9130E099 - Rev. 0

OPERATION and
MAINTENANCE MANUAL
MOSVOLD
SSGD-1000-5750-55-82-10.5
MAIN DRAWWORKS
S/N: 312
Project: E2187
Job No.: C22500
P.O. No.: 4500035049
Ref. No.: ST8554.DW
ADDITIONAL INFORMATION
This document contains proprietary and NATIONAL OILWELL VARCO

confidential information of National Oilwell 6415-75 Street
Varco. Reproduction or use of this design or
distribute information by others is permissible Edmonton, AB
only if expressly authorized in writing by Canada T6E 0T3
National Oilwell Varco. ©Copyrights National Ph. (780) 944-3800
Oilwell Varco
DOCUMENT NO.:
9130E099
WWW.NOV.COM
Document No. 9130E099
Page 1
TABLE OF CONTENTS
1 INTRODUCTION 3
1.1 MANUAL OVERVIEW & SCOPE............................................................................................ 3
1.2 WARRANTY INFORMATION ................................................................................................. 4
1.3 WARRANTY LIMITATIONS ................................................................................................... 5
1.4 EQUIPMENT SERVICE LIFE ................................................................................................. 5
2 SAFETY SUMMARY 7
2.1 SAFETY TERMS & CONVENTIONS ....................................................................................... 7
3 SSGD-1000 DRAWWORKS 9
3.1 GENERAL DESCRIPTION ..................................................................................................... 9
3.2 TECHNICAL SPECIFICATIONS............................................................................................ 10
3.3 POWER FLOW CHART ...................................................................................................... 11
4 PRESERVATION AND INSTALLATION 13

4.1 STORAGE AND PRESERVATION ........................................................................................ 13
4.2 PRE – INSTALLATION PROCEDURE ................................................................................... 14
4.3 INSTALLATION PROCEDURE ............................................................................................. 15
4.3.1 Lifting Procedure........................................................................................................ 15
4.3.2 Transportation Instructions ........................................................................................ 16
4.3.3 Mechanical Installation Instructions ........................................................................... 17
4.3.4 Pre-commissioning Procedure................................................................................... 19
4.3.5 Commissioning Procedure......................................................................................... 21
5 OPERATING INSTRUCTIONS 23
5.1 MANUAL AND EMERGENCY OPERATION ........................................................................... 23
5.2 BRAKE CALIPER REMOTE OPERATION ............................................................................. 23
5.3 BRAKE CALIPER MANUAL / EMERGENCY OPERATION ....................................................... 24
5.3.1 Manual / Emergency Operation (Hydraulic Pumps Operating).................................. 24
5.3.2 Manual/Emergency Operation (Hydraulic Pump Not Operating) ............................... 25
5.4 BRAKE CALIPER DELAY SYSTEM ..................................................................................... 26
5.5 DISC BRAKE CALIPER BURN PROCEDURE ........................................................................ 26
5.6 BRAKE TESTING PROCEDURE .......................................................................................... 29
5.7 DRILL LINE ATTACHMENT TO DRUM ................................................................................. 29
5.8 DEAD WRAPS ON THE DRUM ............................................................................................ 30
5.9 HAZARDS AND PROTECTIVE MEASURES ........................................................................... 30
6 MAINTENANCE AND LUBRICATION 31

6.1 MAINTENANCE OVERVIEW AND SCOPE ............................................................................. 31
6.2 MAINTENANCE AREA AND PERSONNEL ............................................................................ 31
6.3 ROUTINE INSPECTION ...................................................................................................... 32
6.4 PERIODIC MAINTENANCE ................................................................................................. 40
6.5 SSGD-1000 DRAWWORKS - LUBRICATION SCHEDULE ..................................................... 41
7 MAIN OVERHAUL 43
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7.1 PARTS FIT - GENERAL ..................................................................................................... 43

7.2 SHAFTS ........................................................................................................................... 43
7.3 BEARINGS ....................................................................................................................... 44
7.4 SPACERS ........................................................................................................................ 44
7.5 HYDRAULIC SYSTEM ........................................................................................................ 44
7.5.1 Hydraulic Pump – Pressure Compensator Adjustment Procedure ............................ 45
7.5.2 Hydraulic Pump – Volume Adjustment Procedure..................................................... 47
7.6 GEARS ............................................................................................................................ 47
7.6.1 Bull Gear Installation Procedure ................................................................................ 50
7.7 HUB AND SHAFT FITS ...................................................................................................... 52
8 MAJOR REPAIRS AND MODIFICATIONS 55

8.1 GENERAL DRAWWORKS REPAIR INSTRUCTIONS ............................................................... 55
8.2 DISASSEMBLY OF THE BUILDING ...................................................................................... 55
8.3 DRUMSHAFT REMOVAL AND RE-INSTALLATION ................................................................ 56
8.3.1 Main Bearing and Drum Replacement....................................................................... 58
8.4 TORQUE ARM ASSEMBLY ................................................................................................ 58
8.5 LEBUS GROOVING REPLACEMENT ................................................................................... 60
8.6 DRUM SHAFT END BEARING ALIGNMENT PROCEDURE ..................................................... 61
8.7 GEAR ALIGNMENT PROCEDURE ....................................................................................... 62
8.8 PINION REMOVAL, MOUNTING, AND FITTING ..................................................................... 66
8.8.1 Pinion Removal.......................................................................................................... 66
8.8.2 Pinion Fitting .............................................................................................................. 67
8.8.3 Pinion Mounting ......................................................................................................... 68
9 TROUBLESHOOTING 71
9.1 EQUIPMENT FAULT SYMPTOMS AND CAUSES ................................................................... 71
10 TIGHTENING TORQUE GUIDE 73

10.1 BOLT TORQUE CHART ..................................................................................................... 73
10.2 SOCKET HEAD CAPSCREW TENSILE REQUIREMENTS........................................................ 75
10.3 TURN-OF-NUT TIGHTENING .............................................................................................. 76
11 SPARE PARTS 77
11.1 OVERALL DRAWWORKS SPARES ..................................................................................... 77
11.2 2” CONTROL VALVE SPARES ........................................................................................... 79
11.3 LUBRICATION PUMP ‘10S’ SPARES .................................................................................. 79
11.4 SPEED REDUCER 4:1 SPARES (7020B086)...................................................................... 79
11.5 BRAKE CALIPER ASSEMBLY SPARES ............................................................................... 80
12 DRAWINGS 83
13 DATA SHEETS 85
14 VENDOR INFORMATION 87
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1 INTRODUCTION
1.1 Manual Overview & Scope
1.2 Warranty Information
1.3 Warranty Limitations
1.4 Equipment Service Life
1.1 Manual Overview & Scope
This operation and maintenance manual provides instructions for the SSGD-1000
drawworks. The mechanical components discussed here are engineered and selected
for the most reliable and cost-effective operation. However, correct preventive
maintenance should be considered an investment, as it minimizes equipment wear,
failures, and downtime. New parts can be installed at less expense when the equipment
is in the shop for repairs or strip-down than when emergency servicing is required.
The scope of this manual includes only equipment supplied by National Oilwell Varco
and does not pertain to equipment supplied by the Customer or others. In the Vendor
Information section you can find information that pertains to equipment that is supplied,
but not manufactured, by National Oilwell Varco. If there is any overlapping information
between this manual and a manual from a vendor, the vendor’s manual shall take
precedence unless otherwise noted.
Photo: SSGD-1000 Drawworks
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1.2 Warranty Information
1. All National Oilwell Varco equipment built in our plant is guaranteed to be free from
defects in workmanship for a period of 12 months from the date of delivery to the
original customer or as specified in the contract.
2. In the event of any failure on which a warranty claim may be presented the owner
must notify us and follow our instructions relative to the inspection or disposition of
the defective part or parts and to the repairing and/or replacement thereof.
3. The foregoing warranty is contingent on the proper application of equipment and

products by the owner in accordance with the recommendations of the manufacturer
National Oilwell Varco, and shall not apply to any products which shall have been
repaired or altered in any way so as in the judgment of National Oilwell Varco to
affect adversely their performance and reliability nor which have been subject to
misuse, negligence or accident or equipment that has been repaired to the
customer's specifications rather than to National Oilwell Varco’s specifications.
4. Our obligations under this warranty is limited to supplying parts and labour to correct
defective workmanship to an amount not exceeding the charges for the original
repair and shall not include any transportation charges, loss of revenue, or any direct
or indirect consequential damages.
5. Travel time and travel expenses will be charged to customer's account at cost.
6. All warranty work will be done on a straight time basis and the customer will be
charged for the difference between straight time and overtime.
7. The warranty does not cover any hoisting, trucking or transportation charges.
8. Products furnished by National Oilwell Varco, but not manufactured by National

Oilwell Varco, will carry only the warranty of the manufacturer of such products.
9. The entire liability and obligation of National Oilwell Varco with respect to
workmanship is defined by this warranty and is given in lieu of any and all other
warranties, expressed or implied. No oral or written statements or representations
with respect to the subject matter hereof shall be binding. Upon the expiration of this
warranty, all liability on the part of National Oilwell Varco in connection herewith shall
terminate in any event.
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1.3 Warranty Limitations
This manual is prepared as a guide for the proper installation, care, and operation of the
unit. Because of the varying methods and requirements for these functions, it is not
possible to detail all facets of these subjects; when situations encountered are outside
the scope of this publication, refer to the manufacturer's technical services department.
The manufacturer will, upon request and contract, provide trained personnel to assist in
the maintenance and servicing of this equipment.
Improvements in design, engineering, materials, production methods, etc. may

necessitate changes in this product over time. National Oilwell Varco reserves the right
to make these design changes without incurring any obligation for equipment previously
delivered.
1.4 Equipment Service Life
National Oilwell Varco equipment that is properly maintained and operated within rated
loads has a long service life. The service life of the equipment is dependent on the
operator’s operating practices and the codes under which the country is regulated. The
operator will test and maintain the equipment at intervals as per his or her set program.
Operators should compile and retain accurate and clear maintenance records that
include the following information:
• Inspector/Mechanic
• Date of inspection
• Records of performance
• Preventative maintenance
• Repair/replacement history
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2 SAFETY SUMMARY
2.1 Safety Terms & Conventions
2.1 Safety Terms & Conventions
This manual uses the following standard safety terms and conventions that span all
areas of the industry:
WARNING: A warning provides a specific procedure or additional instructions/

information which must be followed while completing the procedure
at hand. Failure to comply with a Warning will result in personal
injury and or equipment damage.
CAUTION: A Caution provides a specific procedure or additional instructions/

information which must be followed while completing the procedure
at hand. Failure to comply with a caution will result in damage to
the assembly / equipment being worked on.
NOTE: This provides information necessary to complete the procedure properly

or information that will make the procedure easier to understand.
Only qualified personnel should be allowed to operate and maintain the equipment.
Personnel should not operate the unit unless they are thoroughly familiar with all unit
operating controls and functions and have read the equipment manual.
Personnel are protected from exposed mechanical dangers by design. Nevertheless,

operating and maintenance personnel should wear suitable protective clothing and
equipment. Keep hands, hair, clothing, jewelry, rags, tools, etc. away from all moving
parts and pinch points during operation and maintenance.
Do not attempt equipment operation with inadequate visibility.
Promote good safety measures, including training, at all times around the equipment
throughout all operating phases. It is the equipment owner's/operator's responsibility to
establish safety measures as well as enforce them.
Equipment used in lifting and moving the unit must be sufficiently rated to handle the
weights involved.
Before performing maintenance on or disconnecting any high-pressure piping or hoses,

ensure the unit has been bled to zero pressure. Observe a similar procedure for
electrical connections, ensuring electrical power is locked out before attempting
maintenance.
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WARNING: Do not breathe cleaning solvent vapors. The toxic effect of some
solvents is cumulative. Continued inhalation can lead to permanent
disability or death. When using flammable cleaning solvents, take
all appropriate fire protection precautions to prevent injury to
personnel and damage to equipment.
WARNING: Do not direct compressed air against any part of the body. High
pressure air can cause injuries. Do not rotate ball or roller bearings
with compressed air. Do not direct compressed air against a fire.
Tag controls and depressurize hydraulic system before
disconnecting or removing any part of the hydraulic piping. Ensure
all tanks, lines, and equipment are depressurized by slowly
releasing pressure through approved means.
WARNING: Use adequate hoisting equipment. Observe all safety precautions.

Ensure that hydraulic systems are depressurized and controls are
tagged “DANGER – DO NOT OPERATE – EQUIPMENT BEING
REPAIRED” before attempting adjustment and repair procedures
on the equipment.
WARNING: Determine if the equipment has preloaded components such as

springs before disassembly. Remove the preload prior to
disassembly by approved format.
WARNING: When working on a system, disconnect electrical power supply

and tag controls to prevent accidental operation. Serious injury or
death could result. Use mechanical shutoff when available.
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3 SSGD-1000 DRAWWORKS
3.1 General Description
3.2 Technical Specifications
3.3 Power Flow Chart
3.1 General Description
The single speed gear driven drawworks

features a direct drive design, ideal for
offshore applications where space,
weight, and power are important
considerations. Braking is achieved by
the use of the AC motors, which are also
the prime movers for the drawworks.
The drawworks is equipped with a disc
type braking system. The primary
function of the disc brake system is
parking and emergency capabilities in
the event of power failure.
Photo: SSGD-1000 Drawworks
The disc brake system employs two discs, one disc on each side of the drum. The
brake’s hydraulic calipers are spring-applied and hydraulically released, providing a fail-
safe braking capability for both park and emergency braking.
The drawworks frame has been designed and analyzed for optimum strength and
minimum weight. The result is an efficient, high-strength weldment design. The frame is
fabricated of high strength plate and structural members to provide a sturdy oil-tight and
weatherproof enclosure for the shafts. Structural support plates are provided for shaft
main bearings. The drawworks frame is carefully fabricated using precision jigs and
fixtures to maintain accurate alignment.
The drawworks design provides for simple installation. Oversize service panels are
located at key locations on the drawworks to provide easy access for all routine
maintenance and major service requirements, ensuring minimum downtime.
The drive assembly uses five electric motors.
The design life of this drawworks is 20 years; an effective lubrication and maintenance
program combined with routine change-out of expendable components is assumed to
be in operation.
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3.2 Technical Specifications
General Specifications
Serial Number: 312
Hoisting Capacity, 14 Lines: 1,000 Short Tons (907 mT)
Max. Block Speed: 14 lines 248 ft/min (1.14 m/s) @ 277 Short Tons
(252 mT)
Max. Block Speed 12 lines 290 ft/min (1.33 m/s) @ 241 Short Tons
(12 part line): (219 mT)
Maximum Line Pull 159,439 lbs (72,320 kg)
Wire Line Size: 2” (51 mm)
Drum Size (bare): Ø 53.75” x 82” wide
Drum dia.@ Root of Grooving: 55” (1,397 mm)
Overall Gear Ratio: 10.5:1
Brake Discs
Number of Brake Disc: 2
Brake Disc Cooling: Air Cooling
Brake Disc Diameter: Ø 117" (2,972 mm)
Brake Disc Thickness: 3” (76.2 mm)
Lube Pump
Motor Operating Speed: 1,800 rpm
Lube Pump Rating: 1.36 L/sec (22 gpm @ 250 psi)
Oil Sump Capacity: 757 Litres (200 US Gal.)
Hydraulic Pump
Motor Operating Speed: 1,800 rpm
Hydraulic Pump Rating: 0.126 L/sec (2gpm)
Hydraulic Sump Capacity: 76 Litres (20 US Gal.)
Overall Dimensions
Length: 30’ – 7 7/16” (9,333 mm)
Width: 12’ – 9 ¾” (3,905 mm)
Height: 14’ – 4 ½” (4,382 mm)
Equipment Weights
Drumshaft Assembly: 92,191 lbs (41,817 kg)
Torque Arm Assembly 3,900 lbs (1,769 kg)
(Two-Motor):
Torque Arm Assembly 4,097 lbs (1,858kg)
(Three-Motor):
Baylor Motor (each): 7,000 lbs (3,175 kg)
Total Weight of Assembly: 195,037 lbs (88,467 kg)
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3.3 Power Flow Chart
MOTOR MOTOR 12 LINES 14 LINES

SPEED TORQUE BLOCK HOOK BLOCK HOOK BLOCK HOOK BLOCK HOOK BLOCK HOOK BLOCK HOOK BLOCK HOOK BLOCK HOOK
RPM FT LBS SPEED LOAD SPEED LOAD SPEED LOAD SPEED LOAD SPEED LOAD SPEED LOAD SPEED LOAD SPEED LOAD
FPM LBS FPM LBS FPM LBS FPM LBS FPM LBS FPM LBS FPM LBS FPM LBS
1st Layer 1st Layer 2nd Layer 2nd Layer 3rd Layer 3rd Layer 4th Layer 4th Layer 1st Layer 1st Layer 2nd Layer 2nd Layer 3rd Layer 3rd Layer 4th Layer 4th Layer
0 10600 0 2,808,833 0 2,643,535 0 2,496,610 0 2,365,158 0 3,276,972 0 3,084,124 0 2,912,712 0 2,759,351

0 9792 0 2,594,726 0 2,442,027 0 2,306,303 0 2,184,870 0 3,027,180 0 2,849,032 0 2,690,686 0 2,549,016
800 8680 95 2,048,849 101 1,928,276 107 1,821,105 113 1,725,219 81 2,356,130 86 2,217,473 91 2,094,229 96 1,983,963
800 8000 95 1,888,340 101 1,777,213 107 1,678,437 113 1,590,064 81 2,171,548 86 2,043,754 91 1,930,165 96 1,828,537
800 7850 95 1,852,934 101 1,743,890 107 1,646,967 113 1,560,250 81 2,130,832 86 2,005,433 91 1,893,974 96 1,794,252
800 7550 95 1,782,121 101 1,677,244 107 1,584,025 113 1,500,623 81 2,049,399 86 1,928,793 91 1,821,593 96 1,725,682
1000 6030 118 1,423,337 126 1,339,574 133 1,265,122 141 1,198,511 102 1,636,804 108 1,540,479 114 1,454,862 121 1,378,260
1200 5028 142 1,186,822 151 1,116,978 160 1,054,898 169 999,355 122 1,364,818 130 1,284,499 137 1,213,108 145 1,149,235
1400 4310 166 1,017,343 176 957,473 187 904,258 197 856,647 142 1,169,922 151 1,101,072 160 1,039,876 169 985,124
1600 3770 190 889,880 201 837,511 213 790,964 225 749,318 163 1,023,342 173 963,119 183 909,590 193 861,698
1800 3351 213 790,979 227 744,430 240 703,055 253 666,038 183 909,607 194 856,077 206 808,498 217 765,928
1987 3036 235 716,625 250 674,452 265 636,967 280 603,429 202 824,103 214 775,605 227 732,497 240 693,930
2300 2172 273 512,684 290 482,513 307 455,696 324 431,702 234 589,575 248 554,879 263 524,040 277 496,448
MAXIMUM INTERMITANT RATINGS WITH NO TRAVELLING BLOCK EFFICIENCY LOSSES

INTERMITTANT OPERATION
CONTINUOUS OPERATION
NOTES: Loads at zero block speed (STATIC) in the first row of the chart are based on no efficiency losses
Maximum load with 12 lines regardless of speed = 1714286 pounds
Maximum load with 14 lines regardless of speed = 2000000 pounds
Fast line pulls are based on the second layer of wireline
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4 PRESERVATION AND INSTALLATION

4.1 Storage and Preservation
4.2 Pre-Installation Procedure
4.3 Installation Procedure
4.1 Storage and Preservation
Proper storage and preservation measures will help ensure the maximum design life for
the drawworks. Accessory items, spare parts, etc. shall be protected in accordance with
these guidelines.
NOTE: The drawworks is shipped dry; however, a preservative is run through the
lubrication system prior to shipping. All applicable reservoirs have been
shipped with sufficient oil in order to minimize the areas that may become
exposed to condensation or corrosion.
Prior to shipping or for long term storage, protect the hydraulic and lube oil systems
from rust and corrosion. Add the Rust Inhibitor “PROCON”. The recommended
treatment rate is 2% to existing oil (engines, manual transmissions, final drives,
hydraulic systems, circulating systems, gear boxes, etc.), and 5% for fuel systems.
Protection is extended for up to two years for most applications.
Oil Sump Capacity: 757 liters (200 US Gal.)

Treatment Amount Required: 15 liters (4 US Gal.)*
(* if oil sump is full to capacity)
NOTE: When putting equipment back into operation, both the lubrication and
hydraulic tank require filling prior to start-up.
Ensure the equipment has been cleaned of all foreign matter and thoroughly dried
before preservation.
Protect all machined surfaces with a rust inhibitor (i.e. Denso Tape or Tecteel spray
or equivalent) where applicable.
Place rubber gaskets and metal blanks over all interface connections. Interface
surfaces, which are not corrosion resistant, is to be protected with a corrosion
inhibitor before sealing.
Ensure all grease points are well-greased.
Indoor storage is preferred for the equipment because condensation and corrosion
can be minimized in a controlled environment.
Remove mud, adhering dirt, and other foreign matter able to hold moisture. If
cleaning is done with steam or a solvent, avoid washing lubricating oil or grease
from unpainted surfaces or close-fitting elements. Touch up the paint if necessary.
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Elevate the equipment some distance from the ground or floor. Enough beams
should be provided to give normal support to the equipment and be high enough to
avoid water accumulation; a drained location is preferable. Remove any
accumulated moisture on or near equipment.
If the equipment must be stored outdoors, moisture must be prevented from
contacting the equipment. All equipment should be packed with heat-shrunk plastic
or tarpaulin of at least 0.15 mm thickness or crated. Ensure the integrity of the
tarpaulin and/or crating.
Where storage temperature is not stable, sufficient sealing of the equipment with
tape and plastic sheet is recommended along with use of desiccant. Cable ends are
preserved with sealing tape or blanks. Desiccant bags are used inside all enclosed
areas such as instrument cabinets and junction boxes. Renew desiccant and sealing
tape as necessary.
Place packing around valve panels (if applicable) to protect against shock or impact.
For long term storage, National Oilwell Varco recommends the drum assembly be
rotated every six months to prevent “brinelling” of bearings. Follow the below
procedure to properly rotate the drum assembly.
1. Remove rust protector from the brake discs.
2. Use the hand pump to pressure up the hydraulic system. (Follow the
instructions outlined in section 5.3.2.)
3. Release the brake calipers.
4. Drum can now be rotated with a “snipe.”
5. After several complete rotations, re-apply the brake calipers and reinstall the
motors’ locking bolts.
6. Re-apply the rust preservatives onto the brake discs (if the equipment is
scheduled for extended storage).
4.2 Pre – Installation Procedure
Various measures have been taken or should be taken to preserve the drawworks
equipment. Note the following instructions when taking the drawworks out of storage
and preparing it for installation:
• Remove tape and plastic sheeting from unpainted machined surfaces, and all
exposed shafts.
• Remove any metal or molded plastic caps from all threaded connections.
• Remove blanks from the exposed piping ends of the air and cooling systems.
• Steam-clean areas covered with corrosion preventative and surface protection
coatings to remove the coating.
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• Re-lubricate areas where steam cleaning may have washed away lubricants from
pivot points and other moving mechanical parts.
• Painted areas may have suffered chipping and wear during preservation. Surfaces
must be cleaned of surface corrosion and thoroughly dried, before being repainted
with machinery enamel.
• Use silicone sealant for all sealing surfaces.
• After rust protector is removed, clean the brake discs again using a low residue
cleaning solvent such as “Electro-Sol” or MEK. Ensure discs are free of all residues.
4.3 Installation Procedure
4.3.1 Lifting Procedure
To lift the drawworks, use a spreader

beam (not part of delivery). The lugs are
located above the corners of the main
doors (on the front) and above the small
doors (on the back) of the drawworks.
Refer to the SSGD-1000-5750
Drawworks Lifting Diagram, drawing
9130L102.
WARNING:
Extreme caution must be exercised

when lifting the drawworks as
personal injury or death can result
from unsafe work practices. Follow
all local laws and regulations
regarding overhead lifting
operations.
Refer to the Typical Drawworks Lifting

Diagram 1 and Typical Drawworks Lifting
Diagram 2 for details on lifting
instructions. Note that this is a typical
drawing for lifting equipment suitable for
the drawworks. Use equivalent, certified
equipment.
Typical Drawworks Lifting Diagram 1
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Typical Drawworks Lifting Diagram 2
4.3.2 Transportation Instructions
Do not support the drawworks on the channel iron at the ends of the skid during
transport, as they are not strong enough to support the weight of the drawworks.
Support the drawworks using the whole base of the drawworks. Refer to the Drawworks
Skid Footprint Layout - Main, drawing 9130C138.
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4.3.3 Mechanical Installation Instructions
WARNING: Extreme caution must be exercised when lifting the drawworks

into position as personal injury or death can result from unsafe
work practices. Follow all local laws and regulations regarding
overhead lifting operations.
The five-motored drawworks has eight mounting locations. Each mounting location shall
be checked according to the procedure below.
The drawworks requires a level, straight base for proper operation. Prior to installation
of the drawworks, check the supporting structure for level and straightness at each of
the mounting locations (refer to drawing 9130C138). The variation from level can not
exceed 1/4” over the length of the drawworks (29’ – 5”) or 1/8” over the width of the
drawworks (11’ – 0”). The structure should also be straight within 1/8”. This means that
measuring from line drawn from one end of the drawworks to the other end of the
drawworks will result in a deviation of no more than 1/16” for the two mounting locations
in the centre of the drawworks.
Straight line from points 1 to 4
1 2 3 4
Points 2 and 3 are no more than 1/16” away from the straight line.
Install shims to bring the supporting structure within the tolerances indicated above.
Once the supporting structure is level and straight, hoist and install the drawworks onto
the structure.
NOTE: Refer to lifting instructions for details.
Prior to installing and torquing the tie down bolts, check to ensure the drawworks skid is
in full contact with the supporting structure at each of the mounting points. If the
drawworks skid is not touching the supporting structure then shim up the skid at the
mounting point.
CAUTION: Do not tighten down the tie down bolts to pull the drawworks skid
tight to the supporting structure. Shim first.
After completing all the shimming, torque all tie down bolts to 1400-1500 ft·lbs (for A325
structural bolts).
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Check the level and straightness of the drawworks skid using a surveyor’s level or
similar instrument to take measurements on the skid at the points indicated (eight points
for five-motored drawworks). Each measurement location is marked with a centre punch
indent on the top flange of the main skid beam. The eight locations are directly above
the tie down bolt locations.
Rear
5 6 7 8
Left Right
1 2 3 4
Front
If level measurements are out of tolerance, shim up the drawworks.
Once the drawworks is attached, levelled, and straight, install the loose components:
Install the motor duct onto the top of the enclosure. Refer to the Drawworks Duct
Flange Details - Main, drawing 9130C140.
Connect all electrical devices.
Connect drip pan drain lines (three places – items N5, N6 & N7). Refer to
Drawworks Skid Nozzle Location - Main, drawing 9130C139.
Connect lube oil tank drain (item N4) and hydraulic tank drain (item N3). Refer to
Drawworks Skid Nozzle Location - Main, drawing 9130C139.
Plumb up water cooling supply and return line (item N1& N2). Ensure 20 gpm of
fresh water is available to provide cooling for the lubrication system.
The drawworks is now ready for the pre-commissioning procedure.
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4.3.4 Pre-commissioning Procedure
Prepare the drawworks for service in accordance with the following instructions:
• Apply two (2) shots of grease to the torque arm support bearings. The grease zerks
are located outside the enclosures and labelled with grease tags.
• Check fluid level in the lube oil and hydraulic tank. Fill if required.
CAUTION: Ensure the tanks have not been contaminated with water during
shipment by opening drain valve and checking the outflow for water.
• Check rotation on lube and hydraulic pumps. Ensure the pump is rotating in the
correct direction.
WARNING: Hydraulic pumps are start/stop controlled by the PLC system.

Running without the start/stop function in operation can result in
over pressurization of the hydraulic system.
• Start and run each lube pump separately. Ensure proper operation. Check flow to
each bearing and all the gears. Check for leaks. Refer to the SSGD-1000
Lubrication Schematic, drawing 9130X059.
• Check pre-charge pressure on Accumulator bottles. Pressure should be at a
minimum of 1,500 psi per bottle. Refer to the SSGD-1000 Brake Hydraulic
Schematic, drawing 9130X058.
• Ensure ball valves on accumulator bottle and inlet are open and that drain valves on
accumulator bottles are closed. Refer to drawing 9130X058.
• Check manual control valves for brake operation are in the remote operation
positions.
o Manual/remote valves are in the remote position (item F)
o Emergency lowering isolation valve is closed (item B)
o Emergency bleed off valve is open (item N)
o Hand pump suction valve is closed (item Z)
Refer to drawing 9130X058.
• Start each hydraulic pump and run until pressure of 3,000 psi is achieved. Check for
leaks. Pressurize and release pressure on system several times.
• With hydraulic system pressurized to 3,000 psi, switch manual/remote valve (item F)
to the manual position. Open the emergency lowering isolation valve (item B) and
close the emergency bleed off valve (item N). Apply pressure until calipers are fully
released by applying pressure on emergency load lowering valve handle (item 2).
• Remove all brake caliper pads and store out of the way.
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NOTE: Always re-install brake pads in the same caliper they were removed from.
• Using a solvent such as varsol, remove the protective coating from the brake discs.
Ensure none of this coating is accidentally splashed on to the caliper pads.
CAUTION: Contamination of the caliper pads with oil. Grease, etc. will result in
reduced brake capacity.
WARNING: Contaminated brake pads must be replaced immediately. Do not

operate the drawworks with contaminated brake pads.
• After the rust protector is removed, clean the brake discs again using a low residue
cleaning solvent such as “MEK” (Methyl-Ethyl-Ketone). Ensure discs are free of all
residues.
• Reinstall brake caliper pads.
• Apply brakes by releasing the handle of the emergency load lowering valve (item 2).
• Release and apply brakes several times. Check operation of hydraulic pumps
Start/Stop system. Pump should kick-out at 3,000 psi and start up at 2,800 psi.
Check each pump.
• Turn on AC Motor Blowers. Ensure dampers are in the open position for all motors.
• Run drawworks drum. Check both directions; investigate any unusual noises or
vibrations. Ensure proper operation of lube and hydraulic system.
• Burn in all brake pads. Refer to the Operation Manual, SSGD-1000 Drawworks
document number S0100688-OPM-800 or Section 5.5 of this manual for instructions.
WARNING: Do not overheat brake discs as this may cause the discs to warp –
maximum temperature is 100°C.
WARNING: A brake capacity test must be performed after any brake

maintenance procedure.
• Attach the wireline to the drum using the wireline clamp assembly.
• Torque the wireline clamp nut to 483 ft·lbs (dry). Refer to the SSGD-1000 Drumshaft
Assembly, drawing 9130A250.
• Ensure 10 dead wraps are left on the drum when the travelling block is in the lowest
position.
• Drawworks is now ready for operation.
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4.3.5 Commissioning Procedure
• Ensure the lube pumps and hydraulic pump are activated when the drawworks is
turned on.
• Ensure the brakes engage/disengage from the driller control.
• Ensure blowers activate when the drawworks switches on.
• Ensure all sensors are operating properly.
• Hoist the block with drawworks and ensure that the driller controls function properly.
• While hoisting, check for excessive noise. Investigate any unexpected vibrations.
• Hoist block up and down several times while checking for these conditions.
• Check the spooling of wire rope. Ensure the rope does not pile up on either side of
the drum. If line plies up, install kicker plates to push the line over on the next wrap.
The kicker plate is installed on to the wear plate at the position just past where the
line starts to climb on top of itself. The plate is just thick enough to push the wireline
over to the next row. Install only one kicker plate on each side of the drum. Refer to
the Drum Kicker Plate Layout, drawing 9130F237.
• Continue running the drawworks up and down for one hour.
• After one hour, check all components for leaks and repair as required.
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5 OPERATING INSTRUCTIONS
5.1 Manual and Emergency Operation
5.2 Brake Caliper Remote Operation
5.3 Brake Caliper Manual / Emergency Operation
5.4 Brake Caliper Delay System
5.5 Disc Brake Caliper Burn Procedure
5.6 Brake Testing Procedure
5.7 Wire Line Clamping Procedure
5.8 Dead Wrap on Drum
5.9 Protective Measures
5.1 Manual and Emergency Operation
For the start, normal operation, stop and emergency stop operations, refer to the
Operation Manual, SSGD-1000 Drawworks document number S0100688-OPM-800.
5.2 Brake Caliper Remote Operation
Refer to the Brake Hydraulic Schematic, drawing 9130X058, for these operations.
1. Ensure the brake control valve handle (item 2 – emergency load release circuit
ONLY) is retracted, fully lifted and locked into place.
2. Ensure all eight manual/remote Valves (item F) are in the remote position.
3. Ensure the emergency bleed-off valve (item N) is open.
4. Verify the emergency lowering valve isolation valve is closed (one of item B –
emergency load release circuit only).
5. Operate brakes with controls in the driller’s cabin.
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5.3 Brake Caliper Manual / Emergency Operation
5.3.1 Manual / Emergency Operation (Hydraulic Pumps Operating)
Refer to the Brake Hydraulic Schematic, drawing 9130X058, for these operations.
1. Ensure the emergency bleed off valve (item N) is closed.

2. Ensure the brake control valve handle (item 2 – emergency load release circuit
ONLY) is fully extended, fully lifted and locked into place.
3. Move all eight manual / remote valves (item F) to manual position.
4. Open the emergency lowering valve isolation valve (one of item B – emergency load
release circuit only).
5. To release the brake, unlock the handle of the brake control valve (item 2 –
emergency load release circuit ONLY) and slowly pull downwards on the handle.
This will increase pressure to the calipers to release them. Allow the handle to move
upwards to reduce the pressure and re-apply the brake calipers.
6. If control is lost, open emergency bleed off valve (item N) to quickly re-apply brakes.
Brake Control
Valve Handle
Emergency Bleed
Off Valve
Emergency Lowering
Isolation Valve
Photo: SSGD-1000 Drawworks,

Emergency Lowering Controls
WARNING: Disc temperature must be monitored during any manual/emergency

lowering operation. Lowering must stop when the disc temperature
reaches 100°C. Lowering the load slowly will reduce the energy to be
absorbed by the disc. Use short steps instead of continuously
lowering the load. If the disc becomes too hot, the operation must
stop until the disc has cooled.
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5.3.2 Manual/Emergency Operation (Hydraulic Pump Not Operating)
If power is lost to the hydraulic pump, the

brakes are released as follows:
1. Ensure the emergency bleed valve (item N)

is closed.
2. Ensure the brake control valve handle (item
2) is fully lifted and locked into place.
3. Ensure all eight manual/remote valves (item
F) are in the remote position.
4. Open the emergency lowering valve
isolation valve (one of item B - emergency
release circuit only).
5. Pump the system up to 3,000 psi using the
hand pump. Photo: Manual / Remote Valves
NOTE: It may be desirable to close one accumulator bottle to allow system to be

charged faster.
6. Once 3,000 psi is achieved, flip all eight manual/remote valves to manual.
NOTE: Manual/remote valves should be switched as quickly as possible to limit

the pressure lost due to the switch over.
7. Brakes can now be released/engaged using the brake

control valve (item 2).
CAUTION: Keep track of system pressure. If system

pressure drops to 2,000 psi, stop the
lowering operation and recharge the
system. Otherwise, at approximately 1,500
psi, system pressure will drop to zero (0)
and the whole operation will have to be
repeated starting at Step 1.
Photo: Hydraulic Hand Pump
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5.4 Brake Caliper Delay System
With eight calipers activated at the same time, light loads will be stopped too quickly.
Thus, four of the eight calipers are equipped with a flow control valve (item R) to slow
the application of the calipers. These control valves are set at the factory to have a one
second delay. In the even that these settings are changed, reset the flow controls by
doing the following:
1. Open all flow controls completely.

2. Release and engage the brakes. Measure time difference between non-flow control
and flow control calipers. The time difference should be approximately one second.
3. If time is too fast, close flow controls one turn more.
Repeat until a one second delay is achieved.
NOTE: Adjusting the flow control to six full

turns in from full open will give a delay
of approximately one second. This is
approximate only and will vary
substantially with each caliper and
each valve.
Flow Control Valve
Photo: Flow Control Valve
5.5 Disc Brake Caliper Burn Procedure
For further instructions, also refer to the National Oilwell Varco Emergency Disc Brake
Caliper Operation and Maintenance Manual, document number EPL-1829, in the
Vendor Information section of this manual.
WARNING: When working in drum area with drill line attached to the drum, lock
out the drawworks AC drives.
NOTE: Only one caliper or linked pair of calipers can be burnt in at the same time.
NOTE: If changing pad or caliper or disassembling the caliper, ensure an air gap
check is done before performing the brake capacity test or continuing
operation.
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Brake burning procedure:
Refer to the SSGD-1000 Brake Hydraulic Schematic, drawing 9130X058, for the
following procedure.
1. Hang off traveling block with the hang off line. Remove the drill line from the drum.
2. Park drawworks and switch it off. Switch to the “Test / Exception” operator screen.
3. Clean the brake discs with white spirit and thereafter with thinner or trichloretylene
prior to inserting any new pads. Install new pads according to the procedure in the
National Oilwell Varco Emergency Disc Brake Caliper Operation and Maintenance
Manual, document number EPL-1829.
4. Ensure all manual / remote valves are in REMOTE position. Refer to the sign located
inside the drum area for selection of correct valves.
5. Install / extend, unlatch, and pin the handle on the “EMERGENCY LOWERING”
valve (Item 2).
6. Close the “EMERGENCY DUMP” valve (Item N).
7. Put the two (2) MANUAL / REMOTE valves (Item F) on the pair of calipers to be
burned (bedded) in the MANUAL position. Refer to the sign located inside the drum
area for selection of correct valves and further instructions.
8. Turn the mode selector switch in the drawworks PLC control cabinet to test position.
Select “Brake Burning” on the “Test / Exception” screen.
9. Start the drawworks and release the brakes as normal. Ensure the hydraulic supply
pressure is approximately 3,000 psi.
10. Select the caliper pair to be burned (T2 – Brake test screen). Ensure it is consistent
with the manually operated valves on the drawworks.
11. Activate the “Act Test” - button followed by confirm on the Cyberbase keypad (this
will disable normal drawworks operation, override brake alarms and disengage the
calipers not selected). Verify that the “Brake Burn Active” indicator is activated.
12. Pull down the “EMERGENCY LOWERING” valve (Item 2) to release the caliper pair
to be burned from the brake disc.
13. Activate the joystick to rotate the drum (the drawworks control system will limit the
speed and motor torque).
14. Slowly raise the “EMERGENCY LOWERING” valve handle (Item 2) to reduce the
pressure on the caliper pair. The pressure should be held between 400 and 600 psi
depending on the number of calipers on the set that is being burned. If the rotation
stops the pressure needs to be adjusted to stay within the available motor torque.
15. Monitor the brake disc temperature with an infrared temperature sensor (or
equivalent. Burn the brake until the disc temperature reaches 212°F or 100°C.
16. Once the disc reaches 212°F or 100°C pull down on the “EMERGENCY
LOWERING” valve (Item 2) to fully disengage the disc caliper from the disc.
17. Select “Disc Cooling” to disengage all calipers by the control system.
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18. Raise the handle on the “EMERGENCY LOWERING” valve (Item 2). Ensure the
calipers remain disengaged from the disc.
19. Continue to rotate the drum and spray clean fresh water (no soaps, detergents,
softeners, salts, oils, etc) onto both sides of the heated disc to cool it down to
approximately 77°F or 25°C.
20. Deselect “Disc Cooling” to engage the previously selected caliper and repeat steps 7
thru 17 until the caliper pair has been burned four times total.
21. After the caliper pair has been burnt and the disc has been cooled down, stop
rotating the drum. Select next caliper pair (REMEMBER the manual operation on the
drawworks hydraulics) and repeat the procedure.
22. Raise the handle on the “EMERGENCY LOWERING” valve (Item 2) and allow the
caliper pair to engage the brake disc.
23. Deselect the “Act. Test” button to disable the test mode.
24. Select the “No Test Mode”.
25. Switch the “MANUAL/REMOTE” (Item F) valve for the caliper pair to the REMOTE
position.
26. Perform an automatic brake capacity test according to the procedure. If the caliper
pair capacity is insufficient burn the caliper pair two more times and perform a new
brake capacity test.
27. If the caliper pair capacity is adequate remove / retract, latch and pin the handle on
the “EMERGENCY LOWERING” valve (Item 2).
28. Open the “EMERGENCY DUMP” valve (Item N).
29. Release the joystick and apply the brake when the complete procedure is finished.
Verify that the brakes are set on the operator screen.
30. Switch the mode selector switch in the drawworks control cabinet to normal.
31. Ensure the “Brake Burning”, “Brake Test On” and “Test Mode On” indicators are off,
that the “Act. Test” button is disengaged, that the brakes are set and no alarms are
active.
32. Reattach the drill line to the drum and disconnect the hang off line.
NOTE: It is possible to burn in one caliper by itself. To do this, it is necessary to

disconnect one end of the brake cylinder from the caliper arm by removing
the pin shown below.
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NOTE: Removing this pin will

allow the other caliper in
the pair to be burnt in by
itself. Thus it is possible
if necessary to burn in
each caliper individually.
5.6 Brake Testing Procedure
Refer to the Operation Manual, SSGD-1000 Drawworks document number S0100688-

OPM-800.
5.7 Drill Line Attachment to Drum
The drill line is attached to the drum with a line clamp and socket on the right hand side
(view from front) of the drum. The line clamp is held to the drum in the socket with two
half clamps. Each half clamp has two bolts; the line clamp has six studs. Refer to the
Drumshaft Assembly, drawing 9130A250, for this operation.
To install the drill line on to the drum:
1. Push the drill line through the opening in the drum side plate.
2. Attach the line clamp to the drill line leaving a 3” to 4” tail past the end of the line
clamp and torque the six studs to 483 ft·lbs.
3. Insert the line clamp into the drum socket and install the two half clamps.
4. Torque the half clamp bolts to 266 ft·lbs.
Leave 3” to 4” tail
past the end of
the line clamp.
Torque bolts to
266 ft-lb (dry)
Torque nuts to
483 ft-lb (dry)
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5.8 Dead Wraps on the Drum
The SSGD-1000 drawworks is designed to have a minimum of 10 dead wraps on the

drum when the travelling block is in the lowest operating position.
WARNING: Operating the drawworks with less than 10 dead wraps may result
in the drill line being pulled from the line clamp on the drum and
consequently an uncontrolled dropping of the travelling
equipment and load.
5.9 Hazards and Protective Measures
• Loss of hydraulic supply or electrical power will result in brake actuation.

