SMITH WELL
SERVICE
C400
SERVICE RIG
MANUAL
UNIT 0072
RIG VIN: 1T94SC2233A532072
DRAWWORKS SN: DD42-148-0072
DERRICK SN: 1290
832 VERDIGRIS PARKWA y
PORT OF CATOOSA,
TULSA OKLAHOMA 74015
PHONE: 918-266-7301
FAX: 918-266-7610
E-MAIL: sales@taylorrigs.com
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ROAD HEIGHT
ROAD WIDTH
FRONT TANDEM
DRIVE AXLE
TRAILER AXLE
TOTAL
I
13'-11 1/8"
8'-6"
33,400 lbs.
20,800 lbs,
21,180 lbs.
75,380 lbs.
(W/O BLOCK OR UNE)
TOLERANCES
(UNLESS OTHERWISE NOTED)
LINEAR:
.X = :f: 1/1
.XX = :f: .030
.XXX = :f: .005
FRACTIONS =
:f: 1/1
ANCLES = :f: 1/2'
HOLE DIAMETER:
PROPRIETARY MATERIAL
The information contained within
is the property of Taylor Rigs. LLC
and shall not be copied or used
in any manner or disclosed to
others except as expressly
authorized.
APPROVED
BY:
DATE:
UP TO .250 =
.251-.500 =
+.005/-.00
+.006/-. 00L_ _ _ _ _--L-:-:~__;_=~_1
.501 -.750 = +.008/-.00
.751- 1.000 = +. O 10/-. ooil--..!:!2~'.::::.'..!..~::::.;..~~.L.....:.==--_l
1.01 &- OVER = +.015/-.00
SMITH C400
UNIT MEASUREMENT
!::Cfi':!!.'K.~.J.B~Y.~
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1-06-0072
72
B
,. ALL DIMENS/ONS ARE /NCHES,1- _ _ _
UM5S0THERW6ESPEQRED'l==-_ _ _ _
2. REMOVE ALL BURRS AND
DWN. BY.· / DATE.·
SHARP EDGES, R.02 MAX - I---=:~~::.:..r-!.......::.::':':':=~~----l
.02 X 45' MAX
TCW
1-9-04
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SEAL
DERRICK
96- 205
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PROP";IETARY MATERIAL
-----:.X;-_--:-~--:I/:-;,:-=16 i:ethi~f;~:~~; ~t~~~roerd R~~~~jnLLC
.~ : ;:~
FRACTlONS - :t 1/16
ANGlES _ :t 1/2'
lKJlE OIAMETéR:
UP ro .250 ... +.005/- .001
:~~~=:m
and snal! r."t be copied or used
in ony marlner or disclosed to
others eXclpt 05 expressly
outhorized.
APPROVED BY:
DATE:
: ~:~::~~I--;;PROO/JC
=;:;;"'1ON
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A ;;;;I'i'OI<=",'--/7;;;D<"'TEo---l
.751- 1.000 - +.OI0/- .001 f-----'-'="'.::::.:...:.:..r-:='-'-='---l
.01 d' O\of'"R - +.015/- .001
1. ALL DlMENSIONS ARE INCHES,
l.wt.ESS OTHERWISE SPfCIFIED
• RDIOVC ALL BURRS AND
SH4RP ffJCES. R.02 -"4X -
C'HK. BY: /
Ll41C:
¡;'+'N. BY: /
MF N
D4TE:
11
072 SMITH C400
COMPON ENT LOCATON
1-04- 0072
RIG INFORMATION SHEET
TAYLOR RIGS, LLC
,O
832 VEROIGRIS PARKWAY
CATOOSA, OK 74015
(9 18) 266-7301
ORAWWORKS MOOEL: 0042-148
ORAWWORKS S/N: 0042-148-0072
DATE OF MANUFACTURE: 12/1/03
SANO ORUM UNE S IZE: 9/16"
SANO ORUM BRAKE SIZE: 42"
TUBING ORUM LEBUS GROOVING: 1"
TUBING ORUM BRAKE SIZE: 42"
MAX. SING LE UNE PULL: 41,500 LBS
ASSIST BRAKE: 48"
O ----------------------------~~O
O ~----------~TAYL O-R-RIGS-,-L-LC --~'O
~
832 VERO IGR IS PARKWAY
-/fl"~'GS, He
CATOOSA, OK 74015
-tift
(918) 266-7301·
CHASS IS V.I. N .: 1T94SC2233A532072
DATE OF MANUFACTUR E: 01/10/04
CHASSIS MOOEL: C400
OERRICI< MOOEL: 96-205
OERRICK CAP.: 205,000 ON 6 UNES
OERRICK S/N: 1290
ORAWWORKS MOOEL: 0042-148
ORAWWORKS S/N: 0042-148-0072
O ~--------------------------~~O
Serial Numbers:
VIN:
1T94SC2233A532072
Drawworks:
Serial # 0042-148-0072
Model # 0042-148
Engine:
Cat C-15
Serial # 8EM01678
Model # C-15
Arrangement
Air Compressor:
Cat # 164 7566
Serial # 100803F
PC # 505192
Fan Belts:
Gates 8-77
Radiator:
Quality Stamping & Tubing
Charge Air Section Serial # 23088
Water Section Serial # 24273
Transmission:
Allison CLT754
Serial # 2510236543
03827
Model # E007905
First Steer Axle:
Eaton
Serial # HU00193995
Model # 20F4
Part # 317253
2
Second Steer Axle:
Eaton
Serial # HU00193992
Model # 20F4
Part # 317253
Transfer Case:
Spicer
Serial # EUSA3120011
Part # H405081-029
Drawworks Gear Box:
Eaton
Serial # HN00599452
Model # RS402
Ratio 00308
Tubing Drum
Clutch:Wichita ATO 3-14 High Torque
Serial # 03-763917-00-002
Sand Drum
Clutch:Wichita ATO 2-14 High Torque
Serial # 03-769495-00-001
Forward Rear End:
Eaton
Serial # HN00790162
Model # OS 463P
Part # 216653
Spec. 0692031
Ratio 00543
Spec Housing: Model463
Serial # U021689273 Part # 319392
Rear Rear End:
Eaton
Serial # HN00790168
Model # RS 463
Part # 217775
Spec. 0692041
Ratio 00543
3
Spee Housing: Model K-463
Serial # U021689285 Part # 319394
Power Steering Pump:
Viekers
V20F-1 P11 P-38C-5F-2-2
Steering Box:
Sheppard
Serial #
Derrick:
Pemeo 96-205 (NOT supplied by Taylor)
Serial # 1290
205,000 lbs on 6 lines
Main Hydraulic Pump:
Commereial
50 gallon per minute
Part # P37X278RZSC20
Hydraulic Filter Element:
Hyeon
Part # 0180-MA-01 O-P
Raising Ram - Commercial
Model # SD83CC-24-131
Part # SD83CC-24-131
Serial # F0603-0748
Engine Oil Filter:
Cat
Part # 1R0716
Transmission Filter:
Luberfiner
Part # LFH4223
Primary Fuel Filter:
Cat
Part # 129-0372
4
Secondary Fuel Filter:
Cat
Part # 1R-0749
Air Filter Element:
Donaldson
Part # P527682
Ignition Key Number:
H6255
Battery Box Key Number:
2268
Forward Tool Box Key Number:
Second Tool Box Key Number:
Cab Door Key:
CH751
5
2268
2268
WARNING!
AFTER 50 HOURS OF SERVICE, ALL HYORAULIC
FILTERS
MUST BE REPLACEO.
00 SO WILL VOIO WARRANTY.
6
FAILURE TO
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3.250
SEL~T/ON
2
REDRAWN F'OR CLAR/TY
5-6-0.
REV
DATE
DESCR/PT/'ON
70- '00'0'0'06
8
3
CHA/N, C'OrrER 14'0 P/TCH X 25' /ng
3'0- '0'0'0236
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V,fl
1- 4'0- '0'0'08
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RIGS, LLC
DATE:
~--1--r---~~-------------~---~--r-+_---_+-------.-------_+----~
7
3'0-'0'0'0249
ASS'Y, /NPUT DRIVE
1-40- 0103
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6
2
5
/TEM QTY
3'0- '0'00262
ASS'Y, DD42-148 COVER
1- 40-0101
3'0- '0'0'0254
WELDMENT, DD42-·148 FRAME
2 - 4'0- '01'09
3'0-'0'0018'0
ASS'Y, TUB/NG DRUM BRAKE
1- 40- 0003
3'0-'0'0'0239
ASS'Y, DD42- 148 DRAWW'ORKS
1- 40- 0092
PART ND.
DESCR/PTl'ON
BILL OF MATERIAL
DWG. ND.
/TEM QTY
PART NO.
DESCR/PT/ON
BILL OF MA TERIAL
DWG. ND.
BY
~~
This informotion conto ined within
is the property of Toylor Rigs,llc
ond shol l not be copied or used
in ony monner or disclosed to
others except os expressly
outhorized.
APPROVED BY.'
JNN
REVISIONS
PROPR IETARY MATERIAL
r---,r--"""T----T"""-----------------,.--------1
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3'0-'0'0'0258
AASSSS"Y.y", ~~D'D DDRR~,'~ BRAKE
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PRDDUCTl'ON APPRDVAL /
DWN. BY.' /
MOSELEY
CHK. BY.' /
DATé
DATE:
3/25/'02
DATE:
148 DRA WWORK S
ASSEMBL y
~
NCIVE
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N.
2
WICHITA CL UTC H
ATD- 314 L.I.
HI TORQU E WITH
PANCAKE TUBE
WIC HITA CLU TCH
ATD - 214 L. I.
HI TORQUE WITH
PANCAKE TUB E
16 5
16
6
17 19
SEAL WITH RTV SILlCONE
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11 1
24
25
28
29
15 26
7
8 27
12 10 2 1
29
76
WASHER, FLAT 5/8" (GR 8)
74
7
25-000083
KEYSTOCK, 3/ 4" X .75" X 7.25"LG
28
28
WASHER, FLAT 3/4 " (GR 8)
73
2
80-000065
RETAINER PLATE
27
2
70-000072
NAnONAL/ FEDERAL OIL SEAL
72
2
25- 000234
LOCATING RING
26
7
80- 000072
CLUTCH HUB
77
2
70- 000772
BEARING CARRIER
25
A/R
80- 000037
LOCTITE (RED)
70
4
70-000700
BEARING RETAINER
3
J-14- o.
CHANGEO BOM &- PART BUBBLES
JNN
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, .------------_t--~~~--i_--------------------~~R~8I~.~DA:r.:E1-----------~D~ES~C:R:~~n~ON~__________1_~B~Y__~
23
6
~
BOLT, SOCKET HEAD 3/8"-76 x .75"LG
~
8
7
80-000777
INPUT ORIVE SHAFT
~
PROPRIETARY MATERIAL
REVISIONS
22
74
~
NUT, NYLOC 3/ 4"-70
(GR 8)
~
7
7
80-000716
~
INPUT ORIVE SHAFr
~
This informotion contoined within
~2-7~8-0~------~~B-~-r-,-~-X-H-E-~O--5-/8-"--'I-X--2-5-1-G-~-R--81--~---~----~-6~-2~-7-0---00-0-7-~~-B-~--m-~--s-~-C-~-R----------------~---~----~.~· pm~~ ~ ~.,
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20
76
~
BOLT, SOCKET HEAO 5/8"-11 X 2"LG (GR 8)
~
5
2
70-000707
BEARING SPACER
~
in ony monner or disclosed to
~-4--~------~f-----------~------------"';""r--------4---r--+-------+------------'-------------+---------1 others except os ex pressly
79
6
70-000009
NAnoNA L/FEOERAL OIL SEAL
~
4
2
70-000703
BEARING SPACER
~
outhorized .
~=:=:~=~~=~=:=:==:~:~:O=O:~~~~=;=:=:;~;=:=~~Lfi=:~:;L:;:=~=:;/~=:=:=G=L=========~=========~=~;=~=~=1=:~:===~~=~=~~~;=:='=:=:=~=:=R=;:=C=T;='P=R=0:=';K.=CT=============1=========:¡-A_PP-;:R:;:::O~V~;::,;,D-::::;:B~Y.·:-:- : ,*I;:;:DA~r.~E.: ; '
76
4
70-000003
SPHERICAL ROLLER BEARING
75
7
25- 000776
KEYSTOCK, .75" X .75" X 2 .5"LG
ITEM QTY
PART NO.
DESCRIPnON
BILL OF MATERIAL
~
~
DWG. NO.
7
7
ITEM QTY
45-000090
GEAR ORIVE
30-000249
INPUT ORIVE ASS',
PART NO.
7 40 0134
~
DESCRIPTION
BILL OF
IÍ':~
TERIAL
DWG. NO.
TITLE
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PRODUCTION APPROVAL /
DWN.
J NANCE
Br:' /
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CHK. BY.' /
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RIGS. LLC
DATE
DATE:
[)
D 42 - 148 DRA WWORK S
NP U T DR/ VE ASS) Y
/
3 72 02
DATE'
Wí
NOIIE
N
7 40 0703
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SIZE
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WARRANTYSTATEMENT
• Warranty. Taylor Rigs warrants that the rig shall be free from defects
in material and workmanship for a period of one (1) year. Provided,
however, in no event does Taylor Rigs warrant the engine, drive train
components, or third party components of the Rig, but Taylor Rigs shall,
to the extent possible, transfer to Customer any original equipment
manufacturer warranty on such components. If any defects covered by
this Warranty appear within the one (1) year warranty period, Taylor
Rigs shall have the option of repairing or replacing the defective
equipment at its expense. This Warranty does not extend to any
equipment which has (a) been subjected to misuse, neglect, accident or
abuse or casualty loss; (b) repaired or altered by anyone other than
Taylor Rigs without its express written prior approval; (e) improperly ,
installed by someone other than Taylor Rigs; or (d) used in violation of
instructions fumished by Taylor Rigs.
• THE ABOVE WARRANTY SHALL BE IN LIEU OF ALL OTHER
WARRANTIES INCLUDING IMPLIED WARRANTIES
OF
MERCHANTABILITY AND FITNESS FOR A PARTICULAR
PURPOSE. TO THE EXTENT PERMITTED BY APPLICABLE LAW,
IN NO EVENT SHALL TAYLOR RIGS BE LIABLE FOR ANY
DAMAGES
WHATSOEVER
(INCLUDING,
WITHOUT
LIMITATION, SPECIAL OR CONSEQUENTIAL DAMAGES, OR
DAMAGES FOR LOSS OF BUSINESS PROFITS, BUSINESS
INTERRUPTION, OR ANY OTHER PECUNIARY LOSS) ARISING
OUT OF THE USE OF INABILITY TO USE THE RIG (INCLUDING
INABILITY TO USE THE RIG BY REASON OF DELAY SPECIFIED
BELOW).
LUBRICATION
C400 COOLANT, FUEL AND LUBRICANT
SPECIFICATIONS
COOLANT SPECIFICATIONS
AL WA YS USE A MIXTURE OF APPROVED FILL WATER, ANTIFREZE AND COOLING
SYSTEM CONDITIONER.
REFER TO THE ENGINE MANUF ACTURER FOR DETAILED SPECIFICATIONS, OR
CATERPILLARFORM SEBD0518.
ALWAYS ADD CONDITIONER TO COOLANT WATER. NEVER USE PLAIN WATER
ONLY IN THE COOLING SYSTEM.
ACCEPTABLE WATER FOR USE IN THE PREPARATION OF ETHYLENE GLYCOL
TYPE ANTIFREEZE AND WATER MIXTURE IS SHOWN IN THE FOLLOWING CHART.
WATER CONTENT
50% ANTIFREEZE/ 50% WATER.
WITHOUT ANTIFREEZE
CHLORIDES
100 PPM OR LESS
50 PPM OR LESS
SULPHATES
100 PPM OR LESS
50 PPM OR LESS
HARDNESSS AS CaC03
200 PPM OR LESS
100 PPM OR LESS
DISSOLVED SOLIDS
500 PPM OR KESS
250 PPM OR KESS
pH
6.5 OR HIGHER
6.5 OR HIGHER
ANTIFREEZE
Always use ethylene gIycol type antifreeze and the correct amount to provide protection to the
lowest expected operating environment.
NOTE: antifreeze must meet ASTM D4985
COOLANT CONDITIONER ELEMENTS
Coolant conditioner elements should be used to maintain a 3 to 6% concentration of conditioner
in the coolant. Use a precharge element when filling the system or changing coolant, Install a new
maintenance e1ement after every 250 hours of service.
FUEL SPECIFICATIONS
Caterpillar manufactured diesel engines have the ability to bum a variety of fuels. These fueIs are
divided into two categories: preferred or permissible. Preferred fuels provide maximum engine
service life and performance. These fuels are distillate fueIs and are commonly called fuel oil,
fumace oil, and diesel fueI gas oil or kerosene. Permissible fueIs are crude oiIs and or blended
fueIs. Use ofthese fuels can resolt in higher maintenance costs and reduced engine service life.
Refer to formSEHS7067 frOm caterpillar for a detailed summary of preferred fueIs and their
specifications.
CETANEREQUrnEMENT
The minimum fuel cretonne number recommended for this engine is 40.
FUEL CLOUD POINT
Fuel waxing can plug the fuel filters in cold weather. The fueI cIoud point must be below the
temperature ofthe surrounding air to prevent filter waxing and power loss. Fuel heating
attachments can minimize fuel filter waxing and are available from your local truck dealer or
Taylor Rigs.
FUEL SULPHUR CONTENT
The percentage of fuel sulfur content will affect the engine oil and filter change intervals (refer to
the following chart).
CRANKCASE OIL CHANGE INTERVALS
FUELSULPUR
OIL CHANGE INTERVAL
O.O%to 0.4%
250 hours
0.4% to 1.0 %
125 hours
1.0 % to 1.5%
62 hours
NOTE!
Ifthe fuel has over 0.5% sulfur content, the CG engine oil must have a Total Base Number of20
time the percentage offuel sulfur as measured by the ASTM D-2896 method. Ifthe sulfur
content is greater than 1.5% by weight, use oil with a TBN of30 and reduce the oil change
interval by one half. Consult your caterpillar dealer for correct engine oil recommendations.
