EMSCO Drwks. ELECTROHOIST V C&O PDF

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Continental Emsco Company

Electrohoist V
SECTION 1
GENERAL INFORMATION
INDEX
DESCRIPTION PAGE/DWG. NO.
GENERAL INFORMATION.................................................. 1.1
SPECIFICATIONS.................................................................. 1.3
PREFORMANCE CHART ..................................................... 1.4
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Electrohoist V
1.1
SECTION 1
GENERAL INFORMATION
The Electrohoist V is a new generation of Drawworks developed by Continental

Emsco Co. exclusively to work in deep waters where heavy risers and B.O.P.
loads will be encountered. It is designed to handle the heaviest loads visualized
in the foreseeable future. The Electrohoist V represents the ultimate in basic
mechanical simplicity and modern high tech controls to provide the Driller
positive control of the hook loads at all times while seated in a comfortable
climate controlled atmosphere.
As the name implies the “Electrohoist” performs only one function; that is to raise
and lower the various sizes and types of pipe used in the drilling of oil and gas
wells. It can perform this task more efficiently than conventional roller chain
driven drawworks that were designed to perform multiple tasks, such as
providing power for the rotary table, sandreel, and catheads. The Electrohoist V
consists of a 48” (1219 mm) diameter by 133” (3378 mm) drum equipped with
grooving for 2” (50.8 mm) wireline. The drumshaft is supported by grease
lubricated spherical roller bearings on each side of the drum. Each end of the
drumshaft is connected by means of flexible couplings to identical three speed
gearboxes. Each gearbox is powered by two GE-752 High Torque DC Motors.
The unit may be operated with any combination of the four motors.
In addition to hoisting the motors are also the primary braking source for the
Electrohoist V, by means of “Regenerative Braking”, replacing the familiar Eddy
Current Brakes, that are normally mounted at the end of the drum shaft.
Regenerative braking is very effective for slowing and stopping the traveling
block, but it can only hold a stationary load for a very short period of time or
severe damage to the drive motors will result. To compliment the regenerative
braking system there are two other braking systems, each of which is capable of
stopping the full rated load of the Electrohoist V.
Secondary braking is provided by two Eaton 36” diameter, 7 plate brake units
mounted on an outboard extension of the main shaft of the three speed gear
boxes. These brakes are air engaged and spring released. They are water
cooled and have the capability of serving as a main brake but because braking
action is by friction from parts rubbing together, more maintenance would be
more required than for regenerative braking.
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Electrohoist V
1.2
An Emsco Sure Stop Disc Brake system is installed on the drum flanges to serve
as a park function and emergency stop. The Park Brake is applied with hydraulic
pressure from the Hydraulic Power Unit (HPU) to caliper cylinders on the drum
rotors. It is actuated by a switch at the Drillers position. A joy stick variable
controller is also supplied to enable the system to assist in event of failure of the
primary or secondary systems. The “Emergency Brake” consists of two calipers
on each rotor that are spring applied and hydraulically released. They will apply
automatically in event of system hydraulic pressure loss or by a switch at the
Drillers position.
The gearboxes provide three possible speed ratios via internal pneumatic friction
plate type clutches. These clutches allow disengaging individual drive motors if
desired, but electronic controls insure that all engaged clutches are in the same
speed ratio. The electronic controls will also insure that shaft rotation is stopped
before shifting is allowed. If one of the drive motors should fail, operations may
continue at a reduced capacity with the three remaining motors.
The power supply and controls for the drawworks are being supplied by others;
refer to the supplier’s manual for information on these products.
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Electrohoist V
1.3
SPECIFICATIONS:
Skid Length ...........................................................................................40’ [12192]

Skid Width .......................................................................................... 15’-6” [4724]
Height ................................................................................................. 11’-6” [3505]
Weight ......................................................................... 270,000 Lbs. [122,472 Kg.]
Drum Diameter (Bare) ............................................................................ 48” [1219]
(Over grooving)........................................................ 49.13” [1248]
Drum length .......................................................................................... 133” [3378]
Drum Capacity (No. of wraps per layer) ............................................................ 53
Drum Speeds........................................................................................................ 3
Transmission Ratios, Low ............................................................................ 16.4:1
Intermediate............................................................... 9.27:1
High ........................................................................... 4.99:1
Input Rating ............................................................................5000 HP [3728 KW]
Wireline Diameter ..................................................................................... 2” [50.8]
HOISTING CAPACITY: (Pounds)
GEAR MOTOR 12 LINES 14 LINES 16 LINES

RPM
LOW 900 1,775,590 2,000,000 2,203,970
INTERMEDIATE 900 1,057,680 1,191,360 1,312,860
HIGH 900 569,350 641,300 706,710
Specifications;
4 GE-752 RB1 Shunt Wound Motors

2nd Layer 2” Wireline
95% Mechanical Efficiency
78.2% Tackle Efficiency W\12 Lines
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Electrohoist V
1.4
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2.0
SECTION 2
INSTALLATION
INDEX
PREPARATION................................................................................................. 2.1
LIFTING THE DRAWWORKS ........................................................................... 2.2
ALIGNMENT...................................................................................................... 2.3
AIR LINES ......................................................................................................... 2.3
WATER LINES .................................................................................................. 2.3
HYDRAULIC LINES .......................................................................................... 2.3
DRILLING LINE CLAMP.................................................................................... 2.4
SCHEMATIC LINE CONNECTIONS ................................................ 6204-0118-02
GENERAL DIMENSIONS................................................................. 6204-0320-10
MECHANICAL SCHEMATIC ............................................................ 6204-0400-02
WATER SYSTEM SCHEMATIC, EATON DISC BRAKE.................. 6204-0400-07
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2.1
INSTALLATION:
Refer to drawing 6204-0320-10
In preparation for installation of the drawworks, the installer should layout the
position of the drawworks on the substructure beams and check to insure they
are flat and level. This should be done with a precision instrument such as a
transit or laser level. Any areas off more than 1/8” (3 mm) should be corrected
by shims. The shims should be full width of the drawworks skid beams and not
less than 12” (300 mm) long. They should be seal welded all around to reduce
corrosion.
The location for the drawworks has no relation to the well center. Its location is
determined by the position of the fastline sheave in the derrick. The position of
the fastline sheave in relation to the well center or derrick legs can usually be
determined from the derrick drawings, which can be used as a reference point in
laying out the drawworks position. The ideal position for the drawworks is to align
the center of drum with the fastline sheave but this is not always possible. A rule
of thumb is that the fleet angle (the angle between a vertical line from the center
of the fastline sheave and a line from the fastline sheave to the drum flanges)
should not be more than 2º nor less than 1/4º. Some angle is desirable to assist
in turning back the wireline onto the next layer. This can be determined by the
following formulas;
For 1/4º; - Height of derrick (In feet) X .0563 = Minimum distance from
fastline sheave to drum flange (In inches).
Example: 160 ft. X .0563 = 9 Inches
For 2º; - Height of derrick X .416 = Maximum distance from fastline

sheave to drum flange.
Example: 160 ft. X .416 = 66.5 Inches
The setback distance (center of well to center of drum) is also determined by the
derrick and can be obtained from the derrick drawings.
Due to the mass of this drawworks, setting it in place can be made much easier
by welding stop blocks to the substructure beams to position the drawworks skid
as it is lowered into place.
2.2
LIFTING THE DRAWWORKS:
It is the Installers responsibility to provide lifting equipment that will safely handle
the approximately 270,000 pounds (122,472 kg.) weight of the drawworks. Also
spreader bars must be used to prevent damage to the equipment from
interference with the sling lines. When making the first lift, the drawworks should
be hoisted only enough to clear the foundation and allowed to set for a few
minutes to insure that all hoisting equipment is adequate.
! WARNING - DANGER !
Do not allow Personnel to walk under the drawworks while it is suspended in the
air or swing it over areas where people are likely to be, such as crew quarters or
offices. Swinging the load can induce higher stress in the hoisting equipment,
which may cause it to fail and drop the load.
After the drawworks has been set in position, use a feeler gauge to check for
clearance between the drawworks skid and the support beams at the
recommended support points marked on the General Dimension drawing. Any
clearance at these points must be filled in with shims. Because of corrosive
conditions, multi-layers of thin shims are not recommended.
The drawworks skid must be securely anchored to the support beams. The
recommended method is by bolting through the skid beam flanges on all three
skid runners with two (2) 1-1/2” (38 mm) diameter grade 5 galvanized bolts at the
recommended support points. It is preferred that the holes be drilled where
possible. The skid may also be welded to the support beams if desired, but only
in combination with the bolting, because flexing of the beam flanges will
sometimes crack the welds.
See General Dimension drawing 6204-0320-10 for recommended support points
2.3
INSTALLATION Cont’d:
ALIGNMENT:
After the tie-down bolts are securely tightened, the alignment between the
drumshaft, transmissions, Eaton brakes and drive motors must be checked. (See
maintenance section for procedure.) If bringing the shafts back into alignment
tolerance will require a large amount of shims under the equipment components,
it may be best to add shims under the drawworks skid.
AIR LINES:
Refer to Hydraulic & Pneumatic Diagram drawing 6204-0314-10, Air Piping

drawing 6204-0441-00 and Control Cabinet drawing for airline connection points.
Supply pressure should be regulated to 150 PSI.
WATER LINES:
SS SURE STOP DRUM BRAKE SYSTEM: Reference Dwg. No. 6204-0435-00
Brake cooling water lines must be connected at points marked on referenced

drawing. The system should be design to supply 60 GPM of cool fresh water at
approximately 75 PSI at the inlet on Side 1. The supply line should not be
connected in series with any other heat generating devise. The return line to the
reservoir should be of sufficient size to prevent back pressure against the
circulating system.
EATON DISC BRAKES: Reference Dwg. No. 6204-0446-00
Supply and return lines must be connected to the Eaton 736 WCB Brakes at both
ends of the Dwks. Skid. The supply for the two brakes should be from a balanced
parallel connection with a source of fresh water that meets the requirements
listed in the Eaton manual in section 5. To prevent back pressure and for more
reliable temperature monitoring, the return lines should be separate lines to the
reservoir. See section 5 for specifications.
HYDRAULIC LINES:
Refer to Hydraulic & Pneumatic Diagram Dwg. No. 6204-0314-10 and Piping
Installation Dwg. No. 6204-0410-00. Refer to SS SURE STOP DISC BRAKE
MANUAL in section 4 for recommendations on pipe size and cleaning
requirements.
2.4
INSTALLATION Cont’d:
DRILLING LINE CLAMP:
The drilling line clamp is located in the side no. 2 drum flange. Install the drilling
line by removing the clamp and inserting the drilling line through the hole in the
flange so that the end extends approximately 6” (150 mm) beyond the end of the
clamp. Reinstall clamp and tighten nuts to 640 ft. lb. dry or 480 ft. lb. lubricated.
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Electrohoist V
3.0
SECTION 3
OPERATION
INDEX
DESCRIPTION PAGE NO.
GENERAL INFORMATION ............................................................... 3.1
REGENERATIVE BRAKING ............................................................. 3.1
EATON 736 WCB BRAKES .............................................................. 3.1
SS SURE STOP DISC PARK BRAKE............................................... 3.1
EMERGENCY DISC BRAKE............................................................. 3.2
OPERATING SPECIFICATIONS....................................................... 3.4
HOISTING CAPACITY ...................................................................... 3.4
LOWERING CAPACITY .................................................................... 3.5
DRIVE MOTOR FAILURE ................................................................. 3.5
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Electrohoist V
3.1
SECTION 3
OPERATION
The power supply and controls for this order are being designed and furnished by
Companies other than Continental Emsco, therefore these instructions will be
limited to basic operations. Refer to the respective manufacturer's manual for
detailed operational procedures.
The Electrohoist V has no drum clutch to disconnect the drum from the drive
transmissions. This is necessary in order to use the drive motors as a source of
braking, but it also improves the efficiency of the drawworks. It is designed to use
electric motor power to lower the traveling block as well as hoisting. The motors
will bring the drum up to top speed faster than free-fall when lowering the empty
block or a light load and the regenerative braking feature will control the rate of
decent within safe limits for heavy loads, then bring the drum to a smooth
controlled stop.
REGENERATIVE BRAKING:
Regenerative braking is the primary braking system and should be used for
slowing and stopping the drum as much as possible because there are no
rubbing friction parts to wear out. This will save on replacement costs for brake
friction disc and wear plates. The regenerative system can only hold a stationary
load for a very short time. The drawworks control system will monitor the load
versus time stopped and automatically apply the parking brake at the appropriate
time.
EATON 736 WCB BRAKES:
The Eaton 736 WCB brakes are the secondary braking source for the
Electrohoist V. They should be used to assist the Regenerative Braking when
needed and to hold the load stationary momentarily. They have adequate cooling
capacity to lower loads alone, but since they are friction brakes it is more
economical to use the Regenerative Braking where possible. To obtain maximum
rated braking capacity the brake must be supplied with a minimum of 135 PSI air
pressure.
SS SURE STOP DISC PARK BRAKE:
The disc park brake is a hydraulically applied, spring release caliper brake
system. Its primary function is to provide a park function for the Drawworks when
it is expected to be inactive for periods of up to three hours. It uses an electrical
switch to actuate two solenoid valves that will apply full pressure to the caliper
cylinders.
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Electrohoist V
3.2
OPERATION Cont’d:
SS SURE STOP DISC PARK BRAKE Cont’d:
Monitor the console gages to insure that 1350 PSI supply is available for both
Side 1 and Side 2, and that water temperature is within specifications. Main drive
motors will be disabled when park brake is applied.
The Park Brake may also be used by crown and floor protection, or other safety
devises.
SS SURE STOP DISC SERVICE BRAKE:
The same calipers that are used for the park function can be used as a service
brake with limited capabilities. It has ample capacity to hold the rated Dwks. hook
load but does not have adequate heat rejection capacity to serve as a main
brake. It can be used to assist the regenerative braking or the Eaton brakes if
one of these systems is unavailable.
Variable control is obtained through a Joy Stick controller which supplies signal
current to two variable pressure hydraulic valves that output 0 to 1350 PSI to the
caliper cylinders. Brake torque is proportional to applied pressure on the calipers.
Applied pressure may be read on the console gages.
EMERGENCY DISC BRAKE:
The Emergency Disc Brake consist of two spring applied, hydraulically released
calipers on each rotor. They will apply automatically in event of hydraulic system
pressure failure. Driller should frequently observe the System Pressure gauge to
insure that system pressure is up to specifications to prevent brake pads from
dragging on the rotors. The emergency brake can be engaged by pushing the
“Emergency Stop” button or by various safety circuits, which are beyond the
range of their set points.
Interlocks are provided to guard against accidental release of the emergency