• Contaminated pads or misadjusted calipers may result in loss of braking.
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6 MAINTENANCE AND LUBRICATION

6.1 Maintenance Overview and Scope
6.2 Maintenance Area and Personnel
6.3 Routine Inspection
6.4 Periodic Maintenance
6.5 SSGD-1000 Lubrication Schedule
6.1 Maintenance Overview and Scope
Before starting maintenance, the maintenance team should read all component
operation and maintenance manuals to become familiar with component requirements.
Refer to the Spare Parts listing, section 11, for the recommended spare parts.
Select suitable lubricants and fluids for the range of operating conditions, in addition to
adjusting maintenance schedules as necessary. Avoid mixing lubricants of different
brands, grades, and/or viscosities.
Operating and maintenance personnel should wear suitable protective clothing and
equipment. Before performing maintenance on or disconnecting any high-pressure
piping or hoses, maintenance personnel should ensure the unit has been bled to zero
pressure. Observe a similar procedure for electrical connections, ensuring electrical
power is locked out before attempting maintenance.
The design of the drawworks is such that some special equipment or tools are needed
for maintenance other than those normally located on a drilling facility. These include:
• a high pressure hand pump (10,000 psi) with adapter for the OEM motor shaft
to pump off the pinion gears
• a 1” square drive 4:1 multiplier
• a 1” square drive torque wrench (600 ft-lbs capacity)
Ensure maintenance crew is aware of and prepared for these requirements before
performing maintenance, as National Oilwell Varco does not provide special equipment
and tools.
6.2 Maintenance Area and Personnel
To ensure maximum performance of any mechanical equipment, users must maintain

good alignment and good lubrication with clean oils and greases. Preventive
maintenance may be carried out by regular operating personnel (see Sections 6.3 and
6.4, Routine Inspection and Periodic Maintenance). Other more complex types of
maintenance should be performed by specialists. Disassembly, mechanical inspection,
and repairs during equipment strip-down are to be performed by a qualified and
experienced mechanic who is familiar with the proper use of the appropriate tools.
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To minimize the chances of injury and equipment damage, all personnel should operate
in a safe working area. Ensure all work pieces are adequately and correctly supported
and/or blocked. When maintenance outside of routine servicing is needed, remove the
unit or major component to an area where ample work space is available and a
hydraulic press, overhead crane, bearing pullers, impact tools, etc. are accessible.
6.3 Routine Inspection
DAILY Checked Recorded

A1 Check lube oil level
A2 Check hydraulic oil level
A3 Check lube oil pressure
A4 Check for fluid leaks (hydraulic and lube oil)
A5 Check work area for cleanliness
A6 Check the hydraulic pressure and the function of
all brake calipers
A1 Check the oil level a few minutes after the shaft has stopped rotating and the
pumps have been shut off to allow circulating oil to accumulate in the lube oil
tank. Test for and drain any condensation in the oil reservoirs at regular intervals,
especially a few hours after shutdown. If dirt or water is found present in the
drawworks housing and lube tank, drain the lubricant and renew as per
instruction E1.
NOTE: It is not possible to check the lube oil level with the drawworks operating.
The drawworks must be stopped and both lube pumps must be shut off
before checking the lube oil level
A2 The hydraulic oil level should be checked

with both hydraulic pumps shut off and
Hydraulic both accumulator bottles bled off and all
Filter the brake calipers engaged. In this
condition, the oil level in the tank should
be 1” from the top of the tank.
Upper Sight Note: Both sight glasses will be filled.

Glass
The hydraulic oil level may be checked
while the machine is running by looking at
the sight glass on the side of the tank.
Lower Sight The oil level should be within 2” of the top
Glass of sight glass. The sight glass will be
completely full when operating if the tank
is filled to within 1” of the top of the tank
as detailed above. These levels are
Photo: Hydraulic Tank indicated on the tank labeling.
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WARNING: Do not fill the hydraulic tank with unfiltered oil. The hydraulic fluid
must have a cleanliness rating of ISO 15/12 (NAS 6) or better. New
oil from a barrel or pail will not meet this cleanliness rating and must
be filtered prior to putting it into the hydraulic tank. The hydraulic
tank is equipped with a filling filter that must be used when filling the
tank. Never fill the tank by pouring the oil from a pail or barrel.
WARNING: Do not fill the hydraulic tank while the drawworks is operating. A low
hydraulic oil level indicates a leak in the system. The operation
should be brought to a stop and the load secured in the slips. The
brakes should be checked to ensure they have not been
contaminated with oil and then the drawworks should be shut off.
The leak should be found and repaired and then the hydraulic tank
should be filled as directed above before continuing operation.

A3 Lube oil pressure is indicated by a gauge in the driller’s cabin (oil pressure
should be approximately 75-150 psi or 517-1034 kPa when the rig is running).
NOTE: Pressure will drop as the temperature rises.
If pressure is too high, perform the following checks:

• Check gear oil spray nozzles for blockage and ensure that the oil holes are
open and delivering oil.
• If no blockage is found, refer to vendor service information for setting the
relief valve and flow controls.
If gauges show no pressure, perform the following checks:

• Check oil level in reservoir and add oil if necessary.
• Check oil filter and clean or renew as necessary.
• Check bypass relief valve on oil pump, turn adjusting screw inward to
increase bypass pressure.
• If all spray nozzles are delivering adequate oil, check pressure gauge
tubing for damage or blockage.
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Perform the following procedure to set lube oil pressure relief and flow control valves.
Refer to the SSGD-1000 Lubrication Schematic, drawing 9130X059 for this operation.
NOTE: This setting should be done when the oil temperature is approximately
18°C (65°F). Setting these valves at other temperatures will affect the
operating conditions of the drawworks and may result in pump damage or
false alarms.
1. Turn off both lube pumps.

2. Close both valves (item T) on the inlet to
pressure filters (item D). Item M
3. Start up pump #1 and read the pressure on
Lube System
gauge (item K).
Flow Control
4. Adjust the relief valve (item R) to set the Valves
pressure at 150 psi.
5. Shut off pump #1.
6. Start pump #2 and repeat steps 4 and 5. Item N
7. Shut off pump #2.
8. Open both valves (item T) on inlet to
pressure filters (item D).
9. Fully open the flow control (item M) to the
motor mount. Photo: Flow Control
10. Start pump #1.
11. Adjust flow control (item N) until pressure on gauge (item K) reads 110 psi.
12. Shut off pump #1 and start pump # 2.
13. Pressure on gauge (item K) should be 110 psi. If lower, adjust flow control valve
(item N) to bring pressure up to 110 psi. If pressure reading is already higher than
110 psi, the flow control is properly adjusted.
14. Start up pump #1 and #2. The pressure on the valve (item K) should be slightly
higher than 110 psi.
15. Shut off both pumps.
16. Remove hose that supplies lube oil to the motor mount housing and direct the flow
into a five gallon container.
17. Start both pumps and run for 30 seconds.
18. Shut off pumps. Container should have approximately two gallons of oil.
19. Adjust flow control (item M) until flow is 3-4 gpm.
20. Shut off pumps and lock flow control valve settings with the lock screw on the valve.
21. The valves have now been set.
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A4 Check piping for leaks (oil and hydraulic) - a substantial leak may be indicated by
a pressure drop in the system. The presence of oil in the drawworks skid integral
drip pan indicates an oil leak within the drawworks.
A5 Check work area for cleanliness. A clean work area minimizes the chance of
contaminants entering the machinery, which causes premature component wear.
A6 Check the setting of the hydraulic pressure operating the brake caliper. It should
read 1800 psi. Function test calipers from the driller’s cabin. Ensure all calipers
engage and disengage when activated.
WARNING: Brake caliper operation should be checked at the start of each shift.
WEEKLY Checked Recorded

B1 Check all safety controls for malfunction
B2 Check wireline clamp integrity
B3 Brake calipers: inspect shoe lining, observe brake
actuation and movements in pins and levers
B4 Check nitrogen pre-charge pressure on hydraulic
system accumulator bottles
B5 Grease end bearings & main bearings
B6 Verify function of all brake system hydraulic valves
B1 Check all safety controls for malfunction. Function test the crown saver system
and drawworks emergency lowering valve.
B2 Check wireline clamp integrity - the wireline must remain securely within the
clamp without slipping. Leave 3” or 4” of rope tail. After the rope has been under
load for a period of time, check the six nuts to ensure tightness. These six nuts
must be torqued to 483 ft·lbs. (Refer to Section 5.7 of manual.)
WARNING: Ensure that the travelling block is secured from falling and that the
brake hydraulic system has been bled off completely. When working
on brakes, brake controls, valves, tubing, hoses, pumps, or any
other brake system component during maintenance/overhaul,
inadvertent release of the brakes may occur resulting in serious
damage to equipment and serious/fatal injuries to personnel.
B3 Inspect pad wear limit and inspect shoe linings. Refer to the National Oilwell
Varco Emergency Disc Brake Caliper manual in Vendor Information section.
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B4 Ensure the accumulator bottles on the hydraulic system are pressurized. If not,
check for leaks in the system and that the system is functioning properly.
(Accumulator pre-charge pressure = 1500 psi)
NOTE: Accumulator pre-charge pressure may only be checked after the entire
hydraulic system has been bled off to zero (0) pressure.
B5 Grease end bearings (2 shots) and both main bearings (4 shots each).
B6 Operate all functions of the brake system including emergency lowering system
and verify proper functions.
WARNING: Absolutely no grease or oil is allowed to contact the brake pads or

the brake disc. Replace contaminated brake pads immediately. Do
not operate the drawworks with contaminated brake pads.
MONTHLY Checked Recorded

C1 Inspect electrical wiring
C2 Inspect wireline, lubricate as necessary
C3 Check availability and condition of tools
C4 Grease fittings on brake calipers
C5 Remove and rotate all brake caliper pins
C6 Check oil nozzles spray pattern
C7 Check adjustment brake caliper stabilizer bracket.
C1 Inspect electrical wiring: visually inspect control system wiring in junction boxes
and instrument cabinets for cut wires, snags or other accidental damage. Unplug
any in-line disconnects and inspect for oxidation, moisture, and signs of arcing.
Clean as required and return to service.
C2 Check wire rope condition monthly. Also, check wirelines prior to use when they
have been unused for more than a few weeks. Slip and cut any wireline that
exhibits broken wires, a significant reduction in cross sectional area, or increase
in length. Pay particular attention to areas around sheaves or yokes. Breaks
often occur in the core of the line and require close inspection to locate. Replace
any rope having damage resulting in distortion of the rope structure. Wireline
corrosion reduces the metallic areas of a rope, thus weakening it. Proper wireline
lubrication will inhibit corrosion
WARNING: Mineral oil based wireline lubricants must not be used on this
drawworks. Asphalt based lubricants and plastic impregnated wire
ropes are acceptable.
C3 Check the availability and the condition of tools, especially those required for
regular service. Tools should be present and in good condition.
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C4 Grease all accessible fittings on the brake caliper with molybdenum rich EP2
grease. If fittings are not accessible, the greasing of these fittings should be
performed at the bi-annual interval (disassemble and clean levers and pins).
C5 Remove, clean and rotate all brake caliper pins. Check for cracks and/or wear.
Apply molybdenum rich grease to all pins prior to reassembly. After reassembly
grease all pins equipped with grease zerks. Remove all excess grease from the
brake calipers and the brake beam.


C6 Check gear oil spray nozzles for blockage and ensure that oil holes are open and
delivering oil to the gears. If oil is not being distributed correctly and evenly,
adjust oil flow according to instruction A3 in this section.
C7 Check adjustment of the brake caliper stabilizer brackets (drawing 9130D625).

Brake pads should be held square to the brake disc when the brake is released.
If not, apply the brake caliper and adjust the screw with the following procedure
(reference drawing 2112424):
1. Adjust air gap for brake pad to 0.060”.

2. Install the brake shoe assembly support in position (items 1 and 2).
3. Install bolts A and B finger tight.
4. Tighten both bolts A and B.
5. Install bolt C into piece 1 (as shown in diagram below).
6. Install acorn nut D and tighten acorn nut onto bolt C.
7. Release any hydraulic pressure from the caliper to ensure it is applied onto
the brake disc.
8. Adjust both bolts C so the acorn nut is just touching the brake pad shoe.
9. Tighten the locking nut on bolt C.
10. Apply hydraulic pressure to release the brake caliper from the disc.
11. Ensure the pad remains parallel to the brake disc.
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THREE MONTHS Checked Recorded

D1 Renew lubricating oil filter
D2 Renew hydraulic oil filters
D3 Check brake caliper fastener torques
D4 Check breather conditions
D1 Renew lubricating oil filter at three month intervals. All gear case spray nozzles
should be checked for blockage after filter renewal.
D2 Renew hydraulic oil filter at three month intervals. All the brake system functions
must be checked after filter renewal.
D3 Refer to the National Oilwell Varco Emergency Disc Brake Caliper manual in
Vendor Information section.
D4 Check the breathers on the hydraulic oil and lube oil tanks. Check the gear case
assembly breather. If there is any indication of dirt or oil clogging the breather,
replace the breathers.

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SIX MONTHS Checked Recorded

E1 Change lube oil in lube oil tank
E2 Inspect lube oil piping
E3 Check all foundation and hold down bolts
E4 Check gears for wear
E5 Check oil nozzles spray pattern
E6 Check condition of hydraulic fluid
E7 Check condition of accumulators
E8 Disassemble and clean caliper assembly levers
and pins
E9 Check all lube fasteners including the taper
bushings shaft
E1 Change drawworks lube oil: Open the lube oil drain valve and drain oil while the
unit is still warm. Renew air breather filter. Ensure the lube tank is clean before
closing the drain valve and refilling the oil tank to the proper level. Approximate
oil requirement is 757 liters (200 US gal.). Rust and oxidation inhibitors may be
beneficial oil additives. Avoid detergent oils because of their tendency to form an
emulsion in the presence of water.
E2 Inspect lube oil piping; Inspect the lube oil distribution lines leading to each pinion
and the motor mount. The lines should not restrict oil distribution in any way to
the components which require the oil.
E3 Check all foundation and hold-down bolts (refer to the Tightening Torque Guide
in Section 10 of manual).
E4 Check gears for wear. Unevenly worn gears may be due to incorrect oil
distribution. Refer to instruction E5 to test and adjust the oil distribution.
E5 Check gear oil spray nozzles for blockage and ensure that oil holes are open and
delivering oil to the gears. If oil is not being distributed correctly and evenly,
adjust oil flow according to instruction A3 in this section.
E6 Check condition of hydraulic fluid. The fluid must remain free from foreign
contamination.
E7 Check the condition of accumulator bottles every 6 months including the bladder
and valves and piping. Replace bladder if there are leaks or cracks, etc.
E8 Refer to the National Oilwell Varco Emergency Disc Brake Caliper manual in
E9 Torque the taper bushing shafts to 400-600 ft-lbs. Taper bushing lock nuts
should be torqued as tight as possible without damaging the lock nut
significantly. The turn buckle lock nuts should be “hammered” tight as possible.
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YEARLY Checked Recorded

F1 Replace all caliper disc springs (every five years)
F2 Visually inspect critical components
F3 Check bolt torques
F1 Refer to the National Oilwell Varco Emergency Disc Brake Caliper manual in

F2 Visually inspect all critical components for signs of wear, distortion, cracks,
mechanical damage, etc. These critical components include brake calipers,
brake mount, hydraulic tubing and hose, lube piping, drum, wireline clamps,
motor mount, gears, pinions, etc.

F3 Check the torque on all fasteners according to the Bolt Torque Charts in Section
10 of this manual.
6.4 Periodic Maintenance
Before starting a new machine, the operator must grease all parts and fill all reservoirs
with the prescribed lubricants. New units should be drained and refilled with oil after the
first few weeks of operation. Thereafter, it should not be necessary to change oil more
than once every six months except when the oil may have become contaminated by
water or other foreign matter, or when the temperature changes sufficiently to require a
change in the viscosity of the oil being used. The sump should be filled with the
viscosity of oil listed in the following chart:
AMBIENT TEMPERATURE RECOMMENDED LUBRICANT

Above 12°C ISO 320 AGMA EP6 Minimum or ISO 460 AGMA
6EP Minimum
-17°C to +12°C ISO 320 AGMA EP6 Minimum
Below -17°C Pour point at least 3°C lower than minimum
ambient temperature
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For many applications, the advantages of using multipurpose grease instead of several
separate grades outweigh the added product cost. Lithium complex soap greases have
been developed and are accepted for their wider operating temperature range and good
water resistance. Use a premium lithium-based multipurpose EP 2 grease (Extreme
Pressure meeting NLGI #2 or National Lubricating Grease Institute grade 2) or
equivalent for all greased components unless otherwise noted.
Where grease fittings are present, apply grease regularly at the fittings until the old
grease starts to seep around the seal, flushing out the used grease along with any
accumulated water and debris. Maintain a coating of grease on all sliding surfaces and
unpainted, machined surfaces for lubrication and corrosion protection.
Where grease fittings are not present and the lubricated component must be
disassembled to replenish the grease (e.g. sealed pillow block), disassemble the
component, remove old lubricant, re-pack with new lubricant, assemble and install the
component. Re-pack all components that lack grease fittings at least once every year.
Remove any exposed grease seepage to minimize dirt accumulation.
NOTE: Proper lubrication is essential for trouble-free performance of all

machinery. Lubricants equivalent to those listed here may be used during
the warranty period only after consulting with and subsequent written
approval by the manufacturer to retain the warranty.
6.5 SSGD-1000 Drawworks - Lubrication Schedule
There are times when a special type of lubricant is justified. Some of the super premium
greases have excellent low-temperature properties.
Rusting and corrosion of the bearings, etc. is normally not a problem during rig
operation, but may become serious over prolonged inactivity in a damp environment.
Ordinary oils and greases provide moderate corrosion protection, but special
compounds may provide increased corrosion protection.
Applying super premium greases to every fitting in quantities sufficient to flush out most
of the old greases will go a long way towards protecting the equipment from rust and
corrosion during storage. For maximum protection against rust and corrosion during
prolonged storage, it is best not to rely on the oil that was clinging to the parts when the
rig was shut down. Use a compound that is specifically designed and formulated for this
purpose and apply according to the manufacturer's recommendations.
In selecting a special storage lubricant, it is best to use one that does not require any
special cleaning before the rig is run again. There are compounds that will be flushed
away by normal lubrication oil and mix with it harmlessly.
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SERVICE
ITEM REMARKS LUBRICANT QUANTITY
PERIOD
Drum Shaft
Main bearings
-- EP2 Grease 4 Shots/wk -
and Torque
Arm Bearing
Apply as required
WARNING:
Avoid use of excess
Monthly
Wireline wireline lubricant. Wireline Lubricant Application
inspection
DO NOT use
mineral oil based
wireline lubricants.
Exxon Univus
N-22
WARNING:
Higher viscosity
hydraulic oil will slow
Access from right
application of the brake
Hydraulic Tank side front enclosure 76 liters 6 Months
calipers. DO NOT USE
door.
higher viscosity
hydraulic oil when
operating in low
temperature (0°C or
less) environment.
Exxon Spartan EP
Access from in-side
Oil Tank Synthetic Gear Oil ISO 757 Liters 6 Months
drawworks rear doors
320
Lightly coat
Hydraulic
-- Silicone-based grease moving 6 Months
Valves
parts
Exxon Spartan EP
Motor Mount
-- Synthetic Gear Oil ISO Forced Oil --
Bearings
320
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7 MAIN OVERHAUL
7.1 Parts Fit – General
7.2 Shafts
7.3 Bearings
7.4 Spacers
7.5 Hydraulic System
7.6 Gears
7.7 Hub and Shaft Fits
7.1 Parts Fit - General
Economic factors influence the normal overhaul job. When the equipment is in the shop
for repairs, new parts may be installed at a lesser expense than when the equipment is
in service. e.g. If the repair shop does not replace a partially worn bearing at the time of
overhaul and the bearing fails within the first few months of new service, the resultant
down time and emergency repairs incur a much larger cost than replacement at regular
overhaul time.
When replacing parts on a shaft assembly, ensure the new part fits within the tolerance
shown. For assembly or removal of parts that range from 0.000 mm to 0.101 mm
(0.004”) tight, heat to approximately 204°C (400°F). For parts ranging from 0.127 to
0.254 mm (0.005” to 0.01”) tight, heat to approximately 343°C (650°F).
7.2 Shafts
Wherever possible, all shafting should be checked by magnaflux or other means to

detect any cracks. Cracked shafts should be replaced, as a crack indicates the shaft's
potential to fail during rig operation.
Shafts should also be checked for straightness by supporting the shaft by any anti-
friction means, placed at the position of the main bearings, and turning the shaft.
Straightness is then checked by means of a dial indicator placed at the extreme ends of
the shaft. The total reading of the dial indicator should not exceed 0.10 mm (0.004”). If a
shaft shows greater run out than 0.10 mm (0.004”), a replacement should be
considered. The lack of straightness in drawworks shafting causes vibration, uneven
gear tooth wear, and a generally poor running rig.
All seals are wear and tear items and therefore should be replaced whenever a shaft is
disassembled. Clean all of the oil passages when working in a given area by blowing air
pressure through the oil passages.
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7.3 Bearings
Roller bearings should always be discarded if they show pitting, rust or corrosion,
chipping or spalling off of small particles, excessive internal looseness which indicates
extreme wear, or cracks in rollers or races. In most cases, it will be necessary to heat
the bearing inner race to remove it from the shaft. It will be necessary to heat the inner
race and cool the shaft for re-assembly.
To pull the bearing and / or the inner race, place a "U" puller behind bearing or inner
race. Arrange balance of the pulling mechanism and tighten sufficiently to remove all
slack. Apply heat evenly to the bearing or inner race, while at the same time increasing
tension on the pulling mechanism. DO NOT OVERHEAT. Maximum Temperature:
125°C
The fits of the outer races to the bearing housing range from 0.127 mm (0.005”) tight to
0.102 mm (0.004”) loose. If the outer race is a tight fit it will be necessary to heat the
housing in order to remove it. The bearing must be cool before it can be re-assembled.
When the outer race is a tight fit, arrange the puller mechanism to apply pressure
toward the open end of the housing. Apply heat to the housing and increase pressure
on the puller mechanism at the same time. DO NOT OVERHEAT. Maximum
Temperature: 125°C
7.4 Spacers
Spacers used between bearings to maintain centre lines of bearings or between

bearings and other parts are usually 0.0508 mm (0.002”) to 0.1524 mm (0.006”) loose.
Spacers that are used to hold a bearing in position which is not adjacent to another part
securely fixed to the shaft are usually 0.0254 mm (0.001”) to 0.0762 mm (0.003”) tight.
To remove a spacer that has shrunk on a shaft, proceed in accordance with instructions
for removing a bearing. To replace, heat the spacer, make sure the shaft is cool, and
proceed the same as for a bearing replacement.
7.5 Hydraulic System
The brake hydraulic system requires that the oil cleanliness be maintained at an ISO
Level of 15/12 (NAS 6) or better. Due to the critical nature of the hydraulic system, the
viscosity of the hydraulic fluid used in this system should not exceed ISO 22.
Consequently, any repairs to the brake hydraulic system should be undertaken with
extreme diligence in the area of cleanliness. Before opening any connections, ports,
lines, etc. in the hydraulic system, the work area should be thoroughly cleaned. Any
openings made in the system should be plugged or blinded immediately. Ensure that
the appropriate plugs, caps and blinds are in hand prior to any disassembly.
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Upon completion of any major repairs, the entire system should be flushed to ensure no
contamination of hydraulic oil occurs. Oil samples should be analyzed on a regular
basis to monitor the system cleanliness.
The brake hydraulic system uses two pressure reducing relieving valves. The first is to
reduce the main system pressure, from 3,000 psi to 1,800 psi. The second pressure
reducing relieving valve is the emergency lowering and the pressure relieving functions
of the valve must be verified before the valve is put into service.
The pressure compensating pump in the brake hydraulic system operates at less than
their maximum displacement. These pumps are set at the factory to have a maximum
flow of approximately 2 gpm. After overhaul or if a new pump is installed, the volume
stop setting must be verified. This is accomplished by ensuring that the electric motor is
not over loaded. This 5 HP motor must draw less than 6.4 Amps of current with a 480
Volt supply.
The pump pressure compensator must be set at 3,000 psi.
The main hydraulic system relief must be set to relieve at a pressure not less than 3,150
psi and not more than 3,300 psi.
7.5.1 Hydraulic Pump – Pressure Compensator Adjustment Procedure
Perform the following procedure to set the pressure compensator; refer to the Brake
Hydraulic Schematic, item X, drawing 9130X058.
1. Set the system relief valve first.

2. Turn the system relief valve in to increase the pressure setting of the valve (right hand
thread on the valve).
3. Turn the compensator pressure setting adjustment on both pumps out to reduce the
pump pressure (right hand thread on the adjustment).
4. Start one of the pumps.
5. Watch the pressure rise – when the pressure stops increasing, adjust the
compensator pressure up a little so the pressure increases again.
6. Increase the compensator pressure setting. If the pressure does not increase, check
the system relief valve and increase as required.
7. When the pressure reaches 3,400 psi, stop increasing the compensator setting.
8. With the pump running, reduce the system relief valve setting down to 3,300 psi.
9. The system relief is now set correctly.
10. Now, adjust the pump compensator pressure setting down until the system pressure
is approximately 3,050 psi.
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NOTE: The system will have to be bleed off by opening one of the bleeder valves
on the accumulator bottles to reduce the system pressure. Leave the
bleeder valve open just slightly (1/2 turn or so).
11. This pump is now set correctly. Check to ensure the pump compensator is higher
than the PLC pump pressure shut off setting. Adjust the pump or PLC to suit. The
final system pressure as controlled by the PLC should not exceed 3,000 psi.
12. Adjust the second pump compensator pressure setting.
NOTE: Only the pump that is being adjusted should be running.
Back Pressure
Regulating Valve
Compensator
Pressure Adjustment
Maximum Volume Stop
Photo: SSGD-1000 Drawworks Hydraulic Pump
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7.5.2 Hydraulic Pump – Volume Adjustment Procedure
The maximum volume stop on the pumps should be set at the factory so the pumps
produce 2 gpm (US). It is relatively simple to ensure if this has been done. Refer to the
Brake Hydraulic Schematic, item X, drawing 9130X059 for the following procedure.
1. Bleed all pressure from the hydraulic system by opening the bleed off valves on the
accumulator bottles.
2. Start one pump and record the time it takes for the system to reach the operating
pressure of 3,000 psi. The accumulator bottles hold 5 gallons of oil at 3,000 psi.
Therefore, the necessary time should be 2 ½ minutes to reach 3,000 psi.
3. If the time to charge is too short or too long, reduce the flow by adjusting the
maximum volume stop. Acceptable time would be between 2 minutes and 15 seconds
and 2 minutes and 45 seconds. Refer to the hydraulic pump manual for directions on
adjusting the maximum volume stop.
4. Check the current draw of power by the motor to ensure it is within the operating
parameters listed on the motor name plate.
NOTE: DO NOT change the maximum volume setting or else the electric motor
could be overloaded!
7.6 Gears
The teeth of almost all gears are surface hardened. This hardening is effective to a
depth of approximately 1.778-2.286 mm (0.070” to 0.090”). When the gear teeth
become worn to a depth near 1.778 mm (0.070”), the rate of wear will accelerate. The
amount of wear may be determined by visual inspection. If inspection shows the amount
of wear to be near 1.778 mm (0.070”), the gear should be replaced at the time of
overhaul.
NOTE: The gears in this drawworks have very hard teeth. Wear rates are very low
with proper lubrication.
Four methods are used for mounting gears on shaft assemblies:
A Press fit without key

B Press fit with key
C Shrink fit without key
D Tapered shaft with key
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When removing and replacing parts mounted according to arrangement A, refer to

instructions for removing bearings. A gear mounted according to arrangement B may
have a straight key that has a tapped hole in the end of it. Screw the puller into this hole
and remove the key. It is recommended that the shaft be cooled with dry ice or liquid
nitrogen to a temperature of approximately -10°C (15°F) prior to attempting to remove
the gear with heat. The gear may then be removed, usually with heat application.
WARNING: DO NOT OVERHEAT! The bull gears on these drawworks are

quenched and tempered during manufacture to produce high
hardness on the gear teeth. The tempering temperature is
approximately 177°C (350°F). Do not heat these gears above 149°C
(300°F) during installation or removal. Temperatures above these
values can result in permanent warping of the gear. A warped gear
is not repairable and may not be useable.
If a tapped hole is not provided in the gear hub, it will be necessary to pull the gear
without first removing the key. It is recommended the shaft be cooled with dry ice or
liquid nitrogen to a temperature of approximately -10°C (15°F) prior to attempting to
remove the gear with heat. Insert puller studs through openings between gear spokes
180° apart. Place steel plates and nuts on stud ends extended through the openings.
Arrange balance of pulling mechanism and tighten only enough to remove any slack.
Apply heat evenly and as near to the hub as possible while increasing tension with the
puller at the same time.

In some cases, the hubs will have two tapped holes in the end so that the puller may be
screwed in. In other cases where neither spokes nor tapped holes are available for
utilization of puller studs, it will be necessary to use a "strongback" or "U" plate behind
the gear and secure the puller studs to it.
Proceed to remove the gear as described above. To replace the gear, first make sure
the shaft is cooled to a temperature of approximately -10°C (15°F) with dry ice or liquid
nitrogen. Heat the gear to approximately 149°C (300°F). Verify the keyways in the shaft
and gear are aligned before the gear tightens on the shaft. Insert key prior to gear
installation.
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CAUTION: Excess heat at the hub and attempting to pull the gear with a chain
attached to the outer rim, powered by a jack on the end of the shaft,
will bend the gear. Gears with shrink fits are very difficult to
remove. This should only be attempted in a shop where a hydraulic
press is available.
If the gear is being removed for salvaging and installing on a new shaft, cut the shaft
near the gear and machine part of the metal from the shaft under the gear. Heat the
gear and press out "Dutchman".

If purpose of removal is to replace the gear with a new one, it is advisable to machine or
torch cut the old gear to remove it. Cool the shaft to a temperature of approximately –
10°C (15°F) with dry ice or liquid nitrogen, and then heat the new gear to 149°C
(300°F), and assemble on the shaft.

NOTE: When a shaft assembly is disassembled for any reason, be sure that
passages for admission of oil are thoroughly cleaned.
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7.6.1 Bull Gear Installation Procedure
This procedure has been prepared to ensure that the bull gear for the SSGD-1000
drawworks will not be warped due to heating during the installation process.
Required Tools:
Quantity Quantity
1 Temperature gun 1 25 Ton hydraulic jack
2 Spray cans of red oxide primer paint 2 Ø 1” puller bar
1 Dial gauge indicator to measure run 1 Puller bar spreader
out
1 Inside micrometer for Ø12” bore 1 Ø 12” by approx. 5ft – long pipe
1 Outside micrometer for Ø 12” shaft 2 Work crews of 2 men each
1 (assort) Tempil sticks: 200F, 250F, 275F & 1 Vernier caliper capable of
300F measuring a dimension of 80”
4 Tiger torches 2 Ø 0.575” pins
3 pairs Hot mitts 1 Dry ice holder
1 Air powered Porta Power pump As req’d Quantity dry ice
1 50 Ton hydraulic jack
Perform the following steps to install a bull gear:
1. Paint key locations of drum shaft with red oxide primer paint to facilitate
temperature reading with the temperature gun.
2. Measure and record the temperature of the shaft.
3. Measure and record the shaft diameter at the gear fit.
4. Install the dry ice holder onto drawworks drum shaft at the location of the gear.
5. Install the key into the shaft.
6. Fill the dry ice holder with dry ice so that the shaft is completely covered with
dry ice for the entire length of the dry ice holder.
7. Install lid on dry ice holder and wrap with insulation.
8. Allow the shaft to cool as long as possible (at least 24 to 48 hours). The shaft
temperature must be below 15°F (-10°C) before attempting to install the gear.
NOTE: The shaft temperature must be 15°F (-10°C) throughout, not just in the
area of the gear fit. If not, the shaft may warm up too rapidly during the
installation of the gear, which could result in the gear locking into the shaft
in the incorrect position.
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9. Prepare the gear for installation once the shaft temperature is below 15°F.
10. Paint key locations of the gear with red oxide primer paint to facilitate
temperature measurements with the temperature gun.
11. Hang the gear from the overhead crane using a chain sling of sufficient
capacity (5,000 lbs).
12. Crew #1 should now heat the gear to the installation temperature of 300°F
(148°C). The heat must be applied evenly. The tiger torch flames must not be
directed at the gear ring (the part with the gear teeth), but at the hub and the
web of the gear only.
WARNING: At no time can the temperature of any part of the gear exceed
300 °F. NO EXCEPTIONS.
13. Crew #2 should now start to rig up the hydraulic jack, puller bar, spreader and
portable power pump.
14. When the gear reaches 300°F, remove the heat and allow the gear
temperature to stabilize for 10 minutes. Recheck the temperature and reheat as
required until the gear is stabilized at 300°F.
15. Crew #2 should now remove the dry ice holder and dry ice from the drum shaft.
16. Clean the drum shaft and remove any ice from the surface.
17. Measure the temperature of the shaft and confirm that it is below 15°F.
18. Measure the outside diameter of the shaft at the gear fir and record.
19. Measure the inside diameter of the gear hub and record.
20. Calculate the clearance between the gear hub and shaft; record it. The
minimum clearance required is 0.007”.
21. If the clearance is above 0.007”, proceed to install the gear.

22. Rig up the pipe, puller bars, spreader bar, and 25-ton jack onto the shaft.
WARNING: Ensure the jack and the pump is fully operational.
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23. Using the overhead crane, move the gear onto position on the shaft but not
onto the gear fit.
24. Push the gear into place on the shaft and ensure the gear is fully shouldered on
the shaft.
25. Insert the 25-ton jack and push the pipe against the gear. Force it into position.
Leave approximately 1,000 psi on the jack to ensure that the gear cools and
locks in the correct position.
WARNING: If the gear will not slide into position with the 25-ton jack,
quickly remove the 25-ton jack and insert the 50-ton jack.
Increase the pressure on the 50-ton jack until the gear moves
into position. Hold at least 1,000 psi on the jack until the gear
and the shaft are close to room temperature.
26. After the drumshaft and gear temperatures have returned to near room
temperature, set up to measure the gear diameter and the side run-out of gear.
27. Measure the run-out of both sides of the gear ring and record.
28. If the run-out of the gear exceeds 0.050”, contact National Oilwell Varco to
determine if the warping is acceptable. If no warping is detected, continue with
the remaining drawworks assembly.
29. Reverse the above procedure to remove the gear.
7.7 Hub and Shaft Fits
The temperature required to expand a hub enough to be assembled easily over an

interference fit can be determined by the following equation:
E
T= + Tr
.00001098 * B
Where:
T = Heated Temperature (°C)
E = Expansion of Bore Diameter Required (millimeters)
B = Bore Diameter (millimeters)
Tr = Room Temperature (°C)
0.00001098 = Approximate coefficient of linear steel expansion per C°
temperature change.
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For example, if we have a 215.9 mm (8.500") diameter bore hub which has a 0.2032
mm (0.008") interference fit with the shaft, and we wish to have 0.2540 mm (0.010")
clearance while assembling the hub over the shaft, the total bore expansion needed will
be 0.4572 mm (0.018"). Therefore:
E = 0.4572
B = 215.9
let Tr = 21.1°C (70°F)
then
0. 4572
T= + 21.1= 214°C (420°F)
. 00001098 * 215. 9
CAUTION: Hardened parts such as bearing races should not be heated to over
204 - 232°C (400 - 450°F), since their hardness might be affected.
Heat should be applied carefully and evenly to prevent distortion.
The general rule for the average interference used in cylindrical fits
is as follows:
Press Fit - 0.0005” X shaft diameter (inches)

Shrink Fit - 0.001” X shaft diameter (inches)
The actual fit will have plus or minus tolerance depending on the shaft and bore
tolerances used in manufacture.
Overhung pinions, etc. are often made with tapered shaft fits for convenience of
assembly and disassembly. The tapers used on National Oilwell Varco drawworks are
normally made to 1.250" diameter per foot of length of engagement or 10.4167 mm
diameter per 100 mm. In many cases, the hub must be shimmed against an adjacent
bearing spacer. Care must be taken to ensure that the shims do not interfere with
drawing the hub up tight on the taper.
A recommended method of assembling hubs requiring shimming is to assemble the hub

firmly on the shaft without shims and without heat. Measure the shim gap behind the
hub. The required thickness of the shim pack will be this measurement minus the draw
allowance to be provided for tightening the hub up on the shaft. For each 0.0254 mm of
diametrical interference on a 10.4167 mm per 100 mm taper, the hub will advance
approximately 0.254 mm. Therefore, for example, if an interference of 0.0762 mm is
desired in the taper fit, the shim gap must allow for a 0.762 mm advance of the hub on
the shaft. The hub may be lightly heated to facilitate the draw.
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8 MAJOR REPAIRS AND MODIFICATIONS

8.1 General Drawworks Repair Instructions
8.2 Disassembly of the Building
8.3 Drumshaft Removal and Re-Installation
8.4 Torque Arm Installation
8.5 Lebus Grooving Replacement
8.6 Drumshaft End Bearing Alignment Procedure
8.7 Gear Alignment Procedure
8.8 Pinion Removal, Mounting and Fitting
8.1 General Drawworks Repair Instructions
• It is essential to safeguard against injury to personnel and damage to equipment. In

all cases, use the proper tools and equipment, provide a safe working area, and
ensure all work pieces are adequately and correctly supported and / or blocked.
• Ensure all power to the drawworks (electrical and hydraulic) is disconnected before
starting to disassemble.
• As in any piece of machinery, all parts are machined to close tolerances. It is
imperative the working area be as clean as possible.
• All seals are wear and tear items and therefore replace them whenever a shaft is
being disassembled. Remove the shaft from skid to get at all the seals on the shaft.
• Clean all of the oil passages when working in a given area by blowing air pressure
through the oil passages.
• Clean all oil passages and tubes before re-installing the cover when repair to a shaft
is completed.
• Ensure all covers are properly sealed before they are installed when reassembling
drawworks components.
• Verify the proper type of lubricant is being used.
• Replace any lubricant that is contaminated or is not of the proper type.
• Check all adjustments, pressures, and fluid levels before restarting the drawworks.
8.2 Disassembly of the Building
Refer to SSGD-1000-5750-55-82-10.5 Drawworks General Assembly – Main, drawing

9130B036 unless otherwise noted. Before disassembling the unit, ensure all proper
tools and overhead cranes are available.
1. Ensure all the power supplies are disconnected from the skid of the drawworks
before starting any disassembly work.
2. Remove the front and rear walls around the motor assembly.
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3. Disconnect all the cooling ducting connected to the motors.

4. Disconnect the cable tray attached to the roof.
5. Remove the roof over the motors and all internal ducting.
NOTE: The end wall does not need to be removed completely to change the
motors. The wall will have to be leaned back approximately 10 to 15° from
vertical to allow removal of the motor mount from the drum shaft.
6. Remove/pull back cabling to the motors to allow motors to rotate.