LUBRICANT SPECIFICATIONS
GENERAL
The classifications listed below follow S.A.E. J183 classifications. The MIL specifications are
USA Military Specifications. The following definitions will be of assistance in purchasing
lubricants. The specific classifications for this machine are found on the Lubricant Chart.
ENGINE OILS (CH)
Only use oils that meet engine service classification CH (MIL-L-2104LD). At the factory, this
machine was filled with BP 15W - 40 . Consult the caterpillar form SEBU5939 for a listing of
CH oil brands.
NOTE!
The engine oil and filter should be changed after the first 50 hours of service on new and
reconditioned engines.
LUBRICATING GREASE (MPGM)
Use on multi-purpose grease (MPGM) which contains 3 to 5% molybdenum disulfide. NLGI No,
2 grade is suitable for most temperatures. Use NLGl No. 1 or No. O grades for extremely low
temperatures.
COMPRESSOR OILS (COMP)
As with any oil do not mix different types of oils. Contamination of synthetic oils with traces of
AFT may lead to foaming of plugging of orifices.
When operating between 80 and 100 deg fah and with relative humidity aboye 80 % a synthetic
hydrocarbon type fluid is recommended.
HYDRAULIC OILS (HYDO)
Use engine service classification CC (MIL-L-2104B), CC/SF (MIL-L-46152B), CD (MILD-L2104D) or industrial-type hydraulic oils that are certified by the oil supplier that have anti-wear, foam, -rust, and - oxidation additive properties for heavy duty usage.
MULTIPURPOSE - TVPE GEAR LUBRICANT (MPL)
Use gear lubricant classification GL-5 (MIL-L-2105B) EP140. Use SHC 75 x 90 in cold ambient
conditions and SHC 5 x 90 in arctic conditions.
REFRIGERATION OIL (REF)
Use ISO 100 refrigeration oil.
WARNING!
AFTER 50 HOURS OF SERVICE, ALL HYORAULIC
FILTERS
MUST BE REPLACEO.
00 SO WILL VOIO WARRANTY.
FAILURE TO
LUBRICATION LIST
SMITH UNIT 0072
LOCATION
TYPE
Spicer Transfer Case
Mach 4 GL-5 80w90
Cat C-15 Truck Engine
Rotella 15w40
Allison CL T -754
Transmission
C4 Transmission 15w40
Radiator
Mach 4 Anti-Freeze & Summer
Coolant 60%, Water 40%
NOTE: Anti-Freeze must meet ASTM D4985
Differentials
Mach 4 GL-5 80w90
Front Wheel Bearings
Factory Filled
U-Joints
Lithium EP-2 Grease NLG 1 No. 2
Meither Drum Bearing
Citgo Lithoplex EP No. 2
Crown Sheaves
Citgo Lithoplex EP No. 2
Hydraulic Tank
Mach 4 A/W ISO-68
RIG OPERATION
(Fig. 1)
(Fig.2)
~'WT.IAJ.(
1010JlM'CIIIU'
..'
-#f~
,." • .
o
(Fig.3)
(Fig.4)
AH control s necessary to operate the Taylor Rig are in four locations:
1.
2.
3.
4.
Cab Control s (Fig. 1)
Rig Up Controls, at rear of rig (Fig. 2)
Operator's Control Console, at rear ofrig (Fig. 3)
Sandline Control Console, at drawworks (Fig. 4)
1
lo CAB CONTROLS
Ao Engine Controls
The primary ignition switch is a three position keyed switch which supplies
power to the rig' s main electrical system.
(Fig.5)
1. The first position is "OFF'.
2. The second position is the "RUN' position. In this position electrical
power is supplied to the dash, heater, defroster and electronic shifter.
3. The third position is unused.
The "START" button is for ordinary starting ofthe rig engine. To operate,
depress button until the engine starts.
NOTE: The ignition switch must be in the "RUN"
position in order for the engine to starto
2
POWER
TOGGLE
SWITCH
(Fig.6)
B. Shifting The Rig
Transmission Shift Control:
The rig is equipped with an Allison CLT754 automatic transmission and
Bennett electronic shift package. There are two Transmission Shift
Controls. One is located in the driver' s cab and the other is located on the
operator's control console at the rear ofthe rig (See Fig. 3).
The Power Toggle Switch located in the cab dash panel (See Fig. 6) decides
which Transmission Shift Control is activated. Only one Transmission Shift
Control is activated at any one time.
3
(Fig.7)
The Transmission Shift Control consists of a L.E.D. display and two shift
buttons. To shift the transmission, press one ofthe shift buttons. The
L.E.D. display wiU indicate which gear the transmission is currently in. The
shift pattem for the transmission is:
1
2
3
4
5
N
R
4
Transfer Case Shift Lever:
"CAB" position: In this position the transfer case is supplying power to the
drive axles. The Transfer Case Shift Lever and Power Toggle Switch
should be in the "CAB" position only when rig movement is desired.
Automatic shifting is done with the Transmission Shift Controllocated in
the cabo
POWER
TOGGLE
SWITCH
(Fig.8)
"WORK" position: In this position the transfer case is supplying power to
the drawworks. The Transfer Case Shift Lever and Power Toggle Switch
should be in the "WORK" position when drawworks movement is desired.
In the "WORK" position the transmission is manual shift only. Shifting is
done with the Transmission Shift Controllocated on the operator' s console
at the rear of the rig.
POWER
TOGGLE
SWITCH
(Fig.9)
5
Power Toggle Switch:
The Power Toggle Switch is mounted in the cab to the left of the
Transmission Shift Control. This switch illuminates the electronic display
on the Transmission Shift Control. In the "CAB" position, the cab
Transmission Shift Control 's display is illuminated. In the "WORK"
position, the operator's console Transmission Shift Control's display is
illuminated.
6
11. RIG UP CONTROLS
(Fig. 10)
8
ERTER
(Fig.20)
D. Assist Brake Control
The Assist Brake Control is located in the middle right of the Operator' s
Control Console.
To engage the assist brake, move the Assist Brake Controllever forward.
The farther you advance the lever forward, the more brake pressure is
applied.
21
SL'
H'
(Fig.21)
E. Air Slip Pressure Regulator
Air pressure can be adjusted through the Air Slip Pressure Regulator. To
operate, pull out from the regulator on the control knob, and then rotate to
adjust pressure. To increase pressure, turn clockwise; to reduce, tum
counter-clockwise.
22
(Fig. 11)
Á.
Hydraulic Flow Control Valve
The rig is equipped with a Hydraulic Flow Control Valve that switches
hydraulic power from derrick moving operations to drilling operations. In
the "RIG UP" position hydraulic power is provided to the hydraulic jacks
and derrick controls. In the "TONG" position hydraulic power is provided
to the Spinner Tool. Accessory winch controls receive full power in both
positions.
9
(Fig. 12)
B. Setting The Hydraulic Jacks
y our Taylor Rig is equipped with four hydraulic jacks with screw type
locks. These jacks are designed to level the rig during operation on uneven
terrain.
10
(Fig. 13)
To Lower Jacks:
Each ofthe four jacks has it's own controllever. To lower the jack, find the
lever that corresponds with the jack to be lowered. Push the desired control
lever down to beginjack movement. To stop jack movement, simply release
the handle and the jack will stop. Once the jack is in the desired location,
rotate the screw lock counter-clockwise untillock is tight against the jack
body.
T o Raise Jacks:
Release the screw lock by rotating clockwise until the lock reaches the end
ofthe threads. Once the screw lock is fully released, raise the jack by lifting
the correspondingjack lever. The jack will rise until the handle is released,
or the jack reaches the built-in stop.
11
To Level Rig:
Step 1. Locate the rig in the desired position over the well or on the substructure. Place the jack stands under the hydraulic jacks and lower jacks
until the jacks are touching the stands. Ensure that all jacks are touching the
jack stands and have a solid foundation. Lower the two rear jacks until the
rig is level from left to right.
Step 2. Lower the front two jacks until the rig is level from front to back.
Step 3. Once the rig is level from left to right & front to back, tighten the
screw locks on each jack as described above.
NOTE: use a good quality carpenter's level during the rig leveling process.
WARNING: Adjust the hydraulic jacks only when the derrick is
in the down position and resting on the derrick support resto
Jack movement at any other time could cause the rig to topple
and resuIt in serious injury or death.
12
c. Moving The Derrick
CAUTION: Special care should be taken to insure that no air has
accumulated in the derrick raising cylinders while the derrick
was in the raised position. (Please refer to your Pemco
Equipment Derrick Manual for instruction on how to operate
derrick and check for air accumulation in the raising cylinder.)
To Raise Derrick:
Locate the "DERRICK" lever to the lower left ofthe Operator's Control
Console (See Fig. 13). Lift "DERRICK" lever to the "RAISE" position to
begin derrick movement. Once the derrick is fully raised, the rear derrick
legs should be resting on the derrick base. At this point, insert the derrick
lock pins into the holes on the derrick base and through the derrick legs.
Secure the lock pins with derrick pin clips.
To Lower Derrick:
Remove derrick pin clips from the derrick lock pins. Remove the derrick
lock pins from the derrick base. Move "DERRICK" lever to "LOWER"
position to lower derrick.
13
(Fig. 14)
To Scope Derrick:
Scope the derrick only when the derrick is in the fully raised position and
the derrick lock pins are securely in place.
CAUTION: Never attempt to seo pe the derrick without the
derrick being in the fully raised position. To scope derrick while
not in the fully raised po sitio n can cause undue stress to the rig
frame and derrick causing damage, serious injury or death.
14
Retract the derrick scope pins by pulling on the pin retract lever located on
the derrick (see Perneo manual). With the derrick scope pins released, raise
the "seoPE" lever to "UP" position.
NOTE: Slight pressure may be required in order for the derriek
seope pins to freely release. To aeeomplish this, gently raise the
"SCOPE" lever and allow hydraulie pressure to slowly build. At
the same time, apply pressure to the derriek seope pin retraet
lever (see Perneo manual). The pins should then release freely.
Once the derrick scope pins are released, the derrick will scope freely. As
the derrick scopes, the racking board will automatically deploy. Operator
should observe these functions to ensure the operations are done properly.
When the upper derrick section is fully scoped, the scope pins will
automatically deploy, securing the upper derrick section in position. Release
the "SeOPE" lever when derrick is fully scoped.
RACKING
BOARD
(Fig. 15)
15
CAUTION: Always visually verify the red seope pins are seeurely
in position. The pins should be visible on the outside of the main
derriek legs.
To Retract Derrick:
Retract the derrick scope pins by pulling on the pin retract lever located on
the derrick. With the derrick scope pins released, move the "SCOPE" lever
to the "DOWN" position.
NOTE: Slight pressure may be required in order for the derriek
seo pe pins to freely release. To aeeomplish this, gently lift the
"SCOPE" lever to the "UP" position and allow hydraulie
pressure to slowly build. At the same time, apply pressure to the .
derriek seope pin retraet leyere The pins should then releas e
freely, not bearing the weight of the upper derriek.
Once the derrick scope pins are released, the derrick will retract freely. As
the derrick retracts, the racking board will automatically retract. Operator
should observe these functions to ensure the operations are done properly.
When the upper derrick section fully retracts, the scope pins will
automatically deploy, securing the upper derrick section in position.
16
111. OPERATOR'S CONTROL CONSOLE
The OPERATOR 'S CONTROL CONSOLE is located at the rear ofthe rig,
on the operator' s side. The Operator' s Control Console contains all the
controls necessary for rig service operations.
(Fig. 16)
17
EMERGENCY STOP
START
STOP
(Fig. 17)
A. Engine Controls
Engine controls are located on the operator' s console at the rear of the rig.
These controls consist of three push button switches, which are not keyed,
and require no activation for operation. Each button operates as follows:
CAUTION:
Be sure transmission is in neutral (N) before
starting the engine. Starting the rig while in gear can cause damage to
the equipment and result in serious injury or death.
1. "START" This button allows the engine to be started from this location.
To operate, simply depress the button until engine starts.
2. "STOP" This button kills the engine. To operate, depress the button
until engine stops running.
3. "EMERGENCY STOP" This button should only be used in the event of
an emergency.
NOTE: Tbe "EMERGENCY STOP" button activates a solenoid,
stopping tbe passage of air into tbe engine. If tbis button is used,
tbe solenoid must be reset befo re engine can be restarted.
18
lT UBING DRUM
(Fig. 18)
B. Hydraulic Pump Switch
Move the Hydraulic Pump Switch to the "ON" position before initiating
hydraulic rig operations. Moving to the "OFF" position disables hydraulic
power to the rig.
19
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SLIP S
HYD. PUMP
OFF
(Fig. 19)
C. Tubing Drum Control
The Tubing Drum Control is located in the middle left of the Operator' s
Control Console. All directional functions as well as throttle controls are
accomplished with the use of a single lever.
To spin the tubing drum (raising blocks) put transmission in a forward gear
and move the Tubing Drum Controllever from the center position to the
first detent aboye center. The tubing drum clutch will engage in this
position and the drum will begin to rotate. To accelerate the tubing drum,
advance the lever up, which will increase drum speed. The engine throttle
will increase as required.
To stop drum movement, move throttle back to idle position and apply
pressure to the Tubing Drum Brake Lever located below the operator' s
console. The "Down" position applies the brakes and the "Up" position
releases the brakes.
20
E
SLIPS
(Fig.22)
F. Air Slip Control
The Air Slip Control is located aboye the Tubing Drum Control on the
Operator' s Control Console. Air Slip equipment is to be provided by the
customer. Outlets connecting to the Air Slip Control are located in the
wheel-well ofthe rear axle on the left side ofthe rig (two hoses, Y4"
diameter each).
23
(Fig.23)
G. Tong Pressure Regulator
Hydraulic pressure provided to the Spinner Tool can be adjusted through the
Tong Pressure Regulator, located next to the Hydraulic Flow Control Valve
(see Fig. 11). To operate, switch Hydraulic Flow Control Valve to "TONG"
position and adjust pressure by tuming the knob on the regulator. To
increase pressure, tum knob clockwise; to reduce pressure, tum knob
counter-clockwise.
24
(Fig.24)
H. Accessory Winch Control
The Accessory Winch Control is located below the operator' s console. The
3-position lever control s the speed and direction ofthe winch. To operate,
move the lever in the desired direction to be moved.
25
IV. SANDLINE CONTROL CONSOLE
The Sandline Control Console is located on the operator' s side of the
drawworks.
E Ef\GENCY STOP.
(Fig.25)
A. Engine Controls
The "EMERGENCY STOP" burton should only be used in the event of an
emergency.
NOTE: Tbe "EMERGENCY STOP" bufton activates a solenoid,
stopping tbe passage of air into tbe engine. If tbis button is used,
tbe solenoid must be reset befo re engine can be restarted.
26
B. Sandline Drum Control
The Sandline Drum Control is located on the left si de of the Sandline
Control Console. All directional functions as well as throttle controls are
accomplished with the use of a single lever.
To spin the sandline drum put transmission in a forward gear and move the
Sandline Drum Controllever to the first detent aboye idle. The sandline
drum clutch will engage in this position and the drum will begin to rotate.
To accelerate the sandline drum, advance the lever up, which will increase
drum speed. The engine throttle will increase as required.
To stop drum movement, move throttle back to idle position and apply
pressure to the Sandline Drum Brake Lever located below the Sandline
Control Console. The "Down" position applies the brakes and the "Up"
position releases the brakes.
27
WARNING AS TO FITNESS FOR
ANY PARTICULAR PURPOSE
~
This product is supplied in accordance with the
Purchaser' s specifications and does not necessarily
include aH accessories and safety devices required
to put this product into operation.
~
Safety devices such as, but not limited to, traveling
block safety controls, ladder climbing devices,
derrickman and floorman escape devices, traveling
block travellimits, spinning wrenches, chains,
cables, etc. are available from other suppliers and it
is the Purchaser's responsibility to obtain all
accessories and safety devices necessary to
complete the product so that the product can be
operated safely.
~ Taylor
Rigs makes no warranties as to the fitness
of this product for any particular purpose.
GAUGEA
GAUGEB
CAUTION
~ BEFORE
LOWERING MAST ENGAGE
HYDRAULIC PUMP AND CAREFULLy RAISE
LEVER "B" UNTIL 300 P.S.!. IS MAINTAINED
ON GUAGE "B".
~ RELEASE
ANY AIR TRAPPED IN RAISING
CYLINDER BY CAREFULLY OPENING AIR
RELEASE VAL VE LOCATED ON TOP OF
RAISING CYLINDER.
~ RE-PRESSURE
AS REQUIRED TO REMOVE
ALL AIR FROM CYLINDER.
~
CLOSE AIR RELEASE V AL VE AND LOWER
MAST.
SAFE OPERATION OF A WELL
SERVICE UNIT
THE FOLLOWING ARE POINTS OF PARTICULAR IMPORTANCE IN THE
SAFE OPERATION OF A SERVICING UNIT.
DO NOT
Raise the mast in to the vertical position without adequate foundation under
the mast and rig for any loads that might be encountered.
DO NOT
Raise the mast to vertical position without wheel chocks, spring applied
brake chambers or other means which are adequate to prevent the unit from
rolling to or away from the well.
DO NOT
Operate mast near power lines that might contact the mast or its guy lines
when it is being raised or moved. If an electricalline is a possible hazard,
the line should be de-energized by qualified personnel.
DO NOT
Lower mast into the roading position before first determining without any
doubt that the hydraulic raising ram is full of oil (on the raising side) and is
ready to receive the weight ofthe mast after it brakes over center.
DO NOT
Go up in mast without a safety belt. Safety belt should be wom at all times
when in the mast.