brake until control of the park brake has been demonstrated. Each time the
emergency brake is actuated, whether by pressing the emergency stop switch,
safety functions, or shut down of the HPU, the park brake must be engaged
before the emergency brake will release.
The Emergency Brake should be used to Park the traveling block load anytime
the Drillers position is unattended. If the Dwks. is expected to be inactive for
three hours or more, the Emergency Brake should be applied and the HPU shut
down. Main drive motors will be disabled when emergency brake is applied.
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Electrohoist V
3.3
OPERATION Cont’d:
The spring calipers are designed to hold more than the single line pull rating of
the drawworks, but they do not have as much stopping power as the parking
brake because the parking brake is designed to stop full hoist capacity on only
one rotor. This is to provide a margin of safety in the event the hydraulic circuit
for one side should fail. If the parking brake is applied, no additional stopping
power is gained by applying the emergency brake, because the braking torque is
limited in this condition to prevent overstressing the drumshaft.
The Park or Service Brake should not be engaged simultaneously with the
Emergency Brake for extended periods because there is danger of washing out
the relief valve (46) (dwg. 6204-0314-10) that limits pressure in this mode.
It is assumed that the Dwks. controls will provide adequate alarms and
monitoring systems to track the pressures, temperatures and other vital
information necessary for operation and safety of the equipment. While operating
the Electrohoist V the console gages should be monitored frequently to insure
that all operating parameters are in acceptable range.
Before attaching the drilling line to the drum, the Drillers should operate the
Dwks. enough to familiarize themselves with the controls and understand the
operating characteristics of the equipment.
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Electrohoist V
3.4
OPERATION Cont’d:
OPERATING SPECIFICATIONS:
While operating the Electrohoist V the console gages should be monitored

frequently to insure that all operating specifications are in acceptable range.
OPERATING SPECIFICATIONS
FUNCTION MINIMUM NORMAL MAXIMUM
Hydraulic System Pressure 1525 1550 1575
Parking Brake (Engaged) 1325 1350 1375
Emergency Brake (Released) 1525 1550 1575
Emergency Brake (Engaged) 0 0 0
Drawworks Air Pressure 145 150 155
Trans. Clutch Air Pressure 135 140 145
Transmission Oil Pressure 15 30 80
Drum Brake Cooling Water PSI. 70 75 80
Water Inlet Temp. (deg. F.) 100
Water Outlet Temp. (deg. F.) 165
Eaton 736 WCB Brake Air Press. 130 135 140
Water Pressure 40
Water Inlet Temp. (deg. F.) 45 100
Water Outlet Temp. (deg F.) 150*
* Fresh Water, See section 5 for other cooling media.
HOISTING CAPACITY:
The Drawworks capacity for hoisting a load is shown in the following chart. The
controls supplier may elect to make the gear selection automatically, but in any
case it is the Drillers responsibility to insure that the values shown in the chart
are not exceeded. The capacities and gear selection for lowering is the same as
for hoisting. Do not exceed these values even though the Dwks. may be able to
hoist more it would place an overload condition on the equipment and the braking
system may not be able to properly retard the load while lowering.
The chart below shows the maximum hook load capacity of the drawworks with
different number of lines strung to the traveling block. Hoisting capacity may be
limited by the wire rope strength. Refer to American Petroleum Institute (API)
specification Spec 9A: Wire Rope and RP 9B Recommended Practice on Wire
Rope. Hoisting capacity may also be limited by other equipment in the hoisting
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Electrohoist V
3.5
OPERATION Cont’d:
HOISTING CAPACITY Cont’d:
system. It is the Operators responsibility to verify the rating and condition of all
components of the system.
HOISTING CAPACITY: (Pounds)
TRANSMISSION MOTOR 12 LINES 14 LINES 16 LINES

GEAR RPM
LOW 900 1,775,590 2,000,000 2,203,970
INTERMEDIATE 900 1,057,680 1,191,360 1,312,860
HIGH 900 569,350 641,300 706,710
LOWERING CAPACITY:
Lowering capacity is the same as hoisting. The same transmission speed should
be used to lower a load as for hoisting. The load should not be allowed to fall
faster that the same load could be hoisted.
DRIVE MOTOR FAILURE:
In event of one drive motor failure the drawworks can be operated at 75% of
rated capacity on three motors. With two motors or one transmission inoperable
the drawworks rating would be reduced to 50%.
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Electrohoist V S/N 10
4.0
SECTION 4
SURE STOP DISC BRAKE SYSTEM
INDEX
DRAWINGS DWG. NUMBER

Operation & Maintenance Manual .......................................... FS-110EH-V10
Hydraulic & Pneumatic Diagram............................................. 6204-0314-10
Disc brake installation............................................................. 6204-0345-10
Hydraulic piping installation .................................................... 6204-0410-00
Service cylinder assembly ...................................................... 6212-1819-00
Emergency cylinder assembly ................................................ 6212-1832-01
Hydraulic Power Unit, General Dimensions............................ 6212-2124-98
VENDOR DATA:
BERENDSEN ACCUMULATORS
FAIREY ARLON FILTERS
SUN CARTRIDGE VALVES
MAXIMATOR “S” SERIES PUMPS
SAUER SUNDSTRAND SERIES L PUMPS
F S-110EHV10
Rev. 11/98
Continental Emsco Co.
Type SS Sure Stop
Disc Brake System
Operation & Maintenance
INDEX
PREFACE .................................................................................... 1
SECTION I
GENERAL INFORMATION........................................................... 3
JOB INFORMATION..................................................................... 4
SECTION II
ADJUSTMENT SPECIFICATIONS............................................... 6
INTRODUCTION .......................................................................... 10
BRAKE ASSEMBLY .................................................................... 11
SYSTEM START UP .................................................................... 11
HYDRAULIC POWER UNIT ......................................................... 12
DISC BRAKE CONTROLS .......................................................... 15
SECTION IV
MAINTENANCE .......................................................................... 20
ADJUSTMENTS ........................................................................... 21
FILTERS ...................................................................................... 22
SERVICE BRAKE ASSEMBLY .................................................... 24
PAD REPLACEMENT. ................................................................ 25
EMERGENCY BRAKE ................................................................. 26
LUBRICATION REQUIREMENTS................................................ 30
MAINTENANCE SCHEDULE ...................................................... 31
TROUBLE SHOOTING CHART .................................................. 33
PREFACE
This manual is provided for guidance of those who wish to install, repair,
maintain, or adjust the Emsco equipment covered herein. This information has
been prepared with a basic viewpoint to give accurate and concise data needed
to perform minor adjustments as well as major overhauls.
This information is not elementary, as it is intended for operators and servicemen

who are familiar with drilling equipment in general. It is not intended, nor would it
be possible in such limited space, to cover every possible condition which may
be encountered. Always use good, sound mechanical practices and safety
precautions.
All specifications are in accordance with Engineering designs and should be

adhered to in all repairs. Operation and maintenance information on equipment
other than Emsco's is taken in part from the various manufacturers' manuals. If
the equipment manufacturers issue later instructions, or in the event of conflict,
the manufacturer's information will take precedence over that shown in this
manual, unless specifically stated otherwise.
Refer to the General Lubrication Bulletin for approved lubricants. If any

discrepancy exists between the recommendations in this manual and the
General Lubrication Bulletin, those in the Lubrication Bulletin will take
precedence.
Specifications and components covered are for standard equipment current at

the time this manual was approved for printing. Continental Emsco Company
reserves the right to discontinue models at any time, or change specifications or
design of any model without notice and without incurring any obligation.
PAGE 1
GENERAL INFORMATION
This manual is a supplement to the standard Drawworks Operation and

Maintenance Manual and deals with the hydraulic disc brakes provided on this
Drawworks.
This manual contains a detailed description of the Emsco Type SS Sure Stop
Disc Brake Drum Control System. This manual also contains instructions and
information necessary for the proper operation and maintenance of the brake
system.
The drawworks model, type and serial number along with a list of the
applicable drawings and documents are provided with this manual. Always
include model and serial number of the equipment when making inquiries or
when ordering spare parts.
EXERCISE EXTREME SAFETY PRECAUTIONS AND EMPLOY SOUND

MECHANICAL PRACTICES WHEN PERFORMING INSPECTIONS,
MAINTENANCE REPAIRS, OR WHEN OPERATING THE EQUIPMENT. IT
SHOULD BE OPERATED ONLY UNDER CONDITIONS FOR WHICH IT WAS
INTENDED.
PAGE 3
ADJUSTMENT SPECIFICATIONS
Specifications for adjustments and settings of various components in the brake

systems will vary dependent upon certain drawworks parameters. Parameters
and adjustment specifications for this drawworks are given below. If parameters
change, contact Continental Emsco Company for appropriate adjustment
specifications.
Parameters:
Drawworks Model: ELECTROHOIST V
Type: ______________________
S/N: _________10____________
Main Drum Grooving: ___2”___________
The hoist capacities shown on the hoist capacity plate of this drawworks are
based on a maximum fast line pull of 189,215 pounds with a 2’’ diameter wire line
on the second layer of the drum. The capacities shown include an allowance for
wire line efficiency per API RP 9B: Recommended Practice on Wire Rope. This
is the rating of the drawworks excluding wire rope. Actual hoist load capacity
may be limited by the wire rope. The wire rope hoisting capacity depends on
wire rope strength, number of lines strung, tackle efficiency, required safety
factor and equipment condition. Please consult A.P.I. specification for wire rope,
Spec 9A, and recommended practice, RP 9B.
PAGE 6
ADJUSTMENT SPECIFICATIONS (CONT.)
COMPONENT SETTINGS
(All hydraulic component settings must be Set within 25 PSI (1.7 BAR). All
pneumatic component settings must be set within 5 PSI (0.3 BAR).
HYDRAULIC POWER UNIT
- ACCUMULATOR PRECHARGE
1. Parking Brake Accumulators (11) ........................................675 PSI(46.5 BAR)
2. Service Brake Accumulators (15) ........................................700 PSI(48.3 BAR)
- PUMP SETTINGS (3)

3. Pressure Compensator Setting........................................ 1550 PSI(106.9 BAR)
4. Volume Stop (at 1800 RPM)...................................................7 GPM(26.5 L/M)
- BACK UP PUMP (4)

5. Air Pressure Regulator Setting (1)...........................................43 PSI(3.0 BAR)
(Adjust the air pressure regulator ...................................................(approximately)
to maintain 1400 PSI system pressure
when the electrical driven hydraulic
pump is not operating).
- OVER PRESSURE RELIEF VALVE (7)

6. Relief Pressure Setting........................................................ 1700 PSI(117 BAR)
- PRESSURE REDUCING AND REGULATING VALVES (10)
7. Parking Brake Supply Pressure Setting.................................1350 PSI(93 BAR)

8. Service Brake Supply Pressure Setting.............................. 1400 PSI(96.5 BAR)
BRAKE CONTROL CABINET
- PRESSURE REDUCING AND RELAY MANIFOLD ASSY. (43)

9. Pressure Relief Valve Setting (46)........................................575 PSI(39.6 BAR)
- EMERGENCY BRAKE INTERLOCK

10.Sequence Valve Setting .............................................................................. N/A
- PARKING BRAKE INTERLOCK

11. ................................................................................................................... N/A
PAGE 7
GAUGE READINGS
(Gauge descriptions given below in capital letters match those used in this
manual and on the actual gauge labels.)
- SUPPLY PRESSURES
12. SYSTEM PRESS........................................................... 1550 PSI(106.9 BAR)
BRAKE SUPPLY
13. SIDE 1 (Main Brake)......................................................... 1400 PSI(96.5 BAR)
14. SIDE 2 (Main Brake)......................................................... 1400 PSI(96.5 BAR)
PARK BRAKE SUPPLY

15. SIDE 1 .................................................................................1350 PSI(93 BAR)
16. SIDE 2 .................................................................................1350 PSI(93 BAR)
DRILLER'S CONSOLE
- SUPPLY PRESSURES (P/I 41)
17. HYDRAULIC SYSTEM (PT1) ........................................ 1550 PSI(106.9 BAR)
- EMERGENCY BRAKE (PT2)

18A. EMERGENCY BRAKE (Released) .............................. 1550 PSI(106.9 BAR)
18B. EMERGENCY BRAKE (Applied)...............................................0 PSI(0 BAR)
- DRUM BRAKE
19A. SIDE 1 (Brakes Released) (PT6) ..............................................0 PSI(0 BAR)
19B. SIDE 1 (Parking Brake Applied) (PT6) ..............................1350 PSI(93 BAR)
19C. SIDE 1 (Main Brake Range) (PT6)............................. 0-1350 PSI(0-93 BAR)
19D. SIDE 1 (Main Brake Fully Applied) (PT6).........................1350 PSI(93 BAR)
20A. SIDE 2 (Brakes Released) (PT5) ...............................................0 PSI(0BAR)