7. Disconnect all the power cables going to the motors inside of the structure. Refer to
the Drawworks Power Cable Coaming Location - Main, drawing 9130C141, and to
the SSGD-1000 Drawworks Operation Manual, document S0100688-OPM-800.
8. Remove the drum guards that are overtop of the drum. Once all of the panels are
removed, the two 4” x 8” box section cross braces can be removed from the
drawworks lifting frames (drawing 9130B036, item 4).
9. Reverse the previous procedure to put the panels back together. When re-
assembling, tighten all bolts as per the Bolt Torque Chart in the next section. (For
bolt diameters larger than 1.5”, refer to the Turn-of-Nut Tightening procedure in
Tightening Torque Guide section).
8.3 Drumshaft Removal and Re-Installation
1. Remove all inner guards and covers.
NOTE: Ensure the wireline is removed from the drum.
2. On the A-side of the drawworks, remove motor #1 (on the top of drawworks).
Remove all the bolts attaching it to the support frame. Ensure all cables and
connections are removed from the motor.
3. Record shim location so they may be placed in the same location upon reassembly.
4. Unbolt the torque arm turnbuckle (#8) off the torque arm and loosen the taper
bushing shaft (#9) so that the arms swing out to the side. Refer to the Drawworks
Torque Arm Assembly, drawing 9130A126. Repeat this step for the B-side of the
drawworks - refer to the Two Motor Torque Arm Assembly, drawing 9130A343.
5. Lock the assembly in place with tie-downs to the torque arm, so that when the
turnbuckles are removed, the assembly will stay in place.
WARNING: Ensure the tie-downs are strong enough to hold the assembly in
place after the motors is removed. The assembly will want to move
after each motor is removed.
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6. Spin the assembly so that the next motor is at the top of the frame. Lock the
assembly in place with tie-downs and remove the motor.
7. Repeat step 6 until all of the motors have been removed from the same end of the
shaft. On the B-side of the drawworks, spin the assembly 45° to access motor #4
then 180° to access motor #5.
8. Remove the shaft end support and the pedestal (#4) - drawing 9130A126.
9. Remove endplates, (#15) and unbolt the retainer plates (#14) –drawing 9130A250.
10. Unbolt gear case locking plates (#3, 5) – drawing 9130A135. Remove all bolts.
11. Heat the spherical bearings (E) and remove the entire motor mount – 9130A250.
12. Remove the motor support frame (item 4), along with bearings (F, E) – 9130A250.
13. Remove spacers (#9, 10), then remove gear (# 23) and spacers (# 11) – 9130A250.
14. Starting at step 4, repeat all steps to remove the torque arm, gears and spacers for
the B-side of the drawworks.
15. Remove the bolts connecting the torque arm bearing housing (#2 on 9130A126,
and #3 on 9130A343) from the support braces.
16. Remove bolts (A) around main bearing housings – 9130A250. Remove drumshaft.
17. Reverse the above procedure to re-install. When re-assembling, tighten all bolts as
per the Bolt Torque Chart in the next section. Refer to the Drum Shaft End
Alignment Procedure, Section 8.6, before re-installing the motors.
NOTE: It is recommended to replace all seals at this time.
NOTE: DO NOT tighten torque arms when re-installing the shaft. Adjust the single
turnbuckle torque arm to suit the equalizer beam. They are used to handle
the torque (tension) from the motors. If they are tightened down, only one
arm would be used as support and the other arm would not be used.
NOTE: Refer to the Motor Accessories Layout – SSGD-1000-5750 Drawworks,

drawing 9130G006, for the accessories location when replacing motors.
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8.3.1 Main Bearing and Drum Replacement
After the drumshaft has been removed, the main bearing and drum can be replaced.
Refer to the Drumshaft Assembly, drawing 9130A250, for the following procedure.
1. Place a block under the drumshaft to hold it in position.

2. Remove the retainer plates (items 6 and 7) off the motor side of the shaft.
3. Remove the retaining plate (item 20) off the B-side of the shaft assembly.
4. Heat the spherical bearing (item E).
5. Remove the bearing housing (item 5) along with the bearing.
6. Remove Drum barrel from the shaft if required. Refer to the B-Loc vendor
information in Section 14 of the manual for proper removal of the locking clamps.
7. Reverse the above procedure to install the new bearing. When reassembling, tighten
all bolts as per the Bolt Torque Chart in Section 10 of manual.
NOTE: It is recommended to replace all seals at this time.
8.4 Torque Arm Assembly
Refer to the following procedure for the torque arm assembly. For the 3-motor torque
arm assembly, refer to the Drawworks Torque Arm Assembly, drawing 9130A126. For
the 2-motor torque arm assembly, refer to the Two Motor Torque Arm Assembly,
drawing 9130A343.
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1. Prior to reinstalling the turnbuckles, ensure the bolt group A, B, C, E & F are torqued
correctly. (Refer to Section 10 of this manual for the appropriate torque values.)
2. Pin the lower end of the turnbuckle or the steady torque arm assembly (item 13 & 8)
into the base lug (item 11) with taper bushing shaft (item 9). Ensure Anti-Seize
compound is applied to the threads of the taper bushing shaft prior to threading it
into the torque arm assembly.
3. After the taper bushing shaft is dead ended into the clevis, use the SKF’s lock
washer and lock nut to seat the taper bushing (item 10) between the bushing shaft
and the clevis ID as shown in the diagram. Ensure the lock nut is snugged against
the taper bushing.
4. Raise the free end of the steady torque arm assembly. Align with the attachment
point of the torque arm assembly (item 1).
5. Pin the upper end of the steady torque arm (item 13) into the torque arm assembly
(item 1) with taper bushing shaft (item 9). Ensure the taper bushing shaft is fully
seated by tightening the SKF lock washer until it is snug.
6. Level the torque arm assembly with the turnbuckle collar.
7. Repeat steps 2 through 4 with the other turnbuckle assemblies.
8. Ensure all four SKF’s lock nuts are torqued against the taper bushings with the
SKF’s hook wrench (HN-15). Bend locking pin of washers into the lock nuts’ slots.
9. Perform a final check on the levelness of the torque arm after both sets of
turnbuckles are secured. Do not adjust the collar to the point that any one of the
turnbuckles is putting a compressive force into the torque arm assembly. In
order for the torque arm assembly to transfer the drum torque properly in either
rotation direction, the torque arm assembly needs to float over the two turnbuckles
assemblies.
10. Secure the turnbuckle lock nut (item 7) to a snug tight condition. At this point, an
additional 1/3 turn of the lock nut is required to secure the adjusting collar.
NOTE: DO NOT tighten the turnbuckle (Dwg. 9130A343, Item #8) when
reinstalling the drum shaft. Adjust the turnbuckle to suit the equalizer tube
(Item #1) after installing the steady torque arm (Item #13). The assembly
transfers the torque from the motors to the skid. If the turnbuckle is
tightened after it is installed, it will not share torque load with the steady
torque arm (Item #13). In this situation the turnbuckle will be overloaded.
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8.5 Lebus Grooving Replacement
The Lebus Grooving installed on the drawworks drum that is fabricated from a high yield
strength alloy steel plate and is considered a primary structural component. Regardless
of the hook load rating of the drawworks, the fabrication and shop notes on drawing
9130F236 (Lebus Grooving Installation Detail) should be used with the following
installation instructions.
1. Only a qualified welder should perform the required weldment. Ensure a National
Oilwell Varco approved weld procedure is available. Due to the high yield strength
of the material, there are restrictions on the preheat and the maximum interpass
temperatures during welding.
2. Measure the drum diameter and width carefully after the worn sleeve is removed.
3. Measure the width of the new sleeve. It should be approximately 1/16” smaller than
the drum width for clearance reasons.
4. Place the “entry” half of the sleeve in place. A small portion of the drill line can be
used to aid this alignment.
5. Position the sleeve half around the drum to suit. Keep the clearance gaps at the
drum flange equal at each flange especially at the split lines.
6. Using chain(s) and jack(s), force the sleeve down tight against the drum barrel in the
area to be welded. Using E8018 welding rod, begin tack welding the sleeve half
starting with the holes furthest away from the split lines and working towards the split
in either direction moving the jack as you go.
NOTE: The tapped holes in the sleeve are for lifting eyes and are not to be
welded. Furthermore, they are not intended for lifting the drum.
WARNING: Drum material is high strength quench and tempered steel. Do not
weld on these parts without assistance from National Oilwell Varco.
Special weld procedures are required.
7. Weld both edges of the first half split to the drum with a 5/8” fillet weld before
installing the second half.
8. Position the second half so the groove lands line up with each other. Equalize the
clearance gap at the flanges; equalize the split line gap between the sleeve halves.
9. Jack down the sleeve half tight against the drum in the area to be welded. Start with
the holes furthest from the split lines and plug weld the holes same as the first half.
10. Weld all plug holes flush to the root diameter.
11. Weld the sleeve halves together at the split lines and the hole opening at rope entry.
12. Grind the grooves smooth in all the welded areas. There should be no welding of the
sleeve around the flanges.
13. Magnetic particles inspection (MPI) shall be performed to all accessible welds.
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8.6 Drum Shaft End Bearing Alignment Procedure
Prior to installing any of the motor mounts or motors on to the drum shaft, measure the
height of drum shaft above the top of the skid beam.
1. Set up the measuring jig fixture on top of the skid beams, directly underneath the
location of the 2” diameter drain hole in the motor mount housing.
2. Permanently mark the location of the jig so it may be reinstalled at a later time in
exactly the same location.
3. Using an inside micrometer, measure the distance from the top of the measuring jig
to the underside of the drum shaft. Record the measurement below.
4. Repeat the above for the other end of the drum shaft.
5. Once all components (except motors) have been installed on the shaft including the
end bearing and end bearing support, re-measure the drum shaft height. The shaft is
accessed through the 2” drain hole in the motor mount housing.
6. Adjust shims on end bearing support until the shaft is at the same height as it was
prior to installation of the motor mounts.
7. Record the final shaft height below.
Shaft End* Initial Measurement (inches) Final Measurement (inches)

Left End
Right End
*View shaft from the front of the drawworks.

[Left side shims installed = ”]
[Right side shims installed = ”]
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8.7 Gear Alignment Procedure
1. Check gear wobble (side run-out). Rotate gear 360°. Total indicator reading should
be 0.050” or less.
2. Install AC motor with pinion on to the motor mount. Ensure motor has been shimmed
up with approximately 0.050” of shims.
3. Check backlash of gears using dial indicator on the tooth face of the pinion or with
feeler gauges. Acceptable backlash is 0.025”/0.035”. Backlash must be checked in 4
positions at roughly 90° intervals. Adjust motor shim to obtain the desired backlash.
4. Apply red lead paint to gear teeth.
5. Apply bluing paste to the pinion teeth.
6. Rotate pinion to mark gear with bluing paste. Check indication of tooth contact.
Contact mark should cover a minimum of 75% (or 5.25 * 0.75 = 3.9375”) of the gear
tooth face. The contact area should be approximately centred on the gear. There
should be no contact at the edge of the gear tooth.
NOTE: Contact area is load dependent and will also vary with the thickness of the
applied bluing paste.
7. Adjust the motor angle (front to back and/or side to side to adjust the contact area as
required.
8. Repeat this for each motor.
9. Record all measurements below.
Gear #1 Wobble = inches

Gear #2 Wobble = inches
Pinion Back Back Back Back Contact Contact

Lash Lash Lash Lash Centered? Width
Position 1 Position 2 Position Position (Yes / No)
3 4
1
2
3
4
5
6
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The only sure method for determining the actual tooth contact is to load the gears and look
at the resulting “loaded” tooth contact pattern. To do this, follow the procedure below after
performing the procedure above.
1. Hang off the traveling block and remove the drill line from the drawworks drum.
2. Remove the access covers on the pinion(s) and the gear(s).
3. Using a solvent cleaner (such as Electrosol) clean the exposed pinion and gear teeth
of “all” oil and oil film. The teeth must be perfectly clean or the blue layout fluid will not
adhere to the teeth and will be washed off by the oil instead of being worn off by the
tooth contact.
4. Apply a thin film of Machinists Blue layout fluid (quick drying aerosol) to the pinion and
gear teeth.
5. Allow the layout fluid to dry for 10 -15 minutes.
6. Rotate the gear and pinion to expose unpainted teeth.
7. Repeat steps 2, 3 & 4 on the new teeth.
8. Repeat until all the pinion and gear teeth have been painted and dried.
9. Set AC drive to limit motor torque to no more than 100% of continuous motor rating.
10. Set the AC drive/control system to power one motor only.
11. Start all auxiliary functions on the drawworks (i.e. lube pump and brake HPU)
12. Check the oil flow to the gears.
13. Reinstall the access covers.
14. Set up the drawworks so the emergency lowering valve is functioning and the disc
brakes can be applied manually.
15. Start the drawworks and rotate the drum at 8 to 10 rpm.
16. Using the emergency lowering valve, apply the disc brakes very slowly until the drum
stops and then release the brakes.
17. Continue to slowly apply and release the brakes for approximately 5 to 10 minutes.
Monitor the brake disc temperature to ensure it does not exceed 100°C (212°F). If the
brake disc overheats, stop the process and cool the brake disc before proceeding.
18. Stop. Shut off the drawworks and all auxiliaries.
19. Remove the access cover for the pinion that was just run.
20. Examine the tooth contact pattern around the pinion and around the gear.
21. The pattern on the bull gear teeth should be the same all the way around the Bull gear.
If this is the case the bull gear is ok and does not need to be examined further.
22. The pattern on the pinion needs to be examined carefully. The pattern indicates
whether the motor is aligned properly or not and indicates what to do to move the
motor to correct the contact pattern.
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23. Check the pinion tooth pattern to see if it is the same on both sides of the teeth. If it is
not the same on both sides of the teeth the pinion teeth are not straight to the bull gear.
24. Check to see where the contact is along the teeth. A perfect pattern would be in the
center of the tooth with no contact on either end of the tooth.
Note: The shaded area represents the blue machinist’s layout fluid that has not been
worn off. The blue shows where the teeth have not made contact.
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25 Adjust the motor position to achieve the perfect tooth contact pattern
NOTE: When adjusting the motor it is important to recognize the orientation of the
motor/pinion to the gear.
26 Verify the back lash is within the range stated above.
NOTE: Small backlash is better than large backlash, but under no circumstances
should the backlash be less than 0.020”.
27 Once the adjustment is complete clean and repaint the pinion gear.
28 Repeat steps 12 to 24 until an acceptable tooth contact pattern is observed.
NOTE: The contact pattern on the lowering side does not need to be as perfect as the
hoisting side of the teeth. The lowering side of the teeth will never be loaded
during operation.
NOTE: The tooth contact must exceed 75% of the tooth width minimum. It is
preferable that the tooth contact area be in the 90% range. It should appear
that the remaining paint would wear off under higher loads. This is evident if
the remaining blue paint is “blotchy”. Typically the remaining blue paint will
always be at the drum end of the pinion teeth. The pattern shown below is an
acceptable pattern.
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29 Once an acceptable tooth contact is obtained, check the backlash in four places
around the gear. Ensure all readings are within the range 0.020” to 0.035”. Large
variations in the backlash readings indicate the bull gear is warped.
30 Repeat for remaining motors.
31 Upon completion of all motors, ensure that all covers have been properly replaced and
sealed and that no parts, rags or tools have been left inside the gear case.
8.8 Pinion Removal, Mounting, and Fitting
8.8.1 Pinion Removal
When removing a hub, use a suitable puller. This is a simple, efficient hydraulic puller
employing the float removal. A complete unit consists of a pump kit, a backing plate, an
adapter, a felt ring, and a bolt.
NOTE: Do not heat the hub before pulling it, and do not use steel wedges
between the hub and bearing cap.
1. Remove the setscrew plug from the tapped hole in the end of the shaft.
2. Screw the backing plate, with felt ring in place, to the end of the shaft as tight as
possible by hand.
3. Back off the backing plate to line up the slot with the tapped hole in the end of the
shaft. This is to provide sufficient clearance for the hub to pop off.
4. Screw the pressure-fitting adapter into the hole in shaft until it seats at the bottom.
5. Attach the pump by screwing the connector on one end of the pressure tube into the
adapter, and the other end into the pump.
6. Close the hand relief valve and work the pump handle to force oil into the groove in
the armature shaft under the hub. When sufficient pressure has been built up, the
hub will pop off the shaft and be stopped by the felt washer and backing plate.
NOTE: The capacity of the pump is 40,000 psi. It holds sufficient oil to remove
eight to ten hubs; check at each use. Periodically, remove the filling plug
and refill with SAE-10 lubricating oil.
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7. Open the relief valve, disconnect the pump from adapter, remove the adapter and
backing plate from the shaft, and lift off the hub. Reinsert the plug to prevent
clogging the hole.
CAUTION: Special precautions should be taken to avoid damage to the rotor,

bearings, or bearing fits, when lifting the rotor in the vertical position
or turning rotor to a horizontal position.
8.8.2 Pinion Fitting
To prevent a pinion from slipping, it should have at least 75% fit on the shaft; i.e., at
least 75% of the tapered bore of the pinion should be in contact with the tapered fit on
the shaft. Before mounting a pinion, check and correct the fit as follows:
1. Lightly cover the bore of the pinion with a bluing compound such as Prussian Blue.
2. Snap the cold pinion forcefully onto the shaft.
3. Mark the relative angular position of pinion with respect to the shaft.
4. Remove the pinion from the shaft. A convenient method of removal is by the use of
two finely tapered steel wedges (hardened and ground), which are carefully driven
between the pinion and the bearing outer sleeve on the shaft.
5. Important! Inspect the taper fit of the shaft; bluing of the pinion bore should
now show on the shaft. If at least 75% of shaft surface shows traces of bluing, the
fit is satisfactory. If, however, only a few spots of bluing show on the shaft, the fit is
not satisfactory.
6. Dress down the blue spots on the shaft very lightly with a fine emery cloth such as
No. 400A Triemite.
7. Blue the pinion bore again (see Step 1) and repeat Steps 2, 4, 5, and 6. Be sure to
place the pinion onto the shaft in the same position as marked.
8. Generally, the fit will be improved, but the foregoing procedure may have to be
repeated several times to obtain 75% fit.
9. Under no circumstances, use a lapping compound since lapping will produce a
shoulder at the large end of the tapered fit. A shoulder will prevent a perfect fit when
the pinion is mounted hot; i.e., when it is mounted in the advanced position.
10. After a good fit has been obtained, clean the shaft and pinion bore thoroughly to
remove all bluing, oil or grease. Then mount the pinion.
CAUTION: Minimum shaft to pinion fit is 75%. It is preferable for this fit to be 90-
95% contact cold. Poor fits will make removal of the pinion difficult
and may result in the pinion coming off the motor shaft and severely
damaging the drawworks.
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8.8.3 Pinion Mounting
P/N 9130D299 pinions are to be installed with an advance of 0.085” to 0.090”. The
advance must never exceed 0.095”.
CAUTION: PST fluid contains a small percent of alcohol, giving it a low flash
point. Keep it away from open flame.
NOTE: The towel should not be wet enough to cause dripping or runs. If runs or
drips are present, the PST fluid will dry out too heavy and must be cleaned
off with MEK.
1. Remove the pinion from the shaft. Wet a Scott No. 150 towel with PST fluid.
2. Wipe the PST Fluid onto the pinion in an even coat.
3. Let the PST fluid dry; DO NOT wipe off. A barely visible white haze will be present
on the surface.
CAUTION: Do not use an oil bath to heat the pinion; this will result in slipped
pinion. Use an oven or slow induction heater, 8 minutes or longer.
4. Place the pinion in an oven. Heat to the required temperature specified below.
Carefully monitor the pinion temperature with a pyrometer.
DO NOT overheat. Refer to the following method of calculating pinion gear temperature.
• Temperature specified for 0.090” advance is 168°C (303°F) above shaft

temperature.
• Shaft temperature is 24°C (75°F).
• Heat pinion to 168°C + 24°C = 192°C (378°F).
CAUTION: Temperature of the pinions or the gear must not exceed 210°C
(410°F) as such temperatures will anneal the metal and cause an
excessive rate of wear.
5. Several minutes before the pinion gear reaches the specified temperature, wipe the
shaft fit with a clean Scott No. 150, C-Fold towel, dampened with MEK. Let it dry.
WARNING: “MEK” (Methyl-Ethyl-Ketone) is a volatile solvent. The fumes should

not be inhaled. Use only in a well-ventilated area and take adequate
precautions to protect the eyes, skin and hands.
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6. Apply PST fluid with another Scott No. 150 towel to the shaft taper avoiding drips or
runs. Watch the underside of the shaft; drips or runs, if present, will be noticed first.
Let the PST fluid dry. DO NOT wipe off. A very light, even white haze should be
visible. Cover with a clean towel.
7. When the pinion reaches the specified mounting temperature, measured by a

pyrometer on the face of the pinion, remove it from the oven with clean heat-
insulated gloves. Do not touch the bore.
WARNING: Heat resistant gloves must be worn while handling hot pinion to
prevent physical injury.
8. Remove the towel from the shaft and apply the pinion to the shaft, in line with the
chalk marks, with a firm snap. Pinion must be applied within 10 seconds after it is
removed from the oven; otherwise, it will cool and the proper advance may not be
maintained.
NOTE: The pinion gear must be applied with a firm snap. The PST fluid on the
shaft and pinion bore impedes “sliding” of the pinion; this tends to limit the
advance.
9. When the pinion gear and shaft have cooled to room temperature, measure the hot
advance position.
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9 TROUBLESHOOTING
9.1 Equipment Fault Symptoms and Causes
9.1 Equipment Fault Symptoms and Causes
Assuming the drawworks equipment is properly installed and operated, and undergoes
routine maintenance and change-out, little or no trouble should be expected from the
equipment. Because the symptoms of a failed or worn component may differ with the
equipment operating conditions, observe those conditions (e.g. load/no load, braking,
etc.) which best indicate the symptoms. Understanding the schematic drawings may be
helpful for isolating faults related to the controls or lubrication systems. Where possible,
use other means to verify operation or fault conditions (e.g. pressure gauges for
hydraulics). Use the following table as a guide for fault diagnosis:
SYMPTOM POSSIBLE CAUSE

Excessive or unusual
• Drawworks brakes, gears, or electric drive motor.
noise from drawworks
Excessive or unusual
noise from drawworks • Bearings, lube system, lube pump.
interior
Improperly functioning
• Brake caliper, hydraulic supply, or controls fault.
brakes
Metallic clanking • Gear wear, inadequate lubrication and/or misalignment
(rotating) of gear.
• Worn bearing (louder upon loaded condition). Possibly
Howling (rotating)
due to inadequate lubrication.
Squealing or grinding • Brake pads worn or faulty caliper. Check brake discs
(rotating) for warping.
Rattling • Loose or worn mounts.
• Check AC motor encoders.
Vibrations
NOTE: Standard bench tests will not prove that the
encoder is functioning properly.
Refer to Section 14 of manual, Vendor Information, for maintenance and troubleshooting

of vendor equipment.
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10 TIGHTENING TORQUE GUIDE

10.1 Bolt Torque Chart
10.2 Socket Head Capscrew Tensile Requirements
10.3 Turn-of-Nut Tightening
10.1 Bolt Torque Chart
Tightening Torque Guide

SAE Grade 5 - Fine Thread
Size Clamp Load Plain Plated
1/4 - 28 (.250) 2,325 10 ft·lbs 87 in·lbs
5/16 - 24 (.3125) 3,675 19 ft·lbs 14 ft·lbs
3/8 - 24 (.375) 6,699 35 ft·lbs 26 ft·lbs
7/16 - 20 (.4375) 7,575 55 ft·lbs 41 ft·lbs
1/2 - 20 (.500) 10,200 85 ft·lbs 64 ft·lbs
9/16 - 18 (.5625) 12,975 122 ft·lbs 91 ft·lbs
5/8 - 18 (.625) 16,350 170 ft·lbs 128 ft·lbs
3/4 - 16 (.750) 23,775 297 ft·lbs 223 ft·lbs
7/8 - 14 (.875) 32,475 474 ft·lbs 355 ft·lbs
1 - 12 (1.000) 42,300 705 ft·lbs 529 ft·lbs
1 - 14 (1.000) 32,275 721 ft·lbs 541 ft·lbs
1 1/8 - 12 (1.125) 47,475 890 ft·lbs 668 ft·lbs
1 1/4 - 12 (1.250) 59,550 1,241 ft·lbs 930 ft·lbs
1 3/8 - 12 (1.375) 72,975 1,672 ft·lbs 1,254 ft·lbs
1 1/2 - 12 (1.500) 87,750 2,194 ft·lbs 1,645 ft·lbs

SAE Grade 5 - Coarse Thread
1/4 - 20 (.250) 2,025 8 ft·lbs 87 in·lbs
5/16 - 18 (.3125) 3,338 17 ft·lbs 13 ft·lbs
3/8 - 16 (.375) 4,950 31 ft·lbs 23 ft·lbs
7/16 - 14 (.4375) 6,788 50 ft·lbs 37 ft·lbs
1/2 - 13 (.500) 9,075 76 ft·lbs 57 ft·lbs
9/16 - 12 (.5625) 11,625 109 ft·lbs 82 ft·lbs
5/8 - 11 (.625) 14,400 150 ft·lbs 112 ft·lbs
3/4 - 10 (.750) 21,300 266 ft·lbs 200 ft·lbs
7/8 - 9 (.875) 29,475 430 ft·lbs 322 ft·lbs
1 - 8 (1.000) 38,625 644 ft·lbs 483 ft·lbs
1 1/8 - 7 (1.125) 42,375 794 ft·lbs 596 ft·lbs
1 1/4 - 7 (1.250) 53,775 1,120 ft·lbs 840 ft·lbs
1 3/8 - 6 (1.375) 64,125 1,470 ft·lbs 1,102 ft·lbs
1 1/2 - 6 (1.500) 78,000 1,950 ft·lbs 1,462 ft·lbs
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SAE Grade 8 - Fine Thread
1/4 - 28 (.250) 3,263 14 ft·lbs 10 ft·lbs
5/16 - 24 (.3125) 5,113 27 ft·lbs 20 ft·lbs
3/8 - 24 (.375) 7,875 49 ft·lbs 37 ft·lbs
7/16 - 20 (.4375) 10,650 78 ft·lbs 58 ft·lbs
1/2 - 20 (.500) 14,400 120 ft·lbs 90 ft·lbs
9/16 - 18 (.5625) 18,300 172 ft·lbs 129 ft·lbs
5/8 - 18 (.625) 23,025 240 ft·lbs 180 ft·lbs
3/4 - 16 (.750) 33,600 420 ft·lbs 315 ft·lbs
7/8 - 14 (.875) 45,825 668 ft·lbs 501 ft·lbs
1 - 12 (1.000) 59,700 995 ft·lbs 746 ft·lbs
1 - 14 (1.000) 61,125 1,019 ft·lbs 764 ft·lbs
1 1/8 - 12 (1.125) 77,025 1,444 ft·lbs 1,083 ft·lbs
1 1/4 - 12 (1.250) 96,600 2,012 ft·lbs 1,509 ft·lbs
1 3/8 - 12 (1.375) 118,350 2,712 ft·lbs 2,034 ft·lbs
1 1/2 - 12 (1.500) 142,275 3,557 ft·lbs 2,668 ft·lbs

SAE Grade 8 - Coarse Thread
1/4 - 20 (.250) 2,850 12 ft·lbs 9 ft·lbs
5/16 - 18 (.3125) 4,725 25 ft·lbs 18 ft·lbs
3/8 - 16 (.375) 6,975 44 ft·lbs 33 ft·lbs
7/16 - 14 (.4375) 9,600 70 ft·lbs 52 ft·lbs
1/2 - 13 (.500) 12,750 106 ft·lbs 80 ft·lbs
9/16 - 12 (.5625) 16,350 153 ft·lbs 115 ft·lbs
5/8 - 11 (.625) 20,325 212 ft·lbs 159 ft·lbs
3/4 - 10 (.750) 30,075 376 ft·lbs 282 ft·lbs
7/8 - 9 (.875) 41,550 606 ft·lbs 454 ft·lbs
1 - 8 (1.000) 54,525 909 ft·lbs 682 ft·lbs
1 1/8 - 7 (1.125) 68,700 1,288 ft·lbs 966 ft·lbs
1 1/4 - 7 (1.250) 87,225 1,817 ft·lbs 1,363 ft·lbs
1 3/8 - 6 (1.375) 103,950 2,382 ft·lbs 1,787 ft·lbs
1 1/2 - 6 (1.500) 126,450 3,161 ft·lbs 2,371 ft·lbs
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Page 75
10.2 Socket Head Capscrew Tensile Requirements
per ASTM A574-83

Screw Threads Inches Tensile Load Min. Tensile Rec. UNC Torque
Dia. (in) Strength in lbs.
UNC UNF UNC UNF psi/Min UNRC UNRF
0.060 - 80 - 324 180,000 - 2
0.073 64 72 473 500 180,000 4 4
0.086 56 64 666 709 180,000 6 7
0.099 48 56 877 941 180,000 10 11
0.112 40 48 1,090 1,190 180,000 15 16
0.125 40 44 1,430 1,490 180,000 20 21
0.138 32 40 1,640 1,830 180,000 28 30
0.184 32 36 2,520 2,650 180,000 49 50
0.190 24 32 3,150 3,600 180,000 64 76
¼ 20 28 5,730 6,500 180,000 150 170
5/16 18 24 9,440 10,400 180,000 305 325
3/8 16 24 13,900 15,800 180,000 545 570
7/16 14 20 19,100 21,400 180,000 840 900
½ 13 20 25,500 28,800 180,000 1,300 1,370
5/8 11 18 38,400 43,500 170,000 1,850 1,970
¾ 10 16 56,800 63,400 170,000 2,630 2,660
7/8 9 14 78,500 86,500 170,000 4,400 4,800
1 8 12 103,000 113,000 170,000 7,000 7,600
1½ 7 12 129,000 146,000 170,000 10,400 11,000
1¼ 7 12 165,000 182,000 170,000 14,900 15,600
1 3/8 6 12 196,000 224,000 170,000 21,000 22,600
1½ 6 12 239,000 269,000 170,000 27,800 29,300
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Page 76
10.3 Turn-of-Nut Tightening
(Ref. RCSC specification, AISC (8)c for more details)
With any tensioning method of making connections, it is important to install bolts in all
holes of the connection and bring them to a snug-tight condition to compact the joint.
Tightening should begin at the most rigidly fixed or stiffest point and progress toward the
free edges both in the initial snugging-up and in the final tightening.
Equipment consistency and reliability depends on assuring that the joint is well
compacted and that all bolts at a joint are at a snug-tight condition prior to application of
the final required partial turn. It is critical that the element not turned in tightening must be
prevented from rotating while the required degree of turn is applied to the turned element.
Nut-Rotation from Snug-Tight Conditiona,b

Disposition of Outer Face of Bolted Parts
One face normal to bolt
Bolt Length axis and other sloped Both faces sloped no more
(under side of Both faces no more than 1:20 than 1:20 from normal to the
head to end of normal to (beveled washer not bolt axis
bolt) bolt axis used) (beveled washer not used)
Up to and
including 4 1/3 turn 1/2 turn 2/3 turn
diameters
Over 4
diameters but 1/2 turn 2/3 turn 5/6 turn
not exceeding
8 diameters
Over 8
diameters but 2/3 turn 5/6 turn 1 turn
not exceeding
12c diameters
a Nut rotation is relative to bolt regardless of the element (nut or bolt) being turned. For bolts installed by
1/2 turn and less, tolerance is ± 30°; for bolts installed by 2/3 turn and more, tolerance is ± 45°.
b Applicable only on connection in which all materials within the grip of the bolt are steel.
c No research has been performed by AISC to establish the turn-of-nut values for bolt lengths exceeding
12 diameters. Therefore, the required rotation must be established by actual test in a suitable tension
measuring device that simulates conditions of solidly fitted steel.
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11 SPARE PARTS
11.1 Overall Drawworks Spares
11.2 2” Control Valve Spares
11.3 Lubrication Pump ‘10S’ Spares
11.4 Speed Reducer 4:1 Spares (7020B086)
11.5 Brake Caliper Assembly Spares
11.1 Overall Drawworks Spares

Part Oper. Comm
Description Dwg(Item #)
Number Qty. Qty.
654920 Clamp, Wireline 9130A250 (26) 1
656031 Stud 6
6300160 Nut 6
9130D049B Taper Bushing* 9130A126 & 8
9130A343 (10)
9130D049A Taper Bushing Shaft* 9130A126 & 8
9130A343 (9)
7006B136 Steel on Steel Spher. Plain Brg 9130A126 & 2
9130A343 (A)
7018B091 Lock Nut* 9130A126 & 8
9130A343 (B)
7018B092 Lock Washer* 9130A126 & 8
9130A343 (C)
7020B081 Axial Piston Hydraulic Pump 9130A226 (A) 2
9130D782A 231 T High Speed Gear 9130A250 (23) 2
9130D299 22 T High Speed Pinion 9130A250 (24) 5
7006B132 Spherical Roller Bearing 9130A250 (D) 2
7006B236 Spherical Roller Bearing 9130A250 (E) 2
7006B237 Cylindrical Roller Bearing 9130A250 (G) 2
7018B089 Vibration Proof Fasteners 9130A250 (H) 64
7018B090 Vibration Proof Fasteners 9130A250 (K) 64
7006B135 Oil Seal 9130A250 (G) 2
7006B427 Oil Seal 9130A250 (M) 2
7018B758 Plate Type Exchanger 9130X059 (A) 2
SS Plate Assy 'A/B' For Exchanger 1
SS Plate Assy 'D' For Exchanger 2
A/B Gasket Only For Exchanger 1
'D' Gasket Only For Exchanger 2
7024B208 Check Valve, 65 psi 9130X059(C) 2
NOTE: The following parts marked with an * is for the torque arms. The quantities
listed are for two torque arms.
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Page 78
Overall Drawworks (continued)

Part Oper. Comm
Description Dwg(Item #)
Number Qty. Qty.
7030B101 15 KW, 440 VAC, 1800 RPM, 60Hz, 9130X059 (F) 2
3 Phase Motor
7056B249 0-300 psi Pressure Gauge 9130X059(K) 2 2
7024B068 Thermal Bypass Valve 9130X059(AB) 1
7046B084 Strainer 150 Micron Screen 9130X059(B) 1
7026B040 1” Relief Valve 9130X059(R) 2
9130A085 1202199 - Pilot Operated Brake 9130X058 (1) 1
Control Valve
7040B171 Manifold 9130A085(A) 1 2
7040B172 Check Valve 9130A085 (B) 1 2
7040B173 Normally Closed Valve 9130A085 (C) 1 2
7040B174 Normally Open Check Valve 9130A085 (D) 1 2
7040B175 Normally Open Valve 9130A085 (E) 1 2
7056B336 0-5000psi Stainless Pres. Gauge 9130X058(E) 11 1
7024B057 Ball Valve 1/2” 2P-3WSS 9130X058(B) 8
7026B037 Pres. Reducing/Relieving Valve 9130X058(H) 2
7032B091 5 Gallon Accumulator Bottle 9130X058(S) 1
7032B093 Bladder only 2
7032B094 Oilair Kit 2
7030B102 Filter – 3000psi, Hydraulic 9130X058 (T) 1
7030B112 Element only 4 2
7036B080 Electric Motor, 4 KW, 440 VACM 60 9130X058 (W) 2
HZ, 1800 RPM, 3 Phase Motor
7024B062 1/2” Check Valve 9130X058 (K) 2
7026B085 High Pressure / Back Pressure 9130X058(AC) 1
Regulator
7028B138 Flow Control (25 GPM) 9130X059(M) 1
7028B139 Flow Control (40 GPM) 9130X059(N) 1
7030B109 Lube Tank Filter 9130X059 (Y) 1 1
7030B132 Breather c/w Element and Adaptor 9130X059 (Z) 2
7032B193 Flow Control Valve 9130X058 (R) 1
7018B463 2” Flexible Rubber Joint 9130X059 (AE) 3
7018B562 3” Flexible Rubber Joint 9130X059 (AC) 4
7018B482 2” Coupling (complete) 9130X059 (AF) 3
7018B464 3” Coupling (complete) 9130X059 (AD) 4
7030B027 Lube Filter Assembly 9130X059 (D) 2
7030B085 Filter Element 8 8
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Page 79
11.2 2” Control Valve Spares

Oper. Comm
Part Number Description Dwg(Item #)
Qty. .Qty.
7024B209 Bypass Valve (assembly) 9130X059 (AA) 1
1570B O-Ring 1
2071 Lip Seal 2
2050 Element 2
2000-Temp Kit 1
11.3 Lubrication Pump ‘10S’ spares

Oper. Comm
Qty. .Qty.
7020B085 Lube Pump (Whole Assembly) 9130X059 (E) 1
713-9080-205 Gear Set 1
213-100-221 Thrust Bearing 2
423-9 Needle Bearing 4
713-9245-270 Seal 1
433-1100-1 Ball Bearing 1
213-60-285 Backdrain Pin 1
92-5380-1636 Screw (housing and flange) 20
92-5380-1224 Screw (bearing cap) 3
466-135 O-Ring (pipe flange) 3
466-196 O-Ring (seal face retainer) 1
11.4 Speed Reducer 4:1 Spares (7020B086)

Oper. Comm
Qty. .Qty.
0220-01001-200 Parallel Shaft Drive 9130X059 (G) 1
0223-00919-200 Gasket 1
0223-04897-066 Shim, 0.002 Red 8
0223-04898-066 Shim, 0.005 Blue 8
8-32-20-58-011 Cup, Bearing 4
8-32-20-68-011 Cone, Bearing 4
8-74-12-25-001 Seal, 18039 or Eq. 2
8-74-80-09-070 O-Ring, -044 4
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Page 80
11.5 Brake Caliper Assembly Spares
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Page 82
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Page 83
12 DRAWINGS
Drawing No. Drawing Title

Overall Assemblies
9130B036 SSGD-1000-5750-55-82-10.5 Drawworks General Assembly - Main
Schematics
9130X058 SSGD-1000 Brake Hydraulic Schematic
9130X059 SSGD-1000 Lubrication Schematic
Miscellaneous Drawworks Drawings
9130A072 Removable Lifting Frame Assembly
9130A085 2P-4W Pilot Operated Brake Control Valve
9130A094 Remote Brake Valve Assembly
9130A097 (AHD-500-4600) Dwwks Guard & Stabilizer Ass’y
9130A126 (SSGD-500-3450) Drawworks Torque Arm Assembly
9130A135 (SSGD-500-3450) Gear Case Assembly
9130A162 (SSGD-650) Mech. Breather Layout
9130A226 Hydraulic Pump Assembly
9130A244 Cool/Hot Ducting Assembly – Baylor 3 Motor
9130A247 Drawworks Enclosure Roof Assembly
9130A248 Drawworks Enclosure Back Side Wall Assembly
9130A250 SSGD-1000-5750-55-82-10.5 Drumshaft Assembly
9130A272 Two-Motor Gear Case Assembly
9130A276 Lube System – Exchanger Piping 2 Assembly
9130A277 Lube System – Return Piping Assembly
9130A280 Lube System – Water Piping Assembly
9130A285 Cool/Hot Ducting Assembly – Baylor 2 Motor
9130A286 Hydraulic System Layout
9130A295 Drawworks Enclosure Building Assembly – Baylor Five Motor
9130A343 Two Motor Torque Arm Assembly
9130A344 Lube System – Exchanger Piping 1 Assembly
9130A345 Lube System – Supply Piping Assembly
9130A346 Lube System Layout
9130A356 200 Gallon Lubrication Tank Assembly
9130C138 Drawworks Skid Footprint Layout - Main
9130C139 Drawworks Skid Nozzle Location – Main
9130C140 Drawworks Duct Flange Details – Main
9130C141 Drawworks Skid Power Cable Coaming Location – Main
9130D449 (AHD-1000-6900) Cont. Caliper Mount. Brkt Ass’y
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Page 84
Drawing No. Drawing Title

Miscellaneous Drawworks Drawings (Continued)
9130D534 20 Gallon SS Hydraulic Tank
9130D625 Stabilizer Bracket Assembly
9130D641 (AHD-1000-6900) Dwwks Lub. Point Locations
9130F236 Lebus Grooving Installation Detail
9130F237 Drum Kicker Plate Layout
9130F291 Brake Calipers Operation Plate – Eight Caliper
9130F313 Drawworks Enclosure Roof
9130F435 SSGD-1000 Specification & Name Plate Details
9130F480 Two Motor Equalizer Tube / Stud Shaft Machine Detail
9130G006 Motor Accessories Layout – SSGD-1000-5750 Drawworks
9130L020 (AHD-1000-6900) Mechanical Breather Layout
9130L031 (AHD-1000-6900) Dwwks Misc. Guards Layout
9130L102 SSGD-1000-5750 Drawworks Lifting Diagram
2112424 Caliper Ass’y, Emergency Brake – Dreco SSGD Dwks
6212-1832-20 Cylinder Emergency Brake
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Page 85
13 DATA SHEETS
Refer to the following attached documents.
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Page 86
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Page 87
14 VENDOR INFORMATION
Manual
Vendor Description/Model
Number
Alberta Model YS 600 SS, 600# ANSI Stainless Steel Screwed /
N/A
Strainers Socket Weld “Y” Strainer Information
Apollo N/A 70-100 Series, Bronze Ball Valve Information
B-Loc N/A Locking Assemblies & Connectors
BSM PS-1003 Models 6S – 14S Pumps Operating Instructions
Crompton N/A Installation & Maintenance Instructions for Flameproof
Greaves Induction Motors
Denison 1-AM0009 PV, PVT Series Piston Pumps for Open Circuits
Doering 1202199 Valve Schematic & Specification Sheet
Enerpac L1763 Instructions for Hydraulic Hand Pumps
FPE 2010-050803 Thermostatic Valves – Model 2010
High Pressure ES-011
Ball Valve Operating and Maintenance Instructions
Equipment
Hub City LI-PS-02 Parallel Shaft Reducers – Lubrication and Installation
Hydac 02073475 Series DF & LF, High Pressure Filter Information
LHA N/A Low Pressure Filter and Breather - Catalog
National EPL-1829 2112424 Emergency Disc Brake Caliper Operation and
Oilwell Varco Maintenance Manual and Spare Parts List
Nutron 97-06 DOC T3 Flanged Ball Valve Operation and Maintenance Manual
Oil Air MM3-97 3,000 PSI Bladder Accumulators Pre-Charging Instructions
Oil Air MMM-94 Accumulator Instruction Manual
2502 Series C Check Valve and Series F Flow Control Valve
Parker
Technical Information
Schroeder Ind. N/A MLF1 Top Ported Return Line Filter – Catalog
Form 1601 54-2200 Series High Pressure / Hydraulic Piston Technical
Tescom
Information and Parts List
Form 1635 54-2100 Series High Pressure / Hydraulic Piston Technical
Tescom
Information and Parts List
Tranter SC-IOM-10 Superchanger Installation and Operation Manual
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INSTALLATION AND REMOVAL INSTRUCTIONS FOR INSTALLATION OF B-LOC LOCKING
B-LOC™ LOCKING ASSEMBLY SERIES B113 ASSEMBLIES OVER SHAFT KEYWAYS
Thank you for purchasing a B-LOC™ Keyless Frictional Locking Device. The Locking Assembly should be positioned so that slits in Locking Assembly
B-LOC™ keyless connectors provide a high capacity, zero-backlash shaft/ collars that contact the shaft are located approximately opposite the keyway.
hub or coupling connection by means of a mechanical interference fit. Please In addition, a locking screw should be centered directly over the keyway.
follow these INSTALLATION AND REMOVAL INSTRUCTIONS carefully to When tightening locking screws, it is important to follow the installation
ensure proper performance of this B-LOC™ unit. procedure outlined above, which specifies equal 1/4 turns of each locking
screw. Failure to follow these instructions could result in excessive tightening
EWARNING E of the screw over
the keyway, Figure 2
When installing or removing B-LOC™ products, always adhere to the possibly causing
following safety standards: p e r m a n e n t
1. Be sure that all power switches are locked out before installing or remov- deformation of the
ing B-LOC™ products. Locking Aassembly
2. Eye protection is required when installing or removing B-LOC™ products collars. Even after
– please wear safety glasses and protective clothing. 1/4 turns can no
longer be achieved,
INSTALLATION it is important to
continue to use
(Refer to Figure 1)
equal turning
B-LOC™ Locking Assemblies are supplied lightly oiled and ready for angles for every
installation. When reinstalling a used unit, make sure that all slits are aligned screw until the
and that front and rear clamp collars are not reversed. The frictional torque specified tightening
capacity of these devices is based on a coefficient of friction of 0.12 for lightly torque is reached.
oiled screw, taper, shaft and bore contact areas.
Therefore, it is important not to use Molybdenum Disulfide (e.g., Molykote, Never-