ELECTRICAL CONTROLS
SECTION 6
1. CAT C-15 ENGINE CONTROL MODULE DIAGRAM
2. OPERATORS CONSOLE WIRING
3. SHIFT WIRING HARNESS DIAGRAM
4. DASH SENDING DIAGRAM
5. DASH WIRING DIAGRAM
6. WIRING COLOR CODE
7. TERMINAL BLOCK DIAGRAM
8. BATTERY BOX WIRING DIAGRAM
9. ENGlNE KILL & EMERGENCY KILL DIAGRAM
10. RIG WIRING DIAGRAM
1 L ENGlNE START / POWER TO CAB
12. HEADLIGHT HARNESS DIAGRAM
PROPRIETARY MATERIAL
FRONT
~R
PRESSURE
FRONT
LOW AlR
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REAR
LOW AIR
LlGHT
REAR
AIR
PRESSURE
RIGHT
SIGNAL
FUEL
OIL
TEMP
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HEAD
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WATER
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PREg~URE DIAG
WARNING
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SPEEDOMffER
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This information contained within
is the property of Taylor Rigs,llc
and shall not be copied or used
in any manner or disclosed to
others except as expressly
authorized.
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TURN - 20A
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SHIFT - 10A
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PROPR IETARY MATE RIAL
This informotion contoined within
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LlGHT
C400
R/G W/R/NG D/AGRAM
DATE.No.fJE
I
1 20. 0.0.0.6 0.0.72
I
B
I
16
BROWN
I Ir.HT
_
_GA
__
_ _-_LEFT
_ _RFAR
_ _TLJRN
___
_ _ _ _ ___+_10 - O 1 16 GA BROWN 16 GA GREEN -
RIGHT REAR TURN LlGHT
10 GA YELLOW 16 GA WHITE -
TAIL LlGHT RUNNING
IO N O
1
16 GA GREEN -
1 O "" O
1
10 GA YELLOW -
LEFT FRONT TURN LlGHT
16 GA BLUE -
MAINTENANCE OVERDUE
16 GA BLUE - RIGHT FRONT TURN LlGHT
16 GA BLUE/WHITE - RIGHT TURN INDICATOR
_ _'_1~
6 _G:..:.A=____P.:.:
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IC.:........:_ _ ___+_
16 GA PINK -
BRIGHT LlGHT INDICATOR
SPEEDOMETER GROUND
~
O
O
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OIL PRESSURE
16 GA YELLOW/RED -
WATER TEMP
16 GA GRAY -
OIL TEMP TRANS
0 -..
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B.::...
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1
16 GA GREEN/WHITE -
1 o '" O
1
16 GA PINK -
Oo O
1
16 GA WHITE/ORG. POWER TO HYD. BIPASS
1
16 GA WHITE/ORG. POWER TO HYD. BIPASS
16 GA GREEN/RED -
TAIL LlGHT RUNNING
O U1 o--1~
16.:........:G=--A'----'0=-RA-'-N=--G:..;:E:l../=--W=--H.:..:.IT.=E-E~C:..:.M.:........:-.:........:M.::...A-'-IN.:..:.T.=E-'NA-'-N=__C:..;:E:........::.
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VE~R.:.:D:..;:U=
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1
RIGHT FRONT TURN LlGHT
16 GA GREEN/WHITE -
RIGHT REAR TURN LlGHT
16 GA WHITE - LEFT FRONT TURN LlGHT
16 GA BROWN/WHITE - LEFT TURN INDICATOR
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16 GA ORANGE/WHITE ECM -
LEFT REAR TURN LlGHT
1
BRIGHT LlGHT INDICATOR
SPEEDOMETER GROUND
O = O I 16 GA GREEN/RED -
OIL PRESSURE
IO N O
1
16 GA YELLOW/RED -
lo o;¡ O
1
16 GA GRAY -
"O
WATER TEMP
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5:
OIL TEMP TRANS
fTl
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16 GA PURPLE/WHITE -
FUEL
1
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16 GA PURPLE/WHITE -
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16 GA
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16 GA YELLOW -
n
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1 O ~ 0+11
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HEATER IN CAB
16 GA YELLOW -
HEATER IN CAB
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16 GA RED /B~CK -
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16 GA BLUE/B~CK ECM -
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WARNING
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8 GA RED -
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RIG SIDE
CAB SI DE
REVIS IONS
PROPRIETARY MATERIAL
This information contained within
is the property of Taylor Rigs,llc
and shall not be copied or used
in any manner or disclosed to
others except as expressly
a uthorized.
DESCRIPTION
REV
ADDED NOTE
1
FRONT
\!\IR
PRESSURE
FRONT
LOW AIR
LlGHT
REAR
AIR
PRESSURE
REAR
LOW AIR
LlGHT
FUEL
RIGHT
SIGNAL
VOLTS
OIL
TEMP
TRANS
HEAD
LlGffP
LEFT
SIGNAL
WATER
TEMP
OIL
PRESSURE
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3/19/01
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TITLE
DASH SENDING DIAGRAM
DWG NO.
NEXT ASSEMBLY:
N/ A
1-2D-Ol04
CHECKED APPR.
1 OF 1
REV
1
-+
PROPRIETARY MATERIAL
This information contained within
is the prop erty of Taylor Rigs,llc
and shall not be copied or used
in any manner or disc losed to
others except as expressly
authorized .
16 GA ORANG E/ BLACK -
25A
ICNlTION
SWITCH
POWER
75A
ECM
UNSWITCHED
3 5A
MAIN POWER
RELAY
STAR TER
RELA Y
MAINT.
OVERDUE
CLEAR
DIR ECTL y TO ENG INE COMPUTER
O:::
w
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8
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27
GA RED -
RELAY IN CAB
10 GA GRE EN 16 GA PURP LE -
16
II
DI RECTLY TO STARTE R AT ENG INE
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GA RED -
16 GA GRAY/RED -
,
,
--_ ..-
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-
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-._---
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----
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-
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STARTER BUTTON IN CAB
GA
TAN - AIR DRYER
@
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f-
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1II
BATTERY
5
1
3-18-9975
BATTERY
UNIT
STARTER RELAY
4
1
3-18-9924
35 AMP BREAKER
3
1
3-18-9927
15 AMP BREAKER
2
2
3-18 - 9925
25 AMP BR EAK ER
1
1
3 - 18 - 9968
OVERDU E
ITEM
QTY
DWG/PART NO .
PARTS LIST
+
#
ENGINEERING NOTES:
-~
~~~
TITLE
M~NT E NANCE
DESCRIPTI ON /
BATTERY
BUTTON
NOMENCLATURE
~IL t.
NEXT ASSEMBLY:
N/A
CHECKED APPR.
B
SCALE
C400 BATTERY
BOX WIRING DIAGRAM
IDWN. BY
I DWG NO.
1 20 0001
M. MOSELEY
ISHEET
NON E
1 OF
0072
1
rEY
TO FUEL RELA y IN BA TTERY BOX
JO GA ORG. /WHITE
ENG/NE
K/LL BUTTON
1-
(REAR)
JO GA
ORGLWHITE SWITCHED POWER DRILLER CONSOLE
1
+
ro +
CAT
EMERGENCY
K/LL
SOLENOID
DR/LLER CONSOLE
EMERGENCY
K/LL BUTTON
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3
10 GA. RED/WH/TE
~
EMERGENCY
K/LL RELAY
4
+
u
3
2
2
2
1
1
ITEM
QTY
3-20-00(4
COlE HERSEE NOMAl lY ClOSED
3-20-0002
COlE HERSEE NORMAlly OPEN
3-20-00C3
COlE HERSEE RElAY
3- 20-0006
CAT SOlENO ID
DWG/PART NO.
DESCRIPTION /
NOMENClATURE
PARTS LIST
UNIT
#
ENGINEERING NOTES:
(STZE
NEXT ASSEMBLY:
N/ A
CHECKED APPR.
IDWN. BY
B 1
M. MOSELEY
SCALE
NONE
IDWG NO.
,REV
1-20-0103-00721
I SHEET
1 OF 1
PURP LE/WHITE
RED/WHITE
DUAL PANEL HARNESS
r
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EXTENSION HARNESS 10 ~ORS CONSOLE
RED/WHITE
_
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CONTROL PANEL
OPERATORS CONSOI_E
CONTROL PANEL
CAB UNIT
BLACK/WHITE TO GROUND
RED/WHITE TO SH IFT BREAKER,~
ORANGE/WHITE TO SH IFT BREAKER ~
~
)
~
-
\
l'--____----{BAT +
MASTER HARNESS TO TRANSMISSION
SHIFTER HARNESS
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SHIFTER CONTACT PLATE WIRING
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l-
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o
,'--------------------
STONE BENNETT
UPSHIFT /DOWNSHIFT
PI LOT VALVE
o
(LOCATED AT TRANSMISSION)
2
10.9/22/0.6
60.0.0.0.330.0. WAS 60.-0.0.0.0./7
DMIZAR
/
, /0./ /4/ 0.4
MODIFlED SHIFTER TERMINAL WIRING
JRG
r-;'~'-~~~7T~~~~~~~------------¡----.
__~____~~__~____~-----~------~R~E~Vl ___DA_T._E~_ _ _ _ _R_E_V,_~_IO_N_D_E_s_c_m_p_n_ON_ _- ,_ _L-_B_Y~
9
/
45 0.0.0.0.2/ SHIFTER, WITH BRACKET
8
/
60.- 0.0.0348
RELA Y, So.LlD STA TE
7
/
45 - 0.0.0.0.0./
VALVE BASE
6
/
40.-0.0.0043
VALVé, UPSHIFT/DOWNSHIFT PILOT
5
/
60.-0.0.0.0./4
SHIFTER HARNESS
To.LERANCES
(UNLESS OTHERWISE NOTED)
...-+--...¡..-------+o----------.....;----;;....;.;;..;------.,...---.--....
~
4
/
3
/
2
2
60.- 0.0.0.0./5
MASTER HARNESS ro TRANSMISSlo.N
60.0.0.0.330.0.
HARNESS, BENNET SHIFTER 60.'
60.-0.0.0.0.2/
SHIFTER CDNTRo.L PANEL
HOLE DIAMETER:
UP ro .250.
.25/-.50.0.
.50./ - . 750.
.75/- /.0.0.0.
1.0./ & OVER
=
=
=
=
PROPRIETARY MATERIAL
The informotion contoined within
is the property of Toy lor Rigs , LLC
ond sholl not be cop ied or used
in ony monner or disclosed to
others except os e xpressly
outhorized .
APPROVED BY:
IDA TE:
+.0.0.5/-.0.0/
+.DD6/-.DD7 f-- _ __ _ _--'-_ _ _ __ ---'
+.0.0.8/-.0.0.7
PRODUCTlON APPROVAL / DATE
+. o. 10/-. DO. /f--:....:..:.::~:..:.:.::.:..:....:..::..Ir-:..:.::.::...::~--=-:.~+.0./5/ .0.0./
SH/FT W/R/NG
HARNESS D/AGRAM
1--1__+ ______-+-__________________________+-___.•__-1 /. ALL DIMENSlo.NS ARE INCHES, '--_ _ _~CH.::..K.::..._=_B~Y·r/.::...-:::D..::..
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30.- 0.0.3/93 BENNETT
ASSEMBLY 2 STATIDN
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/
/
60. 0.0.0.0./6
DUAL PANEL HARNESS
L.-+__
r ITEM DTY
PART NO.
DESCRIPnON
DWG. NO.
SHARP COGES, R.o.2 MAX .0.2 X 45· MAX
DWN BY' /
JRG
I
DA TE.
1/22/0.4
30 - 003793
I
~
I
B
I
2
.."
PRO PRIETARY MATE RIA L
Th is information contained within
is the property of Taylor Rigs,IIc
and shall not be copi ed or used
in any manner or disc losed to
ot hers exc ept as express ly
a ut horized.
16 CA ORANC E/SLACK -
8 CA
@ 8 CA
@
@
MAINT.
OVéRDUé
CLéAR
STARTéR
RéLAY
DIRECTL y TO ENCIN E COMPUTER
O:::
w
RED RED -
<C
DIRECTLY TO STARTER AT ENC INE
10 CA CREEN -
+ Jc/Jw/""~V""~
I
¡5.
ICNITION SWITCH
ECM POWER UNSWITCHED - DIRECTLY TO COM PUTER
16 CA CRAY/RED -
STARTER SUTTON IN CAS
16 CA CRAY/RED -
DIRECTLY TO DRILLER'S CONSOLE STARTER SUTTON
AIR DRYER
10 _~A TAN - ---_."
- - -DIRECTLY TO AIR DRYER
-
~-
--
-
-
- ._-
_.
--
.. -
2
(/)
o
1-
POWéR SWITCH
~
c::::::::
\4
- -
1-
~
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RELAY IN CAS
3
16
35A
MAIN POWéR
RéLAY
1O:::
16 CA PURPLE -
@
25A
IGN/TlON
SWITCH
POWéR
15A
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UNSWITCHéD
1
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I
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NEG -
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~
pos.@- -
NEG -
11I
B,ó.TTERY
5
1
3-18-9975
BATTERY
BATTERY
#
STARTER RELAY
UNIT
ENGINEERING NOTES:
4
1
3-18-9924
35 AMP BREAKER
3
1
3-18-9927
15 AMP BREAKER
2
2
3- 18-9925
25 AMP BR EAKER
1
1
3 - 18-9968
OVERDUE MAINTENANCE BUTTON
ITEM
QTY
DWG/ PART NO .
DESCRIPTION /
PARTS LIST
~~
-~
~~~
TITLE
NOMENCLATURE
NEXT ASS EMBLY:
1:,ILt.
N/A
CHECKED APPR.
B
SCALE
C400 BATTE RY
BO X WIRING DIAGRAM
IDWN . BY
M. MOSELEY
NON E
IDWG NO.
1 20 0001
rEY
0072
¡S HEET
1 OF 1
--
RELAY
TURN SWITCH
~____________________~G~RE=E~N_-~L=En~~FR~O~N~T~T~UR~N~________~f
~==================~J
GRAY - LEn REAR
BLACK/GRAY - STO P Ll GHT SWITCH
FLASHER
POWER
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16 GA GREEN/WHI~
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PURPLE
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16 GA YELLOW/BLA~
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REV
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DESCRIPTlON
DATEI
BY
REVISIONS
PROPRI ETARY MATER IAL
This info rma t ion contained within r---,------------~~~~~--------------~
is the property of Taylor Rigs,lIc
and shall not be copied or used
in any manner or disclosed t o
others except as expressly
authorized.
APPROVED B Y:
~~--
DATE:
TITLE
PRODUCTlON APPROVAL /
ITEM
OTYI
PART NO.
I
DESCRIPTION
BILL OF MATERIAL
J
DWG, NO..
DWN. BY: /
JACKH
I
CHK BY: /
I
C400
DA TE
I
DATE:
ID 11 0.2
DATE:
!-IEADL/GHT HARNESS D/AGRAM
s, :ALE
NONE
I
UWC
NG
40.0.0.3 0.0.72
I
I
~Z~t
B
I
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~
AIR & HYORAULIC SCHEMATICS
SECTION 7
1. PNEUMATIC CONTROL SCHEMATIC
2. AIR BRAKE SCHEMATIC
3. HYDRAULIC SCHEMATIC
4. CLT-754 HYDRAULIC HOSE KIT
r-----------------------------------------------l-1/2" SCH40
PIPE--------~--------------------------_4~----------------------_e---------------
TONG CIRCUIT
}
~1"
I
(CONNECTIONS LOCATED
ON REAR BUMPER)
HOSE---------4----------------
13
¡
¡STEERING
GEAR
1-1/2" HOSE""
suenaN
L/NES
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1/2" HOSE
'---'---@
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'-------1" SCH80 PIPE
--------------------------------------10
re
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0 1---1" HOSE ___________
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lt_
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6
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LF JACK
RF JACK
RR JACK
LR JACK
..+r:-...----, -
L...-_ _ _ _ _ _ _
-
I
:l?+,. :: :
I
I
I
35-000305
VAL VE, BALL 1-1/2"
8
1
40-000629
VAL VE BAN/(, OVA20
7
1
40-000031
VAL VE, O/VERTER
VAL VE BAN/(, OVA35 W/ POWER BEYONO
9
2
6
1
40-001202
15
1
40-000448
W/NCH, PLANETARY 707
5
1
40-000325
VALVE,SUN P/LOT OPERATED VENTEO RELlEF
14
1
40-000326
SUN VALVE
4
3
40-000291
CAUCE, HYDRAULlC PRESSURE 3000PS/
13
1
40-000455
F/LTER, HYO PUMP W/MTG WW
3
1
40-000038
VAL VE, PRESSURE RELlEF
12
1
30-000645
RESTR/CTOR OR/FlCE ASSEMBL y
2
1
40-001140
PUM?, POWER STEER/NG
11
7
40-000296
CYLlNOER, MAST RA/S/NG
1
40-007027
PUM?, P3750GPM
70
4
40-000200
CYL/NOER, LEVELlNG JACK 70"
30-003128
C400 HYORAULlC
/TEM OTY
PART NO.
OESCR/PT/ON
BILL OF MATERIAL
7
OWG. NO.
/TEM
OTY
PART NO.
L
BILL OF MATERIAL
~-~
SCOP/NC CYL/NOER, SUN VAL VF
ANO F/XEO OR/FACE SUPPLlEO
W/TH OERR/CK. NOTE THE OR/FACE
ANO SUN VAL VE ARE THE SAME
AS USEO ON THE RA/S/NC RAMS
MAST RAISE
PROPRIETARY MATERIAL
.X .XX .XXX ..
OESCR/PT/ON
I
I
I
:r
:r
:r
1/16
.OJO
.005
FRACT10NS _ :H/16
ANGtLS -
30-003128
DWG. NO.
r
1/2'
The informatiol. conlcined within
is the properi) 01 Toylor Rigs, lLC
ond .hall nol '::le copied or used
in ony monner or di.dosed to
others except os expressly
authorized.
APPROVED BY:
DoII7'E.:
"':::;:;:: +.005/_.00A-......,==""..-~=,...,.=,.......¡i=
.251-.500 _ +.fXJ6/- .00
PROOlICT1CJIr,' APPROVAl.
