note the maximum pressure required for raising and telescoping the first time the mast is erected. In subsequent mast erections, the hydraulic pressure should be constantly monitored. Any time the pressure is noted to be above the normal maximum pressure, raising or telescoping should be stopped and the problem eliminated. In no case should the pressure exceed 2,500 psi B. _ Raising the Mast ‘This rig is equipped with a twin-box mast which requires guying per API-4F. There are four (4 each) support cables from the crown section of the mast to the rig headache rack. Before raising the mast secure these (4) support cables in their proper position. These cables are an intergral part of the mast structure and are required to maintain structural stability of the mast. Failure to do so could result in personnel injuries and severe damage to mast and related rig equipment. With the cartier transmission in neutral and the engine at idle move the drop gear box selector to the winch position. At the operator's control console move the hydraulic diverter valve to the closed position. Circulate the hydraulic fuid for at least one minute. Check the hydraulic reservoir for proper hydraulic fluid level ‘The following procedure must be followed to remove possible entrapped air from the double acting raising ram: Open the bleeder valve in the top or smallest section of the ram, the section that pins directly to the mast, and move the mast raising control valve handle to the raise position, slowly. Ic is nesessary to open the control valve only slightly so oil will flow in a limited amount. Excessive opening of the control valve during bleeding will result in a waste of oil, and difficulty in determining when air has ‘been purged due to high pressure discharge from the bleeder valve. Foamy discharge from the bleeder valve indicates air. When clear oil is discharging, close the bleeder valve finger tight. Do not use pliers or wrenches, as the seat of the bleeder valve may be damaged by excessive tightening, Replace bleeder valves which leak when properly closed, Open the bleeder valve on the second stage of the ram, which is located just below the upper section bleeder. Move the control valve handle to the lower position slowly, as outlined above. When a clear, air-free, stream of oil flows from the bleeder valve, close it as directed above. Move the raising ram control valve to the mise position. The mast should begin to raise slowly and smoothly. Mast raising may be stopped at any point by releasing the valve handle to neutral. The mast may be lowered any amount by moving the control valve handle to the lower position.As the mast begins to raise, particular attention should be paid to the mast raising cylinder. ‘The mast, raising cylinder is a two-stage cylinder. ‘The largest stage of the cylinder should be the first stage to extend and should be fully extended before the small stage begins to extend. As the cylinder approaches the end of each stage, the speed of extention of the cylinder should be slowed to reduce the shock to the cylinder as it reaches the end of the travel for each stage. It is essential that the cylinder extend in the sequence described to insure safe extention of the raising cylinder. Failing to observe this sequence could result in injury to personnel and damage to the tig. As the mast approaches the vertical position, move the valve handle towards neutml to ease mast into the full upright position. Observe the pecker pins on the mast base to insure they become seated in the line up holes in the pecker pin plates. When the mast is fully raised and the pecker pin plates at the base of the mast are fully in contact with each other, insert bolts into the pecker pin plates to fully secure the mast in the vertical position. ‘To insure stability of the fully extended mast, the mast base must be secured to the mast base beam. ‘Turnbuckles connecting the mast base to the mast base beam must be installed before the mast is extended. Failure to install these turnbuckles will severly reduce the stability of the tig and could result in personnel injury and severe damage to the rig. C. Telescoping the Mast It is always necessary to bleed air in the telescoping cylinders in order to provide smooth safe operations of the telescoping cylinders. Open bleed valves at the top of each scoping cylinder. Move the scoping cylinder control valve to the raise position until air ins been pushed out and clear hydraulic oil is visible. Tighten the bleed valve by hand. Recheck base screws and tighten as required. Recheck the tumnbuckles and tighten as required. Recheck jack cylinders and adjust as required. Recheck rig and mast to make certain they are level. Unchain travel block and make sure all lines and cables on the mast are free and clear. ‘The mast in now ready to be extened, Move the telescoping valve handle to the raise position and telescope the mast, spooling drill line as mast telescopes. Be sure all lines on the mast are free and do not obstruct mast movement. If the scoping cylinders appear to be too spongy, it may be necessary to bleed additional air from the cylinders. Move the scoping cylinder control valve to the lower position and lower the mast back down to the stops. Repeat the procedure for bleeding air from the cylinders. Resume mast raising, Move the scoping cylinder to the raise position and telescope the mast and spooling out drill line as the mast telescopes. As the top section pins move past the bottom section pin saddles, the pins will snap into the saddles. Move the scoping control valve handle to the lower position and lower the top section down the seat in the bottom section saddles. An audible indication should be sounded when the top section pins snap into position in the bottom section saddles. A visual verification that the pins are in proper position should also be made before ‘operating personnel enter the mast. After visual verification is made, retaining bolts must be placed in the mast pins to insure pin security Move the telescoping control valve to the lower position and hold for about five seconds. Move the raising control valve to the raise position and hold for about five seconds. ‘This procedure is required to relieve any pressure in the cylinders. ‘The raising and telescoping cylinders should not carry pressure except during raising and scoping operations. ‘This procedure should be repeated as dictated by increases in ambient temperature.When saising and scoping operations are complete, the hydraulic diverter valve control handle must be moved to the open position D. — Mast Rigging ‘The mast in this rig is guyed per API spec 4F. It does, however, require support cables from the mast to the headache rack and base beams. ‘The cables are essential for safe operations of the rig. Failure to properly maintain these cables could result in personnel injury and severe damage to the rig. See attached drawing for locations. Dwg "A" When the tig is being placed into service the mast must be guyed in accordance with API 4F; if the mast is being used with pipe racked in the mast And - A stable footing cannot be assured under the rig, Or - A stable footing cannot be assured under the base beam, Or = A stable footing cannot be assured under the pipe being racked Or - —__Therigssiteis such that the total rig cannot be set up on level ground causing the operation of the rig to be at risk “The rig may be at risk of turnover under the conditions even without pipe in the mast. The cables are essential to the safe operation of the rig, Failure to properly maintain these cables could result in personnel injury and severe damage to the rig. See attached drawing for locations. Dwg "B". ‘Mast lean can be adjusted to aid in spotting traveling block over well center by moving adjusting back braces to move the mast in the desired direction. In no case should the mast lean exceed 3.5 degrees. ‘They also need to rock tilt valve with pump disengaged to equalize pressure across tilt cylinder as mast, lean is changed. E, _ Retracting the Mast Move the hydraulic system diverter valve at the operator's console to the closed position. Engine speed must remain at idle with diverter valve in this position. Circulate hydraulic fluid for two or three minutes if oil is cold. If hydraulic system has been in use immediately before, this circulation is not required, Remove the mast pin security bolts. Make sure all personnel are clear of the mast. Move telescoping valve to the raise position to lift upper section of mast off pin saddles. Retract pins by moving pin retracting rope at the base of the mast to the retract position. While holding the mast pin retracting rope in the retract position, move the telescoping valve to the lower position and lower top section of mast, spooling drill line as necessary. As the top section pins move down into the racks in the bottom section, the mast pins retraction rope can be released. Be sure all lines on the mast are free and do not obstruct movement.F. Lowering Mast CAUTION TO OPERATOR: Bleed the raising ram before lowering the mast. Do not proceed to lower the mast until raising ram is free from air. Sec section 1.6.B. for bleeding instructions. Remove mast-to-mast beam turntables. Remove mast pecker plate bolts. Be sure all lines on the mast are free and do not obstruct movement Start mast back slowly by gradually moving raising ram control valve handle to the lower position, Loads on the mast and chassis can be reduced if the mast is lowered slowly and smoothly. Abrupt starting and stopping movementscan produce unnecessary and potentially hazardous stress loads in the mast, frame, and ram structures. The three-stage mast ruising cylinder should retract small stage first, and second stage next and largest stage last for proper operation. If the small stage of the cylinder does not retract first as the mast lowering is initiated, move the mast raising control valve to the raise position and bring the mast back to the vertical position. The problem must be investigated and corrected before another attemt is made to lower the mast7. EXTERNAL WIND GUYS Whenever foundations are not adequate to provide stablization for the rig through internal guying, or when wind velocities exceed the wind rating of the mast, external wind guys are essential to stabilizing the rig. Four crown to ground guys of 5/8 inch or larger, wire rope, and two racking boards to ground guys of 9/16 inch or larger wire rope are required. ‘The guys should be fastened to the crown and racking board using the thimble and three wire rope clips torqued to 95 foot pounds on each guy. Ilustrations of proper wire rope fastenings taken from the National Safty Council Accident Prevention Manual for Industrial Operations are shown in the AOSC Recommended Safety Procedures and Guidelines for Oil and Gas Well Servicing and in the Texas Occupational Safety Standard 11-123/1972. The end of the guy line should be attached to the ground anchor by bending the cable over a thimble and securing with wire rope clips. Tension should be taken in the cable with a come-along or other suitable tensioning device. If tensioning devices remain in the string up they must have a breaking strentgh equal to or greater than the breaking strenght of the guy line. Crown to ‘ground guy lines should be tensioned to 1,000 pounds and racking board to ground guy lines should be tensioned to 500 pounds. A tension of 1,000 pounds is roughly equivolent to a 6 to 8 inch sag in the guy line. Racking board guys should be crossed to keep from placing the racking board in tension. Minimum strength for wind guy lines is 13.7 tons For detailed information in guy lines and anchor patterns, strength requirements and load test, refer to the guy line diagram in the instructions. ‘This information may also be found in the API Spec 4E, 4F, ‘Texas Occupational Safty Standard 11-123/1972 or AOSC’s "Recommended Safe Procedures and Guidelines for Oil and Gas Well Servicing" 8. GROUND ANCHORS Ground anchors have only one requirement. They have to hold the load of the guy line without moving. Ground anchors are the most critical component in the guying system and the most often neglected. API Spec 4B and 4F require a minimum test pull of 14,000 pounds on an anchor used on 1 doubles rig and placed at the comers of a 180 foot square pattern with the well in the center. The test pull requirement increases as the size of the achor pattern gets smaller. For exact requirements refer to the guying and anchoring diagram in the instructions. ‘There is only one way to be absolutely sure that an anchor will hold what itis supposed to and that is to test it after it has been set. For this reason, HRI recommends rigging up on tested anchors only.6. 10. 