REMOVAL (Refer to Figures 2 and 3)
Seeze or similar lubricants) in any Locking Assembly installation.
1. Make sure that locking screw, taper, shaft and bore contact areas are Prior to initiating the following removal procedure, check to ensure that
clean and lightly oiled and that all collar slits are aligned. no torque or thrust loads are acting on the Locking Assembly, shaft or
any mounted components.
2. Loosen all locking screws by a minimum of four (4) turns and transfer at
least three (3) screws to equally spaced push-off threads in clamp collar IMPORTANT! Make sure ends of locking screws used for removal are
Item 1 to disengage this part from center collar Item 3. To disengage ground flat and are slightly chamfered to eliminate damage
collar Item 2 from taper interface, lightly tap heads of three (3) equally to screw and collar threads during push-off.
spaced locking screws that have been engaged at least four (4) turns into
collar Item 2 (see Figure 1). 1. Check to ensure that axial movement of clamp collars - necessary for
release of connection - is not restricted. Likewise, ensure that push-off
Figure 1
3. Completed assembly can threads are in good condition.
now be placed on shaft and
inserted into hub bore by 2. Remove all locking screws. Transfer required number of screws into all
pushing against face of push-off threads of clamp collar Item 1 (see Figure 2).
collar Item 1 while ensuring
3. Release collar Item 1 by Figure 3
that collar Item 2 is not
progressively tightening
engaged at tapers during
all push-off screws.
this phase.
Typically, the push-off
4. After placement of Locking screws appear to be
Assembly, relocate locking completely tight after just
screws used for separation one pass of tightening
of collars. without any noticeable
separation of clamp
5. Hand tighten connection collars. Although it seems
and confirm that clamp that the screws cannot be
collar Item 1 is parallel with tightened further, several
face of part to be attached to shaft and/or with the front facing edge of more rounds of torquing in
center collar Item 3. either a clockwise or
counterclockwise
6. Use torque wrench and set it approximately 5% higher than specified tightening sequence will increase
torque MA. Tighten screws in either a clockwise or counterclockwise sequence (it the push-off force in the
is not necessary to tighten in a diametrically opposite pattern), using only 1/4 (i.e., system and ultimately release part of the front collar. Afterwards, only the
90°) turns for several passes until 1/4 turns can no longer be achieved. screws which are still tight should be tightened further until complete
dismounting is achieved. Remove collar Item 1 and cover plate Item 4
7. Continue to apply overtorque for 1 to 2 more passes. This is required to compensate
(cover plate Item 4 is supplied with two [2] smaller threads at the collar
for a system-related relaxation of locking screws since tightening of a given screw
face for this purpose).
will always relax adjacent screws. Without overtorquing, an infinite number of
passes would be needed to reach specified tightening torque. 4. Transfer locking screws used for dismounting of collar Item 1 into all push-
off threads in center collar Item 3 (see Figure 3). Release collar Item 2 by
8. Reset torque wrench to specified torque (MA) and check all locking screws. No
repeating procedures outlined in Step 3.
screw should turn at this point, otherwise repeat Step 7 for 1 or 2 more passes. It
is not necessary to re-check tightening torque after equipment has been in operation.
LOCKING SCREW SIZES AND SPECIFIED TIGHTENING TORQUE MA
NOTE: In installations subjected to extreme corrosion, the slits in clamp collars B113 LOCKING ASSEMBLY - METRIC SIZES ONLY
Item 1 and Item 2, as well as in center collars, should be sealed with a Screw Size Tightening Hex Key
suitable caulking compound or equivalent. Likewise, push-off threads Din 912 Grade 12.9 Torque MA (ft-lb) Size (mm)
should also be protected from corrosion. 180 x 285 to 220 x 325 M22 x 180 675 17
240 x 355 to 300 x 425 M24 x 180 870 19
320 x 455 to 560 x 695 M27 x 220 1,300 19
B-LOC Corporation 26 Gilbert Street Monroe, NY 10950 For technical assistance, please call 1-800-865-7756
Installation and
Maintenance
Instructions for
FLAMEPROOF
Induction Motors
Crompton
Greaves
CROMPTON GREAVES LTD.
LT Motors Division
Ahmednagar 414 111.
Dear Sir,
We welcome you to the family of our valued customers.
We thank you for your implicit faith in our motor and we
are sure it will give you a long and trouble free service to
your satisfaction. Please carefully go through the contents
ot this manual & do the installation, operation and
maintenance of this motor in such a way that the
flameproofness and thus safety of the motor is preserved.
THE INSTRUCTIONS GIVEN IN THIS BOOKLET ARE TO BE
FOLLOWED IN ALL RESPECTS WHILE INSTALLING &
MAINTAINING THE MOTOR.
DEVIATION FROM THE CLAUSES STATED HERE MAY GIVE
RISE TO OPERATION TROUBLES & EXPLOSION HAZARDS DUE
TO DISTURBANCE IN FLAMEPROOFNESS
Should you need any help / information on performance /
service kindly give correct machine no. and excise no. to
any of our offices which are convenient to your location.
Your's faithfully,
Marketing Manager
Crompton Greaves Ltd.
TEST CERTIFICATE
MACHINE NO. / REF. NO.
XAEJ 12189
FRAME :
ENCLOSURE GROUP (✓) I IIA IIB
This is to certify that the above motor is manufactured

in compliance with IS : 2148 & strictly in accordance
with the test reports issued by CENTRAL MINING
RESEARCH INSTITUTE, Dhanbad. All the components
constituting the flameproof enclosure have been
static pressure tested in the factory according to the
above standard. All the flameproof paths / joints have
been checked for required dimensions.
It is also certified that the motor has passed all the
routine tests as per IS 325 or to one or more of the
following Indian standards.
IS 1231 IS 2223 IS 4691 IS 2253 IS 4029
IS 4821 IS 3682 IS 6362 IS 4722 IS 12075
IS 12065 IS 8239
For CROMPTON GREAVES LIMITED
Quality Assurance Dept.

Date 9.1.04 LT MOTORS
GUARANTEE OF SATISFACTION
This motor is guaranteed to be free of any
manufacturing defect.
We undertake to repair or replace this motor at
our option, or any part thereof, which we are
satisfied, was originally defective in material or
workmanship, provided that the motor or its part/s
is returned, freight paid to our nearest branch /
dealer within 12 months from the date of
purchase by the first user.
We cannot however, accept responsibility if the
motor is found to be repaired by persons, other
than those authorised by us to carry out such
repairs. Guarantee does not cover consequential
damage / defects of any nature.
This guarantee excludes every condition or
warranty, whether statutor y or other wise,
whatsoever not herein expressly set out.
Note : To avail the guarantee facility, this card
must be produced at the time of lodging
complaints alongwith the purchase documents,
bearing the motor reference number.
Crompton
Greaves
LT Motors Division
A Business Unit of
Crompton Greaves Ltd.
SAFETY INSTRUCTIONS RELATED TO
FLAMEPROOFNESS
CAUTION
All operations must be carried out by appropriately trained
personnel. For installation and maintenance instructions, refer this
book thoroughly or consult the supplier, if in doubt.
1. Never switch on power supply with any of the inspection covers,
gland plate, sealing box open or loose, when the motor is in a
hazardous area.
2. Ensure the gap of all the joints is less than 0.1 mm in the event of
refitting any opened cover. Use a filler gauge to check the gap.
3. Use of gaskets at joints where it is not originally provided is not
permitted.
4. Use spring washers where originally provided.
5. Use fastners of same size and type as provided originally.
6. Excessive force should not be used for tightening the bolts,
screws. This may lead to slippage of threads leading to
undesired gaps at joints. In case of blind tapped holes clean
the dirt at the bottom of hole before putting the screw.
7. Never apply putty or hardening compound at the joints where
originally not provided to make it weather proof. Before
replacing a cover the flange should be cleaned & lightly
greased. Do not allow the cover joints to be rusted.
8. In terminal box, the terminal nuts are of special design and are
made of brass. Do not replace them with standard nuts. This will
lead to sparking / excessive heating and may cause explosion
hazard.
9. Never allow the bearings to run dry or with excessive noise. This
may lead to bearing seizer followed by sparks coming out of
bearings housing, which may create explosion hazards. For
replenishing grease in the greasable bearings use the
recommended grease and follow the regreasing intervals
mentioned on Nameplate. Replace bad bearings in time.
10. If any of the components of the motor needs to be replaced,
replace by correct spare brought from the company. Never
use any fabricated or built up parts, which is not of original
design, to avoid violating requirements of the flameproofness.
ANY ALTERATION OF A FLAMEPROOF ENCLOSURE IS PROHIBITED.
TERMINAL BOX AND CABLE TERMINATION

Direct termination of cable to winding leads is not permitted in
Flameproof motor. The cables are to be terminated to the terminal
box through either of the following (as applicable).
● Approved type FLP double compression cable gland (should
be approved by CCE)
● A cable sealing box (If provided alongwith motor)
● Approved type FLP plug & socket for Group I application (should
be approved by DGMS). The plug/socket is mounted on the
motor terminal box through an adaptor specially designed to
suit a particular type of plug/socket. Please ensure there is a
proper adaptor available.
1. Use of sealing box - fitted with sealing compound is must for
Group I application. Use bituminous compound or cold pouring
epoxy compound. Use the 2 holes provided in the sealing box
for compound pouring. Make drilled holes on the barrier plate
provided to take the cable cores to the terminal box. The barrier
plate prevents bleeding of compound into terminal box, when
poured.
2. Use correct size of double compression cable gland (the cable
should not remain loose in the rubber bushes of the gland.). Else
the flameproofness of the terminal box will be lost. Ensure the
threads of gland and the gland plate are matching and full
thread length of the gland is engaged.
3. Use proper size of cable sockets. Ensure minimum 10 mm
clearance between live terminals and live to earth.
4. Seal unused cable entries by flameproof plug.
LIFTING :
1. Use all lifting facilities provided - Both lifting points if fitted or
single lifting point if fitted. Do not use any other part of the
motor for lifting.
Note : Maximum handlift is 20Kg below shoulder, but above
ground level.
2. Vertical lifting - Prevent uncontrolled rotation of the motor.
3. Do not lift other equipments with motor lifting points only.
MAXIMUM WEIGHTS : (Unpacked)
Weights 6.5 8 19 25 36 50 115

in KG
Frame size 63 71 80 90 100 112 132
Weights 250 500 1000 1500 2000 3000

in KG
Frame size 160 180 200 250 315 355
225 280
INSPECTION ON RECEIPT :
1. Make sure the right motor is received.
2. Check for transit damage.
3. If necessary, please open packing case in presence of an
authorised Insurance Agent.
4. Please report damages to us giving complete Nameplate
details.
STORAGE :
1. Ensure motors are stored in a place with an ambient range of
-200C to +450C.
2. Store motors under shade and not in open.
3. Ensure that the stored motor does not receive any harmful
vibration.
4. Ensure no water drips on motor & no water logging under the
motor.
5. Energise heaters if fitted.
6. Ensure all plugs originally provided are in place (e.g. Cable
entry hole plugs, drain plug, Fan cover greasing hole plug
for TEFC motors.)
Every 1 Week Rotate shaft
PERIODIC
Every Check Insulation
REQUIREMENTS 3 Months resistance If less than
10 M ohm, dry out.
PRE-INSTALLATION CHECKS :
Ensure TICK WHEN CHECKED
1. Motor not corroded excessively.
2. Fan cover not damaged or touching fan.
3. Foot not broken or cracked.
4. Shaft not damaged/bend.
5. All fasteners are tight.
6. Check all the name plate details.
7. Check free running by hand.
8. Check grease condition if motor is idle for more than
6 months. If bad (Ref. : IS900) replenish with fresh grease.
9. Add Lubricating Oil in the oil seal (If provided).
INSTALLATION - MECHANICAL :
1. Level mounting surface. Clean mounting
foot/flange & shaft of the motor.
2. Check mounting plane. Add shims if necessary (maxm
change of indicator reading - 0.075 mm with mounting
bolts loose and tight - while checking mounting surface
w.r.t motor foot/flange.
3. Check for any misalignment in motor & drive shaft.
(Approx. TIR 0.050 mm)
4. While mounting use appropriate fasteners &
tightening torques.
5. Check all the gaskets, sealants & guards are
correctly fitted.
6. Verify belt tension.
INSTALLATION - ELECTRICAL :
1. Ensure power supply system is grounded.
2. Ensure proper earthing.
3. Check insulation resistance of all windings with 500V dc
megger. If < 10 Mohm, dry out as per procedure given in
IS : 900.
4. Ensure the equipment is fused and isolated correctly.
5. Ensure all the covers are fitted and interior of terminal box
is clean & free of cable residues.
6. Seal unused cable entries by flameproof plugs.
CONNECTIONS :
1. Check connection diagram and ensure correct
terminal arrangement.
2. Ensure all the connections are tight and clean.
3. Ensure air clearance between live & live to
earth > 10 mm.
4. Check driven equipment is free.
5. Check rotation, uncoupled.
6. Ensure rating of fuse, setting of protecting devices are
correct. Recommended protections :
Overload, Single Phasing, Under Voltage, Earth Fault.
7. Ensure space heater (if provided) is off while
starting the motor.
OPERATION :
FREE RUNNING BEFORE COUPLING TO LOAD :
1. Ensure supply voltage as per nameplate & balanced in
all three phases. (Maxm. allowable unbalance i.e. Maxm.
deviation from average is 1%) For more unbalance,
reduce the output by derating factor from the graph.
1.0
0.9
0.8
0.7
0 1 2 3 4 5
% VOLTAGE UNBALANCE
2. Check three phase currents at No Load (Free Shaft) &
tally with the Test Certificate.(First page of this Book)
Note : The currents will be more if the voltage is more.
They will be less if the voltage is less. The increase &
decrease will not be in linear proportion with voltage.
3. No abnormal noise. (Use a screwdriver as a medium
to hear.)
4. Bearing not heating up abnormally.
5. Check direction of rotation. If specific. (Frame 280 &
above 2 pole motors may be fitted with
unidirectional fan).
6. Check vibration. (Vibration level on the mounting
structure immediately below the motor should be within
30% of horizontal vibration level at the bearing housing)
RUNNING ON LOAD :
1. Ensure rated voltage at the motor terminal during
startup and check starting time within designed limit.
(Any normal application, the time required will not be
more than 5 sec. at DOL. For high inertia load the
starting time is longer but special design is required
to cater this. For star/delta & reduced voltage starter
the time will be longer than that in DOL). Refer to
Crompton Greaves in case of doubt.
2. Ensure Full Load Currents are balance in all phases
(Maxm. unbalance 8% corresponding to 1% unbalance
of voltage) and the value is within Nameplate Data.
In case of pulsating load we recommend the
maximum current to be within Nameplate value.
3. No abnormal vibration. (If change in vibration level is
observed, check alignment again preferably in
hot condition.)
4. No abnormal noise.
5. Check maxm. air inlet temperature =
Ambient temperature mentioned on Nameplate
6. No abnormal heating up. Total permissible temperature
including ambient for Class B rated motors are
approximately as follows :
By Thermometer : At Eyebolt : 900C
At Bearing Cover : 800C
On Slipring Surface : 900C
Check the temperature after 4-5 hours of operation, when
it is stabilised.
7. Check no sparking is appearing on the slipring in case of
Slipring Motor.
PROBLEMS :
Noisy
Vibrating
Tripping Refer to supplier with Machine no.
Overheating
Not Starting
MAINTENANCE :
While carrying out maintenance
1. Ensure that the motor is isolated.
2. Refer to supplier, if in doubt.
SPARE PARTS :
While ordering Spare Parts, always quote Machine Number and
Reference number which will be found on the Nameplate.
Please use only genuine spares.
HAZARDOUS AREAS :
If motor is marked with ''Ex'' symbol, special conditions apply.
Refer appropriate installation manual and relevant standards.
All operations are to be carried out by appropriately trained
personnel.
OPERATING & MAINTENANCE TIPS
(ALSO REFER IS : 900 - 1992)
C R O M P TO N G R E AV E S M o t o r s h a v e b e e n d e s i g n e d,
manufactured and tested to a high standard of excellence.
Motors conform to relevant Indian standards as given on the
name plate.
These motors are sound in design and robust in construction and
will give satisfactory service with correct installation and normal
routine maintenance.
SITE :
- Check for proper ventilation. TEFC Motors should be provided
with at least 2'' gap between fan cover and nearest barrier.
- Install DP Motors at a clean dry place.
- Check for ambient conditions, if special treatment on motor
is provided for adverse ambient.
- Ensure passages in between ribs in TEFC Motors are properly
cleaned.
FOUNDATION :
The foundation of the motor should be preferably of concrete, or
structural steel, and must be sufficiently rigid to minimize
vibrations and to maintain alignment between the motor and the
load. Normally a mixture of four parts of stone and two parts of
sand and one part of cement by volume is suitable.
PINIONS, PULLEYS AND COUPLINGS :

- Use flexible coupling. For rigid couplings refer to CROMPTON
GREAVES.
- Use dynamically balanced (with half key) Pully / couplings /
pinions. (Motor Rotors are balanced with half key)
- For belt drive mount belt nearest to motor bearings. Belts
should not be too tight.
- Use pulley diameter and coupling / pulley bore as follows :
PULLEY DIMENSIONS (mm) :
TOLERANCE ON BORE DIA. OF
PULLEY & COUPLING (H-7)
FRAME MIN MAX FACE
DIA WIDTH NOMINAL TOLERANCE
80 75 50 18 to 30 + 0.0
90 75 63 + 0.021
100 75 80
112 100 100
132 120 125
160 150 177 30 to 50 +0.0
180 180 203 +0.025
200 187 280 50 to 80 +0.0
225 197 330 +0.030
250 228 380 80 to 120 +0.0
280 375 380 +0.035
315 400 380
355 500 400
STARTING :
Squirrel Cage Motors are suitable for DOL, Star/Delta or Auto
Transformer Starting.
Slipring motors should be started by stator / rotor starter with
suitable external resistance in rotor circuit which should be cut off
gradually when motor picks up speed.
- In case of star/delta starter, put to `Delta' when the motor
picks up fully in `STAR' position.
- While operating on load & the motor is hot, the motor is
suitable for 2 starts in one hour, unless it is designed for higher
number of starts.
- In case of Slipring Starters, ensure the current and voltage of
the starter are same as specified on the motor name plate
(RV & RA)
PREVENTIVE MAINTENANCE :
Motor should be kept clean and free from oil, dust and moisture.
Care should be taken to see that ventilation passages are not
blocked. The earthing conductor should be regularly inspected
and checked for continuity. The insulation resistance of stator and
rotor windings should be checked regularly between respective
terminals and the frame.
In case of slipring motors, carbon dust should be blown out
regularly from sliprings and brushes. The pressure on brushes and
wear out should be checked.
BEARINGS :
The bearings marked 'ZZ' 0r '2RS' are sealed for life and require no
lubrication.
For greased bearings :
1. Check relubrication interval on name plate. The regreasing
interval should be shortened for high ambient temperature,
presence of corrosive vapours or extreme level of
contamination.
2. For replenishing fresh grease in the bearing :
- Quantity of grease to be filled in bearing
(in gms.) = Bearing bore dia.
- Fill 1/3rd of bearing cover cavities with grease.
Recommended grease is Servogem 2 of M/s. IOCL, or MP2 of
M/s. Bharat Petroleum or AP2 of CASTROL. MIXING OF DIFFERENT
GREASE SHOULD BE AVOIDED.
While removing the bearings from the shaft, use properly
designed draw-off tackle or puller to hold the bearing preferably
at inner race. While pulling out the bearing, rotate the bearing to
avoid damages if the bearing is intended to be used again.
Bearing should be refitted on shaft after heating upto
approximately 900C and by sliping on to the shaft.
SLIPRING/BRUSHGEAR :
Size of brushes on the Slipring motors are as below
FRAME a X t X r (Dimensions in mm)
250 16 X 20 X 30 a - Axial width
280 & 315 20 X 40 X 28 t - Thickness
r - Radial width
(* Radial width should not be allowed to wear below 15 mm
length).
- If Slipring surface is not smooth, smoothen with fine glass
paper
(DO NOT USE EMERY-CLOTH).
- Brushes should be free in holder, recommended brush
pressure is 0.2 KG/SQ.CM. (t X a)
- Ensure that Slipring and Brushes are free from oil and Dust.
Blow out carbon dust from Sliprings and brushes periodically.
- Use brush grade M15E of Assam Carbon or BE22 of Electro
Carbonium.
- For new brushes proper brading is to be done with sand
paper, so that curvatures of brushes and slipring are perfectly
matched.
NOTE :
In case of the Non-standard motors, wherever necessary, special
instructions will be provided.
LIST OF FLAMEPROOF APPROVALS
FRAME CMRS REPORT DGFAS & LI APPROVAL CCE APPROVAL CMRI TEST REPORT DGMS APPROVAL
E80 CMRI/TC/P/H 167 66/6/(P)AB/167 R-1(1)136/CROMPTON Not Not
dt. 26-02-02 2002-TECH GREAVES/13-XV Applicable Applicable
dt. 17-09-02 dt. 31-08-99
E90L CMRI/TC/S/H 436 66/13/P(AB)435/96 R1(1)136/ REV.CERT. No.15 83/279/EHQ
dt. 18-04-00 -TECH CROMPTON/XV-13 V/Rev./867 dt. 25-03-85
dt. 06-08-01 dt. 23-08-00 dt. 16-01-85
E100L CMRI/TC/S/H 437 66/13/P(AB)1181/96 R1(1)136/ REV.CERT. No.16 83/279/EHQ
dt. 06-08-01 dt. 23-08-00 dt. 16-01-85
E112M CMRI/TC/S/H 490 66/13/P(AB)1180/96 R1(1)136/CROMPTON REV.CERT. No.17 83/279/EHQ
dt. 02-05-00 -TECH GREAVES/13-XV V/Rev./865 dt. 25-03-85
dt. 06-08-01 dt. 09-11-01 dt. 16-01-85
E132M CMRI/TC/S/H 491 66/13/P(AB)1170/96 R1(1)136/ REV.CERT. No.19 83/279/EHQ
dt. 06-08-01 dt. 09-11-01 dt. 16-01-85
E160L REV. CERT. No.18 66/8/85-TECH R-1(1)136/ REV.CERT. No.18 83/279/EHQ
(Air Stream V/Rev./864 dt. 20-08-01 CROMPTON/XIV/13 V/Rev./864 dt. 25-03-85
Rated) dt. 16-01-85 dt. 31-12-92 dt. 16-01-85
LIST OF FLAMEPROOF APPROVALS
FRAME CMRS REPORT DGMS APPROVAL CCE APPROVAL DGFAS APPROVAL
NO. DATE NO. LETTER REF. DATE LETTER REF. DATE LETTER REF. DATE
(GR-I)
E160L CMRI/TC/P/H185 5.3.02 119 83/J/2/75/1001 1.9.76
E180L
EHQ
CMRI/TC/P/H169 27.2.02 122 83/1219//EHQ 31.7.02

ü ü
E200L CMRI/TC/P/H568 22.7.02 45 83/1212/EHQ 31.7.02
E225M CMRI/TC/S/H688 26.6.98 80 83/312/EHQ 4.4.00
E225S CMRI/TC/S/H688 26.6.98 78 83/312/EHQ 6.4.00 R1 (1) 136 66/6/S/688/ 12.3.99
E250M CMRI/TC/P/H688 26.6.98 79 83/329/EHQ 6.4.00

ý /CROMPTON 8.6.99
ý 99-TECH
E250S CMRI/TC/S/H688 26.6.98 79 83/329/EHQ 6.4.00 /XIV-13
E280M CMRI/TC/S/H688 26.6.98 127 83/291/EHQ 4.4.00
E315L CMRI/TC/P/H449 7.6.02 160 83/77/863/EHQ 24.678
E315L CMRI/TC/S/H688 26.6.98
E315M CMRI/TC/S/H688 26.6.98 125 83/298/EHQ 4.4.00 þ þ

LIST OF FLAMEPROOF APPROVALS : continued ..
FRAME CMRS REPORT DGMS APPROVAL CCE APPROVAL DGFAS APPROVAL
NO. DATE NO. LETTER REF. DATE LETTER REF. DATE LETTER REF. DATE
(GR-I)
ü ü
EW250M CMRI/TC/S/H688 26.6.98 126 83/76/1619/EHQ 18.12.76
EW280M CMRI/TC/S/H688 26.6.98 252 83/83/691/EHQ 2.8.84 R1 (1) 136 66/6/S/688/ 12.3.99
EW315L CMRI/TC/S/H688 26.6.98 221 83/82/951/EHQ 27.7.82 ýü /CROMPTON 8.6.99 ýü 99-TECH
EW315M CMRI/TC/S/H688 26.6.98 136 83/76/545/EHQ 7.5.77 /XIV-13
1. CMRI : Central Mining Research Institute - Dhanbad 4. DGF AS & LI : Directorate - General Factory Advice
2. DGMS : Director General of Mines Safety - Dhanbad Service & Labour Institute - Mumbai
3. CCE : Chief Controller of Explosives - Nagpur 5. BIS : Bureau of Indian Standards - Mumbai
NATURE OF IMPORTANT FLAMEPROOF JOINTS
SHROUDING GAP
GAP
GAP
FLAME PATH FLAME PATH
FIG. 1-A FIG. 1 -B
1 TERMINAL BOX & STATOR CASE JOINT 1 ENDSHIELD & STATOR CASE JOINT
2 TERMINAL BOX & TERMINAL BOX COVER 2 TERMINAL BOX & TERMINAL BOX
(225-315 frame) COVER (160-200 frame)
SEALING BOX (225-315 frame) SEALING BOX / CONDUIT PLATE
CONDUIT PLATE & GLAND PLATE JOINT (160-200 frame)
3 SLIPRING COVER & END SHIELD JOINT
4 SLIPRING COVER UPPER HALF AND
LOWER HALF JOINT
GAP
FLAME PATH
FLAME PATH
GAP
FLAME PATH
GAP
FIG. 1-C FIG. 1-D

1 INSIDE BEARING COVER & 1 TERMINAL STUD &
ENDSHIELD JOINT TERMINAL BOX JOINT
CONNECTION DIAGRAM FOR 3 PHASE INDUCTION MO
TORS
STATOR MOTOR
WINDING TERMINALS SWITCH
STAR WOUND SWITCHING DIRECT ON TO MAIN TERMINAL

BLOCK WITH STRAIGHT THROUGH CONNECTORS
DIAGRAM NO. 201
STATOR MOTOR
WINDING TERMINALS SWITCH
MESH WOUND SWITCHING DIRECT ON TO MAIN TERMINAL

BLOCK WITH STRAIGHT THROUGH CONNECTORS
DIAGRAM NO. 202
3 POLE SWITCH 3 POLE SWITCH

STAR WOUND SWITCHING DIRECT MESH WOUND SWITCHING DIRECT
ON TO MAINS AUTO TRANSFORMER ON TO MAINS AUTO TRANSFORMER
STARTERS CAN BE USED WITH STARTERS CAN BE USED WITH
MOTOR CONNECTIONS MOTOR CONNECTIONS
AS SHOWN ABOVE AS SHOWN ABOVE
DIAGRAM NO. 301 DIAGRAM NO. 302
TORS
STATOR
WINDING
TERMINALS
A1 B2
B1 C2
C1 A2
L2 L3 L1
A 1 B 2 B 1 C 2 C 1 A2
STAR
DELTA
MUSH WOUND WITH STAR DELTA STARTING

DIAGRAM NO. 304
STATOR WINDING ROTOR WINDING
SLIP RING
3 POLE SWITCH
MOTOR TERMINALS
STARTING RESIST
ANCE
FOR SLIPRING MOTORS
DIAGRAM NO. 3 MS
TORS
TWO WINDING TYPE (STAR WOUND)

LOW SPEED
CONNECT R TO 1U, Y TO 1V, B TO 1W
HIGH SPEED
1U DIAGRAM NO. K52 (1)

1W
1U 2W
1V 2V
SINGLE WINDING TYPE

(MESH/STAR IN TWO PARALLELS)
LOW SPEED
HIGH SPEED
1U AND 1U, 1V, 1W TO BE SHORTED
1W 2W
DIAGRAM NO. K52 (2)
2U
1V 2V
SINGLE WINDING TYPE

(STAR/STAR IN TWO PARALLELS)
LOW SPEED
HIGH SPEED
AND 1U, 1V, 1W TO BE SHORTED
2W DIAGRAM NO. K52 (3)
1W 2U
1U
1V 2V
CROMPTON GREAVES LTD. Regd. Off.:
LT MOTORS DIVISION 6th Floor, CG House,
A-6/2, MIDC, Ahmednagar 414 111. Dr. Annie Besant Rd.,
Tel.: 0241 - 2777507, 372/4/6. Fax : 2777508. Prabhadevi, Mumbai 25.
NORTHERN REGION SALES OFFICES
New Delhi : Vandana, 11, Tolstoy Marg, New Delhi 110 001. Tel.: (011) 3721536 /37.
Fax : 011 - 3324360. Jaipur : Church Road, P.O. Box 173, Jaipur. Tel.: (0141) 376919,
376307. Fax : 0141 - 365371. Jalandhar : 50, Mahavir Marg, Jalandhar 144 001.
Tel.: (0181) 59467, 59478. Fax : 0181 - 226342. Lucknow : Speed Building, 2nd Floor, 3
Shahajahan Lucknow 226 001. Tel.: (0522) 239443, 239345. Fax : 0522 - 237009.
WESTERN REGION SALES OFFICES

Mumbai : Kanjur Marg (East), Mumbai 400 042. Tel.: 022 - 5782451. Fax : 022 - 5794882.
Ahmedabad : 909, Sakar II, Near Ellis Bridge Police Station, Ahmedabad.
Tel.: 079 - 6581729. Fax : 079 - 6586047. Baroda : 10A Kalpana Apartments,
Vrundavan Society, Near Gotri Water Tank, Gotri, Baroda 390 015. Tel.: (0265) 330819.
Fax : 0265 - 332458. Pune : Surya Bhavan, 5th Floor, 1181, Fergusson College Road,
Pune 411 005. Tel.: (020) 5535675, 9665. Fax : 020 - 5534684. Indore : 103 B, Apollo
Trade Centre, 2B, Rajagarh Kothi, Mumbai-Agra Rd., Indore. Tel.: (0731) 498269, 498276.
Fax : 0731- 495667. Nagpur : 3 West High Court Road, Lal Bahadur Shastri Chowk,
Dharampeth, Nagpur 440 010. Tel.: (0712) 530537. Fax : 0712 - 537196.
EASTERN REGION SALES OFFICES

Kolkata : 50, Chowringhee Road, Kolkata 700 071. Tel.: (033) 2829681, 84.
Fax : 033 - 2829942. Bhubaneshwar : Red Cross Bhavan, Sachivalaya Marg,
Bhubaneshwar 751 007. Tel.: (0674) 531429. Fax : 533521, 531592.
SOUTHERN REGION SALES OFFICES

Chennai : No. 3-A, Kodambakkam High Road, P.O. Box 3316, Nungambakkam,
Chennai 600 034. Tel.: (044) 8257375. Fax : 044 - 8231973, 8234113. Bangalore :
Mithra Towers, 1st Floor, No. 10/4, Kasturba Road, Bangalore 560 001. Tel.: (080) 2273686.
Fax : 080 - 2270691, 2240770. Coimbatore : Krishna Towers, IV Floor (E), P.O. Box 6329,
1087, E Avavashi Rd., Coimbatore. 641 037. Tel.: (0422) 495334. Fax : 0422 - 495334.
Cochin : Cherupushpam Building, 5th Floor, 330-6, Shanumugham Road, Ernakulam,
Cochin 682 031. Tel.: (0484) 370860. Fax : 0484 - 373738. Secunderabad : 4th Floor,
Minarva House, 94, Sarojini Devi Road, Secunderabad 3. Tel.: (040) 7847270. Fax : 7842921.
SERVICE CENTRES
New Delhi : 27, Rani Jhansi Road, New Delhi 110 055.
Phone : 011 - 7516993, 7532349. Fax : 011 - 7514899.
Kolkata : 171/1A, 'Acharya" J. C. Bose Road, Kolkata 700 014.
Phone : 033 - 2441557. Fax : 033 - 2429942
Mumbai : Mathuradas Mills Compound, Next to Milton, Lower Parel (W),
Mumbai 400 013. Phone : 022 - 4922572, 4947950. Fax : 022 - 4922572.
Chennai : 3 A, Kodambakkam High Rd., Nungambakkam, Chennai 600 034.
Phone : 044 - 8274610. Fax : 044 - 8274610.
Instruction Sheet
¤
Hydraulic Hand Pumps
L1763 Rev F 10/03
Index:
English ...................................................................1-7
Français .............................................................. 8-14
Deutsch ............................................................ 15-22
Italiano .............................................................. 23-29
Español............................................................. 30-36
Nederlands ....................................................... 37-44
Portuguese ....................................................... 45-51
........................................................... 52-58
................................................................59-64
WARNING: Stay clear of loads supported
Repair Parts Sheets for this product are available by hydraulics. A cylinder, when used as a
from the Enerpac web site at www.enerpac.com, or load lifting device, should never be used
from your nearest Authorized Enerpac Service Center as a load holding device. After the load
or Enerpac Sales office. has been raised or lowered, it must always be
blocked mechanically.
1.0 IMPORTANT RECEIVING WARNING: USE ONLY RIGID PIECES
INSTRUCTIONS TO HOLD LOADS. Carefully select steel
®
Visually inspect all components for shipping damage. or wood blocks that are capable of
®
Shipping damage is not covered by warranty. If supporting the load. Never use a hydraulic cylinder
shipping damage is found, notify carrier at once. The as a shim or spacer in any lifting or pressing
carrier is responsible for all repair and replacement application.
costs resulting from damage in shipment. DANGER: To avoid personal injury
keep hands and feet away from cylinder
SAFETY FIRST and workpiece during operation.
2.0 SAFETY ISSUES WARNING: Do not exceed equipment
ratings. Never attempt to lift a load
Read all instructions,
weighing more than the capacity of the
warnings and cautions
cylinder. Overloading causes equipment
carefully. Follow all safety
failure and possible personal injury. The cylinders are
precautions to avoid personal injury or property
designed for a max. pressure of 700 bar [10,000 psi].
damage during system operation. Enerpac cannot be
Do not connect a jack or cylinder to a pump with a
responsible for damage or injury resulting from unsafe
higher pressure rating.
product use, lack of maintenance or incorrect product
and/or system operation. Contact Enerpac when in DANGER: Never set the relief valve to a
doubt as to the safety precautions and operations. If higher pressure than the maximum rated
you have never been trained on high-pressure pressure of the pump. Higher settings
hydraulic safety, consult your distribution or service may result in equipment damage and/or
center for a free Enerpac Hydraulic safety course. personal injury. Do not remove relief valve.
Failure to comply with the following cautions and WARNING: The system operating
warnings could cause equipment damage and pressure must not exceed the pressure
personal injury. rating of the lowest rated component in
the system. Install pressure gauges in the
A CAUTION is used to indicate correct operating or
system to monitor operating pressure. It is your
maintenance procedures and practices to prevent
window to what is happening in the system.
damage to, or destruction of equipment or other
property. CAUTION: Avoid damaging hydraulic
hose. Avoid sharp bends and kinks when
A WARNING indicates a potential danger that
routing hydraulic hoses. Using a bent or
requires correct procedures or practices to avoid
kinked hose will cause severe back-
personal injury.
pressure. Sharp bends and kinks will internally
A DANGER is only used when your action or lack of damage the hose leading to premature hose failure.
action may cause serious injury or even death.
Do not drop heavy objects on hose. A
WARNING: Wear proper personal sharp impact may cause internal damage
protective gear when operating hydraulic to hose wire strands. Applying pressure to
®
equipment. a damaged hose may cause it to rupture.