C400 HYDRAULlC
SCHEMAT/C
ll41F
.!KJ1- .750 - +.OOlJ/- .OO
.751- 1.000 - +.010/- .00
1.01 .. 0YE1? - +.015/- .00
ALL DlMOiSIONS ~ IN INCHES
{IJNUSS OTHERWISC NOTFD}
DWN. BY:
JRC
ll4TE:
t
'5/~
5C4LE
I
JO OOJ128
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I -
rrHROTTlE ACT.I
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I
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OPERATOR CONSOLE I
AT OERRICK
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PANEL
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~--~~~----~-~-~-o--~COMPRESSOR
TUBlNG DRUM
CONTROL
BRAKE
C4LIPER
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ORIVERS
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CAD
L
1"OPERATOR CONSOLE I
I
AT ORAWWORKS
I
I
I
I
I
I
I
I
srtfNilófM
L ____ ~
DESCRIPTlDN
OWG. NO.
BILL OF MATERIAL
PROPRIETARY MATERIAL
This information contained within ~--------~~=-~~~~~~~=-------------~
is the property of Taylor Rigs,llc
ond shall not be copied or used
in any manner or disclosed to
others except as expressly
authorized.
~~--
APPROVED B Y:
T1TLE
I--OA"-'E,'- - - - - - 1
DWN. BY: /
DATE:
JRG
CHK. BY: /
DATE:
4/3/02
C400 SERIES CONTROLS
PNEUMA TIC SCHEMA TIC
~ .
NONE
N.
7-24-0012
@--
-- -- -- -- -- -- --
--
-- - -
-- --
--
I
18
18
I
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cb í®,
PR: CONTROL
SUPPL Y
12 SECo CONTROL
14 SEC
SUPPL Y
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VAL ~ TWO WAY SHU TTL E CHECK
~
COMPRESSOR (specific fa vehicle)
~
VAL VE, PRESSURE REL/EF (oir)
~
9
J
18
2
40 000069 GUAGE, AIR PSI
~
8
1
~
17
3
40-000029
VAL VE, QU/CK RELEASE
~
7
1
40- 000065
16
1
40- 000019
VAL VE, RELA Y -
~
6
2
60- 000044 SWITCH, LOW PRESSURE
~
5
1
40- 0000 11 GOVERNOR
~
15
40- 000066
2
60- 000048 SWITCH, STOP L/GHT
~
4
4
REAR SPRING BRAKE CHAMBER
~
1
40- 000068
VAL ~ PUSH/PULL
~
3
4
FRONT BRAKE CHAMBER
~
12
1
40 00006/
VAL ~ DUAL FOOT
~
2
J
40 000028 VAL ~ ONE WAY CHECK
""
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ITEM
QTY
PART NO.
~
1
4
65-000013 TAN/(, AIR 12 " DIAMETER
AIR BRAKE SYSTEM, 4 AXLE
~
DESCRIPTION
4
-- -- --
~
I DAll"1
~#
DWG. NO.
ITEM
QTY
PART NO.
DESCRIPTlON
TITLE
DWN. BUY: /
JRG
I
BILL OF MA TERIA L
I
.
4 AXLE A/R
4-24- 0001
DWG. NO.
BY
~~
APPROVED BY:
~
1 24 0006
I
DESCRIPTlON
RE VISIONS
This information contained within
is t he property of Taylor Rigs,llc
an d shall not be copied or used
in any manner or disclosed to
others except as expressly
authorized.
CHK. B Y: /
BILL OF MA TERIAL
4
T
I
DATE:
40 000001 DRYER ,AIR
4
,.... -4 •
PRO PRIETARY MATERIAL
13
1
~
'---
REV
14
10
4
2
~
VAL VE, MANUAL DRAIN
4
j
L
60-000070 L/GH!, INDlCA TOR (r ed)
40-000032
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2
4
4
L_ @
17
--
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11
--
A
GJ e:~ GJ ~8: GJ ~8:
2
--
3
3
4 PORT
--
--
DA TE:
11/29/01
BRAKE S YS TEM
,
,
I
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fJWG
DA ll":
NONE
NC
1 24 0006
S,
7E
B
Rt.V
~
- - - - - - - - ALLISON CL(B)T 754 SERIES ST
,
.,
SPECIFICATlONS
..(
Model
Items
CLBT 754
Speeds forward
Speeds reverse
Max input speed, rpm
Max input tOrQue, N· m Ob-ft)
Input power, kW (hp)
Converter stall torque
Gear ratios-flrst
5
-seco,n~
\i
1
l .
2500
1765(300)
315 (425)
1. 8-3. o
5.18
3.19
2.02
-thlrd
1. 38
1.00
4.72 or 9.92 .
-fo~rth
-fifth
-reverse
Tra nsfer gear 'ratio
Dry w.eig,t, kg (lb)
'1 .
533 (1175)
FEATURES ANO OPTIONS
APPLlCATIONS
Off-highway rear dumps
Loggi ng trucks
Crash and fire trucks
Oi1 fie1d servicing rigs
AG tractors
ChQice of two range se1ection versions
Automatic upshifting and downshifting in all
ranges' with ho 1d in each range and deep reverse
, rati o
Automatic upshifting and downshifting in al1
r.a.nges above second with hold in each range
and manua 1 first
Provision for mechanica1 or pneumatic shift
modu1ation control
Provision for engine-driven and/or converterdriven power takeOff
Inhibitors to prevent hannfu 1 downshifts or
reverse shifts
Lockup c1utch ;n all ranges for maximum fue1
economy
Choice of converters to match w;de range of
di ese 1 engi nes
Va ri ab 1e i npu'!: capac ity converter
Provision for neutral start switch; reverse
signa1 switch; high range signa1 provision,
lockup sjgnal provision
Optiona1 drop box configuration
Optional manual aútomatic contro1s
GENERAL COMMENTS
,1
The CLBT 754 Series transmission is designed and bui1t primarily for off-highway applications
such as construction, mining, lo9g;ng, and agriculture. A1l models have five speeds and are
'available in straight-through and drop box configurations. There are two range selection versions available: automatic 2-through-5 with manual first-hold and automatic l-through-5 ~ith
deep reverse. There is. a choice of engine-mount or remote-mount input options. All !1lode:l,s a.t é
matched primarily with diesel engines.
2-11
~.
.....
mounted to the side of the transmission and projects about 4 in. (l02 IT)m)
outside the transmission envelope in places. There is sufficient clearance
for most typical installations.
The 7pcsition control system shown in figure 8-1 is avaílable from WABCO
and their authorized distributors as WABCO Kit P IN 65.459. The WABCO
components included in the kít are the 7 position .cylinder, rotair valves,
pilotair val ve, shuttle valves, bracket and linkage kit.
MANUAL SHlfT CONTROl
7P-9S ROTA IR VALV[-P6J98H
AUTOIl\>.TlCSHIn CONTROl
7p·9$ ROTA IR VALVI:-P6J985
W SHUffiE VA l VfS
p,l.mo·z
.I1HH B CYLII4DER
S(V[N POS ITloo P6398l-J
'LIIU
7 POSlllON
GENERAL SCHEMA TIC
PNEUMATIC CONTROL CIRCUIT
SUPPORT BAACK[! <lT 6527<
IWO STATIQN CONTRa.
IMNUAL SITP,t,UTOMATlC SaECTIOH
16<196
Figure 8-1. WARCO Shifter Control Schematic
40
1 SCH 80
PIPE COUPLlNG
"'K
SPCS'~
2 5/8
.. ~ 3~/4 ~
10 1/2
--'/'
4
3/4" SCH 80
PIPE COUPLlNG
(TYP. 2 PLCS.)
~
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,
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PIPE COUPLlNG
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fJl1/32 (15 PLCS)
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(16 PLCS)
fJ 11/32 ON
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ITEM 3 DETAlL
ITEM 2 DETAlL
4
10/3/03
ADDED ITEM 15, REVISED NOTES
CJM
J
1/20/03
REVISED TANK TO SHOW HANDLES
CJM
2
10/02
REMOVED ROTARY TABLE OPTIONS/RENUMBER B.O.M.
CJM
REV
DATE
DESCRIPTlON
BY
REVISIONS
TOLéRANCES
(UNLESS OTHERWISE MOTEO)
APPROVED BY:
3
1
25- 001266
PL.
1/4 THK. x 12 x 14 LG.
2
1
25- 001265
PL.
1/4 THK. x 12 x 14 LG.
30- 000019
ASS' Y, HYD.
ITéM
QTY
PART NO.
TANK
DéSCRIPTlON
BILL OF MATERIAL
DATE:
1-22-0100
DWG. NO.
SC:4 'F
(UNLESS OTHERWISE NOTED)
J. NANCé
I
8/6/02
NONE
7JWG. Nr. .
1 22 0100 SHT 2 OF 2
I
SIZE
B
I
RéV
4
9
"
/'
/
NOTE:
,. REMOVE ALL BURRS AND SHARP EDGES
R .02 MAX - 45· x .02 MAX
2. UNLESS NOTED ALL MA TlNG SURFACES TO
BE WELDED 90%- 110% OF THINNEST
MATING PARTS MA TERIAL THICKNESS.
3. REQU/RES INSPECTION BY THE QUALlTY
ASSURANCE DEPARTMENT.
4. ALL COUPLlNGS TO BE 1/2 IN 1/2 OUT
ON ITEM 2 W/ FULL WELDS ON BOTH SIDES
OF ITEM 2.
ALL PIPE NIPPLES SHOULD HA VE SAME
5. AMOUNT OF THREADS EXPOSED.
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40.- 0.0.0.455
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/
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Bo.L!, HEX HEAD 5/76- 18 x 3/4 (GR 8)
~
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4
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GASKET, RUBBER 1/4 THK (VENDDR SUPPLlED)
~
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~
5
1
35-0.0.0.194
Co.UPLlNG,
WASHER, SEALlNG 5/16
~
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35-0.0.0.161
Co.LLAR, 3/4 SCH. 40.
Bo.L!, HEX HEAD 5/16- 18 x
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ASS'Y; DIP STICK
~
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~
WASHER, LOCK 5/16 (GR 8)
~
PART NO..
DESCRIPTlo.N
BILL
OF
MATERIAL
DWG. NO.
3
2
1
1
1
1
ITEM
QTY
25-0.0.1266
25-0.0.1265
4
10/3/03
ADD ITEM 15, REVISED NOTES
CJM
3
1/20/03
REVISED TANK TO SHOW HANDL ES
CJM
2
10/02
REMOVED ROTARY TABLE OPTlONS/RENUMBER B.O.M.
CJM
REV
DATE
DESCRIPTlON
BY
REV/S/ONS
~
1 SCH. 80. 16 3/8 LG.
~
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1
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LINEAR:
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PLA TE, BLANK
PLA TE, HYD. RETURN
SHT 2
30.-0.0.0.611
WELDMEN!, HYD. TANK STANDARD
2-22- 0.104
30.- 0.0.0.0.19
ASS'Y; HYD.
1-22- 0.100
TANK
PART NO.
DESCRIP Tlo.N
BILL
OF
MATERIAL
TOLERANCES
(UNLESS OTHERWISE NOTEO)
DWG. NO..
.X
.XX
.XXX
FRACTlo.NS
ANGLES
=
=
=
=
=
Í
Í
Í
1/16
.0.30.
.0.0.5
Íl/16
Í
1/2'
PROPRI ETARY MATER IAL
The i nfo r m at ion contoi ned within
is the property of Toylor Rigs , LLC
ond shall not be copied or used
in ony monner or disclosed to
others except os expressly
outhorized .
APPRo.VED BY:
DArt.TlTLE
Ho.LE DIAMETER:
=
.251 - .50.0. =
.50.1-.150. =
.151-1.0.0.0. =
UP To. .250.
+.0.0.5/-.0.0.1
+.0.0.6/- .0.0.1
+.0.0.8/- .0.0.1
+.0.10/-.0.0.1
1.0.1 &- o.VER - +.0.15/ .0.0.1
ALL OIMENSIONS ARE IN INCHES
(UNLESS DTHERWISE NOTEO)
PRo.DUCTlo.N APPRDVAL /
CHK. B Y: /
DA TE:
DWN. B Y: /
DATE:
J NANCE
STANDARD
HYDRAUL/C TANK
DATE
8/6/0.2
Sr.:ALt
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1- 22- 0.10.0. SHT 1 o.F 2
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0042-1480RAWWORKS
SECTION 8
1. DRA WWORKS FULL ASSEMBL y
2. DRAWWORKS TUBING DRUM ASSEMBL y
3. DRAWWORKS SAND LINE DRUM ASSEMBLY
4. DRAWWORKS INPUT DRIVE ASSEMBL y
5. DRAWWORKS GEARDRIVEASSEMBLY
6. DRAWWORKS TUBING DRUM BRAKE ASSEMBL y
7. DRAWWORKS SAND LINE DRUM BRAKE ASSEMBL y
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ITEM 5 DETAlL
ITEM 4 DETAlL
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3/15/02
REV/SEo. AND REDRAWN To. MEET CURRENT STANDARDS
M./.M.
REV
DATE
DESCRIPT/o.N
BY
PROPRI ETARY MATERIAL 1-_ _ _ _ _ _ _.;...R;..::E;..;l/¡:-'/S.;;......;IO;....N~S------___1
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~~
This informotion contoined within
~~~~~~~~~~~~~~~~~~~~~~~~ is the property of To~or Rigs,llc
9
25-000755
SPROCKET RETAINER PLA TE
ond sholl not be copied or used
in ony monner or disclosed to
8
25-0007.32
SPROCKET SIDE SPACER
others except os expressly
7
80-000105
TUBING DRUM SPRo.CKET
2
25-00.0.7.37
BEARING CARRIER
5
25-0.0.0.7.30.
BEARING CARRIER MOUNT (STUB SIDE)
4
25- 00.0729
BEARING CARRIER MOUNT (SPRo.CKET SIDE)
.30.- 000779
TUBING DRUM ASS'y
6
ITEM
OTY
PART NO.
DESCRIPTION
BILL OF MATERIAL
AO;;:~~;;d~y.
~~
RIGS. LLC
DATé."
TlTLE
PRo.DUCT/o.N APPRo.VAL /
1- 40.- 0.0.0.9
DWG. NO..
DWN. BY· /
J NANCE
CHK. BY· /
DATE
DA Té."
3 -5-0.2
DD42- 748 DRA WWORKS
TUB/NG DRUM DETA/LS
v
W,.N.
DA Té."
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1-40.-0.0.0.9 SHT .3 o.F .3
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ITEM 7 DETAlL
-'-
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-----+\=----_ _
------L
ITEM 5 DETAlL
3
7- 18-02
NEW TB &- P/N'S
JNN
REV
DATE
DESCRIPTlON
BY
REVISIONS
PROPRIETARY MATERIAL
This information contained within
is the property of Taylor Rigs,llc
and shall not be cop ied or used
in any manner or disclosed to
others except as expressly
authorized.
7
6
5
ITEM
2
1
2
QTY
25-000753
PLA TE, SPRING MOUNTiNG
25- 000752
SHAFT, BRAKE ACTUA TlCN
25 000721
UNKAGE, BRAKE
30 000258
ASS'Y, SANO UNE DRUM BRAKE
PART NO.
DESCRIPTION
BILL OF MATERIAL
-
DWG. NO.
APPROVED BY:
DATE:
TITLE
PRODUCTION APPROVAL /
DWH. BY' /
J NANCE
I
CHK. BY' /
J
DAT[
DATE:
3 - 13- 02
DA TE:
DD42 - 748 DRA WWORKS
SAND L/NE DRUM BRAKE ASS'Y
..5'C4 F
NONE
I
Iti . N .
1 40 0002 SHT 3 OF 3
I
I
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I
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3
1.250
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/
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(TYP 72 PLCS)
1iJ72DDD " BC
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{M. 000
(TYP 4 PLCS
liJO 787
( TYP 72 PLCS)
1iJ26.5DO" BC
liJO 787
(TYP 72 PLCS)
1iJ26.500" BC
A
ITEM 5 DETAlL
ITEM 4 DETAlL
4J
ITEM 7 DETAlL
- (1
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J. I
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t
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ITEM 6 DETAlL
2
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REV
PROPRIETARY MATERIAL
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liJo.. 787
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ITEM 9 DETAlL
----
fJ6. 126
fJ4.688
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,
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ITEM 8 DETAlL
~~-~---~-----------~---~
25- 000755
9
SPROCKU RUA/NER PiATE
8
25-000732
SPROCKU S/DE SPACER
7
80-000105
TUB/NG DRUM SPROCKU
25- 000731
BEAR/NG CARR/ER
5
25- 000730
BEAR/NG CARR/ER MOUNT (STUB S/DE)
4
25 - 000729
BEAR/NG CARR/ER MOUNT (SPROCKU S/DE)
30- 000236
ASS'Y, SAND UNE DRUM
6
/TEM
2
QTY
PART NO.
DESCR/PT/ON
B/LL OF MATERIAL
This informotion contained within
is the property of Taylor Rigs.llc
and shall not be copied or used
in any manner or disclosed to
others except as expressly
:;;;~~;~d~y'.
DATE
CHANCEO BEARINCS ANO BEAR/NC CARR/ER
JNN
DESCR/PT/ON
BY
REV/S/ONS
~._---~
---~
-~.....;.::_
~~
~~:=-----------,
~~
RIGS, LLC
DATE
T/líE
PRODUCTlON APPROVAL /
DWH. BY.' /
DWG. NO.
J NANCE
CHK. BY.' /
DATE
DATE
3 - 5-02
DD42 - J 48 DRA WWORKS
SAND DRUM DETA/LS
v
. N.
DATE
NONE
1-40-0008 SHT 3 OF 3
2
CHART
PART NUMBER W/RE ROPE D/A.
80-000022
16"
1
"
80-000021
"
180-000365
SEE NOTE
NOTE:
DUR/NG /NSTALLAT/ON LOCATE
GREASE /NLET PORT AT :t 15· BDC
MI.M
BY
1--,;...,¡.-4------+-------------4-----I---t--t-__- __-r____- __.........- - - - - - - - - t - - - - - 1
This informatian contained within
is the property of Taylor Rigs,llc
t-::__::_::_::=:-t-____:_::___.........:__:_=_=_=_=_=::_-t-----t inandanyshallmanner
not be copied or
or disclosed
~~....::..-I-::..:......::..::.:~=-+....::...::..::.::::....:.=:.-.----------I-----I_::;-__
used
to
¡....:.,;...,¡.-4------+--=---=-..:...--..::...:...---...:..:.........:....-4-----I---t--t-----r---------:----___:_t-----1 others
except as expressly
authorized.