20B. SIDE 2 (Parking Brake Applied) (PT5) ..............................1350 PSI(93 BAR)
20C. SIDE 2 (Main Brake Range) (PT5)............................. 0-1350 PSI(0-93 BAR)

20D. SIDE 2 (Main Brake Fully Applied) (PT5)..........................1350 PSI(93 BAR)
PAGE 8
MAIN DRUM BRAKE CALIPER ASSEMBLY

- PAD
21. Part Number .......................................................................... 7602-1370-40
22. Thickness (New)................................................................ 1.00Inch(25 mm)
23. Minimum Thickness (Before Pad Replacement)............. .500 Inch(12.7 mm)
- STANDOFF (Total Gap Between Disc and Both Pads)

24. Adjusted........................................................................... .060 Inch(1.5 mm)
25. Maximum (Before Adjustment) ........................................ .120 Inch(4.6 mm)
EMERGENCY BRAKE CALIPER ASSEMBLY
- PAD
26. Part Number ............................................................................ 7602-1370-41
27. Thickness (New)................................................................ 1.00 Inch(25 mm)

28. Minimum Thickness (Before Pad Replacement).............. .500 Inch(12.7 mm)
- EMERGENCY BRAKE CYLINDER
29. Maximum extension of Emergency Brake Cylinder

Adjusting Eye (Before Pad Replacement) ........................ 1.25 Inch (32 mm)
- STANDOFF (Total Gap Between Disc and Both Pads)
30. Adjusted........................................................................... .030 Inch (0.8 mm)

31. Maximum (Before Adjustment) ........................................ .060 Inch (1.5 mm)
BRAKE DISC TOLERANCES
32. Minimum Thickness (At Thinnest Point Before

Replacement) ............................................................... 2.625 Inch(66.7 mm)
33. Maximum Groove Depth (Before Replacement)............... .060 Inch(1.5 mm)
PAGE 9
INTRODUCTION
The Drum Brake consists of a pair of drum mounted discs, caliper assemblies,
hydraulic actuator cylinders, emergency actuator cylinders, driller's controls,
hydraulic power unit, and associated valves and piping. The primary function of
this brake is to act as a Park Brake and an Emergency Stop Brake. It can be
used to assist or in lieu of the other braking systems, f the other braking systems
are unavailable.
In the following description components are identified by name and a symbol,

(xx) , where xx is a number. The (xx) symbol is the identification symbol used
for the component on the hydraulic/pneumatic schematic drawing of the brake
system. Referring to the schematic and assembly drawings while reading the
description will give the reader a better understanding of the system.
HYDRAULIC POWER UNIT REF: 6204-0314-30
The hydraulic power unit provides the hydraulic power for operating the drum
parking and emergency brakes.
The primary source of power on the power unit is an electric motor driven,
variable displacement, pressure compensated axial piston pump (3). The
pressure compensator on this pump is adjusted to provide system pressure. A
volume stop on the pump is set to limit horsepower demand of the pump to the
motor output. An air driven hydraulic pump (4) provides backup system pressure.
Each pump discharges through a check valve (6) and into a common high
pressure filter (8). A pressure gauge (9) on the power unit labeled SYS PRESS
measures system pressure.
A manifold on the power unit contains an over pressure relief valve (7) and two
pressure reducing and regulating valves (10). The pressure relief valve provides
system protection in the case of over pressure. The pressure reducing valves
supply the service and parking brake supply circuits of the power unit.
After the pressure is reduced in the manifold, the service brake supply circuit
splits to supply two 5 gallon bladder type hydraulic accumulators (15). These
store hydraulic fluid for the rotary and Driller's side service brake circuits. Two
gauges on the power unit measure rotary side brake supply pressure and Driller's
side brake supply pressures, respectively.
The other two one gallon accumulators (11) mounted on the power unit are
supplied by the other pressure reducing and regulating valve (10) and store
hydraulic fluid for the rotary and Driller's side parking brake circuits. Gauges on
the power unit measure these two pressures, respectively.
A twenty gallon reservoir (2) stores hydraulic fluid for the system. The reservoir
has two suction strainers (12), filtered filler cap, thermometer, filtered breather,
drain, and level sight gauge. The power unit has two return line filters (14) to
prevent contamination from fluid returning to the reservoir. Two lines return fluid
to the power unit, one for the main (service) and parking brake and the other for
the emergency brake.
PAGE 10
BRAKE ASSEMBLY
- Brake Disc
A water cooled disc is attached to each end of the wireline drum. These discs
have hard faced braking surfaces and are mounted where the band brake
flanges would normally be located. Cooling water is circulated through the discs
from side 1 of the drumshaft assembly.
- Caliper Support
A removable caliper support is installed under each disc and anchored to the
drawworks frame. This support provides the support structure for both the
service and emergency brake caliper assemblies.
- Service Brake Caliper Assembly
Service Brake Caliper Assemblies are mounted on the support. Replaceable

friction pads are bolted to the brake shoes on either side of the caliper assembly.
The calipers are hydraulically actuated by use of the Disc Brake Control
Assembly. The Disc Brake Control Assembly controls the amount of pressure
applied to the hydraulic cylinders (33) and the resulting braking force. The
Service Brake Caliper assemblies also function as the parking brake.
- Emergency Brake Caliper Assembly
Two Emergency Brake Caliper Assemblies with replaceable friction pads are
mounted on each support. The emergency cylinders (32) are spring applied and
hydraulically retracted. In case of loss of system hydraulic pressure the brake
will automatically apply. The emergency brake is also operated from the Driller’s
Console.
SYSTEM START-UP
The hydraulic system must be clean prior to start-up or the service life of the
hydraulic pump and other components will be significantly reduced.
Contamination could also lead to failure of the brake system. CARE MUST BE
TAKEN DURING COMPLETION OF THE HYDRAULIC PIPING TO AVOID
INTRODUCING CONTAMINATION INTO THE SYSTEM.
- PIPING INSTALLATION
DO NOT USE TEFLON TAPE ON HYDRAULIC PIPING. Use Loctite brand

Hydraulic Sealant or equal.
GALVANIZED PIPE SHOULD NOT BE USED FOR PIPING THE HYDRAULIC

SYSTEM since this can be a source of contamination.
ALL PIPE, TUBING, AND HOSE ASSEMBLIES MUST BE CLEANED PRIOR

TO INSTALLATION to avoid introducing contamination into the system.
PAGE 11
- System Flushing
After the installation of all piping the individual components and piping should be flushed
with filtered hydraulic fluid. The components should then be assembled and the entire
assemble flushed in both directions. Use a hydraulic pump other than the main pump
on the power unit for flushing the system. Use the same type of hydraulic fluid for
flushing the system that will be used for operation. Fluid used for flushing should pass
through a 25 micron absolute filter before entering the component or lines being
flushed.
- Bleeding The System
After the system is flushed all piping should be filled with new, clean, hydraulic fluid prior
to starting the hydraulic power unit.
Each service brake cylinder must be filled with fluid. All lines must be filled with fluid.
Bleed the air from all hydraulic lines. Air in the hydraulic lines will adversely affect brake
performance and the hydraulic pump.
- STARTING THE POWER UNIT
Observe all pressure gauges during start-up to confirm proper operating pressures are
obtained. Replenish any oil loss in the reservoir. Refer to the Adjustment
Specifications at the beginning of this manual for specifics of power unit performance.
- Adjustment
The hydraulic power unit components are factory set to the Adjustment Specifications
given at the beginning of this manual. Routine adjustment should not be required
unless one of the system supply pressures is more than 25 PSI from the Adjustment
Specification. Always examine other probable causes of system problems before
adjusting power unit components. Whenever a pressure reading does not comply with
the Adjustment Specifications compare readings with the gauges on the driller's console
to determine if a gauge is faulty.
! CAUTION !
DO NOT USE THE BRAKES WHILE MAKING ANY ADJUSTMENTS OR

SERVICING THE HYDRAULIC POWER UNIT. SET THE LOAD IN THE
SLIPS AND APPLY THE EMERGENCY BRAKE BEFORE ADJUSTING
THE POWER UNIT.
Refer to the diagram of the hydraulic power unit when making any adjustments. The
hydraulic power unit is provided with a number of isolation valves that allow working on
individual components. Always be certain a component or line contains no residual
hydraulic pressure before working on it. The parts book for the power unit provides
details for servicing many of the components.
PAGE 12
! CAUTION !
THIS IS A CLOSED CENTER HYDRAULIC SYSTEM. MANY COMPONENTS ARE

INTERNALLY PRESSURIZED, EVEN WHEN THE POWER UNIT IS SHUT OFF.
ALWAYS RELIEVE THE PRESSURE FROM A COMPONENT BEFORE SERVICING
IT.
- SYSTEM PRESSURE
If system pressure is too high, check the pressure compensator on the hydraulic pump
and check the air pressure regulator for the air driven back-up pump. The output
pressure of the air driven hydraulic pump is directly proportional to the air pressure
applied to the pump.
If system pressure is too low check the pump pressure compensator setting and the
setting of the system over pressure relief valve.(7) As the pump wears it will not provide
full system pressure and should be serviced or replaced.
- SUPPLY PRESSURES
If the service or parking brake supply pressure is too high or too low first check the
system pressure. If system pressure is correct check the pressure reducing and
regulating valve (10) and adjust if required.
During normal operation the isolation valves for the accumulator drains (AD1 through
AD4) should be shut off and the drain line plugged. The isolation valves to the pressure
gauges and accumulators should be open. The shut off valves on either side of both
pumps should be open.
- ACCUMULATORS
The precharge of the hydraulic accumulators (11) & (15) should be checked as indicated
in the maintenance schedule. The precharge should also be checked if the brake
response is slower than normal. If hydraulic fluid is evident at the bladder valve when
checking the precharge, the bladder should be replaced. If hydraulic fluid is evident
anywhere else on the accumulator the seals should be inspected. Always discharge the
hydraulic fluid pressure and gas precharge before servicing an accumulator.
An accumulator charging hose assembly with a pressure gauge is supplied with the
power unit. Use the assembly to check accumulator precharge using the connection on
the top of the accumulator. Adjust the precharge if it is more than 25 PSI from the
Adjustment Specification. Check the precharge when the accumulator is at the ambient
temperature of the power unit. Use only dry nitrogen gas for charging the accumulator.
- PRESSURE LINE FILTER
Replace the element in the pressure line filter (8) when indicated by the indicator on the
side of the filter. The filter must have flow passing through it when the indicator is
inspected. Replace the filter element at the recommended service interval even if there
is no indication it needs to be replaced. The power unit must be shut off and the
pressure line discharged before the filter can be serviced.
PAGE 13
- RETURN LINE FILTERS
Replace the element in either return line filter (14) when indicated by the indicator on the
side of the filter. The filter must have fluid flowing through it when the indicator is
inspected. Replace the filter element at the recommended service interval even if there
is no indication it needs to be replaced.
- HYDRAULIC RESERVOIR
Maintain the fluid level in the hydraulic reservoir at mid-level on the sight level gauge on
the side of the reservoir. Temperature of the hydraulic fluid should not exceed the
ambient temperature around the power unit by more than 60 degrees Fahrenheit. IF
RESERVOIR TEMPERATURE IS TOO HIGH, DETERMINE THE CAUSE AND
CORRECT.
PAGE 14
DISC BRAKE CONTROLS
All of the controls necessary for operating the disc brake are mounted on the Driller's
console. They consist of a "Joy Stick" for control of the four proportional control valves
(48) to apply and release the service brake, "Parking Brake" off-on push-button valve,
"Emergency Stop" .push button valve and Pressure indicators to monitor the critical
hydraulic functions.
DISC BRAKE OPERATION:
The main (service) drum brake is controlled by operation of the Joy Stick handle.
Movement of the Joy Stick handle sends a variable electrical signal to four
electro/hydraulic valves (48) located in the Brake Control Cabinet which produce a
variable 1350 to 0 PSI (93 bar) output to the Side 1 and side 2 service calipers (33). To
prevent accidental release of the service brake, the Parking Brake should be applied
before the Driller leaves his chair. For details on the operation of the Joystick see the
Control Console Manufacturers manual.
PARKING BRAKE:
A detented, two position switch will de-energize solenoid SOV2 and SOV3 (44). The
hydraulic valves will shift to transfer supply pressure from the proportional control valves
to the pressure reducing valve (10) and accumulators (11) which will supply a constant
1350 PSI (93 bar) to the service calipers via lines 36 and 37 to provide a dwks. park
function
The parking brake will be set automatically in event of electrical power loss or loss of
power to the amplifier cards for the proportional control valves (48) due to the normally
closed solenoid valve (44) being spring returned to the closed position.
To release the parking brake, The joy stick must be in the brake applied position. This
two step operation insures that the Driller will have the load under control with the
service brake before the parking brake is released. Pulling the “Parking Brake” button up
will not release the brake unless the required hydraulic pressure has been established.
The parking brake may also be actuated by a signal from the auxiliary brake monitor,
crown saver or kinetic energy monitor or other Customer installed devices. Refer to
manufacture's recommendations for resetting these devices.
The Parking Brake should not be used to keep a load suspended above the drill floor for
more than three hours. If the Rig is to remain idle longer than three hours the Emergency
Brake should be set and the Hydraulic Power Unit shutdown.
Page 15
EMERGENCY BRAKE:
Hydraulic system pressure holds the emergency brake, spring loaded caliper cylinders
(32) in the retracted (off) position. Loss of system pressure allows the spring loaded
cylinders to extend and apply the emergency brake.
Pushing the detented, two position push button switch sets the emergency dwks. brake.
by releasing the hydraulic pressure on the emergency brake cylinders (32) through
solenoid valves SOV1A and SOV1B (49) allowing fluid to drain back to the tank through
line [52]. The emergency brake status is indicated by the Emergency Brake pressure
gauge (41). A gauge reading of 0 indicates “Brake On”. With “Brake Off” the gauge
should read 1550 PSI.
When the Emergency Brake is actuated, pressure is bleed off of two "pilot to close"
check valves (45) causing them to open and allow pressure from the service calipers to
pass over a relief valve (46) limiting the pressure applied to the service calipers to 575
PSI (39.6 bar). The purpose of this function is to limit the combined braking forces of the
emergency and service brakes so as not to exceed the torsional rating of the drumshaft.
No braking force is gained by applying both brakes simultaneously.
The HPU should not be left running for long periods with the emergency and parking
brakes applied as the relief valve (46) may be washed out due to the high velocity of fluid
passing over it. If the Rig is to remain idle for more than three hours the emergency
brake should be applied and the Hydraulic Power Unit shut down. For periods of less
than three hours the Park Brake should be used, provided the Driller remains in the
immediate vicinity of the controls. “Park Brake” must be in the applied position and
To release the emergency brake at least 500 PSI (34.5bar) must be applied to the
service calipers with the Joy Stick or Park Brake to insure that control pressure has been
established for the service calipers. This pressure is indicated on the SIDE 1 and SIDE 2
DRUM BRAKE pressure gauges on the Driller's console. With the Emergency stop
Switch pulled up, solenoid valves SOV1A & SOV1B (49) will shift to apply system
pressure to the Emergency Calipers (32) retracting them to the off position. System
pressure will also be reapplied to the pilot to close check valves (45), restoring regulated
pressure to the service calipers.
The emergency brake will be set automatically in event of loss of hydraulic pressure as
the emergency brake caliper cylinders are held open by hydraulic pressure and closed
by spring force.
The accumulators on the HPU hold enough fluid for several applications of the service or
parking brake but the fluid will be quickly lost down to 575 PSI through relief valve (46)
after the emergency brake actuates.
PAGE 16
SYSTEM READINESS
After any shutdown for maintenance or repair and prior to use of the drum brakes the
following system check should be performed. Read the operating instructions for a
detailed description of brake operation before proceeding. If any gauge readings do not
match the Adjustment Specifications refer to the appropriate area of the maintenance
section of this manual.
This procedure only checks hydraulic system operation. The Service and Emergency
Brake Caliper Assemblies must be observed during application to confirm operation.
Proper adjustment of the service and emergency caliper assemblies is covered
separately in this manual. See the instructions for System Start-up if any of the hydraulic
lines have been disconnected or any hydraulic fluid has been drained from the system.
Refer to the maintenance section for a description of hydraulic power unit maintenance,
including hydraulic fluid level and filter maintenance.
! CAUTION !
DURING THIS PROCEDURE THE TWO BRAKING SYSTEMS ON THE DRUM