IMPORTANT: Do not lift hydraulic Avoid situations where loads are not
equipment by the hoses or swivel directly centered on the cylinder plunger.
couplers. Use the carrying handle or other Off-center loads produce considerable
means of safe transport. strain on cylinders and plungers. In
addition, the load may slip or fall, causing potentially
CAUTION: Keep hydraulic equipment dangerous results.
away from flames and heat. Excessive
heat will soften packings and seals, Distribute the load evenly across the entire
resulting in fluid leaks. Heat also weakens saddle surface. Always use a saddle to
hose materials and packings. For optimum protect the plunger.
performance do not expose equipment to
temperatures of 65 °C [150 °F] or higher. Protect
hoses and cylinders from weld spatter. IMPORTANT: Hydraulic equipment must
only be serviced by a qualified hydraulic
DANGER: Do not handle pressurized technician. For repair service, contact the
hoses. Escaping oil under pressure can Authorized ENERPAC Service Center in
penetrate the skin, causing serious injury. your area. To protect your warranty, use only
If oil is injected under the skin, see a doctor ENERPAC oil.
immediately. WARNING: Immediately replace worn or
WARNING: Only use hydraulic cylinders in damaged parts by genuine ENERPAC
a coupled system. Never use a cylinder parts. Standard grade parts will break
with unconnected couplers. If the cylinder causing personal injury and property
becomes extremely overloaded, damage. ENERPAC parts are designed to fit properly
components can fail catastrophically causing severe and withstand high loads.
personal injury. CAUTION: Always use the handle to carry
WARNING: BE SURE SETUP IS STABLE the pump. Carrying the pump by the hose
BEFORE LIFTING LOAD. Cylinders may damage the hose and/or the pump.
should be placed on a flat surface that can
®
support the load. Where applicable, use a

cylinder base for added stability. Do not 3.0 DESCRIPTION
weld or otherwise modify the cylinder to attach a
base or other support. 3.1 Models P-141, 1001; P-142, 1002;
P-202; P-391, 1004; P-392, 1005; P-802;
SPECIFICATIONS – Use this instruction sheet for the following hand pump models.
Hand Pump Specifications
Model Type Maximum Pressure Oil Volume per Stroke Usable Oil Capacity
(Speed) Rating psi [bar] in 3 [cm 3] in3 [cm3]
EHF-65 1 6,500 [440] .16 [2.62] 22 [360]
P-18 1 2,850 [200] .16 [2.62] 22 [360]
P-25 1 2,500 [170] .58 [9.51] 231 [3786]
P-39, 1003 1 10,000 [700] .16 [2.62] 43 [705]
P-50 1 5,000 [340] .29 [4.75] 231 [3786]
P-51 1 3,000 [210] .25 [4.09] 50 [820]
P-141, 1001 1 10,000 [700] .055 [.90] 20 [328]
P-391, 1004 1 10,000 [700] .151 [2.47] 55 [900]
Stage 1 Stage 2 Stage 1 Stage 2

P-80, 1006 2 350 [25] 10,000 [700] .99 [16.23] .15 [2.46] 140 [2295]
P-84 2 350 [25] 10,000 [700] .99 [16.23] .15 [2.46] 140 [2295]
P-142, 1002 2 200 [14] 10,000 [700] .221 [3.62] .055 [.90] 20 [328]
P-142AL 2 200 [14] 10,000 [700] .221 [3.62] .055 [.90] 9.0 [148]
P-202 2 200 [14] 10,000 [700] .221 [3.62] .055 [.90] 55 [900]
P-392, 1005 2 200 [14] 10,000 [700] .687 [11.26] .151 [2.47] 55 [900]
P-392AL 2 200 [14] 10,000 [700] .687 [11.26] .151 [2.47] 55 [900]
P-462 2 200 [14] 10,000 [700] 7.69 [126.00] .29 [4.75] 462 [7572]
P-464 2 200 [14] 10,000 [700] 7.69 [126.00] .29 [4.75] 462 [7572]
P-801 2 350 [25] 10,000 [700] .99 [16.23] .15 [2.46] 250 [4095]
P-802 2 400 [28] 10,000 [700] 2.40 [39.34] .15 [2.46] 155 [2540]
P-842 2 400 [28] 10,000 [700] 2.40 [39.34] .15 [2.46] 155 [2540]
2
P-842 3.2 Models P-18/P-39, 1003/P-80, 1006/
Figure 1 and the corresponding table show the main P-84/P-801
components of hand pump models P-141, P-142, P- Figure 2 and the corresponding table below show the
202, P-391, P-392, P-802, and P-842. The dual- main components of these hand pump models.
purpose vent/fill cap acts as a pressure relief valve in Model P-84 is equipped with a 4-way, 3-position
case of accidental reservoir pressurization. To valve for use with double-acting cylinders. To convert
provide an access port at the rear of the reservoir for models P-18 or P-39 to foot operation, order Kit PC-
remote valves, use a return-to-tank kit. See the Table 10.
1 for kit model numbers.
Figure 1 Figure 2
WARNING: These pumps are operated

with a non-vented reservoir. If the
reservoir is subjected to high pressure,
the casing may rupture, causing
personal injury and/or equipment damage.
NEVER attempt to return more oil to the reservoir
than it is capable of holding.
Table 1
Fig. 1 P-141, 1001 P-142, 1002 P-202 P-391, 1004 P-392, 1005 P-802 P-842
A Release Valve Release Valve Release Valve Release Valve Release Valve Release Valve 4-Way Valve
B 1 /4 NPTF 1 /4 NPTF 1 /4 NPTF 3/8 NPTF 3/8 NPTF 3/8 NPTF 3/8 NPTF
Outlet Port Outlet Port Outlet Port Outlet Port Outlet Port Outlet Port Outlet Port
C Vent/Fill Vent/Fill Vent/Fill Vent/Fill Vent/Fill Vent/Fill Vent/Fill
Cap Cap Cap Cap Cap Cap Cap
D Mounting Mounting — — — Mounting Mounting
Slots Slots Slots
E — — — — — Return-to-Tank Port —
Return-to PC-20 PC-20 PC-25 PC-25 PC-25 — —
-Tank Kit
Table 2
Fig. 2 P-18 P-39, 1003 P-80, 1006 P-84 P-801
A Release Valve Release Valve Release Valve Release Valve Release Valve
B 3/8 NPTF 3/8 NPTF 3/8 NPTF 3/8 NPTF 3/8 NPTF
Outlet Port Outlet Port Outlet Port Outlet Port Outlet Port
C Fill Plug Fill Plug Fill Plug Fill Plug Fill Plug
D — — 1/4 NPTF — 1/4 NPTF
Return-to-Tank Port Return-to-Tank Port
3
3.3 Models P-462 and P-464 Table 4 and 5
Figure 3 and the table below show the main features Fig. 4 & 5 P-25 P-50 P-51
of hand pump models P-462, for use with single- A Release Valve Release Valve Release Valve
acting cylinders, and P-464, for use with double- B 1/4 NPTF 1/4 NPTF 1/4 NPTF
Outlet Port Outlet Port Outlet Port
acting cylinders.
C Vent/Fill Cap Vent/Fill Cap Vent/Fill Cap
4.0 INSTALLATION
4.1 Connecting the Pump

1. Thread hose into pump outlet. Use 1 1/2 wraps of
Teflon tape (or suitable thread sealant) on hose
fitting, leaving the first complete thread free of tape
to ensure that tape does not shed into hydraulic
system, causing damage. Trim loose ends.
2. Install a pressure gauge in-line from the pump for
added safety and better control.
3. Connect the hose(s) to your cylinder or tool.
NOTE: For single-acting cylinders, connect one
hose from the pump to the cylinder. For double-
Figure 3, Models P-462, P-464 acting cylinders, connect two hoses. Connect
one hose from the pressure port of the pump to
the pressure port of the cylinder. Connect another
Table 3 hose from the retract port of the pump to the
Fig. 3 P-462 P-464 retract port of the cylinder.
A 3-Way 2-Position Valve 4-Way 3-Position Valve
B 3/8 NPTF Outlet Port 3/8 NPTF Outlet Port 4.2 Pump Venting
C Vent/Fill Plug Vent/Fill Plug See table below to determine if your pump should be
D Handle Clip Handle Clip operated with a vented or non-vented reservoir.
Vented pumps provide slightly better performance.
For pumps with nylon reservoir, turn vent/fill cap 1/4
3.4 Models P-25, P-50, and P-51 turn counter-clockwise to vent. For other pumps, see
decal on pump. Close vent prior to transporting
Figure 4 shows hand pump models P-25 and P-50, pump to prevent oil leakage.
both of which are equipped with a handle that
operates in both directions. Figure 5 shows the P-51 VENTING OPTIONS
hand pump. The main components of these pumps
are listed in the table below. EHF-65 ..........non-vented P-142AL.........non-vented
P-18 ...............non-vented P-202 ......................either
P-25 ........................either P-391, 1004 ............either
P-39, 1003 .....non-vented P-392, 1005 ........... either
P-50 ........................either P-392AL ................vented
P-51 ......................vented P-462 ....................vented
P-80, 1006 .....non-vented P-464 ....................vented
P-84 ...............non-vented P-801 .............non-vented
P-141, 1001 ............either P-802 ......................either
P-142, 1002 ............either P-842 ......................either
4.3 Pump Position

See table below to determine the correct operating
Figure 4, Models P-25 and P-50 position for your pump, horizontal or vertical.
OPERATING POSITION
EHF-65. . . . . . . . . either P-142AL . . . . . . . either
P-18 . . . . . . . . . . . either P-202 . . . . . . . . . either
P-25 . . . . horizontal only P-391, 1004 . . . . . either
P-39, 1003 . . . . . . either P-392, 1005 . . . . . either
P-50 . . . . horizontal only P-392AL . . . . . . . . either
P-51 . . . . horizontal only P-462. . . horizontal only
P-80, 1006 . . . . . . either P-464 . . . horizontal only
P-84 . . . . . . . . . . . either P-801 . . . . . . . . . either
P-141, 1001 . . . . . either P-802 . . . . . . . . . . either
P-142, 1002 . . . . . either P-842 . . . . . . . . . either
Figure 5, Model P-51

4
NOTE: When operating the pump in the vertical CAUTION: Close release valve finger
position, the hose end must be pointed down, or the tight ONLY. Using tools on release valve
pump will pick up air and will not build pressure properly. can damage it and cause the pump to
malfunction.
5.0 OPERATION
2. Operate pump handle to deliver hydraulic power
to system. Pressure will be maintained until
5.1 Before Using the Pump release valve is opened.
1. Check all system fittings and connections to be 3. Open release valve (turn counter-clockwise) to
sure they are tight and leak free. release pressure, allowing oil to flow back to the
2. Check oil level in reservoir before operating reservoir.
pump. See "Adding Oil to the Pump" on page 7.
5.4 Single-Acting Applications with 3-Way,
2 Position Manual Valve
CAUTION: NEVER add extensions to
pump handle. Extensions cause 1. Shift valve handle to position 1 as shown in Figure 7.
unstable pump operation. 2. Operate pump handle to deliver hydraulic power
to the system. Pressure will be maintained until
WARNING: In certain situations the the valve is shifted.
pump handle can "kick back". Always
3. To allow oil to return to the reservoir, shift valve
keep your body to the side of the pump,
handle to position 2.
away from the line of force of the handle.
NOTE: To reduce handle effort at high pressure, take
short strokes. Maximum leverage is obtained in the
last 5° of stroke.
5.2 Using Two-Speed Pumps

These pumps provide 2-stage flow. Under no-load,
the pump operates in the high flow first stage for
rapid advance. When the load is contacted, the pump
automatically shifts to the second stage for building
pressure. For P-462 or P-464 models, when pump
pressure reaches approximately 200 psi [14 bar], you
must momentarily stop pumping and raise the handle
to shift to the high pressure stage. For P-802 or
P-842 models, when pump pressure reaches
approximately 400 psi [28 bar], you must momentarily
stop pumping and raise the handle to shift to the high
pressure stage. After the pump shifts, pumping takes
less effort.
Figure 7
NOTE: For best performance, operate pump handle
at moderate speed during the high flow first stage.
Rapid handle speed in the first stage will prevent the 5.5 Double-Acting Applications with 4-Way,
pump from delivering full volume of oil.
3 Position Manual Valve
5.3 Single-Acting Applications with Pumps with 4-way control valves are designed to
Release Valve operate double-acting cylinders. See Figure 8 for
valve positions.
1. Close release valve by turning clockwise, as
shown in Figure 6.
Figure 6 Figure 8a
5
5.6 Relief Valve Adjustment
All pumps contain a factory set relief valve to prevent
over-pressurization of the system. Lower pressure
settings can be obtained. Contact your Authorized
Enerpac Service Center.
6.0 AIR REMOVAL

Removing air from the hydraulic system will help the
Figure 8b cylinder to advance and retract smoothly (see figure 9).
1. Position lever on 4-way valve to select function as 6.1 Pump With Single-Acting Cylinder (A)
follows: 1. Vent pump reservoir (for vented pumps only) and
(A) Flow to Port "A"; port "B" returns flow to the close release valve.
reservoir 2. Position pump at higher elevation than cylinder.
(N) Neutral; ports "A" and "B" are blocked 3. Position cylinder with the plunger end down (up if
(B) Flow to port "B"; port "A" returns flow to the using pull cylinder). See Figure 9 below.
reservoir 4. Operate pump to fully extend the cylinder (retract
if using pull cylinder).
5. Open release valve to retract cylinder (extend if a
pull cylinder). This will force the trapped air to
move up to the pump reservoir.
6. Repeat the above steps as necessary.
7. Add oil if necessary. See page 7.
8. Return vent/fill cap to operating position.
6.2 Pump With Double-Acting Cylinder (B)
1. Vent pump reservoir (for vented pumps only).
2. Position pump at higher elevation than cylinder.
3. Put cylinder in horizontal position with ports up.
See Figure 9.
Figure 8c 4. Fully advance and retract the cylinder 2 to 3 times.
5. Repeat the above steps as necessary.
2. Operate pump to perform work. 6. Add oil if necessary. See page 7.
3. Change valve positions as needed. 7. Return vent/fill cap to operating position.
WARNING: Operate double-acting 7.0 MAINTENANCE

cylinder only when both hoses are
connected to the pump. If one coupler Use only Enerpac hydraulic oil with these pumps to
is left unconnected, high pressure will promote long pump life and to protect your warranty.
build behind the coupler which could cause Viton and EPR seal kits are available for some hand
personal injury and/or equipment damage. pumps. Contact your Enerpac representative for more
information on these products and their applications.
air
air
Figure 9
6
7.1 Adding Oil to the Pump
Check oil level regularly.
WARNING: Always add oil with
cylinders fully retracted (extended if
pull cylinders) or the system will contain
more oil than the reservoir can hold.
1. Remove vent/fill cap from reservoir.
2. Fill reservoir only to level mark shown on pump.
3. Remove air from system if necessary. See page 6.
Recheck oil level after removing air.
4. Return vent/fill cap to proper position. Figure 10
NOTE: Non-vented hand pumps require air in the
reservoir to function properly. If the reservoir is 7.4 Changing the Oil
completely filled, a vacuum will form preventing 1. Drain all oil and refill with clean Enerpac oil every
oil from flowing out of the pump. 12 months. If pump is used in dirty environments,
change the oil more often.
7.2 Keeping Oil Lines Clean
2. Remove vent/fill cap or plug from reservoir.
When coupler halves are disconnected, always screw 3. Tilt pump to drain out old oil.
on dust caps. Use every precaution to guard unit
against entrance of dirt because foreign matter may 4. Fill reservoir only to level mark shown on pump.
cause pump, cylinder, or valve failure. 5. Replace the vent/fill cap or plug.
6. Dispose of used oil properly.
7.3 Lubricating the Pump
To extend pump life and improve performance,
8.0 TROUBLESHOOTING GUIDE
lubricate the beam pin (A), cross pin (B), and piston
head (C) regularly, using roller bearing grease. See The following information is intended as an aid in
Figure 10. determining if a problem exists. For repair service,
contact the Authorized Enerpac Service Center in
your area.
TROUBLESHOOTING
Problem Possible Cause Solution
Cylinder does not 1. Oil level in pump reservoir is 1. Add oil according to the Maintenance instructions on
advance, advances low. page 6.
slowly, or advances in 2. Release valve open. 2. Close the release valve.
spurts.
3. Loose hydraulic coupler. 3. Check that all couplers are fully tightened.
4. Load is too heavy. 4. Do not attempt to lift more than rated tonnage.
5. Air trapped in system. 5. Remove air according to the instructions on page 6.
6. Cylinder plunger binding. 6. Check for damage to cylinder. Have cylinder serviced by
a qualified hydraulic technician.
Cylinder advances, but 1. Leaking connection. 1. Check that all connections are tight and leak free.
does not hold pressure. 2. Leaking seals. 2. Locate leak(s) and have equipment serviced by a
3. Internal leakage in pump. qualified hydraulic technician.
3. Have pump serviced by a qualified hydraulic technician.
Cylinder does not retract, 1. Release valve closed. 1. Open release valve.
retracts part way, or 2. Pump reservoir is over-filled. 2. Drain oil level to full mark. See page 7 instructions for
retracts more slowly than adding oil.
3. Loose hydraulic coupler.
normal.
4. Air trapped in system. 3. Check that all couplers are fully tightened.
5. Hose I.D. too narrow. 4. Remove air according to the instructions on page 6.
6. Cylinder retraction spring 5. Use larger diameter hydraulic hose.
broken or other cylinder 6. Have cylinder serviced by a qualified hydraulic
damage. technician.
7
Enerpac Worldwide Locations ✦ e-mail: info@enerpac.com ✦ internet: www.enerpac.com
Australia Germany, Austria Singapore
ENERPAC, Applied Power Australia Ltd. ENERPAC Applied Power GmbH Actuant Asia Pte. Ltd.
Block V Unit 3, Regents Park Estate P.O. Box 300113, D-40401 Düsseldorf 25 Serangoon North Ave. 5
391 Park Road, Regents Park NSW 2143 Germany #03-01 Keppel Digihub
(P.O. Box 261) Australia Tel: +49 211 471 490 Singapore 554914
Tel: +61 297 438 988 Fax: +49 211 471 49 28 Thomson Road, P.O. Box 114
Fax: +61 297 438 648 India Singapore 915704
Brazil ENERPAC Hydraulics (India) Pvt. Ltd. Tel: +65 64 84 5108, +65 64 84 3737
Power Packer do Brasil Ltda. Plot No. A/571, MIDC, TTC Industrial Area Fax: +65 64 84 5669
Rua dos Inocentes, 587 Mahape-400 701 South Korea
04764-050 - Sao Paulo (SP) Navi Mumbai, India ENERPAC , Applied Power Korea Ltd.
Tel: +55 11 5687 2211 Tel: +91 22 778 1779 163-12 Dodang-Dong
Fax: +55 11 5686 5583 Fax: +91 22 778 1473 Wonmi-Ku, Buchun-shi
Toll Free in Brazil: Italy Kyunggi-Do Republic of Korea
Tel: 000 817 200 6718 ENERPAC , Applied Power Italiana S.p.A. Tel: +82 32 675 08 36
vendasbrasil@enerpac.com Via Canova 4 Fax: +82 32 675 30 02/73
Canada 20094 Corsico (Milano) Spain, Portugal
Actuant Canada Corporation Tel: +39 02 4861 111 ENERPAC , C/San José Artesano 8 Pol. Ind.
6615 Ordan Drive, Unit 14-15 Fax: +39 02 4860 1288 28108 Alcobendas
Mississauga, Ontario L5T 1X2 Japan (Madrid) Spain
Tel: +1 905 564 5749 Applied Power Japan Ltd. Tel: +34 91 661 11 25
Fax: +1 905 564 0305 1-1-11, Shimomae, Toda-shi Fax: +34 91 661 47 89
Toll Free: Saitama Pref. Middle East, Turkey and Caspian Sea
Tel: +1 800 268 4987 Japan 335-0016 ENERPAC Middle East FZE
Fax: +1 800 461 2456 Tel: +81 48 430 2311 P.O. Box 18004
Technical Inquiries: Fax: +81 48 430 1117 Jebel Ali, Dubai
techservices@enerpac.com Mexico United Arab Emirates
China ENERPAC Applied Power Tel: +971 (0)4 8872686
Actuant China Ltd. Mexico S. de R.L. de C.V. Fax: +971 (0)4 8872687
1F, 269 Fute N. Road Avenida Principal, La Paz #100 United Kingdom, Ireland
Waigaoqiao Free Trade Zone Fracc. Industrial La Paz ENERPAC Ltd., P.O. Box 33
Pudong New District 42092 Pachuca, Hidalgo New Romney, TN28 8QF
Shanghai, 200 131 China Tel: +52 771 71851 60 United Kingdom
Tel: +86 21 5866 9099 +52 771 71870 22 Tel: +44 01527 598 900
Fax: +86 21 5866 7156 Fax: +52 771 71352 32 Fax: +44 01527 585 900
Toll Free in Mexico: USA, Latin America
Actuant China Ltd. (Beijing)
Tel: 001 800 590 0130 and Caribbean
709A Xin No. 2 , Diyang Building
The Netherlands, Belgium, Luxembourg, ENERPAC
Dong San Huan North Rd.
Sweden, Denmark, Norway, Finland P.O. Box 3241
Beijing City, 100028 China
ENERPAC B.V., Storkstraat 25 6100 N. Baker Road
Tel: +86 10 845 36166
P.O. Box 269, 3900 AG Veenendaal Milwaukee, WI 53209 USA
Fax: +86 10 845 36220
The Netherlands Tel: +1 262 781 6600
Eastern Europe
Tel: +31 318 535 911 Fax: +1 262 783 9562
Applied Power International S.A.
Fax: +31 318 525 613, +31 318 535 848
Case postale 130, CH-1213 Onex-Genéva User inquiries:
Switzerland Russia and CIS +1 800 433 2766
Tel: +49 (211) 47149 44 (excl. Caspian Sea Countries) Distributor inquiries/orders:
Fax: +49 (211) 47149 40 ENERPAC +1 800 558 0530
France, Greece, Africa Leninsky Prospect 95A Technical Inquiries:
ENERPAC S.A. 117313, Moscow, Russia. techservices@enerpac.com
B.P. 200 Tel/Fax: +7(095) 936-2005
Parc d’Activités Tel/Fax: +7(095) 198-3094
du Moulin de Massy Tel/Fax: +7(095) 938-4655
F-91882 Massy CEDEX (Paris) France Mobil: +7(903) 731-9558
Tel: +33 1 601 368 68 All Enerpac products are guaranteed against defects in workmanship and materials for as long as you own them.
Fax: +33 1 692 037 50 For your nearest authorized Enerpac Service Center, visit us at www.enerpac.com 10/30/02
Model 2010
Three-Way
Thermostatic Valve
2010 2” NPT
2010-1 1 1/2” NPT
2010J24 1 1/2” SAE O-Ring
A2010J32 2” SAE O-Ring
F2010 2” 125# FF Flange
SF2010 2” 150# RF Flange
SF2010X 2” 300# RF Flange
Fluid Power Energy (FPE) Thermostatic Valves utilize the principle of

expanding wax, which in the semi-liquid state undergoes large expansion Features
rates within a relatively narrow temperature range. The self-contained ele-
ment activates a stainless steel sleeve, which directs flow. All FPE
Thermostatic Valves are factory set at predetermined temperatures: no fur-
ther adjustments are necessary. A wide range of temperatures are avail-
Wide Range of Temperatures
able for water and oil temperature control applications.
When used in a diverting application, on start-up the total fluid flow is rout- Heavy Duty
ed back to the main system. As fluid temperature rises to the control
range, some fluid is diverted to the cooling system. As fluid temperature Self-Contained
continues to increase, more flow is diverted. When the thermostat is in a
fully stroked condition, all fluid flow is directed to the cooling system. FPE Replaceable Element
Thermostatic Valves may also be used in a mixing application.
In a mixing application, hot fluid enters the “B” port and colder fluid enters Non-Adjustable
the “C” port. The flows mix and the thermostat adjusts to reach the desired
temperature, exiting the “A” port. Rugged Construction
Standard FPE thermostatic valve housings are made from aluminum and Tamper-Proof
grey iron castings, however, ductile iron, bronze, steel and stainless steel
housings are available.
Operate in Any Position
Available Connections: NPT, SAE O-Ring, 125# FF Flange, 150# and
300# RF Flange. Compact
Optional features: High over temperature element, plated element. Other Available for Refrigeration Service
options available upon request.
FLUID POWER ENERGY, INC. MADE IN

W229 N591 Foster Court • Waukesha, WI 53186
262 • 548 • 6220 Fax 262 • 548 • 6239

ISO 9001-2000 U. S. A.
www.fpevalves.com
Model 2010
* (Replace * with body material type; A=Cast Iron, B=Bronze, D=Ductile, S=Steel, SS=Stainless Steel)
PRESSURE RATINGS
MATERIAL PSI
A, B 150
D 250
S, SS 500
SF, SSF 275
SFX, SSFX 720
*2010-1, *2010, *2010J *F2010, *F2010X
Flow vs. Pressure Drop PART # DESCRIPTION

1 1/2” *2010 VALVE BODY (*See table for material)
*2020 VALVE COVER (*See table for material)
2” 1570** O-RING (Standard material is Buna-N)
2071 LIP SEAL
2050-Temp THERMOSTAT (Temp to follow dash)
1600 HEX BOLT
1601 LOCK WASHER
FPE Model 2000** Replacement Kit (Includes the following:)

1570** BUNA O-RING (Standard material is Buna-N)
2071 LIP SEAL
FLOW IN U.S. GPM
SAE 10 @ 100° F
2050-Temp THERMOSTAT (Temp to follow dash)
(For Viton® (V) or Neoprene (E) O-Ring material, replace ** with V or E)
Recommended Pressure Drop is 2 to 7 PSI
Viton® is a registered trademark of Dupont Dow Elastomers
To Order
FLUID POWER ENERGY, INC. Specify Model Number, nominal
temperature desired, and housing
W229 N591 Foster Court • Waukesha, WI 53186 material. For Model coding information,
visit our website or consult your
262 • 548 • 6220 Fax 262 • 548 • 6239 factory representative.
www.fpevalves.com
FPE-2010-050803
HIGH PRESSURE FILTERS
Series DF & LF • Pressures to 6000 PSI • Flows to 180 GPM
APPLICATION
• HYDAC DF & LF In-line High
Pressure Filters are designed for
use on hydraulic power units,
machine tools, plastics machinery,
mobile equipment, and hydraulic
test equipment.
• These filters can be installed on
the high-pressure side of the
pump to protect control valves
and actuators from contamination.
• These filters can also be used as
In-line Return Filters.
DF Filters LF Filters
PRODUCT FEATURES
• DF Filters are manufactured with • HYDAC indicators have no external • For non-bypass applications,
a ductile iron head and cold dynamic seal. This results in a high Betamicron® BH3HC or Metal Fiber
formed steel bowl. system reliability due to magnetic (V) elements must be installed. If a
actuation, thus eliminating a potential bypass valve is used, Betamicron®
• LF Filters are manufactured with a
(BN3HC) or Wire Screen (W/HC)
leak point.
cast aluminum head and
elements can be installed.
aluminum extruded bowl. • A poppet-type bypass valve (optional)
is mounted in-line between the inlet • All filter media is supported to
• For special finishes and coatings
achieve flow fatigue resistance.
and outlet ports to provide positive
– consult HYDAC for minimum
sealing during normal operation and • Proper support of the filter media
quantities, availability and pricing.
fast opening during cold starts and also provides high Beta Ratio values
• Non-welded housing design flow surges. (particle removal efficiency) even at
reduces stress concentrations and
high differential pressures. The
prevents fatigue failure.
FILTER ELEMENTS efficiency of many competitive
• Inlet/outlet port options include elements drastically deteriorates as
NPT port, SAE straight thread O- • HYDAC DF & LF Filters are available the element clogs and differential
ring boss, and SAE 4-bolt flange with disposable Betamicron® BN3HC pressure increases.
to allow easy installation without elements having 250 psid and
costly adapters. Betamicron® BH3HC elements • High quality epoxy adhesive is used
to bond the end caps to the media
having 3000 psid collapse pressure
• O-ring seals are used to provide and to bond the seam of the media.
and absolute ratings of 3, 5, 10, and
positive, reliable sealing. Choice
20 micron.
of O-ring materials (Nitrile, Fluoro
Rubber, EPDM) provides • HYDAC DF & LF Filters are also
compatibility with petroleum oils, available with cleanable elements.
synthetic fluids, water-glycols, Metal Fiber (V) stainless steel fleece
oil/water emulsions, and high elements have a 3000 psid collapse
water base fluids. pressure and nominal ratings of 3, 5,
10, and 20 microns. Wire screen
• Screw-in bowl mounted below the
(W/HC) elements have a 250 psid
filter head requires minimal
collapse pressure and nominal
clearance to remove the element
ratings of 25, 74, and 149 microns.
for replacement, and
contaminated fluid cannot be
washed downstream when
element is serviced.
Model Code: Filter Assembly DF & LF Filters
DF BH3HC 30 G 3 A 1 .0/3
Filter Type
DF = 6000 PSI (420 bar)
LF = 1500 PSI (100 bar) (not available in sizes 280, 660, or 1320)
Filter Media
BH3HC = Betamicron® BH3HC High Collapse
(Disposable)
BN3HC = Betamicron® BN3HC Low Collapse
V = Metal Fiber
(Cleanable)
W/HC = Wire Screen
Size and Nominal Connection
30 = 1/2" BSPP / NPT / SAE 8
60 = 3/4" BSPP / NPT / SAE 12
110 = 3/4" BSPP / NPT / SAE 12
160 = 1-1/4" BSPP / NPT / SAE 20
240 = 1-1/4" BSPP / NPT / SAE 20
280 = 1-1/4" BSPP / NPT / SAE 20
330 = 1-1/2" BSPP / NPT / SAE 24 (or 2” Flange on DF model only)
Type of Connection
G = Threaded
F = Flange (only available on DF sizes 330, 660, & 1320)
Filtration Rating in Microns
3
5
BH3HC or BN3HC Absolute Filtration Rating (ßx ≥ 200)
10
20
3
5
V
10
20 Nominal Filtration Rating
25
74 W/HC
149
Type of ∆P Clogging Indicator
A = no clogging indicator LF DF
B = visual (pop-up) clogging indicator (Automatic reset) VM5B.1 VD5B.1
BM = visual (pop-up) clogging indicator (manual reset) VM5BM.1 VD5BM.1
C = electrical clogging indicator (electric switch) VM5C.0 VD5C.0
D = electrical/visual (lamp) clogging indicator (electric switch & light) VM5D.0/L... VD5D.0/L...
J = electric switch (Brad Harrison, 5 pin mini) VMH5J.0 VDH5J.0
J4 = electric switch (Brad Harrison, 4 pin micro) VMH5J4.0 VDH5J4.0
Type Number
1
Modification Number
0 = DF 30 & all LF sizes
1 = DF 60 to 1320
Port Configuration
0 = BSPP
3 = NPT Ports
12 = SAE Straight Thread O-Ring Boss Ports
16 = SAE Flange Ports (DF 330, 660, & 1320 only)
Seals
(omit) = Nitrile (NBR) (standard)
V = Fluoro Rubber (FKM)
EPR = Ethylene Propylene (EPDM)
Bypass Valve
(omit) = Without Bypass (BH3HC or V elements recommended)
B3 = 43PSID Bypass (optional)
B6 = 87PSID Bypass (standard)
Supplementary Details
SO103H = Modification of BN3HC (Low Collapse) Element For Phosphate Esters
SO155H = Modification of BH3HC (High Collapse) Element For Phosphate Esters
SO184 = G-1/2 Drain in Bowl Option For Sizes 60 - 280 (standard for sizes 330, 660, & 1320)
SO150H = Anodize Aluminum (LF Filter components for water based fluids) Consult HYDAC for minimums, availability & pricing
SO110 = Indicator with brass piston (for use with water based fluids)
(Consult factory on B
L24 = Lamp for 24 Volts T70 - Indicator Thermal Lockout, 70°F
& BM Indicators for
L48 = Lamp for 48 Volts (D-type clogging T100 - Indicator Thermal Lockout, 100°F
thermal lockout)
L115 = Lamp for 115 Volts indicator only)
L230 = Lamp for 230 Volts
Model Codes Containing Red are non-stock items — Minimum quantities may apply – Contact HYDAC for information and availability
2
Model Code: High Pressure Filter Elements
0030 D 003 BH3HC
Element Size
Housing Size
DF/LF
0030 30
0060 60
0110 110
0160 160
0240 240
0280 280
0330 330
0660 660
1320 1320
High Pressure Element
Filtration Rating in Microns

003 = 3 µm
005 = 5 µm ®
or High Collapse Betamicron® (BH3HC) Absolute Filtration Rating
010 = 10 µm Low Collapse Betamicron (BN3HC) (ßx ≥200)
020 = 20 µm
003 = 3 µm
005 = 5 µm
Metal Fiber (V)
010 = 10 µm
020 = 20 µm
Nominal Filtration Rating
025 = 25 µm
074 = 74 µm Wire Screen (W/HC)
149 = 149 µm
Filter Element Material

BH3HC = Betamicron® BH3HC High Collapse
(Disposable)
BN3HC = Betamicron® BN3HC Low Collapse
V = Metal Fiber
(Cleanable)
W/HC = Wire Screen
Seals
(omit) = Nitrile (NBR) (standard)
V = Fluoro Rubber (FKM)
EPR = Ethylene Propylene (EPDM)
Supplementary Details
SO103H = Modification of BN3HC Element for Phosphate Ester Fluids
SO155H = Modification of BH3HC Element for Phosphate Ester Fluids
Model Codes Containing Red are non-stock items — Contact HYDAC for availability
Approximate Weights Housing Volumes

MODEL WITH ELEMENT WITHOUT ELEMENT Filter type LF and DF
DF 30 4.2 lbs. 1.9 kg 4.0 lbs. 1.8 kg Size Volume
DF 60 9.0 lbs. 4.1 kg 8.6 lbs. 3.9 kg 30 0.14 qt. 0.13 liter
DF 330 49.8 lbs. 22.6 kg 47.2 lbs. 21.4 kg 280* 1.53 qts. 1.45 liters
DF 660 67.2 lbs. 30.5 kg 62.4 lbs. 28.3 kg 330 1.58 qts. 1.50 liters
DF 1320 115.5 lbs. 52.4 kg 105.8 lbs. 48.0 kg 660* 3.17 qts. 3.00 liters
LF 30 1.8 lbs. 0.8 kg 1.5 lbs. 0.7 kg 1320* 5.92 qts. 5.60 liters
LF 60 3.3 lbs. 1.5 kg 2.9 lbs. 1.3 kg
LF 110 4.0 lbs. 1.8 kg 3.3 lbs. 1.5 kg * only for DF filters
LF 160 8.2 lbs. 3.7 kg 7.0 lbs. 3.2 kg
LF 240 9.5 lbs. 4.3 kg 7.9 lbs. 3.6 kg
LF 330 18.1 lbs. 8.2 kg 15.4 lbs. 7.0 kg
3
Engineering Data: DF & LF Filters
Design: Inline Pressure Filter
Mounting Method: 4 Mounting holes in Filter Head
Connections:
Size 30 1/2" NPT or SAE- 8 port (3/4-16UNF-2B)
Size 60/110 3/4" N PT or SAE-12 port (1 -1/16-12UN-2B)
Size 160/240/280 1-1/4"NPT or SAE-20 port (1-5/8-12UN-2B)
Size 330 1-1/2"NPT or SAE-24 port (1-7/8-12UN-2B)
SAE-32 Flange, Code 62 (DF only)
Size 660/1320 1-1/2"NPT, SAE-24 port (1-7/8-12UN-2B),
or SAE-32 Flange, Code 62 (DF only)
Direction of Flow: Inlet: Side Outlet: Side (opposite inlet)
Housing Pressure Ratings: DF (iron head & steel bowl) LF (aluminum)
Operating: 6000 psid/420 bar 1500 psid/103 bar
Proof: 9000 psid/620 bar 2250 psid/155 bar
Fatigue: Contact HYDAC office
Burst: Contact HYDAC office
Element Collapse Standard Elements: BN3HC: 250 psid/17 bar
Pressure Ratings: W/HC: 250 psid/17 bar
(ISO 2941) High Collapse Elements: BH3HC: 3000 psid/207 bar
V: 3000 psid/207 bar
Fluid Temperature Range: (All seal types) -22°F to 250°F (-30°C to 121°C)
Based on Nitrile Seals under maximum continuous operating pressure.
Please contact HYDAC for information on extreme low
temperature applications (below -15°F.)
Fluid Compatibility: Compatible with all petroleum oils, water glycols, oil/water
(ISO 2948) emulsions, high water base fluids, and synthetic fluids
compatible with Fluoro Rubber or EPR seals.
Flow Fatigue Resistance: Filter medium is supported to achieve flow fatigue resistance.
(ISO 3724) Contact HYDAC office for information.
Trip Pressure of Differential Pressure Indicator: DP = 72 psid/5 bar - 10%(Standard)
DP = 29 psid/2 bar - 10% (Optional)
Cracking Pressure of DP = 87 psid/6 bar + 10% (Standard)
Bypass Valve: DP = 43 psid/3 bar + 10% (Optional)
Above subject to Technical Modifications.
Filtration Efficiency: Multi-Pass Filtration Efficiency

Ratings to ISO 4572 for Betamicron® Elements
Absolute Filtration Rating = ßx ≥ 200
Terminal ∆P Across Element = 72 psid (5 bar)
For all micron ratings (3, 5, 10, & 20), both High and Low Collapse Betamicron® Elements
Hydraulic Symbol: INLET
DF & LF
Filter
Bypass
Element
Valve
Pop-up
Indicator
OUTLET
4
Pressure Drop Calculations:
Assembly:
To calculate the pressure drop of the filter assembly use the equation:
∆P Assembly = ∆P Housing + ∆P Element
Housing:
The housing curve is based on test results using mineral oil with a specific gravity of 0.86. Differential pressure increases
in proportion to specific gravity of applicable fluid. To adjust the housing ∆P for the fluid being used, use the equation:
Actual Specific Gravity

∆P Housing = ∆P Curve x
0.86
DF & LF SIZE 30 HOUSING DF & LF SIZES 60 & 110 HOUSING
20 2.0 25
1.2
1.0 15 1.5 20
∆P in bar
∆P in bar
∆P in psi
∆P in psi
0.8
10 1.5 10
0.6
0.4 5 0.5 5
0.2
0 0 0 0
0 1 2 3 4 5 6 7 8 0 5 10 15 20 25 30
Q in gpm Q in gpm
0 5 10 15 20 25 30 0 15 30 45 60 75 90 105120
Q in l/min Q in l/min
DF & LF SIZES 160, 240, & 280 HOUSING DF & LF SIZES 330, 660, & DF 1320 HOUSING
20
1.2 25
3.2
1.0 15 20
∆P in bar
∆P in psi
∆P in bar
2.4
∆P in psi
0.8
10 20
0.6 1.6
0.4 10
5
0.2 0.8 5
0 0 0 0
0 10 20 30 40 50 60 0 30 60 90 120 150 180
Q in gpm Q in gpm
0 40 80 120 160 200 240 0 120 240 360 480 600 720
Q in l/min Q in l/min
Bypass Valves Curve:

Curves shown are applicable for mineral oil with a specific gravity of 0.86. Differential pressure increases in proportion to
the specific gravity of the fluid. To adjust the bypass ∆P for the fluid being used, use the equation:
Actual Specific Gravity

∆P Valve = ∆P Curve x
0.86
DF/LF 30 DF/LF 60/110
200 DF/LF 160/240/280
12 160
10 DF/LF 330/660
∆P in bar
∆P in psi
8 120
6 80
4
40
2
0 0
0 20 40 60 80 100
Q in gpm
0 50 100 150 200 250 300 350 400

Q in l/min
5
Pressure Drop Calculations: (continued)
Element ∆P Calculations: Element Max Recommended
Wire Screen Elements: Size Flow (gpm)
To find ∆P across clean wire screen element, divide Application Flow by Maximum 30 8
Recommended Flow and find percentage; then read ∆P from graph below. 60 16
110 29
160 42
Application Flow
% of Flow = 100 x 240 63
Max. Recommended Flow 280 72*
Example: 330 87
Size 60 Wire Screen @ 10 GPM: 660 174
1320 174*
* Port Size Limited Flow
10 gpm
100 x = 63% of Flow
16 gpm 0.20 3
63% = 1 psi ∆P for 0060D...W element (using graph to the right) 0.15
2
∆P in bar
∆P in psi
...W/HC
0.10
1
0.05
All element curves are based on test results using mineral oil
with a kinematic viscosity of 141 SSU and a specific gravity 0 0
of 0.86. The differential pressure across the element changes 0 20 40 60 80 100 120
proportionally to the viscosity and specific gravity. To adjust figures Q in gpm as % of
Max. Recommended Flow
for a different fluid use the equation:
Actual Specific Gravity Actual Viscosity

∆P Element = ∆P Curve x x
0.86 141
Betamicron® 3 Plus Elements:

Act. Spec. Gravity Act. Viscosity
∆P Element = ∆P Element from Curve x x
0.86 141
0030D..BN3HC 0030D..BH3HC
3µm 3µm
35 60
5µm
30 50
10µm
25 5µm
40
∆P in psid
∆P in psid
20
10µm 30
15 20µm
20µm 20
10
5 10
0 0
0 2 4 6 8 10 0 2 4 6 8 10
Flow in gpm Flow in gpm
3µm 3µm
40 60
35 50
30 5µm
40
∆P in psid
∆P in psid
25 5µm
10µm
20 30
10µm
15 20
20µm
10 20µm
10
5
0 0
0 5 10 15 20 0 5 10 15 20
6
3µm 3µm
40 60
35
50
30 5µm
40
∆P in psid
∆P in psid
25 5µm
10µm
20 30 10µm
15 20µm 20
10 20µm
10
5
0 0
0 10 20 30 40 0 10 20 30 40
3µm 3µm
35 45
30 40
35 5µm
25 5µm 30 10µm
∆P in psid
∆P in psid
20 10µm 25
15 20
20µm
20µm 15
10
10
5 5
0 0
0 10 20 30 40 50 0 10 20 30 40 50
3µm 3µm
35 40
30 35
5µm 5µm
30
25 10µm
∆P in psid
∆P in psid
25
20
10µm 20
15 20µm
15
10 20µm
10
5 5
0 0
0 20 40 60 80 0 20 40 60 80
20 3µm 30 3µm
18
16 25
14 20
∆P in psid
∆P in psid
5µm
12
5µm
10 10µm 15 10µm
8
6 10
20µm
4 20µm
5
2
0 0
0 20 40 60 80 0 20 40 60 80
7
3µm
35 3µm 50
45
30
40 5µm
5µm 10µm
25 35
∆P in psid
∆P in psid
20 30
10µm
25
15 20 20µm
10 20µm
15
10
5
5
0 0
0 20 40 60 80 100 0 20 40 60 80 100
35 50 3µm
3µm
45
30
40
25 5µm 5µm
35 10µm
∆P in psid
∆P in psid
20 30
25
15 10µm
20
20µm
10 15
20µm
10
5
5
0 0
0 50 100 150 200 0 50 100 150 200
12 3µm 16 3µm
14
10
5µm 12
8
∆P in psid
∆P in psid
10 5µm
10µm
6 8
20µm 10µm
6
4 20µm
4
2
2
0 0
0 50 100 150 200 0 50 100 150 200
“V” Metal Fiber Elements:

Act. Spec. Gravity Act. Viscosity
∆P Element = K Factor x Flow (gpm) x x
0.86 141
Metal Fiber
K Factors for ...D...V Elements
Size 3µm 5µm 10µm 20µm
0030 0.98784 0.71344 0.40611 0.20306
0060 0.87808 0.60368 0.35672 0.18110
0110 0.45550 0.32928 0.23050 0.11525
0160 0.24696 0.17562 0.12622 0.07683
0240 0.17561 0.13171 0.10427 0.06037
0280 0.08232 0.06586 0.05488 0.02744
0330 0.11525 0.08232 0.07134 0.04281
0660 0.06037 0.04939 0.03293 0.01701
8
Dimensons: DF Size 1320
DF 1320
1/2-20UNF x 0.67
M12 x 17
in 4 places
4.528
115
6.26 5.433
159 138
2.362
60
6.575
167
6.30
( on 1320 F)
160
DF 1320 F only
SW27
.236 3.811
6 96.8
3/4-10UNC-2B x 1.00
25
(4 Places)
1 1/2 NPT
1 7/8-12UN (SAE-24) 2.047
52
G 1 1/2 1.750
.905 deep 44.5
23
29.212
742 SAE-32 FLANGE
CODE 62 - 6000 psi (414 bar)
4.409
112
SW36
G 1/2 Drain Plug