11 WARNING! FAILURE TO PROVIDE ADEQUATE ANCHORS CAN RESULT IN DAMAGE, SERIOUS INJURY, OR DEATH. SOME DO'S AND DON'T OF ANCHORING Don't set an anchor in or near an old pit location or other disturbed ground. Do set the anchor so that the guy wire will pull straight up the shank. Don't set an anchor so that the guy wire will pull to the side-it will just slice through the ground under a hard pull and let the mast lean, Do pull test the anchor as specified in API 4E & 4F ~ a minimal pull of 14,000 pounds for a doubles mast. Do pull test the anchor at the same angle that the guy line pulls. Do use at least three wire rope clips when bending the guy line around a thimble -- at least four when bending around a snatch block. Don't trust an anchor that goes in too easy —-it will pull out just as easy. Be prepared to run anchors deep enough so that they will hold. Remember, all the wind load may be on one anchor and if it fails, the others may not keep the mast from going over. Don't wait until the wind comes up to make sure the anchoring system is secure. I's too late then. Do flag the anchors and guy lines to make them easy to see. Don't let your rig hit the ground because someone could not see the guy lines and ran over them. Don't allow vehicles inside the anchor pattern and don't park equipment or trailers in the fall of the mast.2 I SNE AL K6666 SERVICE AND INSPECTION General Recommendations A closely followed routine maintenance schedule must be established for each HRI rig. This will prevent premature parts failure in tig assemblies. It will reduce wear, and aid in maintenance of rig assuring longer life with less cost for repairs and downtime. Proper rig maintenance will provide safer conditions and operations throughout the life of the sig HRI rigs are designed and manufactured for long service life under normal operating conditions. However, every rig begins to wear on the day it begins work. This wearing process continues throughout the rig’s life until tll it can no longer perform its original work task. Proper rig ‘maintenance, proper service, and replacement of worn parts as needed will extend the rig's useful life. The Inspector and Service Data listed in this section is based on normal operating service for average conditions. Since the operations of each rig varies depending on the operator and the working conditions, the tig operator should develop a schedule that best fits his rig. ‘The rig operator must be responsible for regular visual inspections to determine the need for repairs or replacement of worn parts. Loose bolts must be tightened, hydraulic or air system problems must be corrected, and any unusual vibrations or noised corrected at the time of detection. This will help prevent any harm to the operating personnel and equipment. In addition to the Inspection and Service Data listed in this section, the rig operator should follow the recommended maintenance and operating procedures in API Specifications 4F for Portable Mast, API RP9B Recommended Practice on Application, Care and Use of Wire Rope for Oilfield Service, and API RP8B Recommended Practice for Hoisting Tool Inspection and Maintenance Procedures. Daily Inspections ‘The following items are listed to assist in rig safety and maintenance. Check sir system pressure (Minimum 90 psi-Maximum 130 psi) Check sir system for leaks, drain water from tanks and air filters. Check mast support cables for proper tension. Insure mast is properly located in headache rack for roading conditions. Check engine oil pressure, coolent temperature, oil and coolent levels. Check transmission for proper oil levels. Check hydraulic reservoir for proper operating level. Check hydraulic oil filter for proper operating conditions. Check drawworks brake for proper operation and adjust as required. Check leveling jacks to verify that unstable conditions do not exsist as a result of foundation settling Check that the locking pins, located in the top of the middle section of the mast, are in the correct position with the upper section resting properly in the saddles. Check that all manual controls, pins, keys, and retainers, are in good operating condition. Lubricate all areas of the rig as specified in the rig Lubrication Data. Visually check for oil leaks. Check for loose bolts and nuts and retighten per the Bolt Torque Chart. Check mast tilt to insure proper block alignment. Check all airlines for leaks, wear or damage, and repair or replace as necessary.Weekly Inspections Y The recommendations listed below must be followed and are in addition to the daily items listed earlier, Overall rig performance due to severe operating conditions, age, and location should be considered and will dictate any additional inspection required to assure safe working conditions. Y Check for missing bolts on all rotating assemblies and replace with correct capscrew. All bolts must be torqued per the Bolt Torque Chart. Y Check brake rims and blocks for uneven wear, misadjustment, and scored rim surface condition, and correct any problems. Y Check operation of all quick release and relay valve. Monthly Inspections ¥ Check all chain drives fpr signs of unusual sprocket wear, excessive chain sag or misalignment. Y Check all keyed assemblies to assure that all keys are in place and tight. Y Thoroughly check the entire hydraulic system for leaks, hose damage, and severely wore areas. All damaged hoses and fittings must be replaced before continuing operation. Y Check all linkages for secure pullleys, pins, and retainers. Check freedom of movement of linkages to be sure all are in safe working condition. Y Thoroughly check entire rig and mast for paint cracking or flaking, Correct these areas to reduce environmental deterioration. Y Check all members of the rig and mast for dents, deformation, cracks, broken welds, and any other problem that may require immediate corrective action. ‘Six Month Inspections YA thorough six month examination is critical to assure extended rig life and personnel safety. In addition to the items listed below, all areas with unusual wear or abuse should be corrected before continuing operations. Y Thoroughly check al items listed previously Y Check all chains and sprockets for excessive wear Y Recheck brake blocks, bands, rollers, and rims for any needed replacement due to wear or damage. Y Check all linkages, particularly brake control linkages, and replace any pins or lugs that show Y Examine all mast components, hydraulic rams, wire lines, sheaves, traveling block, bearings, pins and latches, guy lines and matting material to assure safe operations of rig and to prevent personnel injuries oF rig equipment damage. Y Remove hydraulic oil strainer from tank, clean or replace6. Bolt Torque Chart r) Use the following bolt torque chart to tighten bolts to the torgue settings specified for specific bolt Table 1 - Assembly Torque Valves (Newton/meters) SIZE (mm) SAE Grade2 SAE Grade 5 __SAE Grade 8 64 20 NC 3.6 85 122, 64 28 NF 63 97 136 79 -18 NC 108 176 244 79 24 NF 122 190 2A 9.5 -16 NC 203 312 475 9.5 24 