DATE:
" (GR 8)
DD42 - 748 DRA WWORKS
TUB/NG DRUM ASS y
J
B/LL OF MA TER/AL
NONE
1-40-0009 SHT 2 OF J
J
CHART A'
PART NUMBER WIRE ROPE DIA.
80 - 000022
80- 000021
80- 000365
9/16"
1"
1- 1/8"
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\
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-----
\
/
SEE NOTE
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I
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\
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/
IN
\ ~IDE
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\
12
48
70-000013
SEAL '
70-000011
SEAL
9
25-000755
SPROCKET RETA/AER PLATE
8
25- 000732
SPROCKET SIDE SPACER
2
\
BOL-!, HEX HEAD .3/4"-10 X 225" (CR 8)
S![fE
'" ----- ,
I
t-_II__+----I---------------+-----t--7+-t-8-0--0-0-0-'0-5+-T,-U-Bl_N_G_D_R_U_M_S_P.'?__
OC_K._ET
_ _ _ _ _ _~----I
NOTE:
- --// /
-
PROPRIETARY MATERIAL
This information contained within
2
25- 00073/
BEA"NG CARRIER
"
3/15/02
REVISED ANO REDRAWN ro MEET CURRENT STANDARDS
MJM
'?EV
DATE
DESCRIPTION
BY
REV/S/ONS
I--.--------...:...:.~:...:..::;;;,.:",.:::..:..~=-------------I
~~
~
Ihe pcopecly 01 Toyloc "9,.11,
t-_II__+----I------....:.:..----..:..:..-=:~-+-----t--II--+----I------._-..-:-~....:..::.--~----1 others except as expressly
4
25-000729
BEAR/NG CARR/ER MOUNT (SPROCKET S/DE)
3
30-000232
STUB SHAFT WEWMENT
r-;_-r-----r--~----~~------~----~--r-+-----;-------------------~~~~
2
30- 000231
SPROCKET S/DE ~'HAFT WELDMENT
2 - 40- 0013
/TEM
QTY
30- 000230
TUB/NG DRUM WnDMENT
2 - 40- 0125
30- 000179
TUB/NG DRUM ASS'Y
1- 40- 0009
PART NO.
DESCR/PT/ON
B/LL OF MA TER/AL
RIGS, LLC
authorized.
2-40-0014
DWC. NO.
APPROVED BY'
DURING INSTALLATlON LOCATE
GREASE INLET PORT A T :± 15' BDC
3
~~~~----~-~~~---------~----~~I-~----~-----.~-------~---~
and sholl not be copied or used
5
25- 000730
BEAR/NG CARR/ER MOUNT (STUB S/DE)
in any manner or disclosed to
6
/
DATE:
TI7iE
PRODUCT/ON APPROVAL /
DWN. BY' /
MOSELEY
CHK. BY' /
DA TE
DA TE:
4/23/02
DD42 - J48 DRA WWORKS
TUB/NG DRUM ASSJy
v
W,.N.
DATE:
NONE
1-40-0009 SHT 1 OF 3
3
25-0.00.785
26
25
24
12
48
KEY
11
2
NUT, NYLOC 1 "-8
Bo.LT, HEX HE4D 3/,4"- 10
X 2.25" (GR 8)
70.-0.0.0.0.13
SEAL (SMALL)
lO.
70.-0.0.0.0.11
SEAL (LARGE)
9
25-0.0.0.755
PLATE, KEY RETAINER
8
25-0.0.0.732
SPACER
7
80.- 0.0.0.111
SPRo.CKET, SANO UNE ORUM
25-0.0.0.731
BEARING CARRIER
NOTE:
2
24
24
WASHER, FLAT 7" (GR 8)
23
24
CAP SCREW, FLAT HEAD
22
2
80.-0.0.0.0.16
BRAKE ORUM
21
2
70.-0.0.0.0.0.2
BEARING
6
20.
3
Bo.LT, HEX HEAO 3/,8"-16 X I"(GR 8)
5
25-0.0.0.730.
PLATE, DRUM Mo.UNTING (No.NSPRDCKET SIDE
Bo.LT, HEX HEAO 1 "-14 X 2.5" (GR 8)
4
25-0.0.0.729
PLATE, DRUM MDUNTlNG (SPRDCKET SIDE)
30.- 0.0.0.242
WELDMENT, STUB SHAFT
2-40.-0.011
30.- 0.0.0.241
WELDMENT, SPRo.CKET SHAFT
2-40.-0010.
RED LOCK TIGHT
30.-0.0.0.238
WELDMENT, SANO ORUM
2 - 40.- 0.0.0.9
WASHER, LOCK 3/,4" (GR 8)
30.-0.0.0.236
ASS 'Y, SANO UNE ORUM
19
'"-8 x 3-1/2"
(GR 8)
4-40.-0105
18
25
1" LOCK WASHER
3
17
24
Bo.LT, HEX HEAO 1"- 8 X 5.5" (GR 8)
2
16
15
14
13
80.-0.0.0.0.37
24
24
48
NUT, NYLOC 3/,4"-10. (GR 8)
WASHER, FLAT 3/,4" (GR 8)
ITEM
2
QTY
PART NO.
4/29/0
REV
BILL OF MATERIAL
BY
~~--
DATE:
TITLE
PRDOUCTIo.N APPRo.VAL /' DA TE
OWN. BY· / ' DATE:
OWG. NO.
JNN
OESCRIPTlo.N
REVISIONS
PROPRIETARY MATERIAL
OESCRIPTIo.N
CHANGEO BEARINGS ANO BE4RING CARRIER
DATE
This information contained wi\hin
is the property of Taylor Rigs,lIc
and shall not be copied or used
in any manner or disclosed \0
others except as expressly
a uthorized.
APPRDVEO BY·
DUR/NC /NSTALLA T/ON LOCA TE
CREASE /NLET PORT A T :f: 15· BDC
J NANCE
3 - 9 - 0.2
[)D42 - 148 DRAWWORKS
SAND L/NE DRUM ASSJy
W<.
CHK.
/vo.NE
V
N.
1-40.-0.0.0.8 SHT 2 o.F 3
2
SEE NOTE
25-000785
26
25
24
23
24
24
24
22
2
80-000016
21
2
70-000002
20
3
19
12
48
KEY
11
2
NUT. NYLOC 1"-8
BOLT. HEX HEAD 3/4"-10
X 2.25" (GR 8)
70- 000013
SEAL (SMALL)
10
70-000011
SEAL (LARGE)
WASHER, FLAT 1" (GR 8)
9
25-000755
PLATE, KIT RETAINER
OIP SCREW, FIAT HEAD 1"-8 x 3-1/2" (GR 8)
8
25-000732
SPACER
7
80-000111
SPROCKET. SAND UNE DRUM
4-40-0105
2
[?EV
BEARING
6
25- 000731
BEARING CARRIER
BOLT. HEX HEAD 3/8"-16 X 1 "(GR 8)
5
25-000730
PLATE, DRUM MOUNTlNG (NONSPROCKET SIDE
BOLT. HEX HEAD 1"- 14 X 2.5" (GR 8)
4
25-000729
PLATE, DRUM MOUNTING (SPROCKET SIDE)
18
25
1" LOCK WASHER
3
30-000242
WELDMENT. STUB SHAFT
2-40-0011
17
24
BOLT. HEX HEAD 1 "-8 X 5.5" (GR 8)
2
30-000241
WELDMENT. SPROCKET SHAFT
2-40-0010
RED LDCK TlGHT
30-000238
WELDMENT. SAND DRUM
2-40-0009
30-000236
ASS'r; SAND UNE DRUM
80-000037
16
15
24
WASHER, LOCK 3/4" (GR 8)
14
24
NUT, NYLOC 3/4"-10 (GR 8)
13
48
WASHER, FLAT 3/4" (GR 8)
ITEM OTY
PART NO..
CHANGEO BEARINGS AND BEARING CARRIER
JNN
DATE
DESCRIPTION
BY
REVISIONS
This information contained within
is the property of Taylor Rigs,llc
and shall not be copied or used
in any manner or disclosed to
others exc ept as expressly
authorized.
DESCRIPTlDN
BILL OF MATERIAL
APPROVED BY:
¿;;¡~
DATE:
--
TITLE
PRDDUCTlDN APPRDVAL /
DWN. BY' /
DWG. ND.
DUR/NG /NSTALLAT/ON LOCATE
GREASE /NLET PORT AT ::t 1SO BDC
4/29/a
PROPRIETARY MATERIAL
BRAKE DRUM
2
NOTE:
J NANCE
CHK.
DA TE
DATE:
3 - 9-02
DD42 - 148 DRAWWORKS
SAND L/NE DRUM ASSJy
:4
Wi . N.
NONE
1-40-0008 SHT 2 DF 3
V
2
NOTE:
MOLDED BRAKE SHOE ALWAYS ON LlNKAGE SIDE OF
BRAKE BAND WELDMENT
6
26
2
20- 000268
BLEEDER, BRAKE
25
2
40- 000075
VALVE,
24
7/4 " NEEDLE
24
6
30-000276
ASS 'Y, BRAKE RETRACTOR (LEFT S/DE)
23
4
70-000713
BUSH/NG, BRONZE 1.25"OD X nD
22
2
70-000005
BLOCK, 4 BOLT PILLOW
27
A/R
25-000737
KEY,
1-40-0104
7/2"
20
70
NUT, 5/8"- 7 7 (GR 8)
79
20
WASHER, FLAT 5/8" (GR 8)
18
10
BOLT, HEX HEAD 5/8"-11 x 2.5 " (GR 8)
77
2
BOLT, HEX HEAD 1"- 8 x 8" (GR 8)
76
8
NUT, NYLOC 1 "- 8 (GR 8)
75
16
WASHER, FLAT 1" (GR 8)
14
6
BOLT, HEX HEAD 1 "-8 x 4.5 " (GR 8)
13
8
12
4
71
4
70
6
10
NUT, 3/8"-76 (GR 8)
80- 000034
SPRING
BOLT, SPADE 3/8"- 76 (GR 8)
30- 000265
ASS'Y, BRAKE RETRACTOR (RIGHT SIDE)
1-40-0104
9
30-000263
WELDMENT, SAND DRUM BRAKE QUADRANT
2 - 40- 0101
8
30-000273
WELDMENT, HAND BRAKE LEVER
2-40-0008
25-000753
PLA TE, SPRING MOUNT/NG
7
2
25-000752
SHAFT, BRAKE ACTUATlON
5
2
25-000721
UNKAGE, BRAKE
4
2
40- 000004
CYUNDER, WEST CRAFT
3
2
80-000005
KIT, SAND DRUM BRAKE SHOE
2
2
30-000255
WELDMENT, BRAKE BAND APPL Y BRACKET
2 - 40- 0002
2
30-000259
WELDMENT, SAND DRUM BRAKE BAND
2 - 40-0730
30-000258
ASS 'Y, SAND UNE DRUM BRAKE
QTY
PART NO.
DESCRIPTION
B/LL OF MA TER/AL
PROPRIETARY MATERIAL
This information contained within
is the property of Taylor Rigs,llc
and shall not be copied or used
in any manner or disclosed to
others except as expressly
authorized.
APPROVED BY:
OWG. NO.
7-18-Q
REV
8
6
ITEM
3
DATE
CHK. BY: /
DESCRIPTION
BY
REV/S/ONS
~1'!:
1--_--I--~~TITLEDD42PRODUCTlON APPROVAL /OATE
DATE:
5- 10-02
JNN
~.------------------~--~----------------~
DATE:
DWN. BY: /
J NANCE
NEW TB &- P/N'S
-
148 DRA WWORKS
SAND L/NE DRUM BRAKE ASSJy
DATE:
NONE
1-40-0002
3
12
r
I S . I S S ! IS.ISSl
~~~~~
~~~~~
REQ'D
+
3
3
.~
IIII
4
j - - - - = - c. _
7
REQ 'D
~./, IIII~
17
17
/'
29
2
20-000268
BLEEDER, BRAKE
28
2
40- 000075
VALVE,
27
A/R
25-000737
KEY STOCK,
7/4" NEEDLE
7/2"
74
76
WASHER, FIAT 7" (GR 8)
73
6
BOLT, HEX HEAD 1"-8 X 4.5" (GR 8)
72
8
NUT, 3/8"-76 (GI? 8)
26
4
WASHER, FIAT 3/4" (GR 8)
77
4
80- 000034
SPRING (NOT SHOWN)
25
2
NUT, 3/4"- 70 (GR 8)
70
6
30-000279
ASS'Y, BRAKE RET'?ACTOR (LEFT SIDE)
1-40-0105
24
2
BOLT, HEX HEAD 3/4"- 10 X 2.5" (GR 8)
9
6
30-000278
ASS'Y, BRAKE REl/?ACTOR (RIGHT SIDE)
1-40-0105
23
4
30-0002B2
QUADRANT, BRAKE
2-40-0102
22
4
BDLT, SPADE 3/8"-76
7
25-0.0.0.659
PIATE, SPRING (NOT SHDWN)
27
4
NUT, 5/8"- 7 7 (GR 8)
6
25-00.0769
SHAFT, BRAKE ACi7VATIDN
20.
76
WASHER, FIAT 5/8" (GR 8)
5
2
25-0.00727
LlNKAGE, DRUM
79
8
BDLT, HEX HEAD 5/8"-77 X 2.5" (GR 8)
4
2
40-000005
CYLlNDER, WEST CRAFT
78
70-000773
BUSHING, BRDNZE 7.25"0.0 X
nD
8
2
BLOCK, 2 BDLT PILLOW
3
2
30- 000284
WELDMENT, BRAKE BAND
2 - 40- 0129
70.-0.0.00.0.5
BLOCK, 4 Bo.LT PILLOW
2
2
30- 000255
BRACKET, BRAKE dAND APPL Y
2 - 40- 0002
2
80- 000004
KIT, BRAKE SHDE
30- 000780.
ASS'Y, TUBING BRAKE
2
76
2
BOLT, HEX HEAD 7"-8 X 8" (GR 8)
75
8
NUT, NYLOC 7 "- 8 (GR 8)
ITEM
QTY
PART NO.
DESCRIPT/o.N
BILL OF MATERIAL
DWG. NO.
ITEM QTY
PART NO..
DESCRIPTlDN
BILL OF ;1;1A TERIAL
ADDED SHT 1 AND 2
JNN
DATE
DESCRIPTION
BY
REVISIONS
PROPR IETARY MATER IAL
¿;¡y1r --
This information contained with in
is the property of Taylor Rigs ,lIc
and shall not be copied or used
in any manner or disclosed to
others except as expressly
authorized.
70-000004
77
REV
5-9-02
APPRo.VED BY:
DATE:
PRODUCTlON APPRo.VAL /
OWN. BY: /
DWG. NO..
MDSELEY
CHK. BY: /
DA TE
DATE:
3/27/02
DATE:
TITLE
DD42 - 148 DRAWWORKS
rUB/NG DRUM BRAKE ASSEMBLY
:4
No.NE
7- 40- 0.0.03 SHT 2 DF 3
r------I"-
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70-00.0~0----B___
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I
5-9-02
ADDED SHT I ANO 2
JNN
HEV
DATE
DESCRIPTION
BY
REV/S/ONS
PROPRIETARY MATERIAL
NOTE: 1.
2.
This information conta ined within
is t he property of Taylor Rigs,llc
and shall not be copied or used
in any manner or disclosed to
others except as expressly
authorized.
BREAK ALL SHARP EDGES
PRESS 2 /TEM 23'S FLUSH
/NTO /TEM 5 'S 2 HOLES
APPROVED BY:
30 000180
IITEMI QTYI
PART NO.
I
ASS'Y, TUBING BRAKE
DESCRIPTION
B/LL OF MA TER/AL
DATE:
DWN. BY: /
DWG. NO.
DA TE:
3/21/02
MOSELEY
CHK. BY: /
I
DATE:
rUB/NG DRUM BRAKE ASSEMBL y
sC4 ~t
W(i. N .
NONE
I 40 0003 SHT 3 OF 3
I
I
SIZE
B
I
I
REV
I
NOTE:
MOLDED BRAKE SHOE ALWAYS ON LlNKAGE SIDE OF
BRAKE BAND WELDMENT
3
10
REO'D
29
2
20-000268
BLEEDER, BRAKE
28
2
40- 000075
VALVE,
27
A/R
25- 000137
KEY STOCK,
7/4" NEEDLE-
26
4
WASHER, FLAT 3/4" (GR 8)
25
2
NUT, 3/4 "-70 (GR 8)
24
2
BOLT, HEX HEAD 3/4"-70 X 2.5" (CR 8)
23
4
22
4
BOLT, SPADE 3/8"-76
21
4
NUT, 5/8"- 1 1 (GR 8)
20
16
WASHER, FLAT 5/8" (GR 8)
19
8
18
70- 000ff3
10
1/2"
REO'D
3)
BUSHING, BRONZE f.25"OD X J'lD
BOLT, HEX HEAO 5/8"-ff X 2.5" (GR 8)
70 - 000004
BLOCK, 2 BOLT PILLOW
70-000005
BLOCK, 4 BOLT PILLOW
REO'D
17
2
16
2
BOLT, HEX HEAD 7"-8 X 8" (GR 8)
15
8
NUT, NYLOC 1"-8 (GR 8)
14
16
WASHER, FLAT 7" (GR 8)
73
6
BOLT, HEX HEAD 7 "_ 8 X 4.5" (GR 8)
12
8
77
4
80-000034
SPRING (NOT SHOWN)
10
6
30-000279
ASS'Y, BRAKE RETRACTaR (LEFT SIDE)
1-40- 0705
9
6
30- 000278
ASS'Y, BRAKE RETRACTaR (RIGHT SIOE)
1-40-0705
30- 000282
QUADRANT, BRAKE
2 - 40-0102
25-000659
PLATE, SPRING (NOT SHOWN)
25-000769
SHAFT, BRAKE ACTIVATION
8
7
2
6
REO'D
6
NUT, 3/8"-16 (GR 8)
2
25- 000727
LlNKAGE, DRUM
4
2
40- 000005
CYLlNDER, WEST CRAFT
2
30-000284
WELDMENT, BRAKE BAND
2 - 40- 0129
2
30-000255
BRACKET, BRAKE BAND APPL Y
2 - 40- 0002
2
80- 000004
KIT, BRAKE SHOE
30- 000180
ASS'Y, TUBING BRAKE
ITEM QTY
PART NO.