26.378
670
5.197
132
5.984
152
Dimensions are inches/mm.
9
Dimensions: DF & LF Filters (sizes 30-660) in inches/mm
D3
SIZE B1 B2 B3 B4 B5 D1 D2 D4
NPT BSP SAE
2.72 1.34 1.772 1.181 ø2.64 ø2.05
30 — 1/2 G1/2 3/4-16UNF —
69 34 45 30 ø67 ø52
3.62 1.97 2.205 1.260 1.81 ø3.31 ø2.68 ø1.65
60/110 3/4 G3/4 1 1/16-16UN
92 50 56 32 46 ø84 ø68 ø42
5.04 2.64 3.346 1.378 2.01 ø4.57 ø3.74 ø2.28
160/240/280 1 1/4 G1 1/4 1 5/8-12UN
128 67 85 35 51 ø116 ø95 ø58
6.38 3.35 4.528 2.362 3.23 ø6.30 ø5.12 ø2.56
330/660 1 1/2 G1 1/2 1 7/8-12UN
162 85 115 60 82 ø160 ø130 ø65
SIZE D5 H1 H2 H3 H4 H5 HEX 1 HEX 2 T1 T2
10-32UNF 3.46 5.04 1.34 0.28 3.00 1 1/16 1.00 0.24
30 —
M5 88 128 34 7 75 27 24 6
1/4-28UNF 3.35 5.55 1.61 0.28 3.00 1 1/16 1 1/16 0.04 0.35
60
M6 85 141 41 7 75 27 27 1 9
1/4-28UNF 6.06 8.11 1.61 0.28 3.00 1 1/16 1 1/16 0.04 0.35
110
M6 154 206 41 7 75 27 27 1 9
3/8-24UNF 4.61 7.48 1.89 0.28 3.38 1 1/16 1 5/16 0.04 0.55
160
M10 117 190 48 7 85 27 32 1 14
3/8-24UNF 6.93 9.88 1.89 0.28 3.38 1 1/16 1 5/16 0.04 0.55
240
M10 176 251 48 7 85 27 32 1 14
3/8-24UNF 13.7 17.13 1.89 0.28 3.38 1 1/16 1 5/16 0.04 0.55
280
M10 348 435 48 7 85 27 32 1 14
1/2-20UNF 6.54 9.92 2.01 0.28 3.75 1 1/16 1 7/16 0.04 0.67
330
M12 166 252 51 7 95 27 36 1 17
1/2-20UNF 13.27 16.65 2.01 0.28 3.75 1 1/16 1 7/16 0.04 0.67
660
M12 337 423 51 7 95 27 36 1 17
Dimensions: LF Filters (sizes 30-660) in inches/mm
D3
SIZE B1 B2 B3 B4 B5 D1 D2 D4
NPT BSP SAE
2.68 1.30 1.772 1.181 ø2.64 ø2.05
30 — 1/2 G1/2 3/4-16UNF —
68 33 45 30 ø67 ø52
3.58 1.97 2.205 1.260 1.77 ø3.27 ø2.68 ø1.65
60/110 3/4 G3/4 1 1/16-12UN
91 50 56 32 45 ø83 ø68 ø42
5.00 2.56 3.346 1.378 1.97 ø4.53 ø3.74 ø2.28
160/240/280 1 1/4 G1 1/4 1 5/8-12UN
127 65 85 35 50 ø115 ø95 ø58
6.30 3.35 4.528 2.362 3.15 ø6.18 ø5.12 ø2.56
330/660 1 1/2 G1 1/2 1 7/8-12UN
160 85 115 60 80 ø157 ø130 ø65
SIZE D5 H1 H2 H3 H4 H5 HEX 1 HEX 2 T1 T2
10-32UNF 3.39 5.00 1.34 0.28 3.00 1 1/16 1.00 0.24
30 —
M5 86 127 34 7 75 27 24 6
1/4-28UNF 3.39 5.51 1.57 0.28 3.00 1 1/16 1 1/16 0.04 0.35
60
M6 86 140 40 7 75 27 27 1 9
1/4-28UNF 6.14 8.15 1.57 0.28 3.00 1 1/16 1 1/16 0.04 0.35
110
M6 156 207 40 7 75 27 27 1 9
3/8-24UNF 4.65 7.60 1.85 0.28 3.38 1 1/16 1 5/16 0.04 0.55
160
M10 118 193 47 7 85 27 32 1 14
3/8-24UNF 6.93 9.84 1.85 0.28 3.38 1 1/16 1 5/16 0.04 0.55
240
M10 176 250 47 7 85 27 32 1 14
3/8-24UNF 14.09 17.01 1.85 0.28 3.38 1 1/16 1 5/16 0.04 0.55
280
M10 358 432 47 7 85 27 32 1 14
1/2-20UNF 6.65 10.00 2.01 0.28 3.75 1 1/16 1 7/16 0.04 0.67
330
M12 169 254 51 7 95 27 36 1 17
1/2-20UNF 13.27 16.65 2.01 0.28 3.75 1 1/16 1 7/16 0.04 0.67
660
M12 337 423 51 7 95 27 36 1 17
10
Dimensons: DF & LF Filters sizes 30-660
DF & LF 30 DF & LF 60 to 660
D5 x T2
(4 Places)
D5 x T2
(4 Places)
B3 B2 ø D1 ø D1 B2 B3
B4
B4
B1
B1
HEX 1
(Blanking Plug
in G1/2 IIndicator Port) B5
ø 1.141"
(29 mm)
HEX 1
(Blanking Plug H4 H4
in G1/2 IIndicator Port) T1
H3
H3
0.650
ø D3 (16.5 mm) D3
(2 Places)
INLET OUTLET D4 (2 Places)
(2 Places) INLET OUTLET
H2
H2
H1
H1
HEX 2 HEX 2
G 1/2 Drain
Plug (optional) G 1/2 Drain Plug
H5 (optional for sizes 30-280) H5
D2 CLEARANCE NEEDED FOR
CLEARANCE NEEDED FOR
ELEMENT REMOVAL
ø D2 ELEMENT REMOVAL
DF 330 & 660 Only

3.811
(96.8mm)
3/4-10UNC-2B x 1.00
(4 Places) (25mm)
1.750
(44.5mm)
Dimensions are for general information only. Due to

constant development and updating of details, we ask SAE-32 FLANGE
that all critical dimensions be verified by requesting a CODE 62 - 6000 psi (414 bar)
certified print.
11
Other Products from HYDAC’s Filtration Line
Filtration Solutions For Mobile Equipment
Although there is great diversity in mobile equipment designs, the common demand in
the industry for improved performance has resulted in systems growing in complexity
and cost. Precision hydraulic components – variable displacement pumps and motors,
load control valves, and proportional controls – are increasingly applied to enhance
machine power, speed and versatility. Higher operating pressures – in excess of 6,000
psi – are increasing in usage in order to generate higher force and torque from a smaller
and lighter package. As fluid power systems are built to function more precisely at
higher pressures, protection against wear and malfunction becomes vital. HYDAC’s
range of filtration products are designed to provide the necessary level of protection to
maintain the efficiency, useful life and safety of high performance fluid power systems.
Request catalog # 02069743

BETAFIT® Filter Elements
HYDAC manufactures high quality filter elements that are dimensionally similar
to other manufacturer's elements and will fit interchangeably into their filter
housings. This catalog lists the interchange elements and the models which they
replace and is organized by manufacturer. Even When your hydraulic or lube oil
© Copyright 2001 HYDAC TECHNOLOGY CORPORATION - Brochure - High Pressure Filters DF & LF #02073475 / 4.01
system doesn’t have a HYDAC filter assembly, it doesn’t mean that you cannot
benefit from our Betamicron® Element technology. The high beta ratios and leading
dirt holding capacities of these elements extend service life and provide a greater
price to maintenance cost ratio than elements from other manufacturers.

Condensed Filter Catalog
This condensed catalog serves as a quick reference guide for selecting
HYDAC filters. The models are divided into high, medium, and low pressure
groups. Charts then describe each filter in the group. Each model description
includes mounting method, maximum operating pressure, maximum flow rates,
number of sizes and connection size range, flow path, clogging indicator type,
and a brief description of features and benefits. General information about
clogging indicators, element types, breathers, and filler breathers is also
included.

Filtration Technology
HYDAC Filter Technology is the result of many years of research, development
and performance evaluation both in test stands and actual applications.
HYDAC’s Filter Division produces a complete range of filters. This range
includes in-line, in-tank, inside-tank, direct mount, and manifold mount, modular
stacking filters. Also available are duplex models for systems requiring continuous
operation. This catalog provides a general overview and photos of HYDAC filter
families with information on pressure and flow ratings, and mounting types. It
serves as a handy reference to select the appropriate series of filter(s) for the
application in need of filtration. More detailed literature that includes specific
technical data and dimensioned drawings is available for all models.
HYDAC TECHNOLOGY CORPORATION

2260 City Line Road • Bethlehem, PA 18017
Phone (610) 266-0100 • Fax (610) 264-3540
www.hydacusa.com • powerup@hydacusa.com
Houston, Texas
EMERGENCY DISC BRAKE CALIPER

PART NUMBER 2112424
OPERATION AND MAINTENANCE MANUAL
EPL-1829
Jan 2006
INDEX
PREFACE ......................................................... 2
ADJUSTMENT SPECIFICATIONS ....................................... 3
OPERATION ....................................................... 3
MAINTENANCE ..................................................... 4
LUBRICANT REQUIREMENTS .......................................... 7
MAINTENANCE SCHEDULE ............................................ 8
TROUBLE SHOOTING CHART ......................................... 10
FIGURE 1 - EMERGENCY BRAKE CALIPER ASSEMBLY .................... 11
FIGURE 2 - EMERGENCY CALIPER CYLINDER ASSEMBLY ................. 12
SALES AND SERVICE INFORMATION .................................. 13
Page 1
EPL-1829
PREFACE
This manual is provided for guidance to operate and maintain or

adjust the emergency disc brake caliper. This information has been
prepared with a basic viewpoint to give accurate and concise data
needed to perform minor adjustments as well as major overhauls.
This information is not elementary, as it is intended for operators

and servicemen who are familiar with drilling equipment in general.
It is not intended, nor would it be possible in such limited space,
to cover every possible condition that may be encountered. Always
use good, sound mechanical practices and safety precautions.
EXERCISE EXTREME SAFETY PRECAUTIONS AND EMPLOY

SOUND MECHANICAL PRACTICES WHEN PERFORMING
INSPECTIONS, MAINTENANCE REPAIRS, OR WHEN OPERATING
THE EQUIPMENT. IT SHOULD BE OPERATED ONLY UNDER
CONDITIONS FOR WHICH IT WAS INTENDED.
Page 2
EPL-1829
ADJUSTMENT SPECIFICATIONS
1a. EMERGENCY BRAKE (Released) 1200 PSI (83 bar)

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

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

5. Part Number 6212-1832-24
5. Maximum extension of Emergency Brake Cylinder
Adjusting Eye (Before Pad Replacement) 1.25 Inch (32 mm)
- STANDOFF (Total Gap Between Disc and Both Pads)

6. Adjusted .060 Inch (1.5 mm)
7. Maximum (Before Adjustment) .090 Inch (2.3 mm)
OPERATION
The NATIONAL OILWELL VARCO emergency caliper uses high capacity

springs inside the cylinder to generate force through the lever arms
to opposing friction pads on the disc. Hydraulic pressure is
required to release the caliper. The emergency brakes are set when
the hydraulic fluid is exhausted from them.
Operation of the emergency caliper depends on a hydraulic power unit

to provide the pressure required to release the brakes. An
intelligent system is also required to engage/disengage the
emergency calipers at the appropriate times.
Page 3
EPL-1829
MAINTENANCE
EMERGENCY BRAKE CALIPER ASSEMBLY
Inspect the Emergency Brake Caliper Assemblies as indicated in the

Maintenance Schedule. Whenever the total gap between both pads and
the disc exceeds that shown in the Adjustment Specification, the
caliper assembly should be adjusted. Refer to Figure 1, included at
the end of this manual.
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.
AN ADJUSTMENT EYE ON THE EMERGENCY BRAKE CYLINDER ALLOWS

FOR ADJUSTMENT OF PAD GAP. THE MAXIMUM AMOUNT THE EYE CAN
EXTEND FROM THE ADJUSTING NUT IS GIVEN IN THE ADJUSTMENT
SPECIFICATIONS. REPLACE THE PADS WHENEVER THE EYE IS
EXTENDED BEYOND THE AMOUNT GIVEN IN THE ADJUSTMENT
SPECIFICATIONS.
Page 4
EPL-1829
MAINTENANCE (continued)
PAD WEAR ADJUSTMENT
Adjust the caliper assembly whenever the total gap exceeds the
maximum given in the Adjustment Specifications. Adjust pad gap
while the brakes are released and the Emergency Brake Cylinder is
fully retracted (pressurized). Remove the lockwire from the four
1/2 inch capscrews in the end plate of the cylinder. Remove the
capscrews and the two adjusting nut locks from the cylinder. Rotate
the adjusting nut using a 1/2 inch diameter rod in any of the eight
holes on the outside of the adjusting nut. Adjust until the total
gap between both pads and the disc is as specified in the adjustment
specifications.
Check the amount that the back of the adjusting eye extends from the
face of the adjusting nut. If it exceeds the amount given in the
Adjustment Specifications the brake pads must be replaced.
If the amount the adjusting eye extends from the adjusting nut does
not exceed the adjustment specifications, then reinstall the
adjusting lock nuts. Reinstall the four 1/2 inch capscrews, tighten
and lockwire in place.
PAD REPLACEMENT
This procedure describes replacement of the pads for one caliper

assembly. Replace all Emergency Brake pads at the same time. Use
new hardware (screws and nuts) when a pad is replaced.
When replacing the pads, apply hydraulic pressure to the Emergency

Brake Cylinder to retract it. Use extreme care in handling the
spring-loaded cylinder. Remove the pull pins. Move the hydraulic
cylinder out of the way.
Remove the pull pins and pivot pins necessary to remove the brake
shoes from the caliper assembly. Remove the screws and nuts that
hold the pad to the shoe and dispose of them.
Use new hardware to replace the pad with one that has the same part
number shown in the Adjustment Specifications for the Service Brake
Caliper Assembly. Torque the pad nuts to 20-22 foot-pounds. After
one hour check the torque on nuts and retorque to 12 foot-pounds if
required.
Page 5
EPL-1829
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.
Fill the two pockets in the bushings of each arm with grease. Apply
grease to all pivot pins and bushings. Reassemble the caliper
assembly. If the Emergency Brake Cylinder has been removed it must
be reinstalled with the 1/8-inch pipe plug at the top. Adjust each
caliper assembly for total pad gap as described in the Adjustment
Specifications.
EMERGENCY BRAKE CYLINDER DISASSEMBLY
THE EMERGENCY BRAKE CYLINDER IS UNDER COMPRESSED SPRING

FORCE. THE CYLINDER MUST BE RESTRAINED DURING DISASSEMBLY.
Refer to Figure 2 included at the end of this manual.
To disassemble the emergency brake cylinder, remove the cylinder

from the caliper assembly and place it with adjusting eye facing up.
Remove the adjusting eye, adjusting nut locks and adjusting nut from
the cylinder.
Remove the eight nuts from the rod studs on the cylinder. The
cylinder springs are under a high compressive force. Back off the
eight nuts as a group, turning each one only a small amount at a
time. Back off the nuts in a criss- cross pattern so that the nuts
on one side of the cylinder are not loosened ahead of the others.
Once the nuts are removed the spring compression is released and the
end plate may be lifted off the cylinder body.
Page 6
EPL-1829
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)(Lub). Place
the end plate with the studs so that the studs face up. Lubricate
all seals with hydraulic fluid before installing them. Put the
cylinder shell on the end plate with the O- ring facing the end
plate. Install the piston and seal in the shell. Put both sets of
disc springs on the piston. The disc springs must be installed with
the dished sides of adjacent springs alternating as shown on the
cylinder assembly drawing. Grease the disc springs with a
molybdenum disulfide based grease prior to installation.
Place the other end plate on the cylinder body relative to the other
end plate as shown on the assembly drawing. Lubricate the threads on
the studs and install the eight nuts. Tighten the nuts as a group,
turning each one only a small amount at a time. Tighten the nuts in
a criss-cross pattern with a torque wrench and avoid tightening the
nuts more than 200 ft-lbs (270 Nm)(Lub). Torque the nuts to 200 ft-
lbs (270 Nm)(Lub) in a circular pattern after the end plate is
pulled into place. Reinstall the adjusting eye, adjusting nut, and
adjusting nut locks.
Reinstall the emergency brake cylinder, bleed the hydraulic lines,

and adjust the pad clearance.
LUBRICANT REQUIREMENTS
The disc springs in the Emergency Brake Cylinder should be

lubricated with molybdenum disulfide based grease prior to
reassembly whenever the cylinder has been disassembled.
Lubricate pivot shafts and bushings on caliper assembly components

with molybdenum disulfide grease. DO NOT USE A LUBRICANT CONTAINING
COPPER. Due to the dissimilar metals corrosion will occur that will
cause the shafts to be difficult to remove.
Page 7
EPL-1829
MAINTENANCE SCHEDULE
Components should be inspected or serviced at the frequency listed
unless experience with the equipment under specific operating
conditions indicates the need for a shorter interval between
servicing. Refer to the manufacturer’s literature provided with the
equipment for a description of individual components.
DAILY
1. While operating the emergency brake, monitor the emergency

brake supply pressure to confirm adequate brake supply
pressure. If any system or supply pressure is not within 25
PSI of the Adjustment Specifications stop using the drawworks
brakes and determine the cause.
WEEKLY
1. Inspect Emergency Brake Caliper Assemblies for brake pad

standoff. Adjust if required. Replace pads if worn thickness
of pad is less than that given in the Adjustment
Specifications. Operate Emergency Brake to confirm smooth
operation of all components.
2. Inspect emergency brake cylinders and brake piping for any

evidence of leakage. Replace or repair if leakage exists.
3. With brakes released, adjust screw on brake shoe support to

prevent pads from dragging on the disc.
4. Apply one shot of grease to each Pivot Support Shaft. Clean

off any excess grease.
WHENEVER BRAKE PADS ARE REPLACED
1. Inspect caliper assemblies for bent, cracked or worn

components. Replace any damaged components.
2. Inspect pivot shafts on Emergency Caliper assembly components

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

components with molybdenum disulfide grease. DO NOT USE A
LUBRICANT CONTAINING COPPER. Due to the dissimilar metals
corrosion will occur that will cause the shafts to be difficult
to remove.
Page 8
EPL-1829
MAINTENANCE SCHEDULE (continued)
ANNUALLY
Test the Emergency Cylinders by following the procedures below:

1. Release pressure on cylinders.
2. Disconnect the hydraulic supply hose to the Emergency

cylinders.
3. Connect a hydraulic hand pump, capable of producing 2100 PSI

(145 Bar), to one cylinder with an accurate pressure gauge in
the line. The hand pump should be filled with clean fluid of
the same type used in the brake system.
4. Pump the cylinder up until the pin on the live end of the
cylinder can be removed.
5. Block up under cylinder so plunger is free to move.
6. Release the pressure on cylinder and attach a magnetic base

dial indicator to cylinder end plate with the indicator button
resting on the end of the piston rod.
7. Pressure up on the cylinder to obtain readings at the following

points.
PRESSURE CYL. TO: TRAVEL SHOULD NOT EXCEED:

a) 700 PSI (48 Bar) .380" (9.65 mm)
b) Release Pressure
c) 850 PSI (59 Bar) .540" (13.72 mm)
8. Repeat steps 3 through 7 on the other Emergency Cylinders.
9. If any of these tests fail, proceed with Five Year replacement

of springs.
10. Remove all of the “Caliper Arm and Pivot Shafts”. Inspect for
excessive wear, bending or visible cracks.
11. Inspect all shafts and caliper arms with NDE procedures for
cracks. Any part with crack like indications must be replaced.
Page 9
EPL-1829
MAINTENANCE SCHEDULE (continued)
Every Five Years
1. The Emergency Cylinders should be disassembled per instructions

in the maintenance section and all springs and seals replaced
with new parts.
2. Perform pressure test per number 7 in Annual inspection above.
TROUBLE SHOOTING CHART

This chart highlights the most likely causes of problems with the
emergency brake caliper. Read this manual and refer to the assembly
drawings to understand emergency brake operation. This chart is not
exhaustive, nor does it attempt to cover those items that are
assumed to be routine for experienced maintenance personnel.
SYMPTOM PROBABLE CAUSE
1. BRAKE WON'T HOLD BRAKE SUPPLY PRESSURE NOT BEING DUMPED FROM
CYLINDER
BRAKE PAD CLEARANCE NEEDS ADJUSTING
BROKEN SPRING(S) IN CYLINDER
OIL SOAKED BRAKE PADS
2. BRAKE RESPONSE SLOW RESTRICTION IN FLOW TO/FROM EMERGENCY BRAKE

CYLINDER
BRAKE PAD CLEARANCE NEEDS ADJUSTING
AIR IN EMERGENCY BRAKE CYLINDER
Page 10
EPL-1829
FIGURE 1 - EMERGENCY BRAKE CALIPER ASSEMBLY
1. Support, Brake Shoe 12. Bushing, Brake Pad
2. Cylinder Assy, Emergency Brake 13. Arm, Caliper
3. Shaft, Arm Support 14. Pad, Brake Shoe
4. Shaft, Caliper Support 15. Bushing, Machine
5. Shaft, Pivot Arm 16. Bushing, Machine
6. Shaft, Brake Pad 17. Clamp Assembly
7. Shoe, Brake 18. Locknut
8. Bushing, Caliper Support 19. Fillister Head Screw
9. Bushing, Pivot Arm 20. Cotter Ring Pin
10. Bushing, Pivot Arm 21. Cotter Ring Pin
11. Bushing, Brake Pad
Page 11
EPL-1829
FIGURE 2 - EMERGENCY CALIPER CYLINDER ASSEMBLY
1. Bushing 11. Disc Spring

2. Piston 12. Stud, Cylinder
3. Wiper Seal 13. End Plate
4. Poly-Pak 14. Nut, Stud
5. End Plate 15. Adjusting Nut
6. Plug Pipe, Sq Hd 16. Adjusting Eye
7. O-ring 17. Screw, Drilled Head
8. Poly-Pak 18. Tie Wire
9. Spacer 19. Adjusting Locknut
10. Cylinder Shell 20. Hollow Hex Plug
Page 12
EPL-1829
SALES AND SERVICE INFORMATION
EXECUTIVE OFFICES MANUFACTURING PLANTS
HOUSTON CORPORATE HOUSTON PRODUCTS & TECHNOLOGY HOUSTON PLANT MCALESTER WORKS
HEADQUARTERS 5225 Hollister Street 11919 FM 529 Road 501 N George Nigh Exp
10000 Richmond Avenue Houston, TX 77040 Houston, TX 77041 (Hwy 69 Bypass North)
Houston, TX 77042 P.O. Box 4638 PHONE: 713/849-8000 McAlester, OK 74501
P.O. Box 4888 Houston, TX 77210-4638 PHONE: 918/423-8000
Houston, TX 77210-4888 PHONE: 713/935-8100
PHONE: 713/346-7500
SALES OFFICES
ANCHORAGE, AK DENVER, CO MIDLAND, TX RIO VISTA, CA
PHONE: 907/522-3727 PHONE: 303/298-8112 PHONE: 915/684-5576 PHONE: 707/374-2580
BAKERSFIELD, CA HOUSTON, TX NEW ORLEANS, LA TULSA, OK
CASPER, WY LONG BEACH, CA ODESSA, TX VENTURA, CA
DALLAS, TX LOS ANGELES, CA OKLAHOMA CITY, OK WICHITA, KS
WILLISTON, ND
PHONE : 701/572-3781
UNITED STATES STORES

ANCHORAGE, AK CHEYENNE WELLS, CO GREAT BEND, KS LIBERAL, KS
ANDREWS, TX CLAY CITY, IL HARTSHORNE, OK LINDSAY, OK
BAKER, MT CORPUS CHRISTI, TX HARVEY, LA LONG BEACH, CA
BAKERSFIELD, CA CORTEZ, CO HENDERSON, KY MCALLEN, TX
BIG LAKE, TX CROSSVILLE, IL HOBBS, NM MCCOOK, NB
BIG PINEY, WY DENVER CITY, TX HOMINY, OK MOBILE, AL
BIG SPRING, TX DICKINSON, ND HOUMA, LA MOHALL, ND
BILLINGS, MT ELK CITY, OK HOUSTON, TX MONAHANS, TX
BRADFORD, PA ELLINWOOD, KS KALKASKA, MI MORGAN CITY, LA
BROOKHAVEN, MS EVANSTON, WY KENAI, AK MT. CARMEL, IL
BRYAN, TX FT LUPTON, CO KENEDY, TX MT. PLEASANT, MI
CAMERON, LA FT. SMITH, AR KILGORE, TX NESS CITY, KS
CASPER, WY FREER, TX LAREDO, TX NEW IBERIA, LA
CHARLESTON, WV GILLETTE, WY LAUREL, MS ODESSA, TX
Page 13
EPL-1829
UNITED STATES STORES
OKLAHOMA CITY, OK POWELL, WY SHIDLER, OK VERNAL, UT
PAINTSVILLE, KY PUNXSUTAWNEY, PA SHREVEPORT, LA VICTORIA, TX
PAMPA, TX RATLIFF CITY, OK SNYDER, TX WATFORD CITY, ND
PEARSALL, TX RIVERTON, WY SUNDOWN, TX WILLISTON, ND
PENNSBORO, WV ROCK SPRINGS, WY VENICE, LA WOODLAND, CA
PLAINVILLE, KS SABINE PASS, TX VENTURA, CA
PHONE: 913/434-4624 PHONE: 409/971-2449 PHONE: 805/653-6666
INTERNATIONAL DISTRIBUTORS
NATIONAL OILWELL CANADA LTD. NATIONAL OILWELL NATIONAL OILWELL, INT'L
CANADA DE VENEZUELA, C.A. UNITED STATES
MAIN SALES OFFICE: HEADQUARTERS: MAIN SALES OFFICE:
2300 BOW VALLEY SQUARE III APARTADO 1146, 4001-A 1530 W SAM HOUSTON PKWY N
255 - 5TH AVENUE S.W. CALLE 158 CON AVENIDA 68 HOUSTON, TX 77043
CALGARY, ALBERTA AMPLIACION ZONA INDUSTRIAL P.O. BOX 4638
CANADA T2P 3G6 MARACAIBO, EDO. ZULIA, HOUSTON, TX 77210-4638
PHONE: 403/294-4500 VENEZUELA PHONE: 713/935-8000
FAX: 403/262-9166 PHONE: (011-58-61) 361850 FAX: 713/935-8351
FAX: (011-58-61) 362561
NATIONAL OILWELL (U.K.) LTD. NATIONAL OILWELL PTE. LTD. NATIONAL OILWELL (UAE) LTD.
MACHINERY CENTRE: SOUTHEAST ASIA SALES OFFICE: MIDDLE EAST SALES OFFICE:
Badentoy Road Machinery and Service Centre SALES AND SERVICE CENTRE
Badentoy Industrial Park 30 Tuas Basin Link P.O. BOX 61490
Portlethen, Aberdeen SINGAPORE 638786 RA/08-TA06
SCOTLAND abi 4ya PHONE: (011-65) 861-1566 JEBEL ALI, UAE
PHONE: (011-44-1224) 783-060 Fax: (011-65) 861-0796 PHONE: 971 4 8838776
Fax: (011-44-1224) 783-266 FAX: 971 4 8838795
Page 14
EPL-1829
PRECHARGING INSTRUCTIONS
FOR 3000 PSI
BLADDER ACCUMULATORS
PRECHARGING INSTRUCTIONS FOR
3000 PSI BLADDER ACCUMULATORS
IMPORTANT
USE DRY NITROGEN GAS ONLY to precharge the accu-
mulator.
Check the precharge tag attached to the accumulator.
The accumulator will either be precharged to 25 psig(1.7
bar) for shipping purpose or to the pressure specified
on the purchase order. If the accumulator does not have
the correct precharge, it must be precharged to the re- Charging Kit Standard Accumulator Charging Kit Top Repairable
quired level using only DRY NITROGEN GAS, before it is CG-3000 Accumulator T-CG-3000
installed in the hydraulic system.
Precharge pressures vary according to the application
and operating conditions. Please seek technical support
from the factory if you are not sure about the correct
precharge. Incorrect Precharge pressure can lead to
reduced accumulator performance, reduced bladder life
expectancy, and even bladder failure. It is very impor-
tant to have the correct precharge. As a guidance, the
following values can be used.
Energy Storage:
90% of the minimum system pressure
Pulsation dampening: Charging Head Assembly Standard Charging Head Assembly Top
70% of the system mean operating pressure Accumulator CG-3013 Repairable Accumulator T-CG-3013
Shock absorption
75% of the system working pressure.
Precharge must never be below 25% of the maximum
system pressure.
Always use a pressure regulator valve on the nitrogen
bottle when the accumulator shell pressure is lower than
the gas pressure in the nitrogen cylinder.
Ensure bladder is thoroughly lubricated with system fluid
before precharging.
Whenever you have to replace the gas valve core, re-
place it with a valve core approved for accumulator ser-
vice. NEVER USE AN AUTOMOTIVE TYPE VALVE CORE. Valve Adaptor A11-3-309 Air Chuck CG-3002
CHECKING PRECHARGE
Check the precharge pressure only after the hydraulic
pressure has been completely released. When a new
accumulator is installed, the precharge pressure should
be checked to ensure that there is no leakage. This
should be performed once during the first week of op-
eration, and then every six months thereafter. Under high
cycling or high temperature conditions, the precharge
should be checked once every month.
RECOMMENDED CHARGING KITS FOR

3000 PSI BLADDER ACCUMULATORS
Assembly
Tank Valve CG-3005 Bleed Valve CG-3009
Type Capacity Part No:
Standard
Accumulator 10 CI to 15 Gallon CG-3000
High Flow
Accumulator 2.5 to 15 Gallon CG-3000
Top Repairable
Accumulator 2.5 to 15 Gallon T-CG-3000
High Flow
Top Rep Accumulator 2.5 to 15 Gallon T-CG-3000
Hose Assembly CG-3010 Valve Extension T-CG-3015

PRECHARGING
PRECHARGING PROCEDURE FOR 3000 PSI STANDARD ACCUMULATORS
1. Remove the protective cap and the seal cap. 2. Close the bleed valve on the charging and gauging 3. Install Charging and Gauging Assembly on the 4. Remove the seal cap from the gas charging tank
assembly.Retract the T-handle on the air chuck by accumulator by screwing the air chuck to the gas valve and connect the swivel connector on the hose
turning counter clockwise direction. valve and tighten sufficiently to prevent any leakage. assembly. Hand tighten sufficiently to prevent leakage.
Turn the T-handle on the air chuck clockwise to
depress the valve core. Connect the hose to the
nitrogen bottle regulator.
5. Open the regulator valve on the nitrogen bottle carefully to let nitrogen flow at a slow rate into the accumulator. Proceed to charge until the accumulator reaches desired precharge pressure. Close the regulator and let the
nitrogen stabilize and obtain gauge reading. Adjust the pressure if necessary.
6. Retract the T handle on the air chuck by turning 7. Open the bleed valve to bleed of nitrogen in the 8. Check for leakage through the valve core by soap 9. Replace the valve seal cap and the protective cap.
counter clockwise to close the valve core. hose. Disconnect the charging assembly from the solution or snoop. If the core is leaking, then retighten
accumulator and the gas bottle. the valve core to 4 in-lb torque. If leakage persists then
replace the valve adapter.
10. Check precharge pressure once in the first week of operation, and then every six months during normal working or every month during high cycling or high temperature condition.
PRECHARGING PROCEDURE FOR 3000 PSI TOP REPAIRABLE ACCUMULATORS
1. Remove the protective cap and the seal cap. 2. Close the bleed valve on the charging and gauging 3. Install Charging and Gauging Assembly on the 4. Remove the seal cap from the gas charging tank
assembly. Retract the T-handle on the air chuck by accumulator by screwing the charging block directly valve and connect the swivel connector on the hose
turning counter clockwise direction. on to the bladder valve stem. Hand tighten sufficiently assembly. Hand tighten sufficiently to prevent
to prevent any leakage. Turn the T-handle on the block leakage.
clockwise to depress the valve core. Connect the
hose to the nitrogen bottle regulator.
5. Open the regulator valve on the nitrogen bottle carefully to let nitrogen flow at a slow rate into the accumulator. Proceed to charge until the accumulator reaches desired precharge pressure. Close the regulator and let the
nitrogen stabilize and obtain gauge reading. Adjust the pressure if necessary.
6. Retract the T handle on the block by turning counter 7. Open the bleed valve to bleed off nitrogen in the 8. Check for leakage through the valve core by soap 9. Replace the valve seal cap and the valve guard.
clockwise to close the valve core. hose. Disconnect the charging assembly from the solution or snoop. If the core is leaking, then retighten
accumulator and the gas bottle. the valve core to 4 in-lb torque. If leakage persists
then replace the valve adapter.
10. Check precharge pressure once in the first week of operation, and then every six months during normal working or every month during high cycling or high temperature condition.
11505 West Little York Houston, Texas 77041 Tel: (713) 937-8900 Fax: (713) 937-0438
© copyright 1997 OilAir Hydraulics, Inc. Printed in USA Bulletin #MM3-97
OLAER GROUP COMPANY
Instruction
Manual
for the
INSPECTING THE CONDITION OF Accumulator
DELIVERY
After unpacking the accumulator, inspect it for possible
damage caused during transit. 3 2
1 4
1. Inspect the Locknut and the Jamnut and bleeder plug
for tightness.
2. Check the precharge tag. The accumulator is either
precharged to 25psi (1.7 bar) for shipping purpose or
charged to a pressure specified on the purchase order.
3. Check that the working pressure stamped on the 9
accumulator shell is equal to, or greater than, the
maximum pressure of the system.
7
PROTECTION & PRECAUTIONS
1. Protective Gloves: 10 6
Use chemical resistant gloves, if needed, to avoid
prolonged or repeated skin contact from the clean- 14 13
11 12 8 5
ing solutions or solvents.
2. Eye protection:
Use safety glasses before performing any maintenance SPARE PARTS
on the accumulator.
1. Shell
OTHER PRECAUTIONS: 2. Bladder 8. Spacer
3. Plug & Poppet Assembly 9. Locknut
DO NOT operate the accumulator beyond the allowable
4. Anti Extrusion Ring 10. Name Plate
working pressure and temperature limitations stamped or
5. Metal Back Up Ring 11. Valve Cap
attached to the product.
6. "O" Ring 12. Hex Jamnut
Use only the tools recommended in this manual to perform
7. Rubber Back Up (Not available for 1 quart and 13. Protective Cap
the maintenance procedures.
1 gallon sizes) 14. Bleeder Plug
Use only DRY NITROGEN for charging accumulator.
NEVER USE OXYGEN OR AIR, due to risk of explosion.
Use only valve cores approved for accumulator service and
NEVER USE AN AUTOMOTIVE TYPE VALVE CORE.
PRECHARGING: 9
1. Use DRY NITROGEN ONLY to precharge the
accumulator.
8
2. Use the charging assembly recommended in this
manual to charge the accumulator to the required 5
precharge if it is not already charged at the factory.
3. Check the charging valve for leaks using snoop or soap
water. 4
4. Tighten the jamnut at the gas valve stem and also
the locknut on the fluid port with a wrench.
5. Tighten the protective cap on the gas valve stem to
hand tight.
6. Check the gas precharge pressure periodically. This
must be done after all the hydraulic system pressure is 3 6
released. The precharge must be checked once in the
first week of operation, and then every six months dur- 7 2 1
ing normal working or every month during high cycling
or high temperature condition.
TOOLS
INSTALLATION:
The accumulator should be mounted vertically with fluid 1. Charging & Gauging Assy - P.N. CG-3000 6. Ratchet Wrench (Corresponds to elastic
port on bottom and gas valve on top with supporting brack- 2. Valve Core Tool - P.N. 11-501 stop nut and bleeder plug size)
ets and saddles specifically designed for accumulator 3. Spanner Wrench - P.N. 11-502 7. Bladder Pull Rod - P.N. 11-503
mounting. For other type of mounting, consult factory. 4. Open End Box Wrench (Corresponds to 8. Rubber Mallet
Fluid port must not be used to support the accumulator. valve stem wrench flats width) 9. Tool Box
Do not weld any support to the accumulator. For ease of 5. Open End Box Wrench (Corresponds to
maintenance and periodic checking of the precharge, an hex jamnut size)
automatic discharge valve fitted between the accumulator
and the system pressure line is recommended.
OLAER GROUP COMPANY

DISASSEMBLY
Instructions for disassembling the

accumulator.
Release all the hydraulic system pressure in a safe

manner (eg: bleed valve or automatic discharge valve
installed in the system). Remove the accumulator
from the hydraulic system and place it horizontally in
a vice or a clamping device. Protect the clamping
jaws with wood or rubber so as not to damage the
accumulator shell.
1. Remove the protective cap on the gas 2. Remove the valve sealing cap from the
valve. valve adaptor.
3. Connect a suitable charging & gauging assem- 4. Remove the valve adaptor from the gas valve body. 5. Remove the valve core if the gas valve body has a
bly to the valve adaptor and release all the nitrogen (2 piece valve stem design) core inside. (1 piece valve stem design)
precharge pressure from the accumulator until the
gauge reads zero.
6. Remove the jamnut and the name plate from the 7. Remove the bleeder plug from the fluid port. 8. Remove the locknut and then remove the spacer.
gas valve body. While removing the jamnut hold the Loosen locknut with a spanner wrench by turning
gas valve body with a wrench so that the bladder will 2 or 3 threads, then push the fluid port body into the
not rotate. accumulator shell if there is no hydraulic pressure. *
9. Push the fluid port body into the shell and remove 10. Slide the anti-extrusion ring off of the fluid port. 11 . By squeezing the bladder discharge as much air
the back-up ring , “O” ring and the metal back-up ring. Carefully fold the anti-extrusion ring until it's suffi- as possible by hand, then pull the bladder out slowly
ciently folded to allow removal from the shell and re- through the fluid port opening of the shell.
move fluid port from the shell.
* If the fluid port body does not go inside, then there is some hydraulic pressure left inside the accumulator. If this happens, do not attempt to do any maintenance. Consult the factory.
ASSEMBLY
Cleaning & Inspection

Clean all the metallic parts of the accumulator with
an organic solvent. Avoid exposing the rubber parts
to the solvent to prevent any attack on the rubber.
Inspect the condition of the metallic components of
the fluid port (poppet, spring, stop nut and piston)
and replace the complete fluid port assembly if any
of the components are damaged. Push the poppet
valve head to make sure it slide freely through the
guide in the fluid port. Clean the bladder with
isopropyl alcohol or equivalent. Inspect the bladder
for any visual damages. Replace if necessary. 1. Squeeze the bladder to discharge air from it by 2. Then install the valve adaptor to a torque value of
Check that there is no corrosion inside or outside of rolling it up from the bottom. 90 in.lbs (10 Nm). (For the two piece valve stem
the shell. Replace all parts considered defective. design).
The “O” Rings and back up rings must be replaced.
3. Then install the valve core to a torque value of 4. Lubricate the accumulator shell and the bladder 5. Reinstall the name plate and the jamnut. Do not
4 in.lbs. (.45 Nm). (For the one piece valve stem either with the medium used in the system or a simi- tighten the jamnut.
design). lar product. Attach the bladder pull rod to the valve
and fold the bladder and pull into the shell. Avoid
twisting the bladder while pulling it into the shell.
6. Insert the fluid port and the anti-extrusion ring into 7. Slide the anti-extrusion ring over the fluid port. 8. Install a charging and gauging assembly on the
the shell. Pull the fluid port through the port opening. gas valve and put a low precharge of 30 psig (2 bar)
to seat the fluid port and the anti-extrusion ring in
place.
9. Hammer slightly the fluid port body at various 10. Install the metal back up, O-ring, rubber back up 11. Tighten the locknut .
angles using plastic hammer. and spacer in that order.
12. Install the bleeder plug and tighten it. 13. Rotate the accumulator shell around its axis to
lubricate its inner wall evenly all around.
14. Using a charging and gauging assembly, 15. Remove charging and gauging assembly, install
precharge to the desired pressure at a moderate rate, valve cap and protective cap. Retighten the
using DRY NITROGEN only. Check the valve for Assembly locknut & jamnut.
leaks with snoop or soap water.
STORAGE:
Accumulator storage instructions OILAIR ORIGINAL EQUIPMENT LIMITED
If after reassembly, the accumulators are stored, they must be charged with a low nitrogen pressure of 25 psi (1.5 bar)
and store in a cool and dry area. The fluid port must be sealed. The accumulator can be stored in any position. WARRANTY
The protective cap on the gas charging valve must be securely tightened to protect it from any shock.
OILAIR warrants each of its products against original
Attach a label to the accumulator stating that they must be precharged before installing in the system. defects in materials and/or workmanship and will repair
or replace any product which is determined by OILAIR,
within one (1) year of its installation, to be defective or
If the accumulator is stored for longer than 6 years, all the elastomeric components (bladder, seals etc.) must be below the manufacturing standards of OILAIR, including
replaced. warranty of merchantability, fitness for the purpose intended,
consequential and incidental damage of liability.
This Original Equipment Warranty which anticipates instal-
lation by third parties, expressly excludes warranty of
BLADDER STORAGE INSTRUCTIONS: merchantability, fitness for the purpose and consequential
or incidental damage liability.
DO NOT OPEN PLASTIC BAG UNTIL READY FOR INSTALLATION.
DO NOT USE RAZOR OR SHARP OBJECTS TO OPEN THE PLASTIC BAG. OPERATION OF ANY OILAIR ACCUMULATOR OR
COMPONENT BEYOND THE MANUFACTURER'S
Bladder in the plastic bag must be stored in a cool (preferably below 720 F), dry and dark place out of direct sunlight, WORKING PRESSURE LIMITATIONS, OR IN VIOLATION
fluorescent light, ultraviolet light and away from electrical and welding equipment. OF ANY OPERATING OR SERVICE INSTRUCTION
STAMPED OR ATTACHED TO THE PRODUCT,
Direct sunlight or fluorescent light may cause the bladder to weather check and/or dry rot, which appears on the bladder EXPRESSLY VOIDS THIS WARRANTY AND MAY BE
surface as cracks. DANGEROUS TO LIFE AND PROPERTY.
11505 West Little York Houston, Texas 77041 Tel: (713) 937-8900 Fax: (713) 937-0438/937-1516
copyright 1994 OilAir Hydraulics, Inc. Printed in USA Bulletin #MMM94

OLAER GROUP COMPANY
High Pressure /Hydraulic
maximum 15,000 PSIG in
controlled pressure ranges up to 15,000 PSIG
back pressure/ durable
54-2100 Series
Spring Loaded
Specifications
 Operating Parameters
pressure rating per criteria of ANSI/ASME B31.3
maximum rated inlet pressure . . . . . . . 15,000 PSIG
Air Loaded
controlled pressure ranges . . . . . . . . . 0-500, 0-800,
10-1500, 15-2500, 25-4000, 50-6000,
200-10,000 & 300-15,000 PSIG
design proof pressure . . . . . . . . . . 150% maximum
rated pressure
leakage . . . . . . . . . . . . . . . maximum 2 drops/minute
@150 SUS @ 2500 PSIG
ambient operating temperature 1 . . . . . -15° F to +165° F
(-25° C to +74° C)
flow capacity . . . . . . . . . . . . . . . . . . . . . . . . C v = .08
maximum operating torque . . . . . 40 in.-lbs. (4.5 Nm)
1 For extended temperatures from -65°F to +400°F, consult Tescom.
Dome Loaded
 Media Contact Materials
body . . . . . . . . . . . . . . . . . . . . . . 316 Stainless Steel Advantages
seat & poppet . . . . . . . . . . . . . 17-4 Stainless Steel
o-ring . . . . . . . . . . . . . . . See Part Number Selector • Accuracy ± 1% of relief pressure range
back-up ring: • Set point repeatability exceeds
inlet pressure ranges 2500-10,000 PSIG . . . . . Teflon® conventional relief valves
inlet pressure range 15,000 PSIG . . . . . . . . CTFE
valve seal . . . . . . . . . . . . . . . . . . . . . . . . . . . Vespel® • Easily adjusted, low torque handknob
sensor seal: control, dome and air-loaded versions
inlet pressure ranges 500-10,000 PSIG . . . . . CTFE also available
inlet pressure range 15,000 PSIG . . . . . . . Vespel®

• Hardened stainless steel seats
remaining parts . . . . . . . 300 Series Stainless Steel
• Safe and reliable piston-style sensor
For other materials and modifications, please consult Tescom.
• Panel mounting standard
 Cleaning . . . . . . . . . . . . . CGA 4.1 and ASTM G93
• Compatible with Tescom’s air actuator
 Weight . . . . . . . . . . . . . . . . . . . . . . . 5 lbs (2.2 kg) and ER3000 Electropneumatic PID
Controllers
Pressure Conversion 14.5 PSIG = 1 bar 145 PSIG = 1 MPa
Teflon®, Viton-A®, Kalrez® and Vespel® are registered trademarks of Du Pont.