NF 23.0 33.9 415 1-14 NC 325 475 746 11.1 20 NF 36.6 542 813 127 -13 NC 475 74.6 108.5 127 20 NF 542 88.1 122.0 143 12 NC 746 108.5 149.1 143-18 NC 813 122.0 1763 159 11 NC 1017 149.1 230.5 159 18 NF 115.2 176.3 244.0 19.1 10 NC 1763 212 379.6 19.1 16 203.4 298.3 433.9 22 9 1695 433.9 623.7 e@ 22.2 -14 189.8, 488.1 6779 24 8 257.6 6508 922.0 254-14 284.7 732.1 1030.4 286 7 366.1 813.5 1301.6 286 12 406.7 894.8 14643 318 7 515.2 11389 1843.9 318-12 369.4 12474 2033.7 349-6 664.4 14914 2413.4 349 12 759.3 1708.3 2765.9 381 6 8813 1979.5 3199.7 381-12 989.7 2223.5 3606.5Drawworks Brake Adjustment Check blocks for wear and replace if worn past bolt plugs. With brakes applied, check brake band for stop link clearance Check balance beam for level indicated. If either of these checks indicates a need for adjustment proceed as follows. Using, the adjusting nuts set brake band stop link clearance as shown. After settings are achieved, balance must be leveled and squared as shown. Apply brakes and recheck stop link clearance and balance beam level and square. If stop link clearance is correct and balance beam is level tighten locknuts securely. If not repeat above steps until brakes are adjusted correctly. With brakes engaged adjust band support rollers so there is 3/16” clearance between screw heads and band as shown in Figure 6. Check all block screws for tightness (10 -15 fr/Ibs).. Drawworks Brake Block Replacement Keep lining free of all contaminates such as oil, grease, mud, paint, etc. Periodically check brake rims for uneven or excessive wear. Rim grooving is caused by hard foreign particles embedded in lining. Grind surface of lining to remove embedded foreign particles. Replace rims if worn excessively Retighten lining block mounting bolts as required. A certain amount of loosening will normally occur which is caused by frequent heating and cooling, Replace lining blocks if worn past bolt plugs or roughly ¥/” of block remains. Replace in complete sets When replacing spent linings, care should be taken when removing the bands to keep them free of flat spots, kinks, and twist. Distorted bands are caused from rough handling. Do not lift a complete band by a line attached to center of the band or to either end, as kinks and flat spots will result. Tt is suggested that two or three men gently pick the band up and place it over the drum spool, then life it into position over the brake rim, After cemoval of old lining blocks, distorted bands should be trued to circular shape. ‘The time required to true each band will pay off in extended lining life and smooth brake operation. Brake blocks should be attached with 120 degree tapered brass bolts locknuts supplied with brake block kits. Torque to 10-15 ft/Ibs. Locknuts are superior to conventional nuts. If conventional nuts are used, they should be locked by inserting a cotter key through the end of the screw ot by distorting the ends of the threads with a punch. Lockwashers are unsuitable for mounting brake blocks because the material cannot withstand the forces necessary to make a lockwasher function properly. Once blocks are mounted, fill sctew holes with plugs; which are supplied with the brake block kits. ‘This keeps foreign material from collecting, provides uniform braking susface, and increased friction Reinstall brake bands using the same methods and precautions specified for removing the band. With the bands in place itis essential that the brakes be adjusted For brake adjustment, see Inspection and Service Data.10. Servicing Raising, Scoping, and Tong Cylinders ‘Mast Raising Cylinder-The mast-raising cylinder is a two-stage cylinder equipped with chevron type packing. To prolong packing life, the cylinder’s first and second stage rods should be completely covered with grease each time the cylinder is extended. ‘The grease will lubricate the packing and protect the rods. ‘The chevron packing used in this cylinder is normally supplied in rings. ‘To make field repairs to leaking cylinders the rings will have to be parted with a sharp knife in a 45-degree chamfer across the surface of the ring. To install the packing without parting the ring requires complete disassembly of the cylinder. Mast Telescoping Cylinders-The mast is equipped with two identical single acting cylinders installed in each of the mast’s two box section legs. ‘The cylinders are equipped with chevron type packing. To insure adequate service life of this packing, it is essential that the rod surfaces be covered with grease cach time the cylinders are extended. ‘The chevron packing used in this cylinder is normally supplied in rings. To make field repairs to leaking cylinders the rings will have to be parted with a sharp knife in a 45-degree chamfer across the surface of the ting, To install the packing without parting the rings requires complete disassembly of the cylinder. ‘Tong Cylinder-The tong cylinder is used for breaking out tight tubing joints, ‘The rod of this cylinder should be lubricated each day before operations are begun. This cylinder requires complete disassembly for replacement of packing. Caution: Failure to bleed off hydraulic pressure in any hydraulic cylinder before attempting to perform maintenance, which requires any disassembly, could result in personnel injury. Care of Wire Ropes Recommended practice on application, care and use of wire rope for oilfield service is provided by the APL RP 9B. Careful study of this section is recommended. ‘The following information has been taken from this section for the convenience of the rig owners. Handling on Reel - When handling wire rope on a reel with a binding or lifting chain, wooden blocks should always be used between the rope and the chain in order to prevent damage to the wire or distortion of the strands in the rope. Use of Bars - Bars for moving the reel should be used against the reel flange, and not against the rope. Sharp Objects - The reel should not be rolled over or dropped on any hard, sharp objects in such a manner that the rope will be bruised or nicked. Dropping - The reel should not be dropped from a truck or platform. ‘This may cause damage to the rope as well as break the reel, Mud, Dirt, or Cinder Rolling the reel in or allowing it to stand in any medium harmful to steel such as mud, dirt, or cinders should be avoided. Planking or cribbing will be of assistance in handling the reel as well as in protecting the rope against damage.Stringing of Blocks - Blocks should be strung to give a minimum of wear against the sides of sheave grooves Changing Lines and Cutoff-It is good practice in changing lines to suspend