DESCRIPTlON
B/LL OF MA TER/AL
i7EV
PROPRIETARY MATERIAL
This information contained within
is the property of Taylor Rigs, llc
and shall not be copied or used
in any manner or disclosed to
others except as expressly
5
2
27
Aa;;;~~;~d~y'.
1 - - -______
5-9-02
AODED SHT 1 AND 2
JNN
DATE
OESCRIPTION
BY
I-.-----:-----.
m.. .
REV/S/ONS
-~
----::-------------I
~~
RIGS. LLC
DATE.
--,.¿..---~:=--tT'TLEDD42
DATE
PRODUCTION APPROVAL /
R00 I -_ _...;D_W,....'N_. ..;;B_Y.r-·/'--D._~:-TE.....: ~:---;
DWG. NO.
J NANCE
CHK. BY.· /
5 - 9 - 02
748 DRA WWORKS
TUB/NG DRUM BRAKE ASSJy
w, .
DA TE.
NONE
1- 40- 0003
REQ 'D
-----A
/1
~,
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/1
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/1
DRAWWORKS FRONT
CROSS BRACE WELDMENT
(REF)
22
6
\
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\
,
•
2
=
=
=
=
=
:=
=
=
=
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SECT/ON A-A
13
8
12
4
11
4
10
6
26
2
20-000268
25
2
40-000015
VA LVE,
24
6
30-000276
ASS'Y. BRAKE RETRACTo.R (LEFT SIDE)
23
4
70-000113
BUSHING, BRo.NZE 1.25"0.0 X 1"10
22
2
70-000005
21
A/R
25-000131
20
10
NUT, 5/8"-11 (GR 8)
6
19
20
WASHER, FLAT 5/8" (GR 8)
5
BLEEDER, BRAKE
NUT, 3/8"-16 (GR 8)
80-000034
SPRING
30-000265
ASS'Y. BRAKE RErRACTo.R (RIGHT SIDE)
1-40-0104
9
30-000263
WELDMENT, SANO DRUM BRAKE QUADRANT
2-40-0101
BLOCK, 4 Bo.LT PILLo.W
8
30-00.0273
WELDMENT, HAND BRAKE LEVER
2-40-0008
KEY.
7
25-00.0753
PLA TE, SPRING MOUNTING
25- 000752
SHAFT, BRAKE AC1UATION
25-000721
UNKAGE, BRAKE
1/4" NEEDLE
1- 40-0104
1/2"
2
2
BOLT, SPADE 3/8"-16 (GR 8)
18
10
Bo.LT, HEX HEAD 5/8"-11 x 2.5" (GR 8)
4
2
40- 000004
CYUNDER, WEST eRAFT
2
Bo.LT, HEX HEAD 1 "-8 x 8" (GR 8)
3
2
80- 000005
KIT, SANO DRUM BRAKE SHo.E
16
8
NUT, NYLOC 1 "-8 (GR 8)
2
2
30- 000255
WELDMENT, BRAKE BAND APPL Y BRACKET
2-40-0002
15
16
WASHER, FLAT 1" (GR 8)
2
30-000259
WELDMENT, SAND DRUM BRAKE BAND
2-40-0130
14
6
BOL!, HEX HEAD 1 "-8 x 4.5" (GR 8)
30- 000258
ASS'y' SANO UNE DRUM BRAKE
PART NO.
DESCRIPTlo.N
BILL OF MATERIAL
DWG. NO.
ITEM
QTY
PART NO..
DESCRIPTlo.N
BILL OF MATERIAL
7-18-Q
DATE
!?EV
APPRo.VED BY·
JNN
DESCRIPTlo.N
BY
~1!-
DATE:
TITLE
PRo.DUCTlo.N APPRo.VAL /
DWN. BY· /
DWG. NO..
NEW TB &- P/N'S
REVISIONS
PROPRIETARY MATERIAL
This informotion contoined within
is the property of Toylor Rigs,llc
ond sholl not be copied or used
in ony monner or disclosed to
others except os expressly
outhorized.
17
ITEM QTY
3
J NANCE
CHK. BY· /
OATE
DATE:
3 - 13- 02
DATE:
DD42 - 748 DRAWWORKS
SAND L/NE DRUM BRAKE ASS'Y
:4
No.NE
¡tí
N .
1- 40- 0002 SHT 2 o.F 3
3
IVA Régimen Común - Registro 03-3111-11
Actividad Económica ICA 9309
NO SOMOS GRANDES CONTRIBUYENTES
RESOLUCiÓN OIAN
No 320000964323
NELLY ARANGO DE PERALTA
N IT. 20.317.704-1 de Bogotá
CTURAOO A :
DISCOVERY ENERGY SERVICES COLOMBIA SA
FACTURA DE VENTA
Fecha: 2012/11/29
INDUSTRIAS METALlCAS PERALTA
l
OlA
MES
...... v.
900.238.070-3
NIT.
22138
No.
Habilita del 21434 al 25000
J
......
AÑO
. .1
.¡
OlA
j
VI
MES
J AÑO
... ;;)
FORMA DE PAGO:
DIRECCION: AV KR 9113 52
6203244
TEL. :
1128
ORDEN DE TRABAJO No.
ORDEN DE COMPRA O PEDID O No .
CANTIDAD
CONTADO
SALIDA O REMISiÓN No.
DESCRIPCION
Vr. UNITARIO
ZUNCHOS MALACATE TAYLOR C 400 EN LAMINA ASTM A 36 CAL 1/4
2
$ 900.000
VALOR TOTAL
S 1.800.000
SE ADJUNTA CERTIFICACION DE MATERIAL
r-' ----.--.-.
..
lCANf
.~~.
!'J~ '~: E~
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LEY 1231 DEL ESTATU
TRIBUTARIO
"'<o" "'""" ~ ~m,
...
'''''~SEN'"ESTA
00000
'" OOM'"''
, ,,,"""""
FACTURA.
A ENTERASATISFACCION
OCLAS
0".0
",", DESCRI
ECLARO HABER RECIBIDO REAL YMATERIALMENTE
MERCANCIAS
l/U fU AR..
DE pE.RAL1A.
DE~C~OR
N~e)1
-~
___
RECIBIDO PO
el h
NOMBRE IC.C. y FECHA
VALOR MERCANCIA
1. V.A.
VALOR TOTAL $
1 -19 - Teléfonos: 24723 43 - 23761 04 - 277 27 03 Fax 237 68 32
-
S 1.800.000
S 288.000
S 2.088_000
80 9 otá O.C.
rt l°-'~.
\ \
rAPCiJV
~~An UBEM J -1 TOC~U
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STEEL
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ifT~~IDn.'it§n
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INSPECTION GERTlflCATE
HfppDn Steel Carporatioo
~
H . '7 10.)..0071
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..~tE~º--~f!~[-s.¡~~-~¿jo~\~~~}~fk~l.~·~.'~~'~\~:~ 1¡~';;t41 7!
O:T;" WORKS
. 1.I\(51 !1t:05JJ.0 IT:':.( I!"\".(IiT·,· nfi
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CERnFICATENo·: 1 2K3 1 035ü3
Po :; ~ S
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DISCOVERY ENERGY SERVICES COLOMBIA S.A.
NIT: 900.238.070-3
ORDEN DE COMPRA No
RES
D
St
P
O
C _ ACTO
ARA.N<:;O DE P'ERALTA NELLY
CR 22 16 19
60% ANTICIPO- 40 CONTRAENTREGA
JESUS ALBERTO PERALTA
<l~o.cr6828
NIT
20,317,704
FECHA
09/07/2013
f,ECHA ENTREGA: 12/07/2013
TEL
000023761C4
C.C
3204-13
FAX
00000000000
NTTO-D4-1S0S13 - 523
REQUISICION
NarA: Tenga en cuenta que de su servicio calidad, precio y cumplimiento en lo
acordado en esta negociaci6n
dependen
los resultados de la evaluación y reevaluación ,q ue DISCOVERY ENERGY S,ERVICES COLOMBIA S .A. realiza
para el mejoramiento continuó de nuestro sistema de gestión QHSE.
PRODUCTO
9990001000001
DESCRIPCION
UND
I
•.•••.••• I
CANTID~-' _ _V_/_UN_IT_AR_I_O_ _ _V_/T_O_T_A_L_ _
•• ~...
,I
FABRICACION ZONCHO MALACATE Tl;YLOR C400
I
i
I
I
1
I
I
I
I
I
1
I
I
1
I
¡
1
I
I
I
I
1
1
I
1
I
I
i
1
I
!
I
I
I
¡
I
~------------------------------------------------------_.-------------------------I
~
.1 ;}"1
~~\-&
-tl 000
<r.
LUGAR DE ENTREGA: KM 4 VIA SUBA - COTA
TALADRO D4
COTIZACION No.078/1J
USO DE MATERIAL : MALACATE
BOGOTA
a, I'\.\.
,0 .4~::-e
1 ('~
),) "" 1'v!t.(~!
,
OBSERVACIONES
Para la radicación de la factura se debe presentar
1. Copia de la Orden firmada por el proveedor
2. Copia de la remisión fi rmada por Discovery Ene,rgy Services Colombia S. A,
3. Fra en original y copia adicional para Discovery Energy Services Colombia S,A
SUBTOTAL
IVA
$
$
1,800,000
288,000
NETO A PAGAR
S
2,088,000
I
SON: DOS MILLONES OCHENTA Y OCHO MIL PESOS
1
IF ,
ELABORO
____________ ______~~L-------__
SCO RAMIR
! A1Jl'ORIZACION
-~L-~~~--------I-----------------
!
!IMPALTA
IACEPTACION
_ __ _ __ __
FAD - 007
Actualizaci6n N°2
Vigente 28/10 / 2010 pag 1 de 1
••• Soluciones Integrales
INFORME DE ANÁLISIS IOS013-024
OISCOVERY ENERGY SERVICES
NI 181584
Fecha entrega: 08 - JULIO -13
Fecha Recepción:
08 Julio 2013
CONTACTO:
In9. Johnary Rico Rincón
OBJETIVO:
Medición de dureza de una muestra.
ANALlSIS
IDENTIFICACION PIEZA:
Medición de dureza.
1. MUESTRA
RESULTADOS MUESTRA
Dureza
72-77 HRB
ONCLUSIONES
La Muestra presenta un rango de dureza de 72 - 77 HRB.
De acuerdo a esta dureza el material se asemeja a las durezas de Aceros como A36, o AISI 1030 de
acuerdo a la Norma ASTM A29/A29M-04.
.
NOTA:
• Los análisis y resultados obtenidos en el presente informe solo aplican a las muestras suministradas por
El Cliente.
• El uso y aplicación de los resultados del presente informe son responsabilidad del cliente.
• Las muestras guardadas por T. Ferrotermicos serán preservadas por un tiempo de tres (3) meses,
posteriormente serán dispuestas.
Elaboró:
~==
Ing. Aeronáutico.
____
o
_·_n_o
_v_a_c_ió_n_Y_D
_e_s_a_rr_o_lI_o ____________________________________
--------~CE3)
Calle 18A Sur No. 29a -10 Tel: 4096611
Fax: 7137119
email: info@ferrotermicos.com website: http://www.ferrotermicos.com
FI&D 01 V ERS.OO
VIGENTE: 02-MAY·12
Página 1 de 1
BRAKE":BLOCKS, :.,'
BRAi<E:BAN"DSand
, ,RIMS ", :',
', '
Harr¡sbürg'Suppli~sa; to¡j,plete
maRes
' R~ymark"~ ":" , :',::~<',~'(~C\', :', , Harjisburg's.,
;'" lndu;Stries'-~-!.;::::,\:::;,~'~~;~:;,:,:, 'Manufacturing:;."
'Manufadurer '
'ofRaybestqs®'".:
"EXpértise '
,
:
.~.
';. '," , '
Harris~urg
,
line
brake bloéksare '
,1""
:-, ' óf qualíty brákeb!ocks, brake barigs
manufactlired at the company's
arid rims for'al!
and ~rhodelsof
' Hatrísburg brake blocksaré
,
manüfactUr.íhg faéili:ty in Houston, "' "
' ,.
ks"
" " ,,' ", ,, '
"
produc:ed fram raw materia~ ~\JPplí~ ,
Th 1 "
'fi If" d ' ed +:
draw/''¡or ~
:' ,
'
"
d'
' f' " ' f
" e p ant.ls speCl ¡ca ''j "eslgn , lor ,
by Ráyrriark ln ustries, manv acturerb
precisfof1 rnanufacturing of,brake
, Harrisburg !;lrak~blq~ks'are availabre
in both ásbestos ¡mq," non:,ásbestos: ,
RaybeStos? the world's foremoSt '
bJoeks.
"
industrial frict¡on 'materia1.
;.;:,~. "
materíals. Bothprovicje $)<cé!lent wear
Cutting, drilling, counterboñng and ,o" , i.,
lífe.-Advanced manufacturing proc~sses , : ' 'Raybestos btake matenaJs
roHingequipment, designed ~xdusívely .
ená,ble H~rd~QUI;g to cootrorthe
-'
iilspected fotvisual appearance,
, fo( brake block manufacturing, 1S
pnysical charaGteriStici,of each brake
rTIqterial iritegrity and'dimensional
utilized by skilled workers at the pla'nt. ,"
block from the outer surface to the
teleranees befare they le;:lVe Raymark's
Cutting takes place on a hydraulic
coreo
Thls
promotes
even
wear
Manheím,
Pennsylvania,
plant.
The
saw,
yvhich automatically cLJts the '
.. .
throughout the brake block'sentireRaybestqs name ¡s your assura_nc~ ofbrake blocJ<s to precise Jengths. During
, ....
quálity lining vvith sup~rior
th
tt"
'h
th
t "
lite Ojce.
d l' b'I' 'h h
' e cu Ing p ase, e operatof
Harrisburg brake band~ are
performance ah " re la 11ty t al ,as
carefully measures the dimensions and
eonstructed to meet or exceed OEM
been the industry standard for over 40
confirms the squareness ofeach block.
specificatíons. Unless specifieations
years on al! models of drilling and
Multi-head and single-head drill
require another type of material,
workover ngs.
presses are used to bore brake block
Harrisburg brake bands are made of
holes, A multí-head drill press
A-242 material, which fs '
simultaneoi.Jsly drills and (Ounterbores
considerably stronger and
each block's predetermined hale
has twice the.
pattern. During use of the single-head
atmospheric corrosior
drill press, a jíg is used to assure
resistan ce of the
accurac.y of hole alignment.
commanly-used
The final manufacturrng step
A-36,
involves a mUer machine
Harrisburg
whích applies the ,proper
radius to each block to
weld overlaid
rims are
conform to the designated '
available in
brake band radius. Each
both water'. ,~,
block is checked twice for
"':
tooled and
the prqper radius,
.splashQuality control
eooled
standards are rigíd. Every
models for
brake block is ínspected
all m¡;:¡kes of
duríng each .manufacturing
dravvworks,
step as well as being given
Rims can
a final inspection by our
afso be
, quality control inspector
rpanufactured
prior to shipping, The
to fit special
inspector checks tor quality of
applications.
matenal, proper dimensions,
squareness, radius and hale
alignment. Each block receíves an
tlinspected" stamp of approvál after it
passes all of these QC steps.
are
¡, "
'
...
. . .:
7
PROPRIETARY MATERIAL
This information contained within
is the property of Taylor Rigs,llc
and shall not be copied or used
in any manner or disclosed to
others except as ex pressly
authorized.
10 CA TAN
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BR~KER,____~ ~______~J
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1
=
-111 ro
BLOCK
-111 ro
CHASSIS
1
)
I
BR~KER
BR~KER
+
BR~KER
ro
DRYER
3
3-20-0001
BATTERY
5
1
3-18-99~!5
25 AMP BREAKER
4
2
3-18-9924
35 AMP BREAKER
3
2
3-20-0002
COlE HERSEE RElAY
2
1
3-20-0005
CAT STARTER
2
3-20-0003
COlE HERSEE NORMAlly OPEN
10 GA TAN
BATTERY
L
10 GA TAN
6
+
1
BATTERY
ITEM
L-....- -C2
@
QTY
DESCRIPTION /
DWG/PART NO.
NOMENClATUR E
PARTS LIST
~ r--NEXT ASSEMBLY:
N/A
BATTERY
ENGINEERING NOTES:
TITLE
CHECKED APPR.
ENGINEERING APPR.
1::,ILt.
C400 ENGINE
START / POWER TO CAB
IDWN. BY
B I
M. MOSELEY
SCALE
NONE
IDWG NO.
1-20- 0102-0072
ISHEET
I
1 OF 1
IREV
I
Operator's Manual
750/754 Series
Allison Off-Highway Transmissions
OM1475EN
OM1475EN
Operator's
Manual
;------- - _.. _- -- -_.
- -_._-~_
..
_-_._- ._--_ ..__ __.------_
.
._- _ ._---_._--. _..... _._ ... . .. .. -_
..
Allison Transmission
CBT 750/754
ClBT 750/754
ClBT 750/754DB REMOTE MOUNT
101 ~~e~~~!!I~~!!
P.O. BOl( 894 Indianapolis. Indiana 46206-0894
www.allisontransmission.com
Printed in U.SA
August 2001
. Copyright © 2001 General MotoIS COlp.