54-2100 Series High Pressure/Hydraulic
Flow Chart 54-2122D24
6000
INLET PRESSURE - PSIG

5000
4000
3000
2000
1000
0 .50 1.0 1.5 2.0 2.5 3.0 3.5

(1.9) (3.8) (5.7) (7.6) (9.5) (11.4) (13.3)
FLOW RATE - GPM (LPM)

Hydraulic Fluid - Mobil DTE 20 Series
All dimensions are

reference & nominal
Metric (millimeter)
equivalents are in brackets
Part Number Selector

example part number:
54-21 6 1 D 2 4
Soft Goods Material Inlet &
Basic body Inlet & Outlet Outlet
Series material Inlet pressure Dynamic Static Seat Port Type Port size Loading
54-21 6 – 316 0 – 300-15000 PSIG* D – Buna-N Buna-N 17-4 SST 1 – SAE 4 – 1/4" – Spring
SST (Spring only) (no letter
J – Teflon® Viton-A® 17-4 SST 2 – NPT 6 – 3/8"
1 – 200-10000 PSIG** required)
Encapsulated 3 – MS33649
2 – 50-6000 PSIG 8 – 1/2" H – Dome
(Spring & Air only) T – Viton-A® Viton-A® 17-4 SST 4 – High Pressure (NPT &
A – Air ***
3 – 25-4000 PSIG V – Kalrez
® Kalrez® 17-4 SST 6 – Medium Pressure MS33649 only)
(Spring only) W – Teflon
® Teflon® 17-4 SST
4 – 15-2500 PSIG
(Spring & Air only) Z – Ethylene Ethylene 17-4 SST
Propylene Propylene
5 – 10-1500 PSIG
(Spring & Air only)
6 – 0-800 PSIG * Available with 1/4" & 3/8" High Pressure,
(Spring only) 1/4" & 3/8" Medium Pressure, 1/4" NPT only
For extended temperatures of soft ** Not to be used with 3/8" SAE or 3/8" MS33649 ports
7 – 0-500 PSIG goods material, please consult Tescom. *** 80 PSIG minimum loading pressure needed
(Spring & Dome only)
Repair Kits, Accessories & Modifications may be available for this product. Please contact Tescom for more information.
WARNING! Do not attempt to select, install, use or maintain this product until you have read and fully understood the Tescom
Safety, Installation & Operation Precautions.
The contents of this publication are presented for informational purposes only, and while every effort has been made to ensure their accuracy, they are not to be construed
as warranties or guarantees, expressed or implied, regarding the products or services described herein or their use or applicability. We reserve the right to modify or
improve the designs or specifications of such product at any time without notice.
For information contact:
Tescom Industrial Controls
Tel: 800-447-1250 • 763-241-3238
www.tescom.com Fax: 763-241-3224 • email: ic@tescom.com
12616 Industrial Boulevard • Elk River, MN 55330 USA
©Tescom Corporation, 2006; All Rights Reserved.
Tescom is a business unit of the Regulator Division.
Trademarks are property of divisions of Emerson Process Management.
Form No. 1635 Rev. 3/06 Printed 3/06 5M Printed in the U.S.A.
H E A T E X C H A N G E R S H E A T E X C H A N G E R S
SC-IOM-10
Installation and
Operation Manual

Index
Index
IDENTIFYING YOUR Four Plate Sequence—ULTRAFLEX ........... 22 CLEANING .......................................... 36
SUPERCHANGER® UNIT ................. 3 Multi-Pass Units ........................................ 22 Steps for Manual Cleaning of Plates .......... 37
PLATE DESCRIPTION AND CON- GASKET DATA .................................... 23 PLATE CLEANING TIPS ..................... 38
STRUCTION ....................................... 4 Gaskets—Glued ........................................ 23 Cleaning-In-Place (CIP) ............................. 38
Plate Details ................................................ 5 Gaskets—Glueless .................................... 24 Back Flushing and Strainers ...................... 40
Frame Pressure Ratings .............................. 6 Gasket Storage Procedures ....................... 24 Cleaning Guidelines ................................... 40
Part Number ................................................ 6 Mixed Gasket Materials ............................. 24 TROUBLE-SHOOTING ....................... 41
Plate Data .................................................... 7 INSTALLATION ................................... 26 Leakage Between the Plate Pack and the
Frame Dimensions ...................................... 8 Unpacking ................................................. 26 Frame ..................................................... 42
Plate Pack Widths ....................................... 9 Recommended Procedures ....................... 26 Leakage Between the Nozzle and the End
Plate Pack Tightening Dimensions ............ 10 Tightening the Plate Pack .......................... 27 Frame ..................................................... 42
Plate Material and Date of Manufacture Data Tightening Sequence ................................. 28 Leakage Between the Plates to the Outside of
11 START-UP PROCEDURES ................. 28 the Unit .................................................. 43
Plate Designations ..................................... 12 Precautions Prior to Start-Up .................... 28 Mixing of Fluids ......................................... 43
Drawings ................................................... 13 Disassembly Procedures ........................... 29 Increase in Pressure Drop or a Reduction in
Element Composition Diagram .................. 13 SERVICING ......................................... 29 Temperature Readings ........................... 44
Plate Hole Designation for UX, SX, GC and GF Shutting Down the Unit ............................. 29 How to Find A Defective Plate With Through
Series ..................................................... 14 Removal of Plates ..................................... 30 Holes ...................................................... 44
PASS AND FLOW ARRANGEMENT .. 15 Replacing Plates ........................................ 30 STORAGE PROCEDURES ................. 45
Plate Pass Arrangement ............................ 15 Replacing Gaskets ..................................... 31 MISCELLANEOUS INSTRUCTIONS .. 46
Flow Arrangement ..................................... 16 Removing Old Gaskets ............................ 31 General Maintenance ................................. 46
Drains ........................................................ 16 Installing Continuously Glued Gaskets .... 32 Ordering Parts ........................................... 46
Connecting “C” Frames ............................. 18 Installing Spot-Glued Gaskets ................. 33 Returned Material ...................................... 47
ULTRAFLEX (GX) Plate Design .................. 19 Installing SUPERLOCK® Snap-In Gaskets35 Damaged Shipments ................................. 47
Plate Designations—ULTRAFLEX and WIDE Installing Teflon Encapsulated Gaskets and Additional Information ............................... 47
GAP ....................................................... 20 Unit Assembly ................................... 35
Drawings ................................................... 21
Figure 17b .................................................. 18

Index—Figures Figure 18a .................................................. 18 Index—Tables
Figure 18b .................................................. 18
Figure 19 .................................................... 19
Figure 1 ........................................................ 4 Figure 20a .................................................. 20 Table 1 Frame Pressure Ratings .................... 6
Figure 2 ........................................................ 4 Figure 20b .................................................. 20 Table 2 Plate Data GX Series Plates ............... 7
Figure 3 ........................................................ 5 Figure 20c .................................................. 20 Table 3 UX, SX, GF Series Plates .................. 7
Figure 4 ........................................................ 5 Figure 22 .................................................... 22 Table 4 GF Series Wide Gap Plates ............... 8
Figure 5 ........................................................ 5 Figure 23a .................................................. 23 Table 5 GC Series Plates ............................... 8
Figure 6 ........................................................ 5 Figure 23b .................................................. 23 Table 6 Frame Dimensions, Inches ............... 8
Figure 7 ........................................................ 9 Figure 23c .................................................. 23 Table 7 Plate Pack Tightening Dimensions . 10
Figure 8 ...................................................... 11 Figure 24 .................................................... 25 Table 8 Plate Identification Number Nomencla-
Figure 9 ...................................................... 12 Figure 25a .................................................. 27 ture ............................................................ 11
Figure 10 .................................................... 12 Figure 25b .................................................. 27 Table 9 “A” and “B” Equivalents ................. 14
Figure 11 .................................................... 13 Figure 26a .................................................. 28 Table 10 Temperature Ratings .................... 23
Figure 12 .................................................... 14 Figure 26b .................................................. 29 Table 11 Glue Requirements ....................... 32
Figure 13a .................................................. 14 Figure 26c .................................................. 30
Figure 13b .................................................. 14 Figure 26d .................................................. 35
Figure 14a .................................................. 15 Figure 27 .................................................... 39
Figure 14b .................................................. 16 Figure 28 .................................................... 39
Figure 15 .................................................... 17 Figure 29 .................................................... 41
Figure 16 .................................................... 17 Figure 30 .................................................... 42
Figure 17a .................................................. 17
IDENTIFYING YOUR SUPERCHANGER® UNIT
A data plate like the one shown on the picture below is fixed to the stationary frame of the unit and provides the
following information. This information is helpful when contacting the factory.
DATA PLATE
3
Support
pad
Figure 1 Figure 2
Superchanger Frame, Models HP, UP, SP, MP, FP Superchanger Frame, Models HJ, UJ, SJ, MJ
PLATE DESCRIPTION AND CONSTRUCTION

SUPERCHANGER plate corrugations are available in four patterns. Depending on the applications, the GF, UX,
SX, GC and GX Series plates are used to achieve maximum heat transfer.
UX, SX and GC Series plates: Herringbone (chevron) pattern is ideally suited for handling aqueous solutions.
GF Series: Wide gap and parallel (washboard) patterns are designed for applications where there are high
viscosity fluids or fluids containing fibers or coarse particles.
GX Series: An asymmetrical four quadrant plate suited for low viscosity and close temperature approach appli-
cations or processes involving two vastly different flow rates. It is also well suited for equal flows and close
approach.
All plates are manufactured from die-formed sheet metal in virtually any material that can be cold worked, such
as stainless steel, titanium, Alloy C-276, Alloy-20, etc. There are grooves around the circumference of the plates
which accept the sealing gasket and also add reinforcement because of the ribbed edges. Fluid passage holes
are pierced at the corners of each plate. The number and location of the holes is dependent upon the design
conditions.
The gaskets are single piece, molded construction, and generally bonded to the plates with Pliobond 30 adhe-
sive. The gasket material is selected for compatibility with the fluids being processed and the operating tempera-
tures.
Each plate also contains flow directors at the top and bottom of the heat transfer surface in the port hole areas
which evenly distribute the fluids. Some plates require a hanger which attaches the plate to the upper guide bar.
For most models, the upper guide bar is the plate’s sole support member in the frame, while the lower guide bar
serves as an alignment member in all plates except the UXP-005 and the UXP-001 which are supported by the
lower guide bar. See Figures 3, 4, 5, 6 and Tables 3 through 6 for specific models.
4
Plate Details
Nozzle numbers
Flow directors
on fixed frame *Hanger *Hanger
4 1 4 1 4 1 4 1
Flow
directors
“B” Plate has
narrow gasket
“A” Plate “B” Plate Corrugated “A” Plate “B” Plate groove in this
surface area at ports
#1 and #2
Plate
gasket
3 2 3 2 3 2 3 2
Chevrons point up on “A” Plate Hanger slots “A” Plate has wider
and down on “B” Plate groove in this area at
ports #1 and #2
Figure 3 Figure 4
Typical UX, SX or GC Series Typical GF Series (washboard) plate
(herringbone) plate with gasket and with gasket and hanger.
hanger. Note that the chevron angle for
the herringbone plate can differ on
various models.
*External hanger not required on some models (see Table 3)
4 1
3 2
Figure 5 Figure 6
Typical GX plate with gasket. Note that the Typical GF (wide gap) plate with
chevron angle for the herringbone plate can gasket.
differ on various models.
5
Part Number
Type of plate Number of plates

in the unit
GXD - 042 - H - 7 - UP - 120
Frame type
Flow direction Plate thickness in

Diagonal (D) or tenths of a mm
parallel (P)
Plate
model
Chevron
angle
Frame Pressure Ratings

Table 1 Frame Pressure Ratings
NOMINAL ASME CODE
PRESSURE RATINGS, PSIG
FRAME TYPE Design Pressure Test Pressure
HJ/HP 100 130

UJ/UP 150 195
SJ/MJ/SP/MP 300 390
FP 350 455
6
Plate Data
Table 2 Plate Data GX Series Plates
Plate Data\Models GXD-007 GXD-012 GXD-018 GXD-026 GXD-042 GXD-051
2
Heat Transfer Surface Area (ft .) 0.753 1.292 1.937 2.906 4.736 5.920
Plate Width (in) 4-15/16 9-13/16 9-13/16 15-3/16 15-3/16 19-7/8
Plate Length (in) 27-3/4 27-3/4 37 37 53-1/4 53-1/4
Maximum Connection Size (in) 1 2 2 4 4 6
Maximum Flow (gpm) 75 292 292 1171 1171 2264
Channel Volume Between Plates (gal) 0.0423 0.0872 0.124 0.227 0.351 0.444
Table 2 Plate Data GX Series Plates (cont.)

Plate Data\Models GXD-037 GXD-064 GXD-091 GXD-118 GXD-060 GXD-100
2
Heat Transfer Surface Area (ft .) 3.983 6.889 9.795 12.701 6.028 10.872
Plate Width (in) 19-7/8 19-7/8 19-7/8 19-7/8 27-3/4 27-3/4
Plate Length (in) 42-3/16 61-1/16 80 98-7/8 47-1/8 69-15/16
Maximum Flow (gpm) 2769 2769 2769 2769 4755 4755
Table 2 Plate Data GX Series Plates (cont.)

Plate Data\Models GXD-140 GXD-180 GXD-085 GXD-145 GXD-205 GXD-265 GXD-325
2
Heat Transfer Surface Area (ft .) 15.72 20.559 9.795 16.469 23.035 29.708 36.274
Plate Width (in) 27-3/4 27-3/4 37 37 37 37 37
Plate Length (in) 92-3/4 115-5/8 60-1/8 82-15/16 105-3/4 128-5/8 151-7/16
Maximum Connection Size (in) 8 8 14 14 14 12 12
Maximum Flow (gpm) 4755 4755 10471 10471 10471 9183 9183
Channel Volume Between Plates (gal) 1.162 1.479 0.88 1.334 1.788 2.243 2.695
Table 3 UX, SX, GF Series Plates

Plate Data\Models UXP-005 UXP-010 UXP-100 GFP-030* UXP-200* UXP-060*
Heat Transfer Surface Area (ft2.) 0.64 0.94 2.15 3.40 4.04 6.10
Plate Width (in) 8 8 11-13/16 16-3/4 16-1/2 24
Plate Length (in) 18-7/8 24-9/16 34-11/16 46-1/4 49-5/8 57-11/16
Maximum Flow (gpm) 265 265 520 1060 1060 3825
Table 3 UX, SX, GF Series Plates (cont.)

Plate Data\Models SXP-070 GFP-080* UXP-400* SXP-400 UXP-110* SXP-140 UXP-801
Heat Transfer Surface Area (ft2.) 7.24 7.60 8.20 9.70 11.80 13.69 18.30
Plate Width (in) 26-5/16 24-1/4 24 26-5/16 24 26-5/16 40-13/16
Plate Length (in) 56-5/8 68-3/8 69-11/16 68-3/4 89-13/16 88-9/16 89-1/4
Maximum Connection Size (in) 8 8 8 8 8 8 14
Maximum Flow (gpm) 4754 3450 3825 4754 3825 4754 11200
Channel Volume Between Plates (gal) 0.52 0.90 0.87 0.63 1.21 0.81 2.40
*External Hanger Required
7
Table 4 GF Series Wide Gap Plates
Plate Data\Models GFP-050 GFP-100 GFP-180
Heat Transfer Surface Area (ft 2.) 5.3 9.0 16.8
Plate Width (in) 27.75 27.75 27.75
Plate Length (in) 54 72 110
Max Connection Size (in) 8 8 8
Max Flow (gpm) 4755 4755 4755
Channel Volume (gal) Wide 2.36 3.23 5.08
Medium 2.00 2.61 3.92
Narrow 1.63 1.99 2.76
Table 5 GC Series Plates

Plate Data\Models GCP-010 GCP-026 GCP-028 GCP-051 GCP-060
2
Heat Transfer Surface Area (ft .) 1.46 2.80 0.86 5.81 5.92
Plate Width (in) 9.80 15.16 4.92 19.88 27.75
Plate Length (in) 29.50 37 29.33 53.27 47.12
Max Connection Size (in) 2 4 1 6 8
Max Flow (gpm) 292 1171 75 2324 4755
Channel Volume (gal) 0.1135 0.2642 0.040 0.55 0.783
Frame Dimensions
Table 6 Frame Dimensions, Inches
Model Height Width Connection Model Height Width Connection
Size (in) Size (in)
GXD-007 37 8-1/4 1 UXP-010 31 12 1, 2
GXD-012 39 14 2 UXP-100 45 17 2, 3
GXD-018 48 14 2 GFP-030 58 22 2, 3, 4
GXD-026 54 22 2, 4 UXP-200 62 24 2, 3, 4
GXD-042 71 22 2, 4 UXP-060 74 32 4, 6, 8
GXD-051 72 27 4, 6 SXP-070 71 36 4, 6, 8
GXD-037 60 27 4, 6 GFP-080 85 30 4, 6, 8
GXD-064 79 27 4, 6 UXP-400 85 32 4, 6, 8
GXD-091 98 27 4, 6 SXP-400 83 36 4, 6, 8
GXD-118 117 27 4, 6 UXP-110 106 32 4, 6, 8
GXD-060 69 38 4, 6, 8 SXP-140 103 36 4, 6, 8
GXD-100 92 38 4, 6, 8 UXP-801 105 54 10, 12, 14
GXD-140 115 38 4, 6, 8 GCP-010 38 13 1, 2
GXD-180 138 38 4, 6, 8 GCP-026 54 22 2, 3, 4
GXD-085 81 50 10, 12, 14 GCP-028 31 7 1
GXD-145 104 50 10, 12, 14 GCP-051 72 27 4, 6
GXD-205 127 50 10, 12, 14 GCP-060 69 38 4, 6, 8
GXD-265 149 50 10, 12, 14 GFP-050 71 35 4, 6, 8
GXD-325 172 50 10, 12, 14 GFP-100 88 35 4, 6, 8
UXP-005 24 12 1, 2 GFP-180 126 35 4, 6, 8
8
Plate Pack Widths
“A” DIMENSION FOR STANDARD THICKNESS MATERIALS
Calculating the “A” dimension (Plate Pack Width in Inches) for various SUPERCHANGER Models can be accom-
plished by using the formulas indicated in Table 7. N = Number of Plates.
Figure 7
Plate Thicknesses
PLA TEDESIGNA TION,p PLA TETHICKNESS,t
5 0.019685
6 0.023622
7 0.027559
8 0.031496
0 0.039370
N = Number of Plates
p = Plate Thickness Designation
t = Plate Thickness in Inches
Please contact Tranter PHE for the “A” Dimension when other Plate thicknesses are involved.
9
Plate Pack Tightening Dimensions
Table 7 Plate Pack Tightening Dimensions
Plate Type A Max* (inches) A Min* (inches)
UXP-005 (t + 0.102362) N (t + 0.094488) N
UXP-010 (t + 0.102362) N (t + 0.094488) N
UXP-100 (t + 0.0944) N (t + 0.0866) N
UXP-200 (t + 0.108268) N (t + 0.102362) N
UXP-060 (t + 0.141732) N (t + 0.133858) N
UXP-400 (t + 0.141732) N (t + 0.133858) N
UXP-110 (t + 0.141732) N (t + 0.133858) N
SXP-070, SXP-400, SXP-140 (t + 0.102362) N (t + 0.094488) N
UXP-801 (t + 0.181102) N (t + 0.173228) N
UXP-802 (t + 0.181102) N (t + 0.173228) N
GFP-030 (0.1881N) + 0.07874 (0.1767N) + 0.07874
GFP-080 (0.189013N) + 0.07874 (0.1796N) + 0.07874
GXD-007 (t + 0.10191) N (t + 0.09491) N
GXD-012, GXD-018 (t + 0.11321) N (t + 0.11021) N
GXD-026, GXD-042 (t + 0.13441) N (t + 0.12541) N
GXD-037, -064, -091, -118 (t + 0.11821) N (t + 0.11021) N
GXD-051 (t + 0.13441) N (t + 0.12541) N
GXD-060, -100, -140, -180 (t + 0.13441) N (t + 0.12541) N
GXD-085, -145, -205, -265, -325 (t + 0.13441) N (t + 0.12541) N
GFP-050, -100, -180 (t + 0.3202) N (t + 0.3025) N
GCP-010 (t + 0.1378) N (t + 0.1299) N
GCP-026 (t + 0.1633) N (t + 0.1523) N
GCP-051 (t + 0.1601) N (t + 0.1548) N
GCP-060 (t + 0.1790) N (t + 0.1676) N
*Applicable to units with elastomeric gaskets, round off to the nearest 1/32”. Units with teflon encapsulated
gaskets should be tightened to the “A Max.” formula.
CAUTION: On units operating in excess of 200 psig, the tightening dimension is to equal or approach the
minimum dimension.
The single digit of the model number given just before the frame designation indicates the plate thickness in
tenths of a millimeter . The only exception is the zer o (0) designation which indicates a 1.0 millimeter plate
thickness.
HOW TO USE TABLE 7:

EXAMPLE: Given a model UXP-100-L-6-MP-32, go to the chart showing Plate Designation and Plate
Thickness (page 9). The Plate Designation for a model UXP-100 is 6 and the corresponding Plate Thickness is
0.023622 inches. Now find the Plate T ype row showing UXP-100. The “A Max” dimension is calculated by:
(t+.0.0944)N = (0.023622+0.0944)32 = 3.78 inches. The “A Min” dimension is calculated in a similar manner .
Round off calculated number to nearest 1/32”.
10
Plate Material and Date of Manufacture Data
All plates are stamped with identification numbers. The numbers are located on both ends of the plates as
indicated in the sketches below . The heat number , material and month and year of manufactur e can be deter -
mined from these numbers.
Table 8 Plate Identification Number Nomenclature
GENERAL LOCATION DETAIL
Figure 8
Code stamping configurations
11
Plate Designations
Movable end
frame side
4
1
To and
from
Stationary end additional
A Side plates
frame side B Side
1
4
3 2
2
Items 1–4 indicate nozzle locations
Figure 9
Plate orientation for the UX, SX, GC and GF Series
“B” Plate SUPERCHANGER units are designed so that a fluid which enters the “A”
plate circuit (nozzles S1, S2, M1 or M2) always flows in the “A” circuit
only. Fluid which enters the “B” plate circuit (nozzles S3, S4, M3 or M4)
always flows in the “B” circuit only. Facing the stationary frame, the right
side is always the “A” side, while the left side is always the “B” side. The
“A” and “B” term refers to the gasket orientation. When looking at the
gasketed side of the plate an “A” plate becomes a “B” plate when reversed
(turned upside down). If the flow comes in and out on the left side it is a
“B” orientation.
NOTE: Every other plate has to be rotated 180° A-B-A-B in order to

prevent mixing. The first plate in the unit is called a “D” plate and has a
special gasket arrangement. This arrangement keeps the flow from
contacting the stationary frame. The last is called the “E” plate and is
gasketed normally.
Figure 10
“A” Plate Gasket orientation
12
Drawings
SUPERCHANGER units are custom designed for each application. A drawing is supplied with each unit depict-
ing all required dimensional data, equipment specifications, unit performance, nozzle locations and sequence of
plates in the heat exchanger. Most information contained on the drawing is self-explanatory. However, sections
illustrating the internal functions of a plate and frame heat exchanger are sometimes difficult to interpret. The
following is an aid for understanding the equipment.
Element Composition Diagram
Figure 11 shows an “S” frame (stationary member), “E” frame (moveable member), and plates of the plate heat
exchanger depicted in an element composition diagram. In an element composition diagram, “B” plates are
located at the upper part of the drawing and “A” plates are shown on the lower side.
A plate is indicated by the line centrally located within a rectangular compartment between the “S” and “E”
frames.
The designation of plate holes is written in the hole designation box formed by extending the vertical plate lines
above the center line for “B” plates and below the center line for “A” plates. The plate sequence number is
written in a box above and below the plate hole number, respectively, for “B” and “A” plates.
Plate location
symbol plate
B Side
Plate hole
designation
box
A Side
Plate
sequence no.
Figure 11
Element composition diagram
13
Plate Hole Designation for UX, SX, GC and GF Series
As shown in Figure 12, the pierced holes at the corners of the plate are designated as: 1 for upper right, 2 for
lower right, 3 for lower left, and 4 for upper left when facing the gasketed side of the plate. Plates 1 and 2 in
Figure 12 are represented as A1234 and B1234 respectively. Plates with all four holes pierced can also be
designated with a blank space or an *. Unpierced ports will be represented as a 0. For example, Plate 3 is
represented by a A1004 since there are no holes at position 2 and 3. Table 9 shows A & B equivalents when an
“A” plate is rotated to become a “B” plate.
Figure 12
Hole designations
NOTE: Flow
directors as related
to “A” and “B”
plates
Chevrons point up
on “A” plates and
down on “B” plates
Figure 13a Figure 13b

Correct gasket location Incorrect gasket location
Table 9 “A” and “B” Equivalents
Make sure the gaskets are installed
correctly in relation to the flow “A” Plate “B” Plate “A” Plate “B” Plate
directors. (See Figures 13a and 1234 1234 0204 0204
13b). 1034 1230 0034 1200
1204 0234 1200 0034
Porthole designations shown apply 0234 1204 0004 0200
to all units purchased after June 1, 1230 1034 1000 0030
2002. Refer to unit drawing or 1004 0230 0030 1000
previous IOM (SC-10M-9) for older 0230 1004 0200 0004
UX, SX, S, GF or TW Series. 1030 1030 0000 0000
14
PASS AND FLOW ARRANGEMENT
B Side
Flow Down
Plate
Flow Up
Plate
A Side
Figure 14a
Element composition diagram
*No number indicates that fluid passes through all four holes in the plate.
Plate Pass Arrangement

Positions 1 and 4, as shown above in Figure 14a, are upper connections, right and left respectively, and posi-
tions 2 and 3 are lower connections, right and left respectively. Each vertical line in between the “S” and “E”
members represents a heat transfer plate while the arrows show the directions of flow in the channels between
two plates and in the port holes.
The position of a plate hole is indicated by the intersection between a vertical line representing the plate and a
horizontal line indicating the flow direction and passage. Holes for passage of fluid flowing on the surface of a
“B” plate are always located on the left side (Holes 3 and 4), and holes for passage of liquid flowing on the
surface of an “A” plate are always found on the right side (Holes 1 and 2).
In the element composition diagram (Figure 14a), plate numbers are shown in boxes as:
1 D1004 (“A” side), 1034 2 (“B” side”).
“D” in D1004 represents the plate adjacent to the “S” frame. “D” also denotes that no fluid runs on the heating
surface.
A box with no port hole numbers, 11 , in Figure 14a means 11 1234 . This is done for simplicity as
most plates in a unit have four (4) holes.
15
Flow Arrangement
B Side
Q1
Q1
Q1/2
Q2
Q2
A Side
Q2/3
Figure 14b
Flow arrangement
*No Number indicates that fluid passes through all four holes in the plate.
Figure 14b shows the plate arrangement in which “B” Side is arranged in two parallel channels with three passes
in series and “A” Side is arranged in three parallel channels with two passes in series. In two parallel channels
with three passes in series, the fluid flow Q 1 flows on the heating sur faces of two plates separately (Q 1/2) and
gathers again in the port hole. This operation is repeated three times. In the case of three parallel channels, with
two passes in series, flow Q 2 similarly flows on the thr ee heating sur faces separately (Q 2/3), gathering once again
in the port hole.
The product of the number of channels in parallel, times the number of passes in series, is always equal or
different from each other by one plate when comparing “A” Side with “B” Side. The total number of plates can be
obtained by adding the number of “D” plates to the number gained by adding the products of “A” Side and “B”
Side. In Figure 14b (2 x 3) + (3 x 2) + 1 = 13.
Drains
There are three methods used for draining SUPERCHANGER units:
1. One pass/one pass (also two pass/two pass with all lower nozzles, but not shown) units can be drained by
opening the piping to the lower nozzles or by opening drain valves that can be provided in the field in the con-
necting piping. See Figure 15.
2. Multi-pass units may r equire factor y installed drains, i.e., an additional nozzle in the end frame. These must
be factory installed. See Figure 15.
3. If the number of passes is greater than four as in Figure 16 the above options require the addition of small
holes in plate corner sections as shown in Figure 17. The amount of by-pass through these holes is negligible
and there is no possibility of fluid intermix. These drain holes in the element composition diagram are noted
by , as the small hole is always placed in the corner without a passage hole. For example, 1204 is changed to
12 4 if a drain hole is present. The size and position of the drain hole is separately specified.
NOTE: On multipass units which are sized for a close temperature approach these drain holes are not provided
due to the small amount of bypassing that occurs. Check the drawing to determine whether drains are present.
16
Drains (cont.)
Plate sequence no.
B Side
A Side
Plate sequence no.
Factory installed Field supplied drain
drains through frame
Figure 15
One pass—one pass
Cannot drain out
Plate sequence no.
B Side
A Side
Plate sequence no.
Figure 16
Five-pass unit with 2 passes that are not drainable
Plate sequence no.
B Side
A Side
Plate sequence no.
Figure 17a
Five-pass with pass 3 and 4 as drainable (plates 8 and 9 have small drain holes)
17
Drain Small hole in Plates 8 and 9
Figure 17b
Showing first 12 of the 21 plates in Figure 17a with drains in plates 8 and 9.
Connecting “C” Frames

SUPERCHANGER units can be partitioned into multiple sections by employing the required number of connect-
ing “C” frames when more than one heat exchange operation is required. Connecting frames allow several
liquids to be processed at the same time or allow the same liquid to run through several stages of heat transfer.
The flow arrangement with use of a connecting frame is illustrated in Figure 18a isometrically and in Figure 18b
in an element composition diagram.
“C” Frame
Brine
Liquid Liquid
Water Brine
Water
Figure 18a
Connecting “C” Frame—flow diagram
“C” Frame
Plate sequence no.
B Side Liquid outlet

Liquid inlet
Water outlet A Side

Brine inlet
Plate sequence no.
Water inlet Brine outlet
Figure 18b
Connecting “C” Frame—element composition diagram
18
ULTRAFLEX (GX) Plate Design
Unlike all other SUPERCHANGER models, the GX series of plates is based on a diagonal flow pattern. On a
typical one-by-one pass unit, nozzle numbers 1 and 3 will be the hot inlet and hot outlet connections. Nozzle
numbers 2 and 4 are the cold inlet and cold outlet located lower right and upper left, respectively. Unlike other
plates, GX series can also be designed for parallel flow. The flow direction is always designated in the model
number by a “P” (parallel) or “D” (diagonal) after the letters “GX.”
Figure 19
ULTRAFLEX (GX) plate design
19
Plate Designations—ULTRAFLEX and WIDE GAP
ULTRAFLEX (GX) and WIDE GAP (GF) plates differ from conventional plates in another aspect. Because the
gasket groove lies in the plate’s neutral plane, additional configurations are possible with a given plate. This
feature allows the heat exchanger to be more precisely designed for each application.
Figure 20a Figure 20b

GX Type L Plate GX Type H Plate
Figure 20c
GF Type Plate
20
Drawings
The bottom left hand corner of each GF and GX unit drawing has a plate specification chart and plate arrange-
ment/assembly listing to assist in determining the proper sequence and orientation of the plates in the unit. You
will note that the gaskets used between the first and last plate of the plate pack and the respective frames are half
thickness.
Due to the number of combinations achievable with GX and GF technology, we have simplified the assembly
process by assigning a code letter to each corner of the plate. The plate is installed correctly when the letter is
readable from the upper right corner when facing the front of the unit.
The following examples will help you understand the plate designations:
ULTRAFLEX PLATE ASSEMBLY
PLATE NO. TYPE CODE GASKETS
1 H B Half Gasket Front

Even 2-140 H E Full Gasket Front, Upper RH & Lower LH Port
Odd 3-139 H B Full Gasket Front, Upper LH & Lower RH Port
141 H B Full Gasket Front, Upper LH & Lower RH Port
Half Gasket Back
WIDE GAP PLATE ASSEMBLY
In the Wide Gap (GF) series of plates, three different channel geometries can be created with each model: wide,
medium, or narrow. All units will be wide-narrow, narrow-wide, or medium-medium configuration. The code
letter in the top right hand corner of the plates is used to create the various channel geometries as shown below.
GAP FLOW ON SIDE CODE

Wide A R+L
Wide B S+K
Medium A K + L or R + S
Medium B L + K or S + R
Narrow A K+S
Narrow B L+R
21
Four Plate Sequence—ULTRAFLEX
In some instances, the arrangement in a GX model will follow a repeating four plate sequence. An example is
shown below:
PLATE ASSEMBLY
Plate 1 Type H Code B Half gasket front
Even plates 2 through 206 Type L Code R, Full gasket front, Upper RH & Lower LH port
Odd plates 3 through 207 Type H Code B, Full gasket front, Upper LH & Lower RH port
Even plates 208 through 268 Type L Code S.R, Full gasket front, Upper RH & Lower LH port
Odd plates 209 through 267 Type H Code C.B, Full gasket front, Upper LH & Lower RH port
Plate 269 Type H Code C, Full gasket front, Upper LH & Lower RH port, Half gasket back
In the example above, Even plate Code S.R means Plate 208 will be Code S and Plate 210 will be Code R; Odd
Plate 209 will be Code C and Plate 211 will be Code B;
Plate 212 is Code S and the four plate sequence continues as shown below:
Plate 208 S
209 C
210 R
211 B
212 S
213 C
214 R
215 B
Figure 22
Four plate
ULTRAFLEX
sequence
Plate 208 Plate 209 Plate 210 Plate 211
Multi-Pass Units
Here is an example of plate arrangement and specifications for a multi-pass unit:
PLATE ASSEMBLY
Plate 1 Type H Code B Half gasket front, Ports 2, 3
Even Plates 2 through 24 Type L Code R, Full gasket front, Upper RH & Lower LH port
Odd Plates 3 through 23 Type H Code B, Full gasket front, Upper LH & Lower RH port
Plate 25 turning plate, Type H Code B, Full gasket front, Upper LH & Lower RH port, ports 1, 4
Even Plates 26 through 48 Type L Code R, Full gasket front, Upper RH & Lower LH port
Odd Plates 27 through 47 Type H Code B, Full gasket front, Upper LH & Lower RH port
Plate 49 Type H Code B, Full gasket front, Upper LH & Lower RH port, Half gasket back, Ports 2, 3
22
GASKET DATA
Table 10 Temperature Ratings
Gasket Material Max. Temp. Gasket Material Max. Temp.

EPDM (Industrial Grade and Partial 366°F NBR (Full FDA Approved) 270°F
FDA Approved)
EPDM (Full FDA Approved) 300°F Neoprene (CR) 255°F
Hypalon (CSM) 158°F Fluoroelastomer A, G, GF 350°F
Teflon Encapsulated NBR* 270°F Fluoroelastomer B 320°F

NBR (Industrial Grade and Partial 270°F Hydrogenated NBR 302°F
FDA Approved)
*This gasket requires the use of .8mm (.032”) thick plate and a special double side tape instead of Pliobond. DO NOT OVER
TIGHTEN!
The above temperatures are the maximum allowable regardless of applications. In some cases, the upper limit
may be lower depending on the fluids being handled and on the unit design pressure.
Gaskets—Glued
Each plate has a molded one piece boundary gasket
which is glued into the continuous gasket groove in
each plate. The liquid flowing on the surface of each
plate flows on the inside of each boundary gasket.
Every port hole gasket contains four bleed passages.