(SERVICE AND EMERGENCY) WILL BE RELEASED, ALLOWING THE DRUM-
SHAFT TO ROTATE FREELY. ENSURE THAT THE LOAD IS SET IN THE SLIPS
AND TRAVELING BLOCK IS SECURED BEFORE PROCEEDING
1. With all brakes released compare all pressure gauge readings with those given in
the Adjustment Specifications. Items 19A and 20A should be 0 PSI.(Brake Released).
2 Apply the parking brake. The DRUM BRAKE pressure gauge readings should now
match items 19B and 20B. Release the parking brake.
3. Apply the emergency brake. The EMERGENCY BRAKE pressure gauge should now
match item 18B. Release the emergency brake. It should match 18A.
4. Apply main brake. Apply the emergency brake. The DRUM BRAKE pressure should
drop to match item 9.
5. Compare all pressure gauge readings in the preceding steps to the Adjustment
Specifications. All gauge readings should be within 25 PSI of the Adjustment
Specifications.
PAGE 17
- Adjustment
The hydraulic power unit components are factory set to the Adjustment Specifications
given at the beginning of this manual. Routine adjustment should not be required unless
one of the system supply pressures is more than 25 PSI from the Adjustment
Specification. Always examine other probable causes of system problems before
adjusting power unit components. Whenever a pressure reading does not comply with
the Adjustment Specifications compare readings with the gauges on the driller's console
to determine if a gauge is faulty.
!CAUTION!
DO NOT USE THE BRAKES WHILE MAKING ANY ADJUSTMENTS OR SERVICING

THE HYDRAULIC POWER UNIT. SET THE LOAD IN THE SLIPS AND APPLY THE
EMERGENCY BRAKE BEFORE ADJUSTING THE POWER UNIT.
hydraulic power unit is provided with a number of isolation valves that allow working on
individual components. Always be certain a component or line contains no residual
hydraulic pressure before working on it. The parts book for the power unit provides
details for servicing many of the components.
!CAUTION!
THIS IS A CLOSED CENTER HYDRAULIC SYSTEM. MANY COMPONENTS ARE

INTERNALLY PRESSURIZED, EVEN WHEN THE POWER UNIT IS SHUT OFF.
ALWAYS RELIEVE THE PRESSURE FROM A COMPONENT BEFORE SERVICING
IT.

The hydraulic power unit provides power for operation of the drum brakes. When
properly adjusted and maintained in accordance with Section IV of this manual, no
additional adjustments are required during operation.
- PRESSURE GAUGES
Pressure readings for the hydraulic power unit panel mounted gauges should be within
25 PSI of the pressures given in the Adjustment Specifications in Section I. IF ANY
GAUGE READING IS NOT WITHIN 25 PSI OF THE ADJUSTMENT SPECIFICATION,
STOP USING THE DRAWWORKS AND REFER TO THE MAINTENANCE SECTION
OF THIS MANUAL FOR INSTRUCTIONS.
The availability of hydraulic pressure for application of the drum brake is indicated by the
SIDE 1 and SIDE 2 BRAKE SUPPLY gauges on the Hydraulic power unit. Both of these
gauges are supplied from the same pressure regulator. If they indicate different
pressures it indicates a closed valve in the supply line or a defective gauge. DO NOT
USE THE DRAWWORKS BRAKES UNLESS BOTH BRAKE SUPPLY GAUGES SHOW
THE SUPPLY PRESSURES WITHIN 25 PSI OF THOSE GIVEN IN THE ADJUSTMENT
SPECIFICATIONS IN SECTION I OF THIS MANUAL.
The hydraulic pressures applied to the brake are shown on the pressure gauges on the
disc brake console. Braking force is directly proportional to the hydraulic pressures
applied to the two sides of the brake. The side 1and side 2 of the brake are supplied by
independent hydraulic circuits. Both sides of the brake must be operating to obtain full
braking capacity.
A supply of brake cooling water must be circulated through the brake discs at all times
when the brake is in use. Failure to circulate water will cause the brake to overheat
resulting in brake fade, decreased braking capacity and damage to the brake. Refer to
the drawworks operation and maintenance manual for cooling water requirements.
The drawworks brake should be used primarily as a Park Brake and back-up to the
regenerative braking and Eaton 736 WCB brakes. It does not have sufficient cooling
capacity to be used as a primary brake for tripping in the hole.
! WARNING!
STOP USING THE DRAWWORKS BRAKES IMMEDIATELY IF ANY OF THESE

CONDITIONS OCCURS.
1. EITHER OR BOTH BRAKE SUPPLY PRESSURES DROP BELOW THE

ADJUSTMENT SPECIFICATION. (SEE SECTION I)
2. DRUM BRAKE PRESSURE IS NOT INDICATED ON BOTH DRILLER'S

CONSOLE GAUGES WHEN THE PARK BRAKE SWITCH IS IN THE ENGAGED
POSITION.
3. SYSTEM SUPPLY PRESSURE DROPS BELOW THE ADJUSTMENT
SPECIFICATION. (SEE SECTION I)
4. THE BACKUP PUMP COMES ON AND STAYS ON (SEE PROCEDURE FOR THE
DRILLER'S CONSOLE IN THIS SECTION).
5. BRAKE COOLING WATER IS NOT CIRCULATING THROUGH THE BRAKE

DISCS.
6. ELECTRICAL POWER TO THE HYDRAULIC POWER UNIT IS INTERRUPTED.
7. THEAIRSUPPLYTOTHEAIRDRIVENHYDRAULICPUMPISINTERRUPTED.
PAGE 19
Adjustment
The hydraulic power unit components are factory set to the Adjustment
Specifications given at the beginning of this manual. Routine adjustment should
not be required unless one of the system supply pressures is more than 25 PSI
from the Adjustment Specification. Always examine other probable causes of
system problems before adjusting power unit components. Whenever a pressure
reading does not comply with the Adjustment Specifications compare readings
with the gauges on the Driller's console to determine if a gauge is faulty.
!CAUTION!
DO NOT USE THE BRAKES WHILE MAKING ANY

ADJUSTMENTS OR SERVICING THE HYDRAULIC POWER
UNIT. SET THE LOAD IN THE SLIPS AND APPLY THE
EMERGENCY BRAKE BEFORE ADJUSTING THE POWER
UNIT.
hydraulic power unit is provided with a number of isolation valves that allow working
on individual components. Always be certain a component or line contains no
residual hydraulic pressure before working on it. The parts book for the power unit
provides details for servicing many of the components.
!CAUTION!
THIS IS A CLOSED CENTER HYDRAULIC SYSTEM. MANY

COMPONENTS ARE INTERNALLY PRESSURIZED, EVEN
WHEN THE POWER UNIT IS SHUT OFF. ALWAYS RELIEVE
THE PRESSURE FROM A COMPONENT BEFORE SERVICING
IT.
SYSTEM PRESSURE
If system pressure is too high check the pressure compensator on the hydraulic pump
and check the air pressure regulator for the air driven back-up pump. The output
pressure of the air driven hydraulic pump is directly proportional to the air pressure
applied to the pump. If system pressure is too low check the pump pressure
compensator setting and the setting of the system over pressure relief valve.(7) As the
pump wears it will not provide full system pressure and should be serviced or replaced.
PAGE 21
SUPPLY PRESSURES
If the service or parking brake supply pressure is too high or too low first
check the system pressure. If system pressure is correct check the pressure
reducing and regulating valve (10) and adjust if required.
During normal operation the isolation valves for the accumulator drains (AD1
through AD4) should be shut off and the drain line plugged. The isolation
valves to the pressure gauges and accumulators should be open. The shut
off valves on either side of both pumps should be open.
ACCUMULATORS
The precharge of the hydraulic accumulators (11) should be checked as

indicated in the maintenance schedule. The precharge should also be
checked if the brake response is slower than normal. If hydraulic fluid is
evident at the bladder valve when checking the precharge, the bladder should
be replaced. If hydraulic fluid is evident anywhere else on the accumulator
the seals should be inspected. Always discharge the hydraulic fluid pressure
and gas precharge before servicing an accumulator.
An accumulator charging hose assembly with a pressure gauge is supplied

with the power unit. Use the assembly to check accumulator precharge using
the connection on the top of the accumulator. Adjust the precharge if it is
more than 25 PSI from the Adjustment Specification. Check the precharge
when the accumulator is at the ambient temperature of the power unit. Use
only dry nitrogen gas for charging the accumulator.
PRESSURE LINE FILTER
Replace the element in the pressure line filter (8) when indicated by the
indicator on the side of the filter. The filter must have flow passing through it
when the indicator is inspected. Replace the filter element at the
recommended service interval even if there is no indication it needs to be
replaced. The power unit must be shut off and the pressure line discharged
before the filter can be serviced.
RETURN LINE FILTERS
Replace the element in either return line filter (14) when indicated by the
indicator on the side of the filter. The filter must have fluid flowing through it
when the indicator is inspected. Replace the filter element at the
recommended service interval even if there is no indication it needs to be
replaced.
- SUCTION STRAINERS
The suction strainers (12) in the reservoir should be removed and cleaned at
the recommended service interval given in the maintenance schedule. The
strainers should be cleaned and flushed. If the strainers are damaged they
should be replaced.
PAGE 22
- HYDRAULIC RESERVOIR
Maintain the fluid level in the hydraulic reservoir at mid-level on the sight level
gauge on the side of the reservoir. Temperature of the hydraulic fluid should
not exceed the ambient temperature around the power unit by more than 60
degrees Fahrenheit. IF RESERVOIR TEMPERATURE IS TOO HIGH,
DETERMINE THE CAUSE AND CORRECT.
The hydraulic reservoir should be drained and cleaned at the interval listed in
the maintenance schedule. Thoroughly clean the inside of the reservoir.
Clean or replace the suction strainers. Inspect the reservoir for rust or any
sources of contamination and correct. Refill the reservoir with new hydraulic
fluid. The entire hydraulic system need not be drained.
MAIN DRUM BRAKE WITH PARKING BRAKE
ADJUSTMENT
The main and parking drum brake system components are pre-set to the
Adjustment Specifications given at the beginning of this manual. Routine
adjustment should not be required. Adjustments that may be required are
described in the following paragraphs.
!CAUTION!
DO NOT USE THE BRAKES WHILE MAKING ANY ADJUSTMENTS TO