the traveling blocks from. the crown on a single line. ‘This tends to limit the amount of rubbing on guards or spacers, as well as chances for kinks. ‘This practice is also very effective in pull-through and cut off procedures. Rotation of Reel - The reel should be set up on a substantial horizontal axis so itis free to rotate as the rope is pulled off, and in such a position that the rope will not rub against derrick members or other obstructions while being pulled over the crown. A snatch block with a suitable size sheave should be used to hold the rope away from such obstructions. Jacking - The use of a suitable apparatus for jacking the reel that is off the floor and holding it so that it can be turned on its axis is desirable. ‘Tension on Rope - Tension should be maintained in the wire rope as it leaves the reel restricting the reel movement. A timber or plank provides satisfactory brake action. When winding the wire rope on the drum, sufficient tension should be kept in the rope to assure tight winding, ‘Swivel-Type String Grip - When a worn rope is to be replaced with a new one, the use of a swivel- type-stringing gripe for attaching the new rope to the old rope is recommended. This will prevent transferring the twist from one piece of rope to the other. Care should be taken to see that the grip is properly applied. Kinking - Care should be taken to avoid kinking a wire rope since a kink can be cause for removal of the wire rope or damaged section. Striking with Hammer - Wire ropes should not be struck with any object such as a steel hammer, derrick hatchet or crow bar which may cause unnecessary nicks or bruises. Even when a soft metal hammer is used, it should be borne in mind that such blows could damage a rope. Therefore, when it is necessary to crowd wraps together, any such operation should be performed with the greatest of care; and a block of wood should be used between the hammer and rope. Cleaning - The use of solvent may be detrimental to a wire rope. Ifa rope becomes covered with dirt or grit, it should be cleaned with a brush. Excess or Dead Wraps - After properly securing the wire rope in the drum socket, a minimum of eight dead wraps or turns should be maintained in the drum. New Wire Rope - Whenever possible, a new wire rope should be run under controlled loads and speeds for a short period after it has been installed. This will help to adjust the rope to working conditions. Seizing - Before cutting, a wire rope should be securely seized on each side of the cut by surrounding with soft wire ties. For socketing, at least two additional seizings should be placed at a distance from the end equal the length of the basket of the socket. ‘The toral length of the seizing should be at two rope diameters and securely wrapped with a seizing iron. ‘This is very important, as it prevents the rope untwisting and insures equal tension in the strands when the load is applied. “The procedure for seizing a wire rope is as follows:‘The seizing wire should be wound on the rope by hand as shown ia the detail drawing. ‘The coils should be kept together and considerable tension maintained on the wire. After the seizing wire has been wound on the rope, the ends of the wire should be twisted together by hand in a counterclockwise direction so that the twisted portion of the wires is near the middle of the seizing, Using “Carew” cutters, the owisting should not be attempted, ‘The seizing should be tightened by prying the twist away from the axis of the rope with the cutters as shown in the detail. This tightening procedure should be repeated 2s many times as necessary to make the seizing tight. To complete the seizing operation, the ends of the wire should be cut off as shown in the detail and the twisting portion of the wire tapped flat against the rope. ‘The appearance of the finished seizing is illustrated in the detail,Attachment of Clips - The clip method of making wire rope attachments is widely used. Drop forged clips of either the U-bolt or the double saddle types are recommended, When properly applied as described by this procedure, the method develops about 80 percent of the rope strength using six- strand rope. When attaching clips, the length of rope to be turned back when making a loop is dependent upon the rope and the load to be handled. The recommended lengths as measured from the base of the thimble are shown in the following table. ‘The thimble should first be wired to the rope at the desired point and the rope then bent around the thimble and temporarily secured by wiring the two rope members together. ‘The first clip should be attached at a point about one base width from the short end of the rope and tightened securely. ‘The saddle of the clip should rest upon the long or main rope and the U-bolt upon the short end. See the following detail. The short end of the rope should rest squarely upon the main portion. ‘The second clip should be attached as near the loop as possible. ‘The nuts for this clip should not be completely tightened when it is first installed. The recommended number of clips and the space between the clips are given in the following table. Additional clips should be attached with an additional spacing between clips. Before completely tightening the second and any of the additional clips, some stress should be placed upon the rope in order to take up the slack and equalize the tension on both sides of the rope. When the clips are attached correctly, the saddle should be in contact with the long end of the wire rope and the U-bolt in contact with the short end of the loop in the rope as shown in the detail. The incorrect application of clips is also illustrated in the detail ‘The nuts on the second and additional clips should be tightened uniformly, by giving alternately a few turns to one side then the other. It will be found that the application of a litte oil to the thread will allow the nuts to be drawn tighter. ‘After the rope has been in use for a short time, the nuts on all clips should be retighten, as stress tends to stretch the rope, thereby reducing its diameter. The nuts should be tightened at all subsequent regular inspection periods.Inspection & Service Data Table 2 Attachment of Clips Length of Wire Rope Rope diameter Turned Back Torque Millimeters__ Clip quan Centimete: N/m Ba 2 83 6.1 48 2 95 10.2 64 2 1241 203 79 2 133 407 95 2 165 610 ua 2 178 88.1 127 3 219 88.1 143 3 305 128.8 159 3 305 128.8 19.1 4 457 176.3 2 4 483 305.1 254 5 66.0 305.1 28.6 6 86.4 305.1 318 6 94.0 488.2 349 7 1118 488.2 38.1 7 121.9 488.2 a3 7 1295 583.1 445 7 134.6 800.0 508 8 180.3 