WARNINGS, CAUTIONS, ANO NOTES
IT IS YOUR RESPONSIBILITY to be completely familiar with the warnings and
cautioIlS described in this handbook It is, however, important to lDlderstand that these
warnings and cautions are not exhaustive. Allison Transmission could not possibly
know, evaluate, and advise the service trade of all conceivable ways in which service
might be done or of the possible hazardous consequences of each way. Consequently,
Allison Transmission has not undertaken any such broad evaluation. AccordingJ.y, --ANY0NE WHO USES A SERVICE PROCEDURE OR T00L WHICH IS-NOT
RECOMM:ENDED i3YALLISON TR.ANSMISSION MtJST first be tboroughly
satisfied-tDaí-neitherpersonal saÍety nor equipment safety will be jeopardized by fue
service methods selected.
Proper service and repair is important to the safe, reliable operation of the equipment.
The service procedures recornmended by Allison Transmission and described in this
handbook are effective methods for perfonning service operations. Sorne of these
service operations require the use of tools specially designed for the pmpose. The
special tools should be used when and as recornmended.
Three types of headings are used in this manual to attract your atlention. These
warnÍDgs and cautions advise of specific methods or actions that can result in personal
injury, darnage to the equipment, or cause fue equípment to become unsafe.
NOTE: A note is used when an operating procedure, practice, etc., is
.
essential to highlight.
TRADEMARK INFORMATION
DEXRON® is a registered trademark of General Motors Corporation.
11
TABlE OF CONTENTS
Page
Warnings, Cautions, and Notes. . .. . . . . . . . . . . . . . . .. . . .. . . . . . . . . . . . . .
II
·--··--------INlROOUCnON-··-Keeping That Allison Advantage . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . .
Typical 750/754 Series Off-Highway Transmission Models. . . . . . . . . . . . . .
A Bnef Descnptidií ofthe Allison Autcimatic . . . . . . . . . . . . . . . . . . . . . . . . .
Torque Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lockup Clutch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power TakeoffDrives. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Retarder (CBT, CLBT 750/754) . . . . .. . . . . . . . . . . . . . . . . . . . . .
Transfer Gear Housing (Dropbox) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Manual Disconnect Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Throttle Actuated Modulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cooler, Filter Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
2
3
3
4
4
5
5
6
6
6
SHIFT SElECTORS
Range Selection Positions (5 Speed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8
DRIVING TIPS
Operating in Cold Weafuer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Downshift Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Downshift or Reverse Inhibitor Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Accelerator Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Using fue Engine to Slow fue Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Using the Hydraulic Retarder (CBT, CLBT) . . . . . . . . . . . . . . . . . . . . . . . . . .
Driving on Ice or Snow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rocking Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Towmi oiPiisblng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Temperatures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1lI
9
9
9
10
10
10
10
10
11
11
11
Page
POWER TAKEOFF OPERATION
Converter-Driven PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . .
Engine-Driven PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- - - - - - - - _. .- .. __._---- ...
..
------_.. - -----.------ . -". .. - .. . _. _.- . .... -
-_._-_
_-- ~
_-~._._-_.-
12
12
- . - ..
CARE ANO MAINTENA-NCE
Periodic Inspe.c tions . . . . . . . . . . . . . . . . . . . . . . . . . . . , ... , . . . . . . . . . . . . .
Importance of Proper Fluid Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fluid Check Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cold Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rot Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fluid Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Keeping Fluid Clean. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fluid and Oil Filter Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Row to Keep Little Problems froro Becoroing Big Problems . . . . . . . . . . . . .
13
13
13
14
14
15
15
15
16
CUSTOMER SERVICE
Owner Assistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service Literature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Allison Transmission Distributors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Allison Transmission Regional Offices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
IV
17
19
20
23
INTRODUCTION
KEEPING THAT AlUSON ADVANTAGE
802744
Allison automatic transmissioDS provide many advantages for the driver whose
vehicle may encounter vigorous, tough use and sometimes abuse. Driving is easier,
safer, and more eflicient.
These transmissions are rugged and designed to provide long, trouble-free service.
This handbook will help you gain maximum benefits fromyour Allison transmissionequipped vehicle.
TYPICAl750/754 SERIES OFF-HIGHWAY
TRANSMISSION MODElS
CLBT 7501754 Remate Mount
CLBT 750/7540B Remate Mount
2
A BRIEF DESCRIPTION OF THE AlUSON AUTOMATIC
The basic components of the Allison automatic transmissions described in this manual
include:
• An hydraulic torque converter
,._------_.__ . - - _.
;
• A planetary gear train
- - - - -- - - --- - -- ----- -._._-------- -------• An hydraulic control system
- - -----
-------- ----
---
---- ------ - --- -
The torque converter multiplies engine torque during starts and acts as an hydraulic
cuslúon between the engine and gearing. The c1utches and gear sets provide multiple
fu~<lliiIallge-s
locICUP 6lUfdi engages
automatically after the vehic1e is moving, for maximum fuel economy. The hydraulic
control systern automatically selects the gear ratio for fue best efficiency by
responding to the vehicle speed and the throttle position.
-iUidone-réVerse-rnnge. Thetor<i.u-e converter
TORQUE CONVERTER
The torque converter consists ofthree elements:
• The pump is the input element and is driven by the engine.
• The turbine is the output element and is hydraulically driven by the pump.
• The stator is the reaction (torque multiplying) element.
When the pump (input) rotates at a higher speed than tIte turbine (output) speecl, the
torque converter multiplies the torque. When the turbine speed approaches the pump
speecl, torque multiplication stops and the torque converter functions as a fluid
coupling. With a fixed-capacity stator, engine power is always directed to the vehic1e
power train.
3
ENGINE-DRlVEN
PTO GEARTORQUE
CONVERTER
, - , ' " .. n::-D
PTO GEAR
PlANETARV
H01980
CLBT 750/754 Remote Mount -
Cross Section
lOCKUP ClUTCH
The lockup clutch is designed to hychaulically engage and disengage at predetemñned
tuIbine speeds. When turbine speed approaches the pump speed, hychaulic pressure
automatica1ly engages the lockup clutch. The fimction ofthe lockup clutch is to lock
the input element (pump) and the output element (turbine) together. With fue lockup
clutch engaged, the engine output is directed to the transmission gearing at 1: 1 speed
ratio. Reduction in the tuIbine speed (output speed) automatica1ly disengages fue
lockup clutch. When fue lockup clutch is disengaged, fue converter acts as a torque
multiplier or a :fluid coupling. The lockup clutch is momentarily disengaged during
upshifting and downshifting.
POWER TAKEOFF DRIVES
The CBT, CLBT 750/754 Series off-highway transmission has provisions for three
power takeoff drives - two engine-driven PTO drives, and ane converter-driven PTO
drive. Engine-driven PTOs may be mounted at tap and/or iower-left side of fue torque
converter housing. A converter-driven PTO may be mounted at fue upper-Ieft side of
fue transmission maín housing.
4
HYDRAUlIC RElARDER (CBl, CLBl750/754)
A vaned rotor and two vaned stators are the basic components of the retarder. A
manually-controlled valve:fills the cavity around the rotor with fluid when the vehicle
must be slowed on steep downgrades. When the cavity is emptied, the rotor is free of
drago Added safety and longer service brake life are the benefits gained frOID a
retarder.
TRANSFER GEAR HOUSiNG (Dropbox)
The dtopHóx Isa vemcal1:fañSfer gear case mowteato the rear oftlie trimSrirission
adapter housing. 1t can be mounted vertically (position 1) or in any offour other
positions (positions 2-5) to fue len oí vertical as view frOID me rear ofme áropbox.
These positions are bolt hole specific.
The dtopbox provides al: 1 gear ratio at three specific output locations. The top rear
location is in line with the input. The bottom rear and bottom front are extensions of
the drive, idIer, and driven gears in the dropbox.
REAR VlEW
OF DROPBOX
V07146
Dropbox Mounting Positions
5
MANUAL DISCONNECT ClUTCH
A manual1y-applied disconnect housing ís available at any one or all three of the
dropbox output locations. Linkage controls the movement of the shift lever in the
dísconnect housing, engagíng or dísengagíng the clutch.
- --T-HR-OHl:E-AGT-lJAfEB-M9BtftA16R------- ------ - .------ - -- -- Mechanícallínkage between the engíne throttle and the transmíssíon moves the
-control system modulator vru.ve. 'f4ís fe(!tpre malees the ~_íssion antornq.tic
reSponsrve-tú tiiiottle posltlon. áp-eníng the throttle will mise the speed
at which upshifts occur. Tímíng of shifts and clutch applications are regulated by the
modulator system. Precise and smoother shifts are obtained.
control"systérii
Other modulator control systems may be used includíng air and electrica1ly actuated
devices.
COOlER, FllTER CIRCUITS
A separate oil cooler or connection to the vehicle engine cooling system is used to
cool the transmíssíon fluid An external oil filter is placed in the converter-to-cooler
liIie on a1l models equípped with an hydraulic brake. An auxiliary filter may be
ínstalled in the converter-to-cooler line on non-retarder models at customer option.
6
\
DRIVING TIPS
OPERATING IN COLO WEATHER
Listed below, in Table 1, are the minimum fluid temperatures at which fue
transmission may be safely operated in a forward or reverse range. When ambient
temperature ís below the mínimum fluid temperature limit and the transmissíon is
cold, preheat is required If auxiliary heating equipment is not available, run the
engine to preheat the fluid to the minimum temperature limit before operating in a
forward or reverse range. Pailure to observe the mínimum fluid temperature limit can
result in transmission malfunction or reduced transmission life.
Table 1. Fluid Viscosity Grade and Minimum Operating Temperature
VlScosity Grade*
Mínimum Temperature
SAE 30 (C-4 Approved)
32°F (O°C)
SAE 15W-40 (C-4Approved)
5°P (-15°C)
_17 o p (-27°C)
DEXRON®-ill (C-4 Approved)
_4°P (-20°C)
SAE IOW (C-4Approved)
* These grades may be used at lower ambient temperatures if auxiliary preheat is available to heat the
fluid in the,sump to the temperature shown before operating the transmission.
OOWNSHIFT CONTROL
Downshifting is a manual shift to a lower range to match driving conditions
encountered or expect to be encountered Learning to take advantage of manual
downshifts will give betler control on slick or icy roads, and on steep downgrades.
Downshifting to lower ranges increases engine braking and hydraulic retarder effect.
The selection (jf a lowet tai'ige úfteÍi pteVents cycfuig bétWeeÍl ariinge and the next
higher range on a series of short up-and-down grades.
OOWNSHIFT OR REVERSE INHIBITOR FEATURE
The transmission hydraulic system will not permit a shift into any lower forward range
at a speed that will cause excessÍVe engine overspeed. Any lower forward range may
be selected at any time, but the actual shift into tbat range will not occur until road
speed is reduced - downshifting is progressive as road speed decreases. The inhibitor
effect will cause downshifts to occur at slightly higher speeds tban normal automatic
downshifts.
9
Shifting into reverse cannot be accomplished accidentaIly while traveling fOIward
until vehicle speed is very low, even though the shift lever is moved into the reverse
position. A full stop is required for any shift from forward to reverse or from reverse to
forward to avoid shift shock.
ACCELERATOR CONTROL
--------- .- ._- -
.. -
._... -_ ... . _. __ . - _._ ..
......
- -- ~.-
, - - . _--;--
:-:--.
Tbe Allison automatic transmission can upshift or downshift under influence of
accelerator rnoveiiielit Th-e opefátbt can gef a quiCKer düWris1üft or can ddáy the
upshift by handling the throttle to get the best performance from the transmission.
USING THE ENGINE TO SLOW THE VEHICLE
To use the engine as a braking force, the converter must be in lockup mode_ Iflockup
disengages, the frictional horsepower (braking force) from the engine is lost
Downsbift the transmission to the next Iower range. If excessive speed prohibits a
downshift, apply the service brake - slowing the vehicle to an acceptable
downshifting speed
USING THE HYDRAULlC RETARDER (CBT, CLBn
Each CBT and CLBT transmission model has an hydraulic retarder installed between
the torque converter and the transmission gearing. Apply the retarder to sIow the vehicle
on curves or downgrades. Maximum retarder effect occurs in the lowest range. The
tbrottle must be closed when the retarder is used to maximize the retarder performance
and prevent overheating.
Partial application is permitted when maximum retarder effect is not required
Continuous retarder operation raises the fluid temperature. Short periods of full-release
will aid cooling. Do not exceed 330°F (165°C) during intermittent retarder operation.
DRIVING ONICE OR SNOW
The Allison automatic transmission continuously provides proper balance between
required power and good traction. The operator can have better control of the vehicle
because üfthis smootb, coiiStant flow ofpower tbToügii. the drive train. When driving
on ice or snow, any acceleration or deceleration should be made gradually.
ROCKING OUT
Ifthe vehicle is stuck in sand, mud, or snow, it is often possible to "rock" it out Shift
to D (Drive) or (second to fifth) and apply a steady, light throttle, never fuJl tbrottle.
Then by IDOVing the shift selector back and forth between D (Drive) or (second to
fifth) and R (Reverse), rock the vehicle. Shifts frOID forward range to reverse-range
and reverse-range to forward-range should be made with the tbrottle backed off.
10
FLUID SPECIFICATIONS
Allison approved C-4 fluid is recommended for use in transmissions in off-highway
service. Use the C-4 fluid which conforms to the mínimum temperature (refer to
Table 1 on Page 9), flui<;l viscosity grade, and the deaIer recommended specifications
for the area. Use only SAE 30 fluid in the transfer case (dropbox).
- - - -- - ---- ----- - - - - - - - - ----- -- ..........._ -- -._. __ .. _- - -- . - .. _-_.
_._ --.-
...
_-- ......• _.'
..
KEEPING FLUID CLEAN
It is absolutely necessary that fue fluid put into the transmission be clean. Fluid must
be iialidied in clean contamcis arid :fiIlei's to preveÍJ.t foreigri. material eritéi:ili.g the
transmission.
FLUID AND OIL FILTER CHANGE
Fluid and oil filter change frequency is determined by transmission application and
severity of operating conditions. In general, the fluid and externaI filter elements
shouId be changed afier each 1000 hours of operation. Severe operating conditions
may require more frequent changes.
Allison high efficiency externaI oil filters do not have a mileage limitation. Allison
high efficiency externaI oil filters, which have a change filter indicator, do not have to
be changed when the oil is changed unless restriction is indicated.
To drain the transmission fluid, remove the 1 inch pipe plug (standard oil pan) behind
the oil :fiIlertube flange (orthe 'h inch plug at the rear ofthe deep oil pan). To drain the
dropbox, remove the plug from the botlom of the dropbox housing.
Fluid will drain better ifthe fluid is at operating temperature (hot). Replace the plug
afier the fluid is drained.
Reinove thefilter élement(s) and sealrings from the externaI oil filters. Install new
element(s) and sealrings.
Pour 34 U.S . qua.-ts (31liters) (6 Ol 7 inchpan) or 38 U.S. quarts (36liters) (8 \12 inch
pan) ofC-4 transmission fluid into the transmission. Pour 2.6 U.S. quarts (2.5liters) of
C-4 transmission fluid, grade 30, into the dropbox.
15
HOW TO KEEP LlTTLE PROBLEMS FROM
BECOMING BIG PROBlEMS
By observing the operation of the transmission and making periodic inspections,
minor mechanical problems can be kept from becoming major problems ifyou notify
maintenance personnel when one of these conditions occur:
"" -Uverlieatrng . ---
• Shiftiilg feelS odd
• Unusual sounds
• Transmission automatica1ly upshifts or downshifts at irregular intervals
• Fluid leaks from the transIDÍssion
16
CUSTOMER SERVICE
OWNER ASSISTANCE
The satisfaction and goodwill of the owners of Allison transmissions are of primary
concem to Allison Transmission Division (ATD), its distributors, and their dealers.
As an owner of an Allison transmission, you bave service locations throughout the
world that are eager to meet your parts and service needs with:
•
•
•
•
•
Expert service by trained personnel
Emergency service 24 hours a day in many areas
Complete parts support
Sales teams to help determine your transmissiori requirements
Product information and literature
Normally, any situation that arises in connection with the sale, operation, or service of
your transmission will be bandled by the distributor or dealer in your area (check the
telephone directory for the Allison Transmission service outlet nearest you).
We recognize, however, that despite the best intentions of everyone concemed,
misunderstandings may occur. To further assure your complete satisfaet!op.., 'He have
developed the following three-step procedure to be followed in the event you bave a
problem that has not been handled satisfactorily.
Step One - Discuss your problem with a member of management from the
distributorship or dealership. FrequentIy, complaints are the result of a breakdown
in communication and can quickly be resolved by a member of management. If you
bave already discussed the problem with the Sales or Service Manager, contact the
6eneralMana-get: MtATI> deatérs are-assoCÍ¡¡ted Wiili fu AlU iliStñ1JUfói. If yÓÜI
problems originate with a dealer, explain the matter toa management member of the
distributorsbip with whom the dealer has bis service agreement. The dealer will
provide bis ATD distributor 's name, address, and íelephone number on request.
Step Two - When it appears the problem cannot be resolved readily at the distributor
level without additional assistance, contact the Allison Transmission Regional Office
. responsible for the local distributor. You will be assisted by a member of the Regional
Service Managet's staff, depending on the nature ofyour problem.
17
For prornpt assistance, please have the following information available:.
• Name and location of authorized distributor or dealer
• Type and malee of equipment
• Transrnission rnodel number, serial number, and assembly number (if
equipped with electronic controls, also províde the ECU assembly number)
.... .. _~ _.Transmission delive!Y.~te 'E!~ acc:umula~~~~~ .andL<?!. ho~ º.L<ll:?~r:a.t:ion
• Nature of problem
• Chronological surnmary ofunit's history
Step T-hree - If you contacted a regional office and you are still nOÍ sansfied, present
the entire rnatter to the Borne Office by writing to the foUowing address or
clllling the phone nwnber be!ow:
Manager, Warranty Administration - PF9
Allison Transmission
PO Box 894
Indianapolis, IN 46206-0894
Phone: 1-800-524-2303
The inclusion of a1l pertinent information will assist the Home Oflice in expediting
the matter. If an additional review by the Horne Oflice of all the facts involved
indicates that sorne further acti0l!- can be taken, the Regional Oflice will be advised.