THE CONTROLS OR COMPONENTS IN THE DRILLER'S CONSOLE. SET
THE LOAD IN THE SLIPS AND APPLY THE EMERGENCY BRAKE
BEFORE MAKING ANY ADJUSTMENTS.
PAGE 23
SERVICE BRAKE CALIPER ASSEMBLY
Inspect the Service Brake Caliper Assemblies as indicated in the maintenance

schedule. Whenever the total gap between both pads and the disc exceeds that
shown in the Adjustment Specification, the caliper assembly should be adjusted. If
brake response is slower than normal the service brake caliper assemblies should
be inspected.
- PAD WEAR INSPECTION
Inspect the pad gap with the brakes released. The total gap can be measured by
pushing one shoe of the caliper assembly against the disc. The total gap can be
measured between the opposite shoe and the disc. Adjust the caliper assembly
whenever the total gap is greater than the maximum gap given in the Adjustment
Specifications.
Inspect the thickness of each brake pad when inspecting the Service Brake Caliper
Assemblies. Replace the pads when any portion of the pad is thinner than the
minimum thickness given in the Adjustment Specification.
- PAD WEAR ADJUSTMENT
Adjust the caliper assembly whenever the total gap exceeds the maximum given in
the Adjustment Specifications. Adjust pad gap while the brakes are released.
Adjust the pad gap by adding grease at the grease fitting on the rod of the actuator
cylinder.(33) This extends the adjustment plunger to lessen the gap between the
pad and the disc. Use the same grease used for drawworks lubrication.
Add grease until the gap given in the Adjustment Specification for "adjusted"
condition is obtained. You may place a shim the thickness of the adjusted gap
between one shoe and the disc. Add grease until the other shoe is against the disc
and remove the shim. Do not add too much grease or the caliper will not release
from the disc.
- SHOE SUPPORT ADJUSTMENT
The uppermost Service Brake Caliper Assembly has a bracket on the end of each
arm. The screw in this bracket is adjusted to keep the brake shoes vertical when
retracted from the disc.
This keeps the pad from rubbing the disc when the brakes are released. Adjust the
screw on each shoe every time the pad gap has been adjusted. Loosen the lock
nut and turn the screw in until it holds the shoe vertical. Retighten the lock nuts.
PAGE 24
- PAD REPLACEMENT
This procedure describes replacement of the pads for one caliper assembly. It is
not necessary to replace all service brake pads at the same time in case one
should wear more than the rest. Use new hardware (screws and nuts) when a pad
is replaced.
Remove the quick release connection from the hydraulic cylinder. Remove the
check valve from the adjustment plunger in the service brake hydraulic cylinder.
Push the adjustment plunger in as far as it will go to purge all grease from the
cylinder. Avoid getting grease on the face of the brake shoes, brake pads or discs,
since this will adversely affect braking performance. Reinstall the check valve and
grease fitting into the adjustment plunger.
Remove the two springs that retract the cylinder. These springs are under tension
and care must be used in removing them. A spring removal tool is provided with
the drawworks. Place the tool on the end of the pin that holds the spring. Rotate
the tool to lift the spring out of the groove on the pin. The spring can now be
pulled off the end of the pin. Remove the pull pins. Push the pins through the
arm, remove the hydraulic cylinder and place the cylinder out of the way.
Remove the pull pins and pivot pins necessary to remove the brake shoes from
the caliper assembly. Remove the screws and nuts that hold the pad to the shoe
and discard them.
Use new hardware to replace the pad with one that has the same part number
shown in the Adjustment Specifications for the Service Brake Caliper Assembly.
Torque the pad nuts initially to 20-22 foot-pounds. After at least one hour check
torque on nuts and retorque to 12 foot-pounds.
!CAUTION!
DO NOT USE BRAKE PADS FROM THE EMERGENCY

BRAKE ON THE SERVICE BRAKE. THE PAD PART
NUMBER LISTED IN THE ADJUSTMENT SPECIFICATIONS
MUST BE USED. USING A DIFFERENT PAD MAY
ADVERSELY AFFECT BRAKE PERFORMANCE.
PAGE 25
Inspect all brake components while removed for replacing the pad.
1.Pad wear should be even for all pads since the calipers are hydraulically
equalized. If any pad or set of pads shows excessive wear, investigate to
find the cause.
2.Inspect pins and bushings for excessive wear and replace if necessary.
3.Inspect all brake components for evidence of damage. Replace any

bent, cracked or damaged components.
4.Check the brake disc for grooves, warpage and thickness. Replace the
disc if groove depth is greater than or disc thickness is less than that
shown on the Adjustment Specification.
Fill the two pockets in the bushings of each arm with grease. Apply grease to all
pivot pins and bushings. Reassemble the caliper assembly. The procedure
described for the spring removal tool may be used in reverse to install the
springs that retract the cylinders. Adjust each caliper assembly for total pad gap
as described in this section.
DRUM EMERGENCY BRAKE
Routine adjustments should not be required for the Emergency Drum Brake
hydraulic system. The Emergency Brake uses system pressure which is
described in this Section under the Hydraulic Power Unit.
Page 26
EMERGENCY BRAKE CALIPER ASSEMBLY
Inspect the Emergency Brake Caliper Assemblies as indicated in the

maintenance schedule. Whenever the total gap between both pads and the disc
exceeds that shown in the Adjustment Specification the caliper assembly should
be adjusted. Refer to Figure 2, included at the end of this manual, and the
applicable documents listed at the beginning of this manual.
!WARNING!
THE EMERGENCY BRAKE CALIPER CYLINDERS

ARE SPRING LOADED. LOSS OF HYDRAULIC
PRESSURE WILL CAUSE THE EMERGENCY BRAKE
CYLINDERS TO CLOSE RAPIDLY AND WITH GREAT
FORCE. USE EXTREME CARE WHILE ADJUSTING
THE EMERGENCY BRAKE.
- PAD WEAR INSPECTION
Inspect the pad gap with the emergency brake released. The total gap can be
measured by pushing one shoe of the caliper assembly against the disc. The
total gap can be measured between the opposite shoe and the disc. Adjust the
caliper assembly whenever the total gap is greater than the maximum gap given
in the Adjustment Specifications.
Inspect the thickness of each brake pad when inspecting the Service Brake
Caliper Assemblies. Replace the pads when any portion of the pad is thinner than
the minimum thickness given in the Adjustment Specification.
!CAUTION!
An adjustment eye on the Emergency Brake Cylinder

allows adjustment of pad gap. The maximum amount
the eye can extend from the adjusting nut is given in
the Adjustment Specifications. Replace the pads
whenever the adjustment eye is extended beyond the
amount given in the Adjustment Specifications.
- PAD WEAR ADJUSTMENT
Adjust the caliper assembly whenever the total gap exceeds the maximum given
in the Adjustment Specifications. Adjust pad gap while the brakes are released
and the Emergency Brake Cylinder is fully retracted (pressurized).
PAGE 27
Remove the lockwire from the four ½” inch capscrews in the end plate of the
cylinder. Remove the capscrews and the two adjusting nut locks from the
cylinder. Rotate the adjusting nut using a ½” inch diameter rod in any of the eight
holes on the outside of the adjusting nut. Adjust until the total gap between both
pads and the disc is less than that given in the adjustment specifications.
Check the amount that the back of the adjusting eye extends from the face of the
adjusting nut. If it exceeds the amount given in the Adjustment Specifications the
brake pads must be replaced.
If the amount the adjusting eye extends from the adjusting nut does not exceed
the adjustment specifications, then reinstall the adjusting lock nuts. Reinstall the
four ½” inch capscrews, tighten and lockwire in place.
- PAD REPLACEMENT
This procedure describes replacement of the pads for one caliper assembly. Use
new hardware (screws and nuts) when a pad is replaced.
When replacing the pads, apply hydraulic pressure to the Emergency Brake
Cylinder to retract it. Use extreme care in handling the spring loaded cylinder.
Remove the pull pins. Move the hydraulic cylinder out of the way.
Remove the pull pins and pivot pins necessary to remove the brake shoes from
the caliper assembly. Remove the screws and nuts that hold the pad to the shoe
and dispose of them.
Use new hardware to replace the pad with one that has the same part number
shown in the Adjustment Specifications for the Service Brake Caliper Assembly.
Torque the pad nuts to 20-22 foot-pounds. After one hour check the torque on
nuts and retorque to 12 foot-pounds if required.
PAGE 28
! CAUTION !
DO NOT USE BRAKE PADS FROM THE SERVICE BRAKE ON THE

EMERGENCY BRAKE. THE PAD PART NUMBER LISTED IN THE
ADJUSTMENT SPECIFICATIONS MUST BE USED. USING A DIFFERENT
PAD MAY ADVERSELY AFFECT BRAKE PERFORMANCE.
Inspect all brake components while removed for replacing the pad.
1. Pad wear should be even for all pads. If any pad or set of pads shows
excessive wear, investigate to find the cause.
2. Inspect pins and bushings for excessive wear and replace if necessary.
3. Inspect all brake components for evidence of damage. Replace any bent,
cracked or damaged components.
4. Check the brake disc for grooves, warpage and thickness. Replace the disc
if groove depth is greater than or disc thickness is less than that shown on
the Adjustment Specification.
Fill the two pockets in the bushings of each arm with grease. Apply grease to all pivot
pins and bushings. Reassemble the caliper assembly. Adjust each caliper assembly for
total pad gap as described in this section.
- EMERGENCY BRAKE CYLINDER DISASSEMBLY
!WARNING!
THE EMERGENCY BRAKE CYLINDER IS UNDER COMPRESSED SPRING

FORCE. THE CYLINDER MUST BE RESTRAINED DURING DISASSEMBLY.
To disassemble the emergency brake cylinder remove the cylinder from the
caliper assembly and place it with adjusting eye facing up. Remove the adjusting
eye, adjusting nut locks, and adjusting nut from the cylinder.
Remove the eight nuts from the rod studs on the cylinder. The cylinder springs
are under a high compressive force. Back off the eight nuts by turning each one
only a small amount at a time in a circular pattern until the spring compression is
released. Once the nuts are removed the end plate may be lifted off the cylinder
body.
PAGE 29
- EMERGENCY BRAKE CYLINDER REASSEMBLY
Prior to reassembly of the emergency brake cylinder the springs should be NDE
checked by a qualified Inspector. If a crack is detected in a spring, the entire set
should be replaced. Inspect the threads on the eight tie rod studs. If the threads
are damaged replace the studs. Inspect all cylinder components and replace
those that are damaged.
If the studs have been removed from the end plate, lubricate the threads,
reinstall and torque to 105 ft. Lbs.(142 Nm). Place the end plate with the studs
so that the studs face up. Lubricate all seals with hydraulic fluid before
installing them. Put the cylinder shell on the end plate with the “O” ring facing
the end plate. Install the piston and seal in the shell. Place the disc springs on
the piston. The disc springs must be installed with the dished sides of adjacent
springs alternating as shown on the cylinder assembly drawing. Grease the
disc springs with a molybdenum disulfide based grease prior to installation.
Place the other end plate on the cylinder body relative to the other end plate as
shown on the assembly drawing. Lubricate the threads on the studs and install
the eight nuts. Tighten the nuts as a group, turning each one only a small
amount at a time. Tighten the nuts in a circular pattern with a torque wrench
and avoid tightening the nuts more than 200 ft. Lbs. (270 Nm). Torque the nuts
to 200 ft. Lbs. (270 Nm). After the end plate is pulled into place, reinstall the
adjusting eye, adjusting nut, and adjusting nut locks.
Reinstall the emergency brake cylinder, bleed the hydraulic lines, and adjust
the pad clearance.
LUBRICANT REQUIREMENTS
Pneumatic components and mechanical brake components should be

lubricated in accordance with the Continental Emsco Co. General Lubrication
Instructions. For adjustment of the pad gap on the Service Brake Caliper
Assembly cylinder use the same grease as used for drawworks lubrication.
The disc springs in the Emergency Brake Cylinder should be lubricated with a
molybdenum disulfide based grease prior to reassembly whenever the cylinder
has been disassembled.
HYDRAULIC FLUID
The hydraulic fluid must be a Dexron II automatic transmission fluid that meets
Allison C-3 requirements. Viscosity of the fluid to be 150 to 190 SUS at 100
degrees Fahrenheit. (Mobil Universal ATF or equal).
Any fluid added to the system should be passed through a filter with a 25
micron absolute rating. Refer to the description of System Start-Up for a more
detailed description of how to handle the hydraulic fluid.
PAGE 30
MAINTENANCE SCHEDULE
Components should be inspected or serviced at the frequency listed unless

experience with the equipment under specific operating conditions indicates the
need for a shorter interval between servicing. A more detailed description of
some procedures are provided elsewhere in this section of the manual. Refer to
the manufacturers literature provided with the equipment for a description of
individual components.
DAILY
1. While operating the drawworks brake, monitor the SYSTEM, BRAKE SUPPLY
and PARKING BRAKE SUPPLY pressure gauges to confirm that all brake
components have an adequate brake supply pressure. If any system or supply
pressure is not within 25 PSI of the Adjustment Specifications stop using the
drawworks brakes and determine the cause.
WEEKLY
3. Inspect service and emergency brake cylinders and brake piping for any
evidence of leakage. Replace or repair if leakage exists.
4. Check indicator on side of return line filters while fluid is flowing through filters
at operating temperature. Replace element if indicated on filter.
5. Check indicator on pressure line filter while fluid is flowing through filter at
operating temperature. Replace element if indicated on filter.
6. Inspect hydraulic power unit for any evidence of leakage. Identify and repair
cause if leakage is evident.
7. Check fluid level in reservoir and add fluid if low. If fluid level is low, examine
brake system for cause and correct.
8. Check temperature of hydraulic fluid in reservoir. If fluid temperature is more
than 60º F. (15º C.) above ambient temperature surrounding power unit
determine the cause and correct.
9. Drain condensate from air filter on hydraulic power unit.
10. Fill air line lubricator on Air Pump with SAE 10 Wt. Motor oil.
MONTHLY
1. Inspect Service Brake Caliper Assemblies for brake pad standoff. Adjust if
required. Replace pads if worn thickness of pad is less than that given in the
Adjustment Specifications, item 31. Operate main (service) and parking brake
functions to confirm smooth operation of all components.
2. Inspect Emergency Brake Caliper Assemblies for brake pad standoff. Adjust
if required. Replace pads if worn thickness of pad is less than that given in
the Adjustment Specifications, item 36. Operate Emergency Brake to confirm
smooth operation of all components.
PAGE 31
3. a) With no load on the hook, set the Emergency Brake and release the
Service Brake.
b) Apply Drawworks power, note and record the DW motor amperage at the
point where the drum begins to rotate. Amperage should be more than it
takes to hoist the drill string.
c) If test fails replace friction pads and retest. If retest fails proceed with
annual test.
EVERY SIX MONTHS
1. Drain and clean reservoir, clean or replace suction strainers, replace drained
fluid with new hydraulic fluid. It is not necessary to drain the entire system.
2. Replace element in pressure line filter.
3. Replace elements in return line filters.
4. Inspect all piping in the brake system. Replace any hoses that show signs of
deterioration. Replace any damaged piping components. Repair any causes
of leakage.
5. Check precharge pressures in hydraulic accumulators against the

Adjustment Specifications. Charge accumulators if pressure is not within
25 psi of precharge pressure. Replace bladder in accumulator if any
hydraulic fluid is evident on the bladder valve stem when checking
precharge.
!CAUTION!
Before beginning the following procedures, set

load on the slips and hang-off traveling block.
WHENEVER BRAKE PADS ARE REPLACED

1. Inspect brake discs for wear. Replace if deeply grooved or if thickness at
thinnest point is less than shown in the Adjustment Specification.
2. Inspect caliper assemblies for bent, cracked or worn components. Replace

any damaged components.
3. Inspect pivot shafts on Emergency and Service caliper assembly components

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

molybdenum disulfide grease. DO NOT use a lubricant containing COPPER.
Due to the dissimilar metals a corrosion will result that will cause the shafts to
be difficult to remove.
Page 32
ANNUALLY
Test the Emergency Cylinders by following the the procedures listed below:
1. Push the “EMERGENCY BRAKE” button to release pressure on cylinders.