1017.0 572 8 185.4 1017.0 6 9 213.4 1017.0 699 10 254.0 1017.0 76.2 10 269.2 1627.2 Note 1: If pulley is used in place of a thimble for tuning back the rope, add one additional clip Note 2: The table applies to: 6 x 19 or 6 x 37 clas, right regular or lang lay, IPS or EIPS, fiber or independent wire rope core; ‘And 38 mm and smaller, 8 x 19 class, right regular lay, IPS, FC; And 45 mm and smaller, 18 x 7 or 19 x 7, right regular lay IPS or EIPS, with the following exceptions: for ropes 25.4 mm and larger, 6 x 19 class, and one additional clip.ATTACHMENT OF CLIPS CHART, TABLE, Correct method of attaching clips to wire rope Incorrect methodu Cold Weather Operations Al steel materials used in the construction of this rig were designed for use in cold operations. As a result of this however, repairs to these materials require the use of manufacturing processes designed specifically for the use in processing these materials. To insure all repairs are done in a manner consistent with the original manufacturing specifications, consult with HRI before making field repairs or modifications. Failure to consult with HRI before making repairs or modifications could result in personnel injury and severe damage to rig, At the owner’s option, cold weather equipment has been furnished as a part of this rig. As a result of this it is critical that the operators observe the minimum operating temperatures for all lubricants used in this rig, See the lubrication chart in the Inspection and Service Data section of this manual for recommended minimum operating temperatures for the lubricants used in the rig. Operation of the rig in ambient temperatures below those recommended in the lubrication chart without provision for maintaining the recommended minimum operating temperatures of the lubricants could result in damage to the rig, At the owner’s option, cold weather equipment has been furnished as a part of this rig. However the coolant water in the water spray brake cooling system is not protected from ambient temperatures below freezing, To insure continued operation of the system in ambient temperatures below freezing, provision for maintaining water reservoir temperature above freezing is necessary. Failure to operate brake water spray cooling system during pipe tripping operations could result in overheating drawworks braking system and loss of control of the braking system. Hydraulic raising and telescoping cylinders and all the piping and hoses associated with these cylinders become part of the inactive hydraulic system after the mast has been raised and telescoped. To prevent the hydraulic fluid in this part of the hydraulic system from freezing, any time temperatures below 45 degrees Fahrenheit are anticipated, all hydraulic fluid in the raising and telescoping cylinders and the associated piping and hoses should be drained.u Grease crown sheave dail A 8B) 9 Dd) £) CHECK LIST RIGGING UP Check for overhead obstructions and/or power lines. DO NOT RAISE MAST WITHIN 10' OF ANY HIGH VOLTAGE LINE. Raising mast to vertical position: 1) Make sure the foundation is adequate 2) Run leveling jacks and outriggers down solidly 3) Level the rg for side-to-side leveling 4) Remove any mast tie-downs to headrest, 5) Check hydraulic oil level (6) Make suze all guys and wireines are free and clea. While rising 1) Keep block positioned in its rade 2) Continue to make sure all the guys and wireline remain free. Before telescoping: 1) Check to ensuze that all wireline are free. 2). Check that the tubing platform and rodman platform are free to fold. While telescoping 1) Continue to see that all wireline stay free and clea. 2) Ifram stabilizers are provided, check to see that they move into place and secure the telescoping sam 3) Visually inspect to see that the load latches are fully extended and bearing properly on load transfer to bottom section 4) All guy lines ate securely anchored and propedy tensioned 5) Alljacks and outriggers should be properly adjusted. RIGGING DOWN ‘Telescoping top section down: 1) Before telescoping, make sure al guy lines are loose to permit retraction of load latches. 2) Ifram stabilizers are provided, make sure they are properly extended While telescoping: 1) Ram stabilizer remains around hydsaulc eyinder until propery released by the top section 2) Allwitelines remain free and clas. 3) Racking platform and roman platform fold freely into the mast Lowering mast to the horizontal: 41) Before lowering, make suze air is bled ftom the thing cam. THIS STEP IS AN ABSOLUTE MUST. 2) Traveling block is positioned at its carrying cradle 3) Masts unlocked from its base section. 44) Watch and make sure tha the ram cylinders retract in theie proper sequence 3) Keep traveling block positioned in the exadle LUBRICATION INSTRUCTIONS Grease catline sheaves and tong counterweight sheaves weekly. Grease automatic folding sheaves each time mast is rigged down or weekly whichever occurs first. Oil all hinge points each time hinge is moved or weekly whichever occurs first. TThe hinge points include tilt ram pivots top and bottom, mast hinge, tubing board hinge, fipboard on monkey board, Coat all fixed pins with grease to protect against rust. NOTES: 1. All sheaves are equipped with grease fittings and should be greased with a grease gun using clean chassis lube. 2. Use lightweight lubricating oil applied with a squirt can on hinge points. [Loader Industries, LTD PO Box M28, Bray, TX 7625 325 97-2911 +325 597.0781 Fax 10-8108n ECK LIST RIGGING UP A) Check for oveshead ubsinuctias and oe powcr ines DO NOT RAISE MAST WITHIN 10° OF ANY HIGH VOLTAGE LINE 18) Rassing anasto ver 1) Make sue the 2) Rum leveling sacks ant cuter 1 soll 3) Level dhe ag fr aden se lech 8) Remove any mast we desens 1 headrest, 5). Check hydraulic 6). Make sue all © While easing 1) Keep block positianed ats esa 2) Continue D) Before telescoping V) Check to ensure that all wets ane free 2). Check chat the tubung, plats and sexta plate av F) While telescoping: 1) Continue to see that all wwelines stay free ad clear 2). Wear sablizers ae provided, check to se that they move mito place and secure the telescoping 3) Visually spect to see tha dhe atl latches ae fully estended! and bearing property on load make suee all the pus anil welines sete fold to bottom section 4). Al guy lines are securely anchored and pr 5) Alljacks and outazyere shill le prope adjusted RIGGING DOWN A) Telescoping wp section down 1) Before teleser 2). fram stalnirers ave pron While teles 1) Ram stalin 2) Allwicelines seman free anal clear 3) Racking platform ad wl pst fll ©) Lanwermg mast to