(See Figure 23a). If one of the liquids should leak
beyond a boundary gasket, it will flow to the outside of
the unit, thus preventing any possible intermix. (See
Figures 23b and 23c). Figure 23b
Flow to exterior from damaged boundary gasket
Bleed ports typical
four places
Gasket code
number
Gasket Plate
Figure 23a Figure 23c
Four bleed passages Flow to exterior from damaged boundary gasket
23
Gaskets—Glueless
Functionally, Tranter’s patented SUPERLOCK glueless gaskets perform in the same manner as glued gaskets (see
Figures 23a, 23b, and 23c). SUPERLOCK’s unique lock-in design allows simple installation and removal without
glue. The gasket has tabs which press easily into the holes in the plate. Please note that the differences between
glueless gasket plate assemblies and glued gasket plate assemblies do not allow for the use of a glued gasket on
a SUPERLOCK style plate. The use of a glueless gasket on a plate requiring a glued gasket is also incorrect.
(NOTE: the D, E, and any special turning plates will be standard spot-glued gasketed.) The SUPERLOCK design is
indicated by replacing the “X” in the model number with an “M” for a mechanically attached gasket. It is available
in the following models: UMP-005, UMP-010, UMP-060, UMP-200, UMP-400, GMP-026 and GM-010.
Gasket Storage Procedures

When SUPERCHANGER heat exchanger plate gaskets are maintained as spare parts, it is important that certain
storage procedures be followed to assure that the elastomeric compounds making-up the gaskets do not deterio-
rate and the useful life of the gaskets is preserved.
1. Store in an area where the temperature does not exceed 70°F. The ideal storage temperature is 60°F. NEVER
STORE IN AN AREA WHERE THE TEMPERATURE MAY FALL TO OR BELOW 32°F.
2. Maintain a maximum of 70% relative humidity.
3. Store in a darkened room. Ultraviolet light must be avoided.
4. Store gaskets so they are free from tension. Do not store in a stretched or severely bent condition.
5. All potential sources of Ozone, such as operating electric motors, or welding equipment, must be removed
from the storage area.
6. Organic solvents, acids, etc. must not be kept in the storage area.
7. Do not store near heating system radiators.
8. Cover or keep the gaskets in bags or boxes to minimize exposure to air circulation.
9. Keep gaskets free from dust and particulates.
Mixed Gasket Materials

Most SUPERCHANGER units are equipped with gaskets made of one material. However, there are two condi-
tions that dictate the use of different material on a plate.
The first is gasket/fluid compatibility. In this case, one material is not suitable for both fluids in the heat ex-
changer. An example is heating quench oil with 285°F steam. Quench oil dictates the use of nitrile rubber
gaskets, while steam temperature requires EPDM gaskets.
24
Mixed Gasket Materials (cont.)
The second reason for using two gasket materials on a single plate is cost. This is encountered when an expen-
sive material (usually viton) is required on only one side of the SUPERCHANGER unit. A significant savings can
be realized by using a less expensive gasket material on the other side.
As an example: cooling 180°F sulfuric acid with tower water requires viton on the acid side, but nitrile is suffi-
cient on the water side.
Each plate has contact with both fluids in a SUPERCHANGER unit. One fluid travels across the plate while the
other fluid passes through the gasketed port holes. In a mixed gasket unit, each plate will have two materials.
The fluid traveling across the “A” plate requires gasket material 1. The fluid on the “B” plate requires gasket
material 2.
In the case of a UX, SX, GF or GC series model, the “A” plate will have material 1 on the perimeter while port
holes 3 and 4 are material 2. The “B” plate will have material 2 on the perimeter with port holes 1 and 2 of
material 1. GX models with mixed gaskets would be similar. However, flow is diagonal so diagonally opposed
ports would have the same gasket material.
All SUPERCHANGER gaskets are purchased as one piece-molded items. To physically accomplish mixing
gaskets on a plate, the port holes are cut from both gaskets. Subsequently, the port holes of material 1 are
matched with the perimeter of material 2 and vice versa. See Figure 24.
The following illustrates the above in a typical UX Series Plate.
= Gasket Material 1
= Gasket Material 2
Fluid on “A” Plate uses port “A” Plate “B” Plate
holes 1 and 2.
Fluid on “B” Plate uses port

holes 3 and 4.
NOTE: Chevron orientation as related to

“A” & B” Plates.
Porthole designations shown apply to all units pur

-
chased after June 1, 2002. Refer to unit drawing or
previous IOM (SC-IOM-9) for older UX, SX, S, GC or TW Figure 24
series. Multiple gasket materials on a UX Series plate
25
INSTALLATION
Unpacking
SUPERCHANGER units (with optional shroud) are bolted to and shipped assembled on a skid. Other optional
items, if supplied, are packed separately. All items should be checked against packing lists. SHOULD ANY
PARTS BE MISSING OR DAMAGED, NOTIFY TRANTER PHE, INC., P O Box 2289, Wichita Falls, Texas 76307,
Phone: (940) 723-7125, IMMEDIATELY.
Recommended Procedures
All frame models are provided with special lifting eyeholes for transportation and installation by crane. Rigidly
set all models on the floor by means of foundation bolts. The following installation tips are also recommended:
1. Level the unit.
2. Locate the unit in an area that is not congested with piping and other equipment. For units with nozzles on
the movable frame, refer to Figures 25a & 25b, on page 27.
3. Provide three feet of working area around the unit.
4. The piping system must allow for thermal expansion. This can be accomplished inherently within the piping
layout or by flexible connections.
5. Debris can cause damage to the gaskets. The gasket areas must be free from sand, gravel, pieces of iron,
etc. before the unit is closed.
6. Lubricate the tie bolts.
7. Tighten all tie rod nuts. Tighten the unit to plate pack dimension per assembly drawings prior to making any
assembly connections.
8. Uniformly tighten the plate pack. (See tightening instructions following.)
9. Flush connecting piping of all debris prior to “hook-up” with the heat exchanger.
10. Correctly center gaskets inserted between pipe flanges.
11. Do not apply valve and piping loads to the nozzles. Use pipe supports.
12. Install shutoff valves at all nozzle locations.
13. Place vent valves for draining at the highest possible point.
14. Provide pumps sending liquid into the SUPERCHANGER with throttling valves.
15. Install a safety relief valve if the maximum pressure output of the pump is greater than that of the heat
exchanger.
16. When a pressure control valve is installed, place it at the inlet of the heat exchanger, even if a pressure
control switch is provided.
26
Recommended Procedures (cont.)
CAUTION: Do not expose plate and frame heat exchangers to continuous vibration and/or high frequency cyclic
on/off operation since damage from fatigue may occur. Do not use metering and pulsating type pumps. If the
SUPERCHANGER unit is used in cyclic operation, the equipment should be tightened to the minimum dimension
(see Table 7) to prevent fretting failure. Contact the factory for assistance.
Tightening the Plate Pack

The plate pack tightening length (distance between the facing surfaces of the “S” and “E” frames) is given on the
assembly drawing and on the unit data plate. The tightening dimension is identified as A Max and A Min. The
unit is normally tightened at the factory to the average dimension between A Max and A Min. A Min is a mini-
mum length. Consult the SUPERCHANGER Engineering Department before tightening the unit to a smaller
dimension. CAUTION: On units operating in excess of 200 psig, the tightening dimension is to equal or
approach the minimum dimension. The wrench size required for the various SUPERCHANGER tightening bolt
diameters is shown below. Refer to the SUPERCHANGER drawing for the actual bolt diameter.
BOLT DIAMETER WRENCH SIZE (Across Flats)

3/4” 1 1/4”
1” 1 5/8”
1 1/4” 2”
1 1/2” 2 3/8”
1 3/4” 2 3/4”
2” 3 1/8”
2 1/4” 3 1/2”
2 1/2” 3 7/8”
Due to manufacturing tolerances, a unit is sometimes shipped with a plate pack dimension greater than the
minimum dimension stated on the drawing. If leakage occurs, after a period of time, tighten the unit to the
minimum length. If the plate pack length is shorter than the minimum length, damage to the plates at contact
points may result. If leakage occurs at the minimum length, contact the SUPERCHANGER Engineering Depart-
ment for recommendations regarding gasket replacement or additional tightening.
The end frame is

immovable with
this piping
arrangement
Figure 25a
Correct piping installation—disconnecting Figure 25b
A and B connections will permit Incorrect piping installation—the end frame is immovable
movement of the end frame (top view) (side view)
27
Tightening Sequence
WARNING: DO NOT TIGHTEN THE PLATE HEAT EXCHANGER WHEN IT IS HOLDING LIQUID, UNDER PRES-
SURE OR OPERATING. RUPTURE OF THE GASKETS AND EXPOSURE TO PHYSICAL INJURY MAY OCCUR.
ALWAYS COOL AND DRAIN THE HEAT EXCHANGER BEFORE TIGHTENING. Figure 26a gives the tightening
sequence for all units. When facing the stationary frame, tighten using the 1, 2, 3, and 4 bolts in sequence as far
as possible before installing the remaining bolts. Be careful to tighten uniformly so that the moveable frame is
kept parallel with the fixed frame within 1/4”. Check the plate pack length on both sides of the plate pack at all
tightening bolt locations. Tighten the unit, according to this procedure, to the plate pack dimension stated on the
assembly drawing or unit data plate. Measure the dimension with a metal tape and tighten all bolts within 1/32”
of the “A” dimension. (See Table 7).
4 bolt unit 6 bolt unit 8 bolt unit 10 bolt unit 12 bolt unit 14 bolt unit 16 bolt unit
Figure 26a
Tightening sequence for all units
START-UP PROCEDURES
Precautions Prior to Start-Up
1. Before connecting the unit to the system, all piping must be cleaned to prevent entrance of
gravel, sand, welding flux, etc. into the plate assembly. Damage to the plates and gaskets could
result if the unit is contaminated with solid matter.
2. Confirm that the plate pack length is correct.
3. Open all outlet valves completely.
4. Completely close the pump discharge valves to the heat exchanger.
5. Provide venting on both sides of the heat exchanger to facilitate the removal of air from the system.
6. Start pumps and increase the pressure by opening the pump discharge valve slowly.
7. When all air is out, liquid will flow out of the vent. Close the vent.
8. Slowly and simultaneously open the inlet valves for both fluids to avoid extreme over-
pressure due to hydraulic shock.
9. Control the amount of heating or cooling by using throttling valves and product thermometers in
conjunction.
28
Precautions Prior to Start-Up (cont.)
CAUTION: To reduce the possibility of water hammer, do not use fast opening and closing valves. The pressure
surge caused by a sudden change in the fluid velocity can be several times higher than the normal operating
pressure of the system.
SERVICING
Shutting Down the Unit
1. GRADUALLY DECREASE THE PRESSURE OF BOTH FLUIDS SIMULTANEOUSLY UNTIL ALL PRESSURE IS
RELIEVED.
2. NEVER OPEN A SUPERCHANGER UNIT WHEN IT IS HOT. COOL THE UNIT TO A WARM TEMPERATURE
BEFORE OPENING TO PREVENT PERSONAL INJURY AND GASKET LOOSENING.
3. COMPLETELY DRAIN FLUIDS FROM THE UNIT.
Disassembly Procedures
To open the exchanger, it is necessary to disconnect all connections (if any) to the “E” moveable frame. Lubri-
cate all bolts prior to disassembly. Then completely loosen and remove all bolts except those indicated by a
“filled circle” in the sketch below for the size unit involved. The four (4) remaining bolts can then be loosened in
any left-right sequence at 1/4” increments until they can be lifted out.
4 bolt unit 6 bolt unit 8 bolt unit 10 bolt unit 12 bolt unit 14 bolt unit 16 bolt unit
Figure 26b
Loosening Sequence
29
Removal of Plates
CAUTION: Exercise care when handling plates: the edges are sharp. Leather gloves must be worn.
1. Remove the plates one by one from the frame.

2. Clean and/or inspect the plates hanging in the frame by removing them one at a time.
3. To remove a plate from the frame:
(a) For UXP-005, UXP-010, UXP-100, SXP-070, SXP-400, SXP-140, GC, GX and GFP-050, GFP-100 and
GFP-150 series, tilt the plate and remove it.
(b) GFP-030, GFP-080, UXP-200, UXP-060, UXP-400 and UXP-110 series lift the plate, push down on the
hanger to release it, tilt the plate and remove it.
(c) UXP-801 and UXP-802 series remove the sectional guide bar track which is bolted into the bottom of
the upper I beam near the moveable end. Tilt the plate and remove them one at a time. (There are three of
the removable track sections along the guide bar length to facilitate plate removal.)
Replacing Plates
A faulty plate can easily be removed and replaced by a spare plate. Check that the new plate has the holes and
gaskets arranged in the same way as the faulty one, and that the hangers are arranged in the same direction as
the original installation. When the plates are properly assembled, the edges form a “honeycomb” configuration
as seen in Figure 26c.
Correct Incorrect
Figure 26c
Plate assembly
If a 4-hole plate is defective and no spare plate is available, the defective plate and one adjacent 4-hole
plate can be removed. The capacity of the plate heat exchanger is then reduced, but usually only slightly. When
plates are removed calculate new “A” tightening dimensions from Table 7.
30
Replacing Gaskets
See Figures 3, 4, 5, 6, & 24
Removing Old Gaskets

When a gasket requires replacement, steps A1, A2, and A3 may be followed or alternately steps B1, B2, and B3
may be used if facilities are available.
A1. Remove the plate from the frame and lay it on a clean, flat, horizontal surface. Examine and note exactly
how the gasket is positioned on the plate, particularly what grooves the gasket does and does not occupy.
A2. Insert a pointed tool (screw driver) under the gasket until a finger can be inserted. Then pull slowly until the
gasket is removed.
A3. Clean the gasket groove. Adhesive residue, oil, grease and other foreign matter can be removed by applying
a solvent such as Methyl Ethyl Ketone (MEK), Acetone, or other Ketones with a nylon or stainless steel
brush. Commercial paint stripping compounds are also effective in removing the gasket adhesive. Dry/wipe
the gasket groove. (NOTE: Use all solvents at room temperature and in a well ventilated area not exposed to
open flame, electric motors, etc.). Torches, grinding wheels and powered steel wire brushes are not to be
used to remove adhesive residue since such tools will damage the plates.
B1. When a gasket requires replacement, remove the plate from the frame and lay it on a clean, flat, horizontal
surface. Examine and note exactly how the gasket is positioned on the plate, the orientation of the bleed
grooves, and particularly what grooves the gasket occupies.
B2. For gasket removal immerse the plate assemblies in a 10% to 15% caustic bath solution at 140°F to 180°F
for approximately 8 hours. The caustic will soften the glue and the gaskets can be removed. Brushing with
a nylon brush will help remove the softened residual glue. (NOTE: Soak time will vary depending on the type
of service and the length of exposure that the plates have seen.)
B3. The caustic solution will normally remove most of the residue scale buildup on the heat transfer surface.
Brushing with a nylon brush will help remove excess residue. Always rinse thoroughly.
To remove spot-glued gaskets, follow steps A1, A2, and if necessary, step A3.
Remove scale deposits, such as calcium compounds, by immersing the plates in a 5% to 10% nitric acid
solution at room temperature. This procedure must be followed by a thorough rinsing. See the section on
“Plate Cleaning Tips”, discussed later.
31
Installing Continuously Glued Gaskets
1. Make sure the gasket groove area is clean and dry prior to regasketing.
2. Apply a uniform layer of adhesive in the appropriate gasket grooves. (A plastic bottle makes an ideal
applicator, provided the tip of the applicator is designed to provide a bead that is approximately 1/8” wide.)
Do not apply adhesive in amounts that will allow it to ooze out when the gasket is pressed into the groove.
Apply adhesive at room temperature. After the glue is applied to the plate, it should be allowed to set for a
minimum of 30 seconds before the gasket is set in place. Work on pairs of plates to allow for this curing
time.
The recommended adhesive for all elastomeric gaskets is Pliobond 30. Pliobond 20, Henkel 4330, and Silaprene
6249 can also be used, if Pliobond 30 is not available. Hardening adhesives are not to be used. The number of
gaskets which can be glued from one pint bottle of Pliobond 30 glue may be approximated as follows:
Table 11 Glue Requirements
Model Number of Gaskets/Pint Model Number of Gaskets/Pint
UXP-005 122 GXD-037 30
UXP-010 100 GXD-064 18
UXP-100 85 GXD-091 15
UXP-200 60 GXD-118 13
GFP-030 50 GXD-060, GCP-060 20
UXP-060, SXP-070 35 GXD-100 18
UXP-400 30 GXD-140 14
UXP-110 30 GXD-180 15
SXP-400, SXP-140 30 GXD-085 16
GFP-080 25 GXD-145 14
UXP-801, UXP-802 10 GXD-205 12
GXD-006 50 GXD-265 10
GXD-012 50 GXD-325 8
GXD-018, GCP-010 35 GFP-050 19
GXD-026, GCP-026 30 GFP-100 18
GXD-042 20 GFP-180 15
GXD-051, GCP-051 17
32
Installing Continuously Glued Gaskets (cont.)
3. Position the gasket on the plate making sure that the recess in the gasket at the bleed passage location is
up. Also, when the proper side is up, the gasket code number will be visible in the bleed passage area. Proper
groove fit and flow diverter access is dependent on end-to-end positioning. (See Figures 13a and 23a).
4. Using finger pressure, firmly press the gasket into the same grooves from which the original gasket was
removed.
5. Compress the gasket by placing the plate under a weighted sheet of wood. The longer the compression
time, the better the bond. Twelve (12) hours cure time at room temperature (70°F) should be allowed to
assure minimum required adhesion of the gasket to the plate for all elastomers except EPDM. EPDM
gaskets require a minimum of twenty-four (24) hours cure time at room temperature (70°F) to assure an
adequate bond. (When several plates are being gasketed, they can be stacked on top of each other with the
weighted wood sheet placed on the top plate of the stack.)
6. After compression time (step 5), use solvent to remove any excess adhesive that may have seeped out past
the edges of the gasket.
7. Reinstall plate(s) in the unit insuring that the gasket surface and the sealing surface of the plate ahead are
wiped clean to provide a positive seal.
8. Note that the “D” plate (always the plate next to the fixed frame end) requires different gaskets. The purpose
of the “D” plate is to prevent fluid from flowing across the fixed end frame. The only sealing surface on the
“D” plate is the port hole gaskets. “D” plate gaskets for the UX series consist of two half gaskets.
“D” plate gaskets for the GFP-030 and GFP-080 plates consist of four (4) port hole gaskets and straight strips
which fit in the gasket groove around the periphery of the plate. The wide port gasket fits the widest groove and
the narrow port hole gasket fits the narrow groove.
NOTE: Refer to page 24 when using mixed gaskets.
Installing Spot-Glued Gaskets

Spot gluing of Elastomeric gaskets is cover
ed under Tranter’s U.S. Patent #5070939.
In the following procedure, after the glue is applied to the plate at the appropriate spots, allow it to set for a
minimum of 30 seconds before the gasket is mounted. Work on pairs of plates to allow for this curing time.
Work in a well-ventilated area.
1. Clean the gasket groove in one plate with a rag moistened with Methyl Ethyl Ketone (MEK).
33
Installing Spot-Glued Gaskets (cont.)
2. Apply a 1/8” diameter spot of Pliobond 30 approximately every 4 inches centered in the gasket groove of the
plate just cleaned.
a) Apply the glue so there are no thin spots.

b) Apply spots of glue at the “T” joints (see Figure 26d).
3. Clean the groove of a second plate, as in Step 1.
4. Apply adhesive to the second plate, as in Step 2.
5. Install the gasket on the first plate. Make sure the gasket is oriented as shown in Figures 13a and 23a.
6. Install the gasket on the second plate, as in Step 5.
NOTE: The purpose of working with two plates simultaneously is to allow the adhesive to set for a minimum of
30 seconds before the gasket is applied. When working with small plates, a third plate can be incorporated
into the above procedure to obtain set time. The curing time must not exceed 3 minutes.
7. Compress the gasket by placing the plate under a weighted sheet of wood. The longer the compression
time, the better the bond. Twelve (12) hours cure time at room temperature (70°F) should be allowed to
assure maximum adhesion of the gasket to the plate for all elastomers except EPDM. EPDM gaskets require
a minimum of twenty-four (24) hours cure time at room temperature (70°F) to assure an adequate bond.
(When several plates are being gasketed, they can be stacked on top of each other with the weighted wood
sheet placed on the top plate of the stack.)
8. After adequate compression time, use solvent to remove any excess adhesive that may have seeped-out past
the edges of the gasket.
9. Reinstall plate(s) in unit insuring that the gasket surface and the sealing surface of the plate ahead are wiped
clean to provide a positive seal.
34
Circled
areas show
the 14 “T”
joints
Figure 26d
Locations at “T” joints where
glue must be applied
Installing SUPERLOCK® Snap-In Gaskets
SUPERLOCK gaskets are covered under Tranter’s U.S. Patent #4995455.
1. Position the gasket on the plate making sure that the recess in the gasket at the bleed passage location
is up. When the proper side is up, the gasket code number will be visible in the bleed passage area. Correct
end-to-end position is also important for a proper groove fit and fluid access to the flow diverter. (See
Figures 13a & 23a.)
2. Make sure that the tabs of the SUPERLOCK gaskets are lined up with the slots in the gasket groove of the
plate.
3. Insert each tab inside its corresponding slot and push firmly until the tab locks into the slot. Make sure that
each of the porthole tabs (located in the bleed port area towards the middle of the plate) is also snapped into
its slot.
NOTE: Refer to page 24 when using mixed plates.
Installing Teflon Encapsulated Gaskets and Unit Assembly

CAUTION: On units operating in excess of 200 psig, the tightening dimension is to equal or approach the
minimum dimension.
1. Install double-sided tape in the center of the gasket groove. Use continuous strips. Do not contaminate the
tape surface.
2. Do not overlap tape strips as this will cause leakage in that area.
3. Install Teflon such that bleed ports (notches) in each section in rubber core are installed in the up position.
35
Installing Teflon Encapsulated Gaskets and Unit Assembly (cont.)
4. Install plates per the assembly drawing that is received with the unit.
5. Check top surface of Teflon and gasket seal surface for cleanliness.
6. Install all bolts and tighten the unit (snug tight only).
7. Refer to page 28 for tightening sequence.
8. Tighten unit in 1/16” increments to ensure even compression of gaskets.
9. Tighten to maximum dimension as shown on assembly drawing.
10. Single side hydrostatic test to design pressure shown on assembly drawing.
11. Double side hydrostatic test to test pressure shown on assembly drawing.
12. If unit leaks during either of the above tests, run 150°F - 170°F hot water for one (1) hour. Let the unit cool
and tighten to average dimension as shown on assembly drawing using same increments as in step 8.
13. Re-conduct the hydrostatic test.
14. If unit still leaks, mark plate and area of leakage.
15. Disassemble unit and check gasket and seal surface for defects, especially at the leakage sites. If no appar-
ent defect is found, apply an even thin layer of “Teflon TFE Pipe Thread Sealer” furnished by McMaster Carr
(www.mcmaster.com, part #4538K1), to teflon gasket at leakage site.
16. Retighten unit using same procedure as listed above.
17. Re-conduct the hydrostatic test.
18. Unit should not seal. If unit is still leaking, contact the factory.
CLEANING
SUPERCHANGER plate and frame type heat exchangers are designed for both manual cleaning and cleaning-in-
place operations. Where possible, utilize a cleaning-in-place system which will allow pumping water or cleaning
solutions into the unit without disassembling. A CIP system may be purchased through Tranter PHE, Inc. If this
is not feasible, use the manual method. Descriptions of the two cleaning procedures follow.
36
Steps for Manual Cleaning of Plates
1. Open the unit in accordance with disassembly procedures on page 29.
2. Clean each plate separately. Depending upon the amount of cleaning to be performed, the plate can be
cleaned while still hanging in the unit or removed, placed on a flat surface and cleaned.
3. NEVER USE A STEEL BRUSH OR STEEL WOOL ON THE PLATES. If a brush is required, use one with
bristles that are softer than the plate material. If iron is forcibly rubbed on a stainless steel surface, it is
impossible to remove all imbedded particles and will result in accelerated rusting and/or corrosion. If it is
absolutely necessary that a metal brush be used, the brush material must be compatible with the plate
material.
4. Be careful not to scratch the gasket surfaces.
5. After brushing, each plate should be rinsed with clean water.
6. Use high pressure rinse when cleaning continuously glued plate assemblies.
7. See “Plate Cleaning Tips” on page 38 for specific types of deposits.
8. THE GASKETS MUST BE WIPED DRY WITH A CLOTH. Solid particles adhering to the gaskets cause damage
and result in leakage when the unit is put back in operation.
9. The lower portion of each plate as hung in the unit should be inspected carefully and cleaned appropriately
as this is the primary area where residual solid material tends to accumulate.
10. Wipe off the mating surface, i.e.; the rear of the plate where the gasket seats.
11. Upon completing the cleaning, inspection and installation of each plate, the unit may be closed, tightened per
the assembly drawing and the tightening instructions (page 28), and placed into operation.
CAUTION: Do not use chlorine or chlorinated water to clean stainless steel, Hastelloy , Incolloy , Inconel and
254SMO. Chlorine is commonly used to inhibit bacteria growth in cooling water systems. It reduces the corro-
sion resistance of stainless steel, Hastelloy , Incolloy , Inconel and 254SMO. The “pr otection layer” of these steels
is weakened by chlorine and makes them more susceptible to corrosion. This increase in susceptibility to
corrosion is a function of time and the chlorine concentration. For any applications where chlorination must be
used with non-titanium equipment, please contact the factor y.
37
PLATE CLEANING TIPS
1. Do not use hydrochloric acids, or water containing in excess of 300 ppm chlorides, with stainless steel.
2. Do not use phosphoric or sulfamic acid for cleaning titanium plates.
3. Limit cleaning solution concentration to 4% in strength, with temperatures not exceeding 140°F unless
otherwise specified.
General guidelines for cleaning are tabulated below. (Please refer to notes (1) through (3) above for precau-
tions.)
Type of Fouling Suggested Cleaners
Calcium Sulphate, Silicates Citric, Nitric, Phosphoric or Sulfamic Acid
Calcium Carbonate 10% Nitric Acid (1 volume concentrated Nitric Acid

with specific gravity 1.41 to 9 volumes of water),
Oakite 131
Alumina, Metal Oxides, Silt Citric, Nitric, Phosphoric, or Sulfamic Acid. (T o

improve cleaning add detergent to acid.)
Barnacles, Mussels, Seaweed, Back flush per cleaning-in-place procedure on page 39,
Wood Chips Figure 27
Biological Growth Sodium carbonate or sodium hydroxide
Cleaning-In-Place (CIP)
Cleaning-in-place is the preferred cleaning method when especially corrosive liquids are processed in a
SUPERCHANGER unit. Install drain piping to avoid corrosion of the plates due to residual liquids left in the unit
after an operation cycle. (See Figure 27).
To prepare the unit for cleaning, follow the procedures listed below:
1. Drain both sides of the unit. If it is not possible to drain, force liquids out of the unit with flush water.
2. Flush the unit on both sides with warm water at approximately 110°F until the effluent water is clear and free
of the process fluid.
3. Drain the flush water from the unit and connect CIP pump. (See “Plate Cleaning Tips” above for suggested
cleaners.)
38
Cleaning-In-Place (cont.)
4. For thorough cleaning it is necessary to flow CIP solution bottom to top to insure wetting of all
surfaces with cleaning solution. When cleaning multiple pass units it will be necessary to reverse flow for at
least 1/2 the cleaning time to wet all surfaces.
5. For optimum cleaning, use the maximum flow rate of water, rinse, or CIP solution that the CIP nozzle size
will allow (2” @ 260 GPM, 1” @ 67 GPM.) A CIP operation will be most effective if performed on a regularly
scheduled basis and before the unit is completely fouled.
6. Flush thoroughly with clean water after CIP cleaning.
IF BRINE IS USED AS A COOLING MEDIUM, COMPLETELY DRAIN THE FLUID FROM THE UNIT AND FLUSH THE
UNIT WITH COLD WATER PRIOR TO ANY CLEANING OPERATION. CORROSION WILL BE KEPT AT A MINIMUM
IF ALL TRACES OF BRINE ARE ELIMINATED BEFORE USING HOT CIP SOLUTIONS ON EITHER SIDE OF THE
HEAT EXCHANGER.
Figure 27
Cleaning-in-place
flow chart
Figure 28
Piping using brine (top view)
39
Back Flushing and Strainers
Often, when fibers or large particulates are present, back flushing of the unit proves to be very beneficial. This
is accomplished by either of the following methods:
1. Flush the unit with clean water in reverse flow pattern to the normal operating direction.
2. Arrange piping and valves so the unit may be operated in reverse flow mode on the product side for fixed
periods of time. This method is particularly well suited for steam-to-product units.
3. The use of strainers are recommended in supply lines ahead of the exchanger when the streams contain
significant solids or fibers. This will reduce the requirements for back flushing.
Cleaning Guidelines
1. Never open the unit when hot, under pressure, holding liquid or operating.
2. Never clean the plates with a steel brush or steel wool.
3. Always wipe the gaskets clean before closing the unit to prevent damage resulting
from adhering particulate matter.
4. Always use clean water (free from salt, sulphur, chlorine or high iron concentrations) for flushing and
rinsing operations.
5. If steam is used as a sterilizing medium, do not exceed 270°F steam temperature with nitrile gaskets, and
350°F with EPDM gaskets.
6. If chlorinated solutions are used as the cleaning media, employ a minimum concentration at the lowest
temperature possible. Minimize the plate exposure time. The chlorine concentration must be less than 100
PPM and temperatures must be under 100°F with a maximum plate exposure time of 10 minutes. Follow the
cleaning recommendations of suppliers, relative to concentration, temperature and treatment time.
7. Always add concentrated cleaning solutions to water before circulating through the unit. Never inject these
solutions while the water is circulating.
8. Remove rusted or pitted areas that appear on the plates with commercial scouring powder. Follow this by
flushing with clean water.
9. Cleaning solutions should always be circulated with a centrifugal pump.
10. Do not use hydrochloric (muriatic) acid for cleaning plates.
11. Thoroughly rinse the plates with clean water following any type of chemical cleaning.
40
TROUBLE-SHOOTING
Figure 29
Trouble-shooting sources of leaks
41
Leakage Between the Plate Pack and the Frame
(See Figure 29, Item 1)
PROCEDURES AND OBSERVATIONS SOLUTIONS
1. Use a felt tip marker to identify the area where the

leakage seems to be occurring and then open the plate
pack.
2. If the leakage occurs in the area of a nozzle, then Remove all foreign matter, relocate the gasket, or
observe the gasket condition of the “D” plate or “E” replace the damaged gasket.
nozzle “O” ring. Foreign matter, scars, other damage
to the gasket surfaces, and any gasket dislocation may
be the problem.
3. Check the end frame for foreign objects, surface Remove any interference between the gasket and the
unevenness, or any other condition which might surface of the end frame.
interfere with the seal between the gasket and the
adjacent surface.
4. Check the plate for cracks or holes. If a plate has perforation, it must be replaced.
Leakage Between the Nozzle and the End Frame

1. Fluid is flowing from the area between the nozzle Check the integrity of the continuous pressure weld
and the end frame (point A on Figure 30) and/or the between the stub end and the seal point (point C on
interior of the end frame and the seal plate (point B Figure 30). Dye-check for small cracks. If the dye-
on Figure 30). check reveals any linear indication, the area needs to
be ground down and re-welded using TIG welding, and
A B the appropriate welding wire. If the weld damage
occurred due to a blow to the nozzle, some of the plate
assemblies may be damaged. Damaged plates should
be replaced.
Figure 30
Trouble-shooting nozzle/end frame leaks
42
Leakage Between the Plates to the Outside of the Unit
1. Mark the area of the leak with a felt tip marker.
2. Check the plate pack dimensions to insure they Depressurize unit and adjust the plate pack as neces-
agree with Table 7. Overtightening may cause plate sary. Disassemble unit per procedure on page 29.
damage.
3. Look for mislocated, loose, or damaged gaskets. Relocate gaskets, reglue loose gaskets, and replace
damaged gaskets.
4. Check for plate damage in the area.
A damaged plate usually must be replaced. For
5. Make sure the plate pack sequence is A-B-A-B-etc., temporary duty, if the damaged plate has four holes,
see Figure 13. and an adjacent plate (front or back) has four holes,
remove both plates and retighten the plate pack
according to Table 7. Contact the factory if temporary
operating characteristics need to be developed for a
smaller number of plates. See “How to Find a Defec-
tive Plate” on page 44.
Inspect the plate pack for damage and place the plate
assemblies in the correct order.
Mixing of Fluids
1. Make sure the piping is connected to the correct Relocate piping to the correct connections.
locations on the heat exchanger.
2. Make sure the plates are properly arranged on each Open the plate pack and replace the plate gasket
adjacent plate according to the assembly drawing. (A- assembly.
B-A-B...arrangement)
3. Make sure the gaskets are correctly oriented on the Replace gaskets correctly.
plates with the “bleed port” of each gasket facing away
from the plate surface. See Figures 23a through 23c.
4. Follow the steps described in “How to Find a Remove and replace as discussed on page 31.
Defective Plate” on page 44. If a leak is found, use a
felt tip marker to locate the place.
43
Increase in Pressure Drop or a Reduction in Temperature
Readings
1. The pressure drop from the inlet to the outlet on Try cleaning-in-place (CIP) as described in Figures 27
one or both sides of the unit is too high compared to and 28. Check the accuracy of the instrumentation.
the original specified pressure change. Pressure taps should be installed 10 and 5 pipe
diameters upstream and downstream, respectively,
from flow disturbing source, i.e.; elbow, valve,
reducer, etc.
2. The temperature readings are correct for the The plate surfaces are clean enough, however, the
process, however, the pressure drop is high. inlet of the unit could be clogged. Back flushing the
equipment or CIP may solve the problem.
3. The temperature readings do not correspond to the The pressure drop is probably also increasing. The
original temperature settings or specifications. change in the temperature readings indicates that
there is a buildup of deposits on the plate surfaces. If
CIP or back flushing the equipment does not work, the
unit will need to be opened and the plates cleaned.
4. The pressure drop is too low and the unit is known The pump capacity may be too small. Check the
to be clean. pump manual.
How to Find A Defective Plate With Through Holes

Severe corrosion may cause defect to occur. The following method is recommended to determine the location of
the defective plate or plates:
1. Open the unit, remove all fouling from surfaces and dry the plates after cleaning. Make sure the bleed port
areas (see Figure 23a) are clear.
2. After completely drying the plates, reassemble the unit.
3. Supply water to one side (side A) and raise the water pressure to approximately 50 psig.
4. Open the drain valve at the lowest point or break the flange on side B. By removing the flange and fittings, it
is possible to look into the nozzle and measure to the exact leaking plate.
5. Stop the test if water flows out of the drain valve or flange on side B.
6. Open all valves and empty the unit of all water.
44
How to Find a Defective Plate With Through Holes (cont.)
7. Open the unit promptly and find which plate is wet on side B. This plate and the preceding plates may have
defects.
8. The defect can be found by placing a lamp on the rear side of the plate and by observing the light that passes
through.
9. If the defect is small, the use of dye penetrant may be required to locate the defect. Because of the metal to
metal contact of the plates, the defect can be larger when the plate pack is compressed than when it is in the
free state.
NOTE: A unit with multiple pass circuits that does not allow the fluid to drain out of each channel on one side
cannot be tested in this way unless the special center plates are first removed. See Figure 16 as an example.
STORAGE PROCEDURES
When a SUPERCHANGER plate and frame heat exchanger is to be placed in storage for six months or longer, the
procedures listed below must be followed:
1. If the unit has been recently shipped from our factory and is unused, disregard statements 2, 3, and 4; follow
instructions 5-10.
2. If the unit has been used and long-term storage is required, it must be completely drained. Prior to draining
remove the optional shroud, if provided, and let the unit cool to ambient temperature. Units with plate packs
arranged with one pass on each side (all nozzles on the stationary end frame) are self-draining. Simply vent
at the upper nozzle location and drain from the lower nozzle for each side individually. A two pass/two pass
or one pass/two pass plate arrangement is also self-draining, provided all two pass side nozzles are at the
lower elevations (numbers S2, S3, M2 and M3). Other units may be self-draining if they have been fitted
with separate drain and vent nozzles, or with vents and drain holes. Units that are not self draining must
have the plate pack completely loosened to drain all liquids. Before opening the plate pack, wipe off the
exterior surfaces to make sure no fluids or debris fall onto the plate pack.
3. Open the plate pack and thoroughly clean the unit internally and externally. Dry the unit. (Blowing dry, hot
air at approximately 150°F on all areas is an excellent method.)
4. Install blind flanges with gaskets on all nozzles. Plug all other openings.
5. Coat all unpainted carbon steel component surfaces with light grease, SAE 30 oil, or other rust inhibiting
products.
6. Coat all bolt threads with light grease.
45
STORAGE PROCEDURES (cont.)
7. To minimize gasket compression set, the plate pack length dimension needs to be adjusted. This must be
greater than the unit’s stated minimum tightening dimension (T.D.). As a guideline, the unit’s minimum
tightening dimension should be increased by a factor of 1.20 (e.g. 50” T.D. x 1.20=60”). When preparing the
unit to go back into service, check to ensure that it is retightened to its original T.D.
8. Protect the unit from direct sunlight, intense heat radiation, or ultraviolet radiation by loosely covering the
unit with an opaque, reflecting type plastic film or similar material. Make sure air is allowed to circulate
around the unit.
9. It is preferable to store the unit indoors, well protected from the weather. The temperature in the storage
area should ideally be 60°F to 70°F with a relative humidity of 70% or lower.
NEVER STORE THE UNIT IN AN AREA WHERE THE TEMPERATURE IS AT 32°F OR LOWER.
10. All potential sources of Ozone, such as operating electric motors, or welding equipment, should be removed
from the storage area to preclude Ozone attack on gaskets. Gaskets should not be exposed to direct sunlight
(ultraviolet radiation) and should be stored in dark plastic bags. Under proper storage conditions, gaskets
generally have a shelf life of approximately four years.
MISCELLANEOUS INSTRUCTIONS
General Maintenance
It is recommended that tightening bolts and tightening nuts be lubricated periodically in order that they can be
easily loosened at time of disassembly. The upper guide bars where the plates slide should be coated with a
lubricant to avoid corrosion and to enable the plates to slide smoothly. Rollers in the moveable end frame and
connecting frames should be lubricated with oil periodically.
Ordering Parts
When ordering parts or requesting information, always give the Model and Serial Number of the unit.
Refer to the parts list on your assembly drawing for correct nomenclature and numbers.
46
MISCELLANEOUS INSTRUCTIONS (cont.)
Returned Material
Units or parts are not to be returned without first sending pre-notification to the factory. Parts accepted for
credit are subject to a service charge plus all transportation charges. Any items authorized for return must be
adequately packed to reach Tranter PHE, Inc., at the address shown below without damage.
Damaged Shipments
Tranter PHE, Inc.’s equipment is carefully packaged at the factory to protect it against the normal hazards of
shipment. If Tranter PHE, Inc. equipment should arrive in a damaged condition, the customer must file a dam-
age report with the carrier. A copy of this claim should be sent to:
TRANTER PHE, INC.

1900 OLD BURK HIGHWAY
WICHITA FALLS, TX 76306
Additional Information
For any additional information concerning the operation, care or maintenance of your SUPERCHANGER, feel free
to contact our SUPERCHANGER technical specialists at the address indicated above, or call at (940) 723-7125 or
(800) 414-6908. Our FAX number is (940) 723-5131. Visit our web site for parts quotations at
www.tranterservice.com.
47
NOTES
48
NOTES
49
NOTES
50
Superchanger
Superchanger
SUPERCHANGER units are plate and The thin fluid interspace coupled with uses an external support column
frame type heat exchangers consisting the corrugated plate design induces (Models HP, UP, SP, MP and FP) while
of corrugated heat transfer plates, turbulence that produces extremely the other type uses a self-contained
frames, nozzles and tightening bolts. high heat transfer coefficients. supporting pad (Models HJ, UJ, SJ
The corrugated plates are held in be- and MJ). The “J” Models conserve
tween the stationary and moveable Plates are manufactured in standard more space, but have a limited plate
frames and are compressed by tighten- sizes in virtually any material that can capacity while the “P” Models can
ing bolts. Optional shrouds are avail- be cold worked. The size, number and contain up to 640 plates in a single
able on request. arrangement of the plates is contin- frame. See Figures 1 and 2.
gent upon the duty to be performed.
The plates are equipped with elastomeric Accordingly, the units are custom de- Information in this brochure is
gaskets and have port holes pierced in signed for each application. subject to change without notice.
the corners. When the unit is tightened, The manufacturer reserves the
the gaskets seal the structure and, in SUPERCHANGER frames are provided right to change specifications at
conjunction with the port holes, allow in two basic designs, differing prima- any time.
fluids to flow in alternate channels and rily in their support systems. One type
almost always flow counter-currently.
Tranter PHE, Inc. ▲ P.O. Box 2289

1900 Old Burk Highway ▲ Wichita Falls, Texas 76307
Telephone: (940) 723-7125 ▲ Fax: (940) 723-5131
http://www.tranterphe.com ▲ E-mail: sales@tranterphe.com
5M/602/KP/650428 © 2002 Tranter, inc.

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OPERATION and

This document contains proprietary and NATIONAL OILWELL VARCO

4 PRESERVATION AND INSTALLATION 13

6 MAINTENANCE AND LUBRICATION 31

7.1 PARTS FIT - GENERAL ..................................................................................................... 43

8 MAJOR REPAIRS AND MODIFICATIONS 55

10 TIGHTENING TORQUE GUIDE 73

1.1 Manual Overview & Scope

Photo: SSGD-1000 Drawworks

1.2 Warranty Information

3. The foregoing warranty is contingent on the proper application of equipment and

8. Products furnished by National Oilwell Varco, but not manufactured by National

1.3 Warranty Limitations

Improvements in design, engineering, materials, production methods, etc. may

1.4 Equipment Service Life

This page left intentionally blank.

2.1 Safety Terms & Conventions

WARNING: A warning provides a specific procedure or additional instructions/

CAUTION: A Caution provides a specific procedure or additional instructions/

NOTE: This provides information necessary to complete the procedure properly

Personnel are protected from exposed mechanical dangers by design. Nevertheless,

Do not attempt equipment operation with inadequate visibility.

Before performing maintenance on or disconnecting any high-pressure piping or hoses,

WARNING: Use adequate hoisting equipment. Observe all safety precautions.

WARNING: Determine if the equipment has preloaded components such as

WARNING: When working on a system, disconnect electrical power supply

3.1 General Description

The single speed gear driven drawworks

Photo: SSGD-1000 Drawworks

The drive assembly uses five electric motors.

3.2 Technical Specifications

3.3 Power Flow Chart

MOTOR MOTOR 12 LINES 14 LINES

0 10600 0 2,808,833 0 2,643,535 0 2,496,610 0 2,365,158 0 3,276,972 0 3,084,124 0 2,912,712 0 2,759,351

MAXIMUM INTERMITANT RATINGS WITH NO TRAVELLING BLOCK EFFICIENCY LOSSES

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4 PRESERVATION AND INSTALLATION

4.1 Storage and Preservation

Oil Sump Capacity: 757 liters (200 US Gal.)

4.2 Pre – Installation Procedure

4.3 Installation Procedure

4.3.1 Lifting Procedure

To lift the drawworks, use a spreader

Extreme caution must be exercised

Refer to the Typical Drawworks Lifting

Typical Drawworks Lifting Diagram 1

Typical Drawworks Lifting Diagram 2

4.3.2 Transportation Instructions

4.3.3 Mechanical Installation Instructions

WARNING: Extreme caution must be exercised when lifting the drawworks

Straight line from points 1 to 4

NOTE: Refer to lifting instructions for details.

If level measurements are out of tolerance, shim up the drawworks.

The drawworks is now ready for the pre-commissioning procedure.

4.3.4 Pre-commissioning Procedure

WARNING: Hydraulic pumps are start/stop controlled by the PLC system.

Refer to drawing 9130X058.

WARNING: Contaminated brake pads must be replaced immediately. Do not

WARNING: A brake capacity test must be performed after any brake