2. Shut down the Hydraulic Power Unit and turn off air pump.
3. Disconnect the hydraulic supply hose to the Emergency cylinders.
4. Connect a hydraulic hand pump, capable of producing 1850 PSI(127.6 Bar),
to one cylinder with an accurate pressure gauge in the line. The hand pump
should be filled with clean fluid of the same type used in the brake system.
5. Pump the cylinder up until the pin on the live end of the cylinder can be
removed.
6. Block up under cylinder so plunger is free to move.
7. Release the pressure on cylinder and attach a magnetic base dial indicator
to cylinder end plate with the indicator button resting on the end of the
piston rod.
8. Pressure up on the cylinder to obtain readings at the
following points.
PRESSURE CYL. TO; TRAVEL SHOULD BE; .
a) 750 PSI (51.7 Bar) .099"±.020"(2.51mm±.51mm) Release Pressure

b) 900 PSI (62.0 Bar) .242"±.020"(6.1mm ±.51mm) Release Pressure
c) 1020 PSI (70.3 Bar) .345"±.020"(8.8 mm±.51mm) Release Pressure
d) 1850 PSI (127.6 Bar) .345”±.020”(8.8 mm±.51mm) Wait one hour.
e) Recheck dimension (d)
9. If any of these test fail, proceed with Five Year replacement of springs.
11. Repeat steps 4 through 8 on the other Emergency Cylinder.
12. Remove all of the Caliper Arm and Pivot Shafts. Inspect for excessive
wear, bending or visible cracks.
13. Inspect all shafts and caliper arms with NDE procedures for cracks. Any
part with crack like indications must be replaced.
14. Inspect Caliper Support Arms for cracks with NDE procedures. Check for
worn holes where the caliper support shafts go through.
Each five years
1. The Emergency Cylinders should be disassembled per instructions in the

maintenance section and all springs and seals replaced with new parts.
2. Perform pressure test per number 8 in Annual inspection above.
3. Reinstall cylinders and perform stall test as described under “monthly”.
4. Disassemble the Service Caliper Cylinders and inspect for wear and cracks
with NDE procedures. Replace any part with excessive wear or crack
indications. Reassemble with new seals.
Page 33
TROUBLE SHOOTING CHART
This chart highlights the most likely causes of problems with the brakes. Read
the Description Section of this manual and refer to the hydraulic diagram and
assembly drawings to understand brake operation. This chart is not exhaustive,
nor does it attempt to cover those items which are assumed to be routine for
experienced maintenance personnel. Under Item 2 for example it is expected
the experienced person would check for electric power to the motor or a loose
pump coupling.
The page numbers shown in the trouble shooting chart refer to the appropriate
page in the Maintenance Section of this manual. Additional information is
obtained in the Description and Operations Sections of this manual.
SYMPTOM PROBABLE CAUSE PAGE
1. SYSTEM PRESSURE TO HIGH

PUMP COMPENSATOR PRESSURE 21
SETTING TO HIGH
AIR PRESSURE REGULATOR FOR 21

BACKUP PUMP SET TO HIGH
2. SYSTEM PRESSURE TO LOW SYSTEM PRESSURE RELIEF VALVE 21

SET TO LOW
PUMP COMPENSATOR PRESSURE 21

SET TO LOW
ELECTRIC DRIVEN PUMP NOT 21

FUNCTIONING PROPERLY
SUCTION STRAINER(S) PLUGGED 22

OR SHUT OFF
3. BRAKE SUPPLY PRESSURE(S) SYSTEM PRESSURE TO LOW 22

TO LOW
PRESSURE REDUCING AND 22
REGULATING VALVE SET
TO LOW
BROKEN SPRING IN PRESSURE

REDUCING VALVE.
4. BRAKE SUPPLY PRESSURE(S) PRESSURE REDUCING AND 22

TO HIGH REGULATING VALVE SET
TO HIGH.
Page 34
SYMPTOM PROBABLE CAUSE PAGE
5. BRAKE WON'T HOLD SYSTEM OR BRAKE SUPPLY 21

PRESSURE(S) TOO LOW
BRAKE PAD CLEARANCE NEEDS 24

ADJUSTING
OIL SOAKED BRAKE PADS.
DISC COOLING WATER LEAKING

ON PADS.
6. BRAKE RESPONSE SLOW BRAKE PAD CLEARANCE NEEDS 24

ADJUSTING
BRAKE ACCUMULATORS NOT 22

FUNCTIONING
7. PARKING BRAKE WON'T HOLD SYSTEM OR PARKING BRAKE 22

PRESSURE(S) TOO LOW
SERVICE BRAKE CYLINDER LEAKING

OIL SOAKED PADS.
8. PARKING BRAKE WON'T BRAKE SUPPLY PRESSURE TOO LOW

RELEASE
CROWN SAVER NOT RESET.
9. EMERGENCY BRAKE WON'T EMERGENCY BRAKE CALIPER 27

HOLD ASSEMBLIES OUT OF ADJUSTMENT
SYSTEM PRESSURE NOT BEING 26

DUMPED FROM CYLINDERS
OIL SOAKED PADS.
BROKEN SPRING IN CYLINDER.
10. EMERGENCY BRAKE WON'T SERVICE BRAKE NOT APPLIED. 16

RELEASE
SYSTEM PRESSURE TOO LOW 22
SEQUENCE VALVE NOT ADJUSTED.

PROPERLY. * 16
Page 35
R
Electrohoist V
SECTION 5
EATON 736WCB DISC BRAKE
INDEX
DESCRIPTION PAGE/DRAWING NO.
INTRODUCTION ..................................................................... 5.1
BRAKE INSTALLATION........................................................ 6204-0425-00
COOLANT PIPING Sht. 1 & 2................................................. 6204-0446-00
EATON MAINTENANCE MANUAL..................................... WCB 11062
Z:\WordDocs\Manuals\Dwks\FalconP-8\EH5\Sec05.doc
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Electrohoist V
5.1
INTRODUCTION:
As explained in section 1, this Drawworks is equipped with three separate

braking systems. Any one of which is capable of stopping and holding the
full rated load capacity of the Electrohoist V, however each of them has an
intended function and they should be operated in the manner for which they
were designed. The Eaton 736WCB brake system is intended to act as a
secondary to the Regenerative Braking and to hold the load stationary for
short periods of time. They are air applied and spring released. Brake torque
is proportional to applied air pressure. The brakes are water cooled by large
volumes of water and have the capability of acting as the main brake in case
the regenerative braking system is not available. When the Drawworks is
inactive for periods of up to three hours, the Park Brake should be applied.
This is a hydraulically applied caliper brake system attached to the drum
flanges. For periods longer than three hours, the Emergency Brake should be
engaged and the Hydraulic Power Unit shut down.
The Eaton seven plate disc brakes are mounted on an outboard extension of
the transmission output shaft, which in effect, makes them direct connected
to the drumshaft. They are an extremely rugged piece of machinery, but like
all machinery they require proper care and maintenance. It is very important
to the life of the units that the air and water specifications be adhered to.
Adjustment is required occasionally to compensate for wear on the friction
discs and pressure plates. The Eaton Operation & Maintenance Manual is
included in this section.
5.2
5.3
5.4
R
Electrohoist V
6.0
SECTION 6
3-SPEED GEARBOXES
INDEX
Introduction.............................................................................. 6.1
Gearbox Installation ................................................................ 6204-0398-00
Gearbox Lube Piping............................................................... 6204-0437-00
Outline Dimension Drawing.................................................... D3790-100
Assembly/Parts List ................................................................. D3790-200
Airflex CH Multiple –Disc Clutch Assemblies....................... HY 13100
Recommended Spare Parts List for Airflex CH Clutches.......
Z:\MW\MANUALS\DWKS\FalconP-8\EH5\SEC06.DOC
R
Electrohoist V
6.1
GENERAL INFORMATION:
Hoisting power for the Electrohoist V Drawworks is supplied by four 1250

H.P. electric motors. Combined they develop the 5000 H.P. rating of the
Electrohoist V. Two motors are located at each end of the drumshaft, driving
into a three speed gear box which is connected to the drumshaft with flexible
couplings.
The three speed ratios are obtained by engagement of air friction clutches
mounted on the shafts inside the gearboxes. There are three clutches for each
motor input drive for a total of six clutches in each gearbox. For each speed
ratio there will be four clutches engaged. It is imperative that these clutches
be energized simultaneously and in the correct order. Although they are
friction type clutches, to prevent damage to the drives, shaft rotation must be
stopped before changing speeds. Individual drive motors may be disengaged
if desired. Speed ratios that can be obtained are;
High ………………...4.99 : 1
Intermediate…………9.27 : 1
Low………………….16.4 : 1
See section 1 for hoisting capacities of each speed ratio.
For extreme cold weather operation it may be necessary to add heaters to the
gearboxes to warm the oil, to prevent overload of the oil pump motor. See
section 4 for maintenance of lubrication system.
Oil Capacity (each gearbox) 290 U.S Gal.)
For ambient temperature -4° to 65° F. (-20° to 18° C.) Use AGMA #4 EP
For ambient temperature 65° to 125° F. (18° to 52° C.) Use AGMA #5 EP
RECOMMENDED SPARE PARTS LIST FOR AIRFLEX CH CLUTCHES:
Quantity Part Number Description .
2 146196XA Repair Kit for CH1250 Clutch

Each kit contains the following components:
Friction Discs
Separator Discs
Separator Springs
Shaft Seals
Cylinder Seals
Seal Lubricant
Seal Adhesive
Instructions
R
Electrohoist V
7.0
SECTION 7
MAINTENANCE
INDEX
ROUTINE MAINTENANCE SCHEDULE...................................... 7.1

DAILY ................................................................................... 7.1
WEEKLY............................................................................... 7.2
MONTHLY............................................................................ 7.2
SEMI ANNUALLY............................................................... 7.2
ANNUALLY ......................................................................... 7.3
EACH FIVE YEARS............................................................. 7.3
REPAIR PROCEDURES .................................................................. 7.4