the horizontal 1 Before towering, make sure aur ble finn the wlan any THIS STH gs make sure all guy hnes are house to peemt (head latches nl, make sure th are pevpedly extended ») ISAN ABSOLUTE Must 2) ‘Traveling block is nities ws carry eral 3) Mast is unlocked fri ts ase see toon 4) Watch and ma har the sam eslnwlers retract 3) Keep travelig block postion nthe cradle LUBRICATION INSTRUCTIONS, Grease automat Oilall hinge pounts each time ange vs wv ve eck wh The funge points include alt ran pvt ep aad eto mast hinge, ruby bese age, Raps on ronker board Cont all xed puns wath wrease to paoeet agaist st NOTES, AL AM sheaves are equappea icra a anneaaaett nflIndustries, Ltd. EQUIPMENT SERVICING & LUBRICATION SCHEDULEOIL MAINTENANCE INFORMATION Clean the oil ‘This is the most important factor in a hydraulic system to prevent system-wide trouble. A hydraulic system should be properly cleaned when assembled and extreme care should be used when adding or changing oil When to drain ‘The real purpose in draining hydraulic oil is to remove the undesirable impurities and compounds that form or are accidentally added to the system. The simplest way to determine oil condition is by sight and smell. A sample of oil should be placed in a clean glass bottle, if it smells sweet and is clean and bright, itis probably in good condition. If it has a burn or rancid smell or is cloudy or dark in color, then trouble is on the way. If water appears in the bottom of the bottle after it has stood for a time the system should be drained. If the fluid is kept clean and operated at a reasonable temperature it will maintain its properties Operation in excess of 150° Fahrenheit will result in the system components wear and breakdown of the oil. (Most companies recommend 120° Fahrenheit tank temperatures). Hydraulic oil should have the following properties: 1. Proper Viscosity at startup and at operating temperature, VISCOSITY: A measure of fluidity (flow). The oil must have sufficient body to provide adequate sealing effect between working parts of valves and pump, but not enough to cause sluggish valve action, pump cavitation, or in extreme cases, resistance to flow. 2. Excellent oxidation stability — (will not form sludge). 3. Good protection against wear — (will lubricate). 4. Protection against rust 5. Rapid demulsibility — (will separate from water). 6. Good resistance to foaming. Approximately 70% of all service problems come directly from poor oil conditions, and the other 30% from mechanical faults or improper usage. DO NOT MIX OIL UNLESS YOU ARE SURE: Improper mixing of oils may cause reactions, which breaks down the oil and causes harmful effects. ‘There are a number of additives on the market which materially improve characteristics of the hydraulic oil, but proper use of additive agents requires specialized knowledge based on research. ‘Therefore, if additives are required the oil manufacturer should add them before the oil is sold — NOT IN THE FIELD.FACTORS EFFECTING OIL PERFORMANCE ARE: ‘A. — High Operating Temperature B. - Excessive Contamination C. = Presence of Water D.—Cold Weather High operation temperatures (In excess of 150 degrees Fahrenheit) thin down the oil and reduce its ability to lubricate and seal effectively, thus permitting greater wear and seepage. Also, the rate of oxidation is increased forming deposits of corrosive acids. For the best results, system temperature should reach 120 degrees Fahrenheit as an ideal maximum. It should never exceed 150 degrees Fahrenheit. Excessive contamination of the system (any contamination should be classed “excessive”) may cause the pump to score and seize, valves to leak or become blocked and restrict normal line of flow, and hasten oxidation of the system. All possible means should be taken to prevent the entry of any foreign matter. Water may be called a contaminant. Its presence in the atmosphere makes it impossible to prevent small quantities from entering the system. Precipitation will occur due to tank temperature change, Small quantities will not cause harm, although it is recommended to check the tank weekly, draining off excessive water. Foaming is caused by the slow release of small air bubbles entrapped in the oil. Presence of air in the hydraulic oil will cause irregular operation of the system because it changes oil from non-compressible to a compressible one. Pump volumetric efficiency is reduced; thus high pressure cannot be attained. Power consumption will need to be inereased to do the same work. Increased noise and pump damage as well as surging of the system will occur. ‘THE MOST COMMON CAUSE OF OIL FOAMING ARE: A Allowing oil level to get too low, permitting the pump to “suck ait”. B. Defective Valve Operations. c Leaks in the suction line: ‘To check this condition, run the pumps at moderate high speed, if itis too noisy, pour oil over each connection point from tank to pump. Ifa leaky joint is reached the noise will subside, as the oil poured in will act as a momentary seal. D. Poor conditions, or wrong grade of oil. The only solution is to drain and refill the system. In cold weather the oil may thicken to a point that flow will be retarded, causing cavitation. Special grades of low temperature oil may be used. Also, pre-heating by a number of means is satisfactory9poarosou syBra Ty “ax teomnenpuy yerpeet 10029) e STAY § MOAYI NOISWAAIG THALIND vor Lotz 007 1/18srinaatos NouYoRUgTT oNIDLAKaS ENaWAIND 03 VonEDHT 19 ENNEL PIED | WEN sees aOR [Hr i aE ir ase a ia ST 7 IR UT LPH Seas 7 OAT ‘won == sais | ass/or | on fon sos oymng sue we Sa a cu Es SPA 7977 Saag wa ih © © os aor oso. ae or owe, yy 09 so [ow | aw ery iy 01 TRS ER ss 0s 0S Soya PA7TRO. panos rs z 05 [stor pT Osu =D Pan = «st VWNO as | ats traps emneren | igang RUE | AFOSR —[z a a se srr woorenir [1 NPE war] eee Pomcmea| a Ss aes ane eRueO RR = == => pao |F SFINGAHS NOLLVORIT-¥ ONIOLAWAS INAWAINDALpearesoy SyuBry ITY “CUT somsnpuy yexpeoy 10029) AISWSSY AVMUIVIS 20012-002HPART BOOK VEHICLE SECTION Drawing # Assembly 1200-21002 STAIRWAY ASSEMBLY Item Part Number Description Quantity STAIRWAY WELDMENT 1 HANDRAIL WELDMENT 2 Loaderaft Industries Ltdpaarasoy siMBPE TTY “aLT seunsnpuy yex2peOT 10029) ANINGTAM (A¥AO CNW ISOH Fars "WIdO 12602-002H ®PART BOOK VEHICLE SECTION Industries, Ld: Drawing # Assembly, 1200-20927 OPER SIDE HOSE MUD GUARD. Item Part Number Description Quantity 1 H200-20927-001 ‘Top Bar 1 2 3 H200-20927-003 Bottom Bar 1 4 490301-001 Washer 3 5 401006-005 Bolt 4 6 401010-003 Nut 4 7 401012-003 Lock washer 4 Loadcraft Industries LtdPART BOOK VEHICLE SECTION Vndustries, Ltd. Drawing # Assembly 1H1200-20722-100 MUD FLAP INSTALLTION Trem Part Number Description Quantity 1 1800-83835 HRI Mud Flap 2 2 7127000065 Mud Flap Bracket 2 3 7129600033 Mud Flap Retainer 2 4 401008002 Bolt 8 5 401010-002 Nut 8 6 491011-002 Flatwasher 8 Loadcraft Industries Ltdpearosoy Sura Ty “QT semsmpty yez2peoT 20070) NOLLWTTVISNI a¥Lx aot oot-22z02-00zH (NADHS LON A3IA) WW38-; ‘sexoy, ‘ApergPART BOOK VEHICLE SECTION Wndustries, Ltd: Drawing # Assembly 1500-51471-201 Guyline Anchor Installation Item Part Number Description Quantity 1 2 80569 TURNBUCKLE REF a H500-51471-003 PLATE 2 4 H1300-51371-004 PLATE 2 3 1500-51375 PLATE 4 6 PLATE 2 7 11500-51471-007 PLATE 2 8 11500-51472 LUG 4 9 H1300-51471-009 PLATE 2 10 H300-51471-010 PLATE > Loadcraft Industries Ltdpoarosou suBRE ITY “QUT Sornsnpuy expe 70079) NOLLYTIWISNI YOHONY ANITAND ‘TO2-TZbTS-00SH 6PART BOOK /EHICLE SECTION Drawing # Assembly 11200-21040 Heater Duct Installation Item Part Number Description Quantity 1 BALL LOUVER ASSEMBLY 2 2 LOUVER ASSEMBLY 3 3 11800-83782 2” HEATER DUCTING 10° 4 1800-83783 HEATER COLLAR 1 3 11800-83784 DUCTING UNION 1 6 —400308-005 WIRE TIES, NYLON 20 7 11800-82385 AUXILIARY BLOWER 1 Loaderaft Industries Ltdpoaresey S1UBRE TYPART BOOK VEHICLE SECTION Vndustries, Ltd) Drawing # Assembly 11200-21043 Cab Side Console Assembly Item Part Number Description Quantity 1 11200-21043-001 SIDE COVER 1 2 H1200-21043-002 TOP COVER) 1 Loaderaft Industries Ltdpaaresoy SY6RY ITY “QU Somnsnpuy yexpeor 10020) KIGIASSY TIOSNOO AIS AYO eb012-002H RoPART BOOK VEHICLE SECTION Industries, Ltd: Drawing # Assembly tem _Pat Number Desrpton Quansy Loaderaft Industries LtdPART BOOK VEHICLE SECTION —— Tndustries, Ltd: Drawing # Assembly 11400-40160-205 Carrier Wiring 12V single C15, Item Part Number Description Quantity 46 400213-003 RING LUG 4 47 400208-001 RING TERMINAL i 48 400205-001 FLANGED SPADE TERMINAL 24 49 401186-001 PUSH ON TERMINAL 7 50 400206-007 BUTT CONNECTOR Is 51 400206-008 FLANGED SPADE TERMINAL 30 52 401186-003, PUSH ON TERMINAL 15 53 H800-80345 GROMMET 6 11800-80342 GROMMET 5 1800-83785 FRONT WIRING HARNESS i H1800-83786 REAR WIRING HARNESS, 1 57 H800-83787 HARNESS 1 58 H800-83788 HARNESS 1 59 60 BATTERY TERMINAL, Loadcraft Industries Ltdpeazosoy SIUBPE ITY “QUT SersMpUT yeXPeOT 10020) AZI- STO ‘ONTHLM WIN: $02-0910%-00FHPART BOOK JEHICLE SECTION Tndustries, Ltd: Drawing # Assembly 1200-21044 Cab Heater Plumbing Item Part Number Description Quantity 1 400533-003 HEATER HOSE 28 2 400532-004 HOSE CLAMP. 6 3 400098-010 HOSE BARB 2 4 400350-019 BUSHING, HEX 1 5 400331-076 NIPPLE, CLOSE 4 6 400726-007 GATE VALVE 2 7 400462-004 HOSE BARB 2paarasay syybry Iy “GUT sevsmpuy yyexopeoy 10020) ONIN Td WALWaAH €¥D ‘bbOT2-002H | 3U0N 33SPART BOOK VEHICLE SECTION Tndustries, Ltd Drawing # Assembly H200-20414-201 Seat Installation for 2004 Cab Item Part Number Description Quantity 1 11800-82942, SEAT 1 2 4200-21035 SEAT MOUNT 1 A 11800-82626 SEAT BELT 1 4 401006-007 BOLT, HEX HEAD 3/8"-16 UNC 6 5 401006-004 BOLT, HEX HEAD 3/8"-16 UNC 4 6 —— 401011-003 FLATWASHER, 3/8” 10 7 400710-005 HEX LOCKNUT, 3/8"-16 UNC 10 Loaderaft Industries LtdH200-20414-201 SEAT INSTALLATION FOR NEW CAB (©2007 Loadcraft Industries LTD. All Rights ReservedPART BOOK VEHICLE SECTION Tndustries, Ltd. Drawing # Assembly 11200-20417 Air Horn Installation Left Hand Drive Item Part Number Description Quantity 1 11200-20437 CHAIN, #8 STEEL SASH 1 2 1200-20436 HORN VALVE BRACKET 1 3 11800-82398.-201 AIR HORN KIT 1 4 400547-003 BUTTON CAPSCREW 2 5 400847-008, BUTTON CAPSCREW 2poarasoy SyUBTE TIY “QUT S¢snpUT yer9eOT 10020) AADAC GNYH Li3T - NOLLYTTVISNI NUOH UY 11¥02-002HPART BOOK VEHICLE SECTION Tndustries, LEd. Drawing # Assembly 11200-20418 Mirror Installation Item Part Number Description Quantity 1 1200-20432 BRACKET, MIRROR 1 2 H200-20406 SOCKET, MIRROR BRACKET 1 4 5 H200-20418-001 MIRROR 2 6 = ——_H200-20418-002 MIRROR MTG ASSEMBLY 1 7 8 9 400105-006 BOLT, HH CPS 2 10 400197-007 NUT, HEX 2 Loaderaft Industries LtdPART BOOK VEHICLE SECTION (bie Industries. Ltd. Drawing # Assembly 11200-20413-201 Steering Parts Installation, 2004 Slant, Left Hand Drive Item Part Number Description Quantity 1 11800-82936 STEERING WHEEL 1 2 1800-82935 UPPER STEERING COLUMN 1 3 1200-21108 STEERING COLUMN BRACKET 1 4 H1800-82644-201 STEERING COLUMN 1 3 #200-20413-001 COVER PLATE, 1 6 — 401006-002 CAPSCREW 4 8 401012-003 LOCKWASHER 4 9 400103-006 ‘CAPSCREW 2 10 400116-004 FLATWASHER ry 1 400294-005 LOCKNUT 2 12 H800-81631 HORN BUTTON KIT 1 Loadcraft Industries Ltdapearasoy siybry ITY “GUT Sepsnpuy yex9peoT 70020) (1) Att - S10 HS¥a avo 802-68402-002Hpoarosoy swuBna TY “QUT Serajsmpur yexpe0T 10070) (2) Azt-St-O HS¥a a¥D. 802-6£F02-002H “ e —— Tndustrles, Ltd. PART BOOK VEHICLE SECTION Drawing # Assembly 1500-52018-300 110° Mast Dual Raising Cylinder Installation With SD93-CB-147 Item Part Number Description Quantity 1 11500-52206 TUBE 1 2 PLATE 2 3 PLATE 2 4 PLATE 2 3 1500-52209 PLATE 1 6 1200-20076 TUBE 1 7 1500-52226 TUBE 1 8 ——_-H200-20075 TUBE 2 9 1200-20074 BAR 1 10800-81973, CYLINDER 2 11 HS00-51524-003 DRIVE PIN 2 12 400608-002 SAFETY PIN 2 13500-52208, PLATE 2 14 HS00-52018-214 PLATE 2 Is 16 H500-52018-216 LUG 4 Loadcraft Industries Ltdz YAGNFTAD ‘D1 6012-002 1 aAVTD GOW ALL 1S¢18-008H, z OOH dOLS NYY ONNITALS 9SL07-00CH t OND 6.8/4 XH “LAN Z1O-L6100% t 3 AAHSVAMDOT Z1O-L1100r b ONN 6.8/4 GVH XH “L108 010-1100 9 ‘OND Oc" XH “LAN £00-L6100P 91 «LY ATHSV MDOT 600-L1 100 9 ONN 0@-.7/ GVH XAH “L108 $00-€0100r 9 aWV'D ASO 100°69s00% 1 DNOWd XF ‘Nid WALLOD £00-02¢00r 1 ANN vl-.8/L XH “LAN £00-Z1c00r 1 ANN pls.8/L GVH XSH “L108 100-Ss 100% a ONN 81-.91/5 XH “LAN 900-6100 zu <9US YAHSVMNDOT £00-L1 100% za ONA 81-.91/5 GVH XH “L108 500-0100 z LHDIVULS O1f/Adld “WL €10-PS000r z 33 NNW FIV $00-6S000F 1 LHDIVLS ONRE-O WALaVaV 500-0600 1 SSO8 ONP-O -06 MORTA Z10-1L000r z LMDIVALS O1f/Adld “WaLAVaV L10-PS000r z SSOH ONTO .06 MONT 100-1o00r z AINRID «ONG ASOH $00-L0600r oe «1 3SOH $00-80600r 1 0009/000¢ SNIHSNa Ig0-PLs00 z “Sh OM/adld WALAVaY L10-9s000r t 0009/000¢ NISL 9c0-rLE00r z Sb OM /adid WALdvaV z10-95000r 8 AINRID ON ASOH £00-L0600r .09 '3SOH £00-80600r 1 AddIN ASOD 940-1500 i SUANOIA AWS “ANTVA 8828-008 an ONDITIIS “aNd 6828-00811 I MOAYISTY “LAVAS ZSO0E-008H 8 1 XIGWASSV WOAWISTL ¥e978-008H 1 LANDOS WOLLIA @seloosziL 9 1 ASANTTAD ONRITALS. 08-008H 1 al ATEWASSY NNITOV¥A Tr9e8-008H z % Vans TIVa esploosziz an WV NVALUE sssos-o0sHh 1 ATaWaSSY UID ONISALS ¥ssos-008H Tnuend Wondnosoc TOqWON Bed WT sony z “uyooig somo 28e4PSH-UORETTESUT £0e-£1¢02-007H aawaassy y Fumes NOLLOUS A TOIHAA MOOd Luvd p37 “sossasnpul