REMOVAL OF DRUMSHAFT ........................................................ 7.4
DISASSEMBLY OF DRUMSHAFT ................................................ 7.6
REASSEMBLY OF DRUMSHAFT ................................................. 7.8
REINSTALLING DRUMSHAFT IN FRAME ................................. 7.10
ALIGNMENT SPECIFICATIONS ................................................... 7.10
R
Electrohoist V
7.1
SECTION 7
MAINTENANCE
Routine inspection of the drawworks is the most important form of preventive
maintenance and will result in considerable savings by detecting any major trouble that
might be developing, and allowing the necessary repairs to be made on a planned or
normal rig down-time.
The following is a guide to some of the key points, which should be observed during
routine inspections. The prevailing operating conditions surrounding each individual rig
will dictate the frequency at which the inspections should be made; however, it is
recommended that the intervals listed below be considered maximum for optimum
performance from the equipment.
ROUTINE MAINTENANCE SCHEDULE
NOTE: Refer to section 4 for instructions on disc brake system.
DAILY:
1. While operating the Drawworks frequently observe control console gauges for
proper Air, Oil, hydraulic and water pressures. Also monitor the temperature of oil
and cooling water.
2. Grease Drawworks drumshaft bearings with 12 shots from a standard hand grease
gun.
3. Check oil level in gearboxes.
4. Check fluid level and temperature of fluid in HPU reservoir.
R
Electrohoist V
7.2
ROUTINE MAINTENANCE SCHEDULE Cont”d:
WEEKLY:
1. Inspect brake calipers for proper stand-off gap and pad thickness.
2. Inspect brake cylinders and piping for sign of leakage.
3. Check flow indicators on HPU filters.
4. Check oil level in air pump lubricator, drain water from filter and observe air
pressure on regulator gauge.
5. Drain condensate from air volume tank in Dwks. control cabinet.
MONTHLY:
1. Check precharge pressure in hydraulic accumulators.
2. Test Emergency Brake with Dwks. power.
SEMI ANNUALLY:
1. Take oil sample from gearboxes for laboratory analysis.
2. Drain oil from gearboxes and refill.
3. Clean or replace gearbox oil filter elements.
4. Relubricate flexible couplings on gearboxes.
5. Drain, clean and refill HPU fluid reservoir.
6. Replace HPU filter elements.
R
Electrohoist V
7.3
ROUTINE MAINTENANCE SCHEDULE Cont”d:
ANNUALLY:
1. Test the Emergency Cylinder spring tension. (See Sec.4, page 33)
2. Inspect caliper arms and shafts.
3. Check motor and gearbox alignment to drumshaft.
4. Remove old grease from flexible couplings and relubricate.
5. Measure and record clearance in drumshaft and gearbox bearings.
6. Check all accessible bolts and nuts for tightness.
EACH FIVE YEARS”
1. Replace springs and seals in emergency cylinders.
2. Inspect service caliper cylinders with NDE procedures.
R
Electrohoist V
7.4
REPAIR PROCEDURES:
DRUMSHAFT ASSEMBLY:
Figure 7.1
REMOVAL OF DRUMSHAFT:
To remove the drumshaft assembly from the frame for repairs, without disturbing the
gearboxes proceed as follows;
1. Hang-off traveling block and spool drilling line off of drum.
2. Remove the wire line clamp and pull drilling line out of rope pocket.
3. Remove all guards and covers over drumshaft assembly.
4. Remove one of the caliper shafts (item 8 dwg. 6204-0345-10 sh.2) from the
Emergency Brake cylinders and swing the cylinders out untill they disengage the
caliper arm (item 7). Apply the Emergency Brake to release the pressure on the
cylinders. Disconnect the hoses and plug the ends. Remove the cylinders, pull the
ends of the arms together and secure with wire.
R
Electrohoist V
7.5
REMOVAL OF DRUMSHAFT:Cont’d
5. Place Service Brake controller in the Off position. Open bleed valves (42 dwg.
6204-0314-10) in Drawworks Control Cabinet.
6. Shut down the HPU and pad lock the motor starter in the off position. Turn off the
air supply to air pump.
7. Disconnect the supply hoses from the Service Cylinders at the quick disconnect
couplers. Remove the grease fitting and check valve from the Service Cylinders (12
& 15 dwg. 6212-1819-00) to allow the cylinders to fully retract.
8. Remove the hose and tubing assemblies from the caliper supports and plug the open
ends of the supply lines.
9. Remove the bolts (R3 & R8 dwg. 6204-0345-10) that attach the caliper supports to
the frame and hoist the supports off the skid.
10. Remove the rotorseal and water tube from the gearbox main shaft at both sides of
the drawworks.
11. Remove the bolts that connect the flexible coupling sleeves together, from both ends
of the drumshaft and slide the sleeves back past the ends of the drum and gearbox
shafts.
12. Disconnect the grease lines from the pedestal bearing housings and position them so
they will not be damaged.
13. Remove the bolts that attach the bearing housings to the frame.
14. The drumshaft assembly is now ready to hoist off the skid pedestals. The hoisting
equipment should be rated for lifting in excess of the estimated weight of 56,756
pounds (25,745 kg.). A two part sling should be wrapped around each end of the
drum barrel as close to the drum flanges as possible. The sling lines should be long
enough to form approximately a 60º angle between the two lines.
R
Electrohoist V
7.6
MAINTENANCE:
DISASSEMBLY OF DRUMSHAFT:
The drumshaft assembly consists of; a) the shaft, b) the drum, which is a one piece
fabricated assembly, c) two pedestal type carrier bearings and, b) two flexible couplings
to connect the shaft to the driver gearboxes. To disassemble for coupling, bearing or
disc replacement proceed as follows; Refer to Figure 6.1
15. Remove the 3/4” X 2-9/16” bolts that hold the end ring to the coupling sleeve (1)
and slide the sleeve off the hub.
16. Rig-up a puller with puller bolts screwed into the 1-1/2”-6 tapped holes in the face
of the hub and a 75 to 100 ton hydraulic jack. Refer to Chart 1, Position H for fit
data.
NOTE: Couplings used on some early EH Vs. did not have puller holes in the hubs. In
this instance the hub can be pulled by welding two 1-1/2” nuts to the face of the hub
180° apart. Be sure to attach the ground directly to the hub before welding.
17. Rig support for the hub and pulling equipment to prevent it from falling when it
disengages the shaft.
18. Pressure up on the jack to maximum capacity and heat the hub evenly around the
OD of the hub with a minimum of three rosebud heating torches. As the hub begins
to move, reduce the heat by about 50% and continue to apply heat until the hub is
almost off the shaft. Do not heat the hub to more than 450º F. (230º C.) If hub has
not moved by the time this temperature is reached, remove the heat and allow the
hub and shaft to cool to ambient temperature. Do not apply water or compressed air
to cool the parts while temperature is over 200º F. (95º C.).
19. Heat the hub again with more or larger torches. Repeat step 11.
20. Slide spacer (2) off of shaft.
21. Remove capscrews (4) from both sides of the bearing housing (5) and slide housing
off of bearing outer race. Refer to Chart 1, Position F for fit data. Some heat may be
required for the housing to slide off the bearing easily.
R
Electrohoist V
7.7
MAINTENANCE:
DISASSEMBLY OF DRUMSHAFT Cont’d.:
22. Heat the oil seal wear ring (3) and slide off the shaft. Refer to Chart 1, Position D
for fit data.
23. If the bearings are to be replaced, the best way to remove the bearing is to burn the
outer race into at two places, allowing the race to fall away. Remove the rollers and
cage. Apply heat directly to the inner race until it can be slid off the shaft.
24. Heat the inner oil seal wear ring and slide it off the shaft.
25. Remove the water hoses (7)
26. Rotate the drum to position the ¾”drain plug at the top. Remove the plugs and
fabricate a lift eye by welding a ring to a ¾” NPT forged steel pipe plug.
27. Support the shaft assembly underneath the drum barrel with the disc barely clearing
the floor.
28. Suspend the disc (8) from the lift eye and remove the bolts (10) that go through the
drum flange. Do not remove the four bolts that attach the disc to the spacer (9).
29. Lay the disc and spacer flat on the floor and remove the four bolts to separate the
two parts.
30. Repeat steps 15 thru 29 for the opposite end of the shaft.
If it should be necessary to remove the drum from the shaft, it should be done in a shop
with movable overhead cranes and a large horizontal press, which has at least 300 Ton
capacity. Refer to Chart 1, Position A for fit data.
R
Electrohoist V
7.8
MAINTENANCE:
REASSEMBLY OF DRUMSHAFT:
Figure 7.2
Opposite side of drum is symmetrical.
CHART 1
DESCRIPTION POSITION FIT (INCHES) FIT (MM)

Drum Flange to Shaft A T.008 - T.011 T.20 – T.28
Drum to flange B T.003 - T.007 T.08 – T.18
Spacer to Shaft C L.002 – L.013 L.05 – L.33
Spacer to Shaft D T.001 – T.003 T.03 – T.08
Bearing to Shaft E T.0016 – T.0026 T.041 – T.066
Bearing to Housing F T.0006 – L.0014 T.015 – L.035
Spacer to Shaft G L.014 – L.025 L.35 – L.63
Coupling Hub to Shaft H T.006 – T.009 T.15 – T.23
L = Loose T = Tight
R
Electrohoist V
7.9
MAINTENANCE:
REASSEMBLY OF DRUMSHAFT:Cont’d
Refer to Figure 7.1, 7.2 and Drawing 6204-0312-30
31. Before beginning any reassembly work, all of the parts involved should be
thoroughly cleaned, deburred and inspected for serviceability. Check the parts
dimensionally to insure they conform to fits listed in Chart 1. Replace any parts not
deemed serviceable.
32. Heat the inner oil seal wear ring (3) to 200º F. (95º C.) and slide on the shaft. Hold it
against the shoulder on the shaft until it seizes the shaft.
33. Install new oil seals in the bearing retainers with the seal lips pointing inward. Place
the gasket in position on the retainer, and lubricate the seal lips with grease. Insure
that the wear ring is cool, then slide the inner retainer over the wear ring.
34. Apply a coat of motor oil to the shaft bearing journal. Heat the inner race of the
bearing (6) to 125º F. (50º C.) above ambient temperature and slide on the shaft,
tight against the oil seal wear ring. Hold it in place until it seizes the shaft.
35. Heat the outer oil seal wear ring (3) to 200º F. (95º C.) and slide on the shaft. Hold it
against the bearing until it seizes the shaft.
36. After the bearing outer race has cooled to the touch, warm the bearing housing (5) if
needed and slide it over the outer race.
37. Repeat step 33 for the outer bearing retainer and bolt both the inner and outer
retainers to the bearing housing. Torque the capsrews to 130 ft. lbs. (Lubricated).
38. Slide the spacer (2) and coupling end ring over the shaft.
39. Trial fit the key in the coupling hub. It must slide freely through the keyway, if not
dress with a file or emery cloth until it does.
40. Position the drumshaft with the keyway at top dead center and insert key in keyway.
It should be .002 - .004” loose (.05 - .10 mm). Coat the shaft and key with motor oil
or a light antiseize compound.
R
Electrohoist V
7.10
MAINTENANCE:
41. Heat the hub to 300° over ambient temperature. Use the puller bolts to guide and
push the hub into position on the shaft. Hold it tight against the spacer until it seizes
the shaft.
42. Burn the puller nuts off the coupling hub and grind smooth.
43. After the hub has cooled, lubricate the splines with an approved lubricant and slide
the sleeve half (1) over the hub and bolt the end ring to it. Torque the ¾” bolts to
175 Ft. Lb. (237 N-m) (dry)
44. Install new water packing rings in the counterbore in both ends of the drumshaft.
REINSTALLING DRUMSHAFT IN FRAME:
The drumshaft assembly can be installed by reversing the removal procedures 1 thru
15, but before the coupling sleeves are bolted together the alignment must be checked
between the drumshaft and gear box.
45. Use a dial indicator to check the alignment similar to the illustrations in figure 7.3.
OFFSET ALIGNMENT ANGULAR ALIGNMENT
(a) (b)
Figure 7.3
ALIGNMENT SPECIFICATIONS:
Offset alignment fig. 7.3 (a) .024” (.61 mm) maximum

Angular alignment fig. 7.3 (b) .012” (.30 mm) maximum
Gap between hubs .50” (12.7 mm)
CE-538E
Rev. 4-27-99
CONTINENTAL EMSCO CO.
GENERAL LUBRICATION BULLETIN
FOR CE DRILLING EQUIPMENT
SUPERSEDES
CE538E 11/12/97
GENERAL LUBRICATION INSTRUCTIONS

FOR CONTINENTAL EMSCO PRODUCTS
C:\WINNT\Profiles\naiserka\Desktop\Section 09.doc
1
CE-538E
Rev. 4-27-99
DRILLING EQUIPMENT
Using the right kind of oil or grease on a regular basis extends the service life of
machinery. Where and how to lubricate is described in each Maintenance Manual
for the particular piece of equipment.
The following information lists the recommended type of lubricant to use, and the
chart identifies individual manufacturers products. Companies not listed can use the
chart to recommend their equivalent brands.
CROWN AND TRAVELING BLOCKS: Use a multipurpose lithium base grease.

Ambient temperatures; 0BF to 125BF (-18BC to 52BC) NLGI #2
-20BF to 40BF (-29BC to 4BC) NLGI #0
SWIVELS:
Main reservoir - Use an extreme pressure, non-corrosive, anti-foaming gear

lubricant.
Ambient temperatures; 0BF to 155BF (-18BC to 68BC) AGMA #6EP
-20BF to 40BF (-29BC to 4BC) AGMA #4EP
Wash pipe packing, oil seals and bail pins - Use a multipurpose lithium base
grease.
Ambient temperature; 0BF to 125BF (-18BC to 52BC) NLGI #2
ROTARY MACHINES and UNITIZED ROTARY CHAIN COUPLING:
Main reservoir - Use an extreme pressure, non-corrosive, anti-foaming gear

lubricant.
Pinion Cartridge - Use a multipurpose lithium base grease.

GB & GBH CATHEADS: Use a multipurpose lithium base grease.

2
CE-538E
Rev. 4-27-99
GENERAL LUBRICATION INSTRUCTIONS Cont=d.;
DRAWWORKS, COMPOUND TRANSMISSIONS, UNITIZED ROTARY TRANSMISSIONS,

ECR UNITS & PUMP DRIVES:
Grease lubricated bearings, drum brake centralized lubrication system, and all
miscellaneous grease fittings - Use a multipurpose lithium base grease.
Motor couplings require a multipurpose lithium base NLGI #1 grease.
Electrohoist III, IV & V gear couplings require Texaco Crater Compound #0 or equivalent.
Oil lubricated bearings and roller chains - Use a non-detergent machine oil as follows;
Ambient temperatures; 80BF to 125BF (27BC to 52BC) SAE 40
32BF to 100BF (0BC to 38BC) SAE 30
0BF to 40BF (-18BC to 4BC) SAE 20
ELECTROHOIST II GEAR BOX:
Use an extreme pressure, non-corrosive, anti-foaming gear lubricant.

-20F to 40BF (-29C to 4BC) AGMA #4EP
ELECTROHOST III, IV & V GEAR BOX:
Use an extreme pressure, non-corrosive, anti-foaming, mineral base gear lubricant.

Ambient temperatures; Below 40BF* to 80BF (4BC to 26BC) AGMA #3EP
80BF to 120BF (27BC to 49BC) AGMA #6EP
*Heaters are required to bring oil to 40° F (4°C) for starting.
AIRLINE LUBRICATORS: Use SAE 10 Wt. Motor oil.
DUPLEX & TRIPLEX MUD & SLURRY PUMPS:
Use an extreme pressure, non-corrosive, anti-foaming gear lubricant.

NOTE: See page 4 for initial filling of triplex pumps.
OVERRUNNING CLUTCH: Use SAE 50 Wt. Non-detergent machine oil.
Equipment not manufactured by Continental Emsco Company should be lubricated

as specified by the manufacturer.
CAUTION: Do not mix greases with different bases. Always clean reservoirs thoroughly
when changing to a grease with a different base.
3
CE-538E
Rev. 4-27-99
Addendum to
GENERAL LUBRICATION INSTRUCTIONS

FOR CONTINENTAL EMSCO COMPANY
DRILLING EQUIPMENT BULLETIN CE-538E
Continental Emsco has recently made a change in the design and material of the gears used in our
triplex mud pump line. The new gears will be made from a harder material which will ultimately
provide better performance and longer life but they do require some special treatment during the
break-in period. Effective immediately CE Co. will begin using a specially designed gear oil, for the
test runs in our manufacturing facilities, which is highly saturated with liquid soluble molybdenum
disulfide, and other extreme pressure and corrosion resistant additives.
This oil will help to polish the gear tooth surfaces to prevent initial pitting which is common on mud
pump gears. This is especially important on the new harder gears as they are more susceptible to cold
welding and scoring during the break-in period. The product will also provide rust prevention during
storage periods. It is strongly recommended that the End User also use this product for at least the
initial filling of the pumps. At the first oil change it would be at the user’s discretion whether to
continue it’s use or change to one of the approved AGMA EP oils.
The above product is made by; Schaeffer Oil & Grease Mfg. C.O.
Phone (800) 325-9962 Fax (314) 865-4107
(See Recommended Lubrication Product Chart for specifications)
If the Operator chooses not to use this oil for the initial filling, then a 5% by volume of a good Moly
product, such as Dow Corning M Gear Guard, should be added to the approved AGMA EP gear oil.
Implementation of the above recommendations will be well worth the extra cost of the products by
extending the life of the equipment and power savings due to reduction of friction.
4
R
Electrohoist V
7.11
MAINTENANCE:
46. Clean the flange faces of the flex coupling sleeves, insert a new gasket and bolt the
sleeve halves together with lubrication plugs positioned 180° apart. Torque the bolts
to 870 Ft. Lbs. (1180 N-m).
47. Remove two lubrication plugs 180° apart. Rotate the shaft to position the holes 45°
off vertical. Pour or pump 2 ¼ U.S. gallons (8.5 liters) of Texaco Crater Compound
# 0 or equivalent into the coupling. Reinstall the plugs and torque to 350 Ft. Lbs.
(475 N-m).
CE-538E
Rev. 4-27-99
RECOMMENDED LUBRICATION PRODUCT CHART

MANUFACTURER AGMA # 4 EP AGMA # 5 EP AGMA # 6 EP NLGI #2 NLGI #0 SAE 20 Wt. SAE 30 Wt. SAE 40 Wt. Hydraulic Oil
MULTIPURPOSE MULTIPURPOSE Non-Detergent Non-Detergent Non-Detergent
Machine Oil Machine Oil Machine Oil
AMOCO AMOGEAR EP AMOGEAR EP AMOGEAR EP Rykon Grease #2 Rykon Grease #0 Industrial Oil #68 Industrial Oil #100 Industrial Oil #220
Lubricant #150 Lubricant #220 Lubricant #320
ARCO Pennant NL 150 Pennant NL 220 Pennant NL 320 Litholine HEP 2 Litholine HEP 00 Rubilene 68 Rubilene 100 Rubilene 220
BP Energol Energol Energol Grease NLGI #2 Grease NLGI #0 Bartran HV 68 Bartran HV 100 Bartran 220 Bartran HV 22
GR-XP 150 GR-220 GR-XP 320
CHEVRON OIL CO Chevron NL Chevron NL Chevron NL Chevron Chevron AW Machine Oil AW Machine Oil AW Machine Oil
Gear Compound Gear Compound Gear Compound Polyurea EP Polyurea EP 100 150 220
150 220 320 Grease #2 Grease #0
CITGO EP Compound EP Compound EP Compound Citgo AP Citgo AP Pacemaker 68 Pacemaker 100 Pacemaker 150
150 220 320
CONOCO Gear Oil 150 Gear Oil 220 Gear Oil 320 EP Conolith #2 EP Conolith #0 Redlind 68 Redlind 100 Redlind 150
EXXON Spartan EP 150 Spartan EP 220 Spartan EP 320 Unirex #2 Lidok EP #0 Teresstic 33 Teresstic 100 Teresstic 150
LUBRIPLATE APG 90 APG 120 APG 140 Lubriplate 1200-2 Lubriplate MAG 1 3V Motor Oil # 3 Motor Oil #4 Motor Oil
MOBIL OIL CORP Mobilgear 629 Mobilgear 630 Mobilgear 632 Mobilgrease 77 Mobilux EPO DTE Heavy Med. DTE Extra Heavy DTE Extra Heavy ATF 220 or
DTE 24
PENZOIL CO. Maxol EP Gear Maxol Gear MP 705 MP 170 AW Hydraulic # 68 AW Hydraulic # 100 AW Hydraulic # 150
Lube #64 Lube Lube # 152
PHILLIPS PETRO. Philube SMP Philube SMP Philube SMP Philube L-2 Philube L-0 Condor Oil 68 Condor Oil 100 Magus Oil 150
Gear Oil Gear Oil Gear Oil (Grade 315) (Grade 465) (Grade 700)
SAE 90 SAE 120 SAE 140
QUAKER STATE Super Super Super Lithium EP Lithium EP SAE 20 Motor Oil SAE 30 Motor Oil SAE 40 Motor Oil
Quadrilube Quadrilube Quadrilube NLGI #2 NLGI #0
SAE 90 SAE 120 SAE 140
SCHAEFFER 209A Gear Lube 209A Gear Lube 209A Gear Lube Moly Ultra 800 #2 Moly Ultra 800 #0
150 220 320
SHELL OIL CO. Omala Oil 150 Omala Oil 220 Omala Oil 320 Alvania EP 2 Allvania EPRO Tellus Oil 68 Tellus Oil 100 Tellus Oil 150 Tellus Oil 32
STATOIL Loadway 150 Loadway 220 Loadway 320
TEXACO INC. Meropa Meropa Meropa Multifak EP 2 Multifak EP 0 Regal Oil R&O 68 Regal Oil R&O 100 Regal Oil R&O 150 Rando Oil HA 32
Lubricant 150 Lubricant220 Lubricant320
UNION OIL CO. OF Extra Heavy NL Extra Heavy NL Extra Heavy NL Unoba EP #2 Unoba EP #0 Unax 68 Unax 100 Unax 150
CALIFORNIA Gear Lube 4 EP Gear Lube 5 EP Gear Lube 6 EP
5
CE-538E
Rev. 4-27-99

OIL CAPACITIES FOR CONTINENTAL EMSCO EQUIPMENT
DRAWWORKS
C-1 Type II 105 U.S. Gal. 400 Liters

C-1 Type III 105 U.S. Gal. 400 Liters
C-3 Type I 60 U.S. Gal. 230 Liters
D-1 78 U.S. Gal. 296 Liters
EH-II 41 U.S. Gal. 155 Liters
EH-III, IV & V See Operation & Maintenance Manual
TYPE AU@ CATWORKS 45 U.S. Gal. 170 Liters

W/Right Angle Drive 50 U.S. Gal. 190 Liters
COMPOUNDS
CT-5 130 U.S. Gal. 493 Liters

D-221 W/Separate Lube System 80 U.S. Gal. 303 Liters
D-232 W/Separate Lube System 80 U.S. Gal. 303 Liters
F-SERIES TRIPLEX PUMP
F-350 40 U.S. Gal. 152 Liters

F-1000 75 U.S. Gal 284 Liters
F, FA, FB & FC-1300 100 U.S. Gal. 380 Liters
F, FA, FB & FC-1600 100 U.S. Gal. 380 Liters
FC-2200 120 U.S. Gal. 454 Liters
UNITIZED PUMP DRIVE FOR

ELECTRIC MOTOR, PER GUARD 20 U.S . Gal. 76 Liters
6
CE-538E
Rev. 4-27-99
TYPE "F" UNITIZED PUMP CHAIN DRIVE
F-500 30 U.S. Gal 15 Liters
DUPLEX PUMPS
DB-550 58 U.S. Gal. 220 Liters
DC-700 65 U.S. Gal. 246 Liters
ROTARIES
T-1750 (S/N 181 only) 6 U.S. Gal. 23 Liters
T-1750 (S/N 182-253) 12 U.S. Gal. 46 Liters
T-1750 (S/N 254-268) 8 U.S. Gal. 31 Liters
T-1750 (S/N 269 & UP) 10 U.S. Gal. 38 Liters
T-2050 (S/N 31 only) 5 U.S. Gal. 19 Liters
T-2050 S/N 111 & UP) 6 U.S. Gal. 23 Liters
T-2750 (S/N 89-94) 9 U.S. Gal. 34 Liters
T-2750 (S/N 95-228) 13 U.S. Gal. 50 Liters
T-2750 (S/N 229 & UP) 10 U.S. Gal. 38 Liters
T-3750 15 U.S. Gal. 57 Liters
ROTARY TRANSMISSIONS
RT-3A VERTICAL 21 U.S. Gal. 80 Liters
RT-3A HORIZONTAL 28 U.S. Gal. 106 Liters
CHAIN COUPLING 1 U.S. Gal. 4 Liters
SWIVELS
LB-140 3 ¾ U.S. Gal. 14 Liters
LA, LB-200 4 ¾ U.S. Gal. 18 Liters
LA, LB-300 6 ¾ U.S. Gal. 26 Liters
LA, LB-400 10 U.S. Gal. 38 Liters
LB-500 15 U.S. Gal. 57 Liters
L, LB & LC-650 19 ½ U.S. Gal. 74 Liters
7
R
Electrohoist V
10.0
SECTION 10
VENDOR MATERIAL DATA
INDEX
DESCRIPTION CE CO. PART NO.
KOP-FLEX 12CM COUPLING ASSEMBLY ........................... 7602-0835-48
KOP-FLEX 5-1/2 SERIES H COUPLING ASSEMBLY ........... 7602-0835-51
REXROTH P52935-0004 ½” QUICK RELEASE VALVE ....... 7602-2910-59

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R

Continental Emsco Company

DESCRIPTION PAGE/DWG. NO.

GENERAL INFORMATION.................................................. 1.1

PREFORMANCE CHART ..................................................... 1.4

The Electrohoist V is a new generation of Drawworks developed by Continental

Skid Length ...........................................................................................40’ [12192]

HOISTING CAPACITY: (Pounds)

GEAR MOTOR 12 LINES 14 LINES 16 LINES

4 GE-752 RB1 Shunt Wound Motors

DESCRIPTION PAGE/DWG. NO.

LIFTING THE DRAWWORKS ........................................................................... 2.2

AIR LINES ......................................................................................................... 2.3

WATER LINES .................................................................................................. 2.3

HYDRAULIC LINES .......................................................................................... 2.3

DRILLING LINE CLAMP.................................................................................... 2.4

SCHEMATIC LINE CONNECTIONS ................................................ 6204-0118-02

GENERAL DIMENSIONS................................................................. 6204-0320-10

MECHANICAL SCHEMATIC ............................................................ 6204-0400-02

WATER SYSTEM SCHEMATIC, EATON DISC BRAKE.................. 6204-0400-07

Refer to drawing 6204-0320-10

Example: 160 ft. X .0563 = 9 Inches

For 2º; - Height of derrick X .416 = Maximum distance from fastline

Example: 160 ft. X .416 = 66.5 Inches

LIFTING THE DRAWWORKS:

See General Dimension drawing 6204-0320-10 for recommended support points

Refer to Hydraulic & Pneumatic Diagram drawing 6204-0314-10, Air Piping

SS SURE STOP DRUM BRAKE SYSTEM: Reference Dwg. No. 6204-0435-00

Brake cooling water lines must be connected at points marked on referenced

EATON DISC BRAKES: Reference Dwg. No. 6204-0446-00

DRILLING LINE CLAMP:

DESCRIPTION PAGE NO.

GENERAL INFORMATION ............................................................... 3.1

REGENERATIVE BRAKING ............................................................. 3.1

EATON 736 WCB BRAKES .............................................................. 3.1

SS SURE STOP DISC PARK BRAKE............................................... 3.1

EMERGENCY DISC BRAKE............................................................. 3.2

OPERATING SPECIFICATIONS....................................................... 3.4

HOISTING CAPACITY ...................................................................... 3.4

LOWERING CAPACITY .................................................................... 3.5

DRIVE MOTOR FAILURE ................................................................. 3.5

EATON 736 WCB BRAKES:

SS SURE STOP DISC PARK BRAKE:

SS SURE STOP DISC PARK BRAKE Cont’d:

SS SURE STOP DISC SERVICE BRAKE:

EMERGENCY DISC BRAKE:

Interlocks are provided to guard against accidental release of the emergency

While operating the Electrohoist V the console gages should be monitored

* Fresh Water, See section 5 for other cooling media.

HOISTING CAPACITY Cont’d:

HOISTING CAPACITY: (Pounds)

TRANSMISSION MOTOR 12 LINES 14 LINES 16 LINES

DRIVE MOTOR FAILURE:

SURE STOP DISC BRAKE SYSTEM

DRAWINGS DWG. NUMBER

Continental Emsco Co.

Type SS Sure Stop

Disc Brake System

Operation & Maintenance

DESCRIPTION PAGE NO.

This information is not elementary, as it is intended for operators and servicemen

All specifications are in accordance with Engineering designs and should be

Main Drum Grooving: _2”_________