When contacting the Regional or H ome Office, please keep in mind that ultimately the
problem willlikely be resolved at the distributorshíp or dealershíp utilizing their
facilities, equíprnent, and personnel. Therefore, it is suggested that the aboye steps be
followed in sequence when experiencing a problern.
Your purchase of an Allison TransIIiission product is greatly appreciated, and it is our
sincere desire to assure complete satisfaction.
18
CENTRAL REGION
Caribe Detroit Diesel-Allison
Division of GT Corporation
Ceramic Ind. Parle, Campo Rico Ave.,
. __ ~loc~_~ . _____ ________ ______ _
Carolina, Puerto Rico 00982
787-750-5000
Inland Diesel, Inc.
13015 West Custer Avenue
Butler, WI 53007-0916
262-:78J~_7100 _
Central Detroit Diesel-Allison, Inc.
Liberty, MO 64068
816-781 -8070
Interstate Detroit Diesel
2501 East 80th Street
Minneapolis, MN 55425
612-854-5511
Clarke Detroit Diesel-Allison, Inc.
3133 East Kemper Road
Cincinnati, OH 45241
513-771 -2200
Inland Detroit Diesel-Allison, Inc.
210 Alexandra Way
Carol Stream, IL 60195
630-871 -1111
Florida Detroit Diesel-Allison, Inc.
5105 Bowden Road
Jacksonville, FL 32216
904-737-7330
Williams Detroit Diesel-Allison
Midwest, Inc.
1176 Industrial Parkway, North
Brunswick, OH 44212-2342
330-225-7751
noo Liberty Drive
SOUTHWESTERN REGION
Detroit Diesel-Allison De MeXÍco S.A.
DeC.V
Av. Ejercito Nacional #843
Colonia Granada, Mexico D.F.
C.P. 11520
52509_01-:3.057
United Engines, Inc.
5555 West Reno Avenue
Oklahoma City, OK 73127
405-947-3321
Stewart & Stevenson Power, Inc.
5840 Dahlia Street
Commerce City, CO 80022
303-287-7441
Stewart & Stevenson Services, Inc.
2707 North Loop West
Houston, TX 77008
713-868-7700
21
WESTERN REGION
Pacific Detroit Diesel-Allison Company
7215 South 228th Street
Kent, WA 98032
253-854-0505
Valley Detroit Diesel-Allison, Inc.
425 South Hacienda Boulevard
City ofIndustry, CA 91745-1123
626-333-1243
Sierra Detroit Diesel-AllisoD, Inc.
1755 Adams Avenue
San Leandro, CA 94577-1001
510-635-8991
williams Detroit Díesel-Allison
Southwest, Inc.
2602 S. 19thAvenue
Phoenix, AZ 85009
502-257 -0561
Smith Detroit Diesel-AllisoD, Inc.
250 West 3900 South
Salt Lake City, UT 84107
801-262-2631
CANADIAN REGION
Detroit Diesel-Allison
British Columbia Ud.
9300 - 192nd Street
Surrey, British Columbia V 4N 3R8
604-888-1211
Midwest Detroit Diesel-Allison Ud.
1460 Waverley Street
Winnipeg, Manitoba R3T OP6
204-452-8244
Detroit Diesel-Allison Canada East
(Div. ofIntegrated Power Systems Corp.)
2997 Rue Watt
Ste. Foy, Quebec G IX 3Wl
418-651-5371
Waterous Detroit Diesel-Allison (Div.
ofIntegrated Power Systems Corp)
10025 - 51 Avenue
Edmonton, Alberta T6E OA8
780-437-3550
Harp.er Ue.troit Diesel Ud.
10 Diesel Drive
Toronto, OIitario M8W 2T8
416-259-3281
22
AlllSON TRANSMISSION REGIONAL OFFICES
EASTERN REGION
WESTERN REGION
19 Oaklynn Drive
P. o. Box400
Columbus, NJ 08022-0400
. . CíO-9-=-2-98-2541 -----. ·.
39465 Paseo Padre Parkway
Suite 2400
. frenlp nb_CA!l4538 ..
510-498-5208
CENTRAL REGION
CANADIAN REGION
P. O. Box894, Speed Code PF06
Indianapolis, IN 46206
317 -242-2327
P. O. Box 5160, StationA
London, Ontario N6A 4N5
519-452-5256
SOUTHWESTERN REGION
Phone: 936-321-4248
Fax: 936-321-4278
23
OM1475EN 2000108
www.allisontransmission.com
Printed in USA 200111
PORT 'KK'
Ho.SE
PORT 'I!'
#
Po.RT
Ho.SE DESCRIPTlo.N
A
1/4" X 9"LG
B
1/4" X 2o."LG
3
C
4
D
5
6
1
PORT 'L'
2
. _-~--
FlL TER ASSEMBL y
(
PORT 'E '
PORT M'
PART NO.
M
40.-0.0.0.246
BB
40.-0.0.0.247
1/4" X 14"LG
CC
40.-0.0.0.248
1/4" X 22"LG
DD
40.-0.0.0.249
E
1/4" X 15''LG
EE
40.-0.0.0.250.
F
1/4" X 38''LG
FF
40.- 0.0.0.251
7
G
1/4" X 9"LG
GG
40.-0.0.0.252
8
H
1/4" X 26''LG
HH
40.-0.0.0.253
9
I
1" X 3o."LG
11
40.- 0.0.0.254
lO.
J
1" X 56''LG
JJ
40.-0.0.0.255
11
K
1" X 28"LG
KK
40.-0.0.0.256
12
L
1" X 54''LG
To. ENG.
40.-0.0.0.257
13
M
1" X 3J''LG
To. ENG.
40.-0.0.0.258
14
N
1" X 2J''LG
NN
40.-0.0.0.259
/~ .~'-....,
AIR OVER HYDRAULlC VALVE
(BECKET)
"----
Po.RT
..·····0
C"'" ,
~
,y
PORT 'D'
'G~TI
'cc'
,t
PORT 'FF'
PORT JJ
PORT 'HH '
PORT 'N'
PORT 'NN'
(---=======~----
PORT
ELECT. OVER
PORT 'H'
HYDRAULlC VAL VE
PORT A'
PORT 'B'
PORT 'GG'
DUAL MODE VAL VE
FlL TER ASSEMBL y
,
~/ .fij
\
>
SHIFTER
REY
DESCRIPTlo.N
BY
REV/S/ONS
PROPRIETARY MATERIAL
This information contained within
is the property of Taylor Rigs,lIc
and shall not be copied or used
in any manner or disclosed to
others except as expressly
authorized.
APPRo.VED BY:
TITLE
I-:-:-::DAr.=--E;_ _ _
40.-0.0.0.2/1
ITEM
QTY
PART NO.
CLT-754 HYD. Ho.SE KIT
DESCR,PTlo.N
B/LL OF MA TER/AL
DWN. BY· /
DWG. NO..
Mo.SELEY
CHK. BY· /
--t
eL T-754 TRANSMISSION
HOSE KIT
DATE:
4/18/0.2
DATE:
W<.N.
No.NE
1-22-0.121
LUBRICATION CRARTS
RECOMMENDED GREASES:
» L.E.
~
TEXACO
ALMAPLEX NO. 1275 or NO. 3752
MARFAKMULTI-PURPOSE-2
OR EQUIVALENT
RECOMMENDED MOTOR OILS:
~ L.E.
» EXXON
. MONOLEC MUTOR OILS 10V./ ---EXXON MOTOR OIL 10W
OR EQUIVALENT
LUBRICATION DATA
96-180-C
CROWN SHEA~s
B-589, B-590
MULTI-PURPOSE-2
WEEKLY
LATcn TUBJ;S
B-592
1OW MOTOR OIL
MONTHLY
LATcn RE'IRACTOR
D-198
MUTI-PURPOSE-2
6 MONTHS
TURNBUCKLES
A-541
MULTI-PURPOSE-2
MONTHLY
LUBRICATOR
SEENOTE
lOW MOTOR OIL
MONTHLY
T.B. CROWN PULLEY
A-526
MULTI-PURPOSE-2
MONTHLY
STABILIZERS
..
_-~
.
C-29~
NOTE: SEE NORGREN NIP-350 BULLETIN
-tyflJLTI-PlJP,J>OSR 2 ... -..... _ .. _
o, .
-
TB~1Q61
-TB-106'O
I
i
i
_~~
... ....r-1
L......;.I~
1
!
i
@
j
i
i
NOTE:
S:an d-Une
Sheave
.
24" McKissick She~ves
- - PEMCO EQUIPMENTCOMP.ANY
'Odessa, TX
\TlB-1064
.. . .
.i . .. . .
. ,.
.....
0-172
... ...... . ...... .. ... . .... . . . ... . ..... .. . ....
'
......... ....... ......... .......................... .... ........ ..
.. ............ ...... . .... .. .... , ................
..,
.. ............... ..
CRQ.\NN - 6 LINE
®
Q}
(21 1(4
G~
(~
m I(D
@
Travel Block
®
Tmvel Blook
. 0 ..172
O,.;172erown
5n
I
By:~.Vega ~e
'"--
None
'ate 6 .. 10w 76
IC-t07
3/4~
t-E-----
,
3/4
.....
¡'-
24
: 1--
'=
131/2
j
T,S 1061 C~O~SHEAVE AS'SEMBLY
,..;
---~'----~----------~
PEMCO EaUIPMENT COMPANY
O~essa TX
,-;'-
---~...;.:.------I
r!>ou13 le .$h-eaveAssemblyfor
,TB.. 10S'1P' ,meo Crown
DI'lBV
R. Ve a::~ 11~~
8-590
' ~,--~~------~--~
315/16
~1/2
1/2
23/4
24 _
,i .
:
,
!
13 1/2
[
1
--"---------r-~ -~~. _.~ -
- +--
'----t--r
'
f
,r
,
TB 1064 CROVVNJ SIHE:AVE ASSEMBLY
;
PEMCO fEQUIPMENTCOMP.ANY
OdesSa,
TX
.
1---'-- .
SingfeSheave As.sembly
forPe.m:co .Crowns
DrawnByR V
.
. Scale
. . ' ~ga
Date
None
11~30 ..79
B-589 .
I
. . ... ... J ..
.
..
.
• • . • . _... _.
- .• .... -" , .. -.... .... --...
. ..••.. . .....•..- ............... ..... '•.....• -'
..•.
........... ....
. o..
"
,".
"0' • • • •
_'0_'
0 __
EQUIPMENT COMPANY
P.O. BOX 472 • ODESSA. TEXAS 79760-0472
2238 STEVEN ROAD.
915 / 366-2895
•
FAX #915-366-1264
TB1014
2
TB1064-2
SIDE PLATES 1/2" X 10" X 18 1/2"
1
T131064-7
CENTER PIN 23/4" DIA. X 5 11/16"
2
ITB1064-7A
CENTER PIN NUTS
1
T81064-8
SHEAVE 24" OlA. - 9/16" W.L.
1
T81064-8A
SHEAVE 24" OlA. - 5/8" W.L.
1
T81 064-1 O
TIMKEN 8EARING ASSEMBLy 2 3/4"
2
T81064-11
GREASE SEALS
2
T81064-44
OUTER SHEAVE SPACER 2 49/64" X 31/2" X 9/16"
• • - - _ .• • • -
• •-
-"'
•
-
•• -
."-
. . . ~ .... -
••• •
...
. . , - - " ' ..... _ •
.,..~._ .......
I'.
~
........" - , , , : ,
5
~
3/4 -
3/4
6
41/4
24
13 1/2
TB 1060CROWN ~HEAVE A·SS.EM·B·Ly
,
¡
,
¡
PEMCb EQUIPMENT COMP,6J\JY
OdesSaTX
.
.
. "
I
.. ' I
sin2,le~he~v~ ~$sembly
"Qr PémeOCrOWM$
Di'8'#nBv
$C8Ie
R. v'.ga
None
!
,' ,
•
• ....
.
~
. ..
•
•• '
•••• u •• •••
',
. . ..
.
.
. . . . . . . .. . . . .
"" _ '
B~5S9
"
[)et,'
, e
.... .
1t~30·79
. __ ,
. ..... ~
~ ••
•
o ••
"
• • ••
•
• •• • • • • • •
,_
"
. . .. . . . _
••_
•• _ • • •
••
EQUIPMENT COMPANY
P.O. BOX 472 • ODESSA, TEXAS 79760 -0472
2238 STEVEN ROAD
915/366-2895 •
FAX # 915-366-1264
111. ClOWN BLOCK
QNTY
- - -- - - ------
-
PART
NUMBER
DESCRIPTION
- ... --- .
2
TB1060-2
SIOE PLATES 3/4"X 12" X 191/2"
1
T81060-7
CENTER PIN 4 1/4" OlA X 6 3/4"
2
T81060-7A
CENTER PIN NUTS
1
T81060-8
SHEAVE 24" OIA_ - 1" W_L.
1
TB1060-10
4 1/4" TIMKEN BEARING ASSEMBLy
2
TB1060-11
GREASE SEALS
2
TB1060-44
417/64" X 5" X 13/16" OUTER SHEAVE SPACER
-- -
-
-.
~
- - - ---------
EQUIPMENT COMPANY
P.O. BOX 472 • ODESSA. TEXAS 79760-0472
2238 STEVEN ROAD
1011
QNTY
915/366-2895 ó FAX # 915-366-1264
ca
PART
NUMBER
.~
MI
CK
DESCRIPTION
- .. - .
.
~
.. .
3
TB1060-2
SIDE PLATES 3/4/1 X 12" X 19 1/2"
1
TB1061-7
CENTER PIN 4 1/4/1 OlA. X 11 1/8;1
2
TB1060-8
SHEAVES 24" - 1" W .L.
2
T81060-7A
CENTER PIN NUTS
2
TB1 060-1 O
4 1/4/1 TIMKEN BEARING ASSEMBLy
4
TB1060-11
GREASE SEALS
1
TB1060-44A
4 17/64" X 5/1 X 7/8" INNER SPACER
2
TB1060-44
4 17/64/1 X 5" X 13/16" OUTER SPACER
:# 4,4 4 112 McKisslck Block
/ "
_ _ _ _ _ _o
Crown Frame
D-172 CATLINE$IHEVEASSEMBLy
PEMCO EQUIPMENTCOMP,ANY
OdeSS8.IX
L.yout f()r CatlineSheaves
8-507
-~
----~-------------~
.
TUBI NG BOARD C~RO~I PULLEY ·A SSEMBLy
r---
.~
~
.
!
PEMCO EQUIPMENT COMP~Y
~....--........-..
__t
.
Odessa, TX
I
..
Tubing Board Orovvn Pulley
Draw~By
-,..,-
......... J ....... ' ..
R. Vega
$cale
None
Date 5/19/$0 .
A..526
TOTAL RACKING CAPACITY
D-95 TUBING BOARD 96-150-C, 96-180-C
RE V. 1-8-81
NOM.SIZE
OUTSIOE OlA.
COUPLlNG DlA.
NO. of FEET
2.500
3.000
3.500
2.875
4.000
3.500
4.250
4.750
20,400
13,400
10,560
2.500
3.000
3.500
2.875
3.500
4.000
3.668
4.500
5.000
18,360
12,000
10,200
2.875
4.500
3.750
5.500
17,280
NON-UPSET
TUBING
~.50Q
.-
EXTERNAL UPSET
TUBING
INTERNAL UPSET
DRILL PIPE
I
EXTERNAL UPSET
DRiLL PiPE
...
.... . .
.-_ . - -, ... _.
-.,
-- ." -,._. - -. _..- . -
..
.. , . .
- --
-
2.,8Z~L
3.500
4.000
I
___ .. . . _-4,t2.§ ---. - - 4.625
5.500
I :::~~ l · ::~~~ I
- j~_,iQ~Q
_____
._-_._-
,
1'pj71
t
'v ¡
I
!
\
i
¡
¡
i
I
I~_~
~
__
Side·Platform
~_.,
• . ¡ - - - - , _.. f- ' ~.:L..t:
.
,
¡
¡
¡
J
,i
I
¡
oI
o
raCking
O)
-Jo.
1\.)
O)
O)
,i
-Jo.
AI'ea
f
l
J\3
Cantar
Plátform
Racking
Area
¡
t
f
t
I
1.
¡
(
¡
.
lY~ +r
,
¡
J
f
3 1/2
347/8
,
,
I
I
~.¡-
96
TUBING BOAR~ RPfcKING AREA
i
i
I
I
•
•
••
••
•
••
• .. ' .0 . .. _,
.
"
" '
"
' . • .• •••
•• • . '
• .••
• ~
¡
SCOPE RAM AS~E BLY
PEMCO EQUIPMENT COMP,ANY
OdeSS8, TX
B..3·~3 Scope Ram Assembly
sca1e
UrawnlW R¡, v
~
.
. ega .
None
Oete
806-80
A..531
PEMCOEQUIPMENTCOMP#iJY
·OdeSS8¡ TX
SCOPE RAM )BIR4CKET
AS'SEMBLY :
¡.
8 ..380 Se<>pe Ram·· Braeket
¡
DI'8'M\By
!
R. \legar ..Sc8Ie
¡,
N;one
I~e
•
• ••
••
o',
•• • • • • •
•
...
.
........... .
_
• "
.
,_
••• __ ,
•
4
'"
• •• •
•
•
•
O"
A..;S25
5..19'.;80
••
o',
"
.
••
•
• • ~"
o., , _ _
••••••
••
•
•
....
.
.'
o.,
. . ... u·
._ ,
•• "
••• • _
. . O"
..
.
-
-
. 8-373 Scope Ram
Assembly
.
~ C-329 Base
.
F!. Assembly
Plan View
f
q=
6 Each -3/4 NC X 21/2 Capscrews
wlNuts & Lockvvasher
I
I .
6 1/4
!
--
)
End View
INS-rALLATION B-~73 SCOPE RAM
PEMCO EQUIPMENT COMP,ANY
Odessa,TX
I
Installation
8-373 ScopeRam
.
Drawn By
.
Seale
R. Vega
.
,
t
.. .
.. . . .
/
.
Date
3/16
. 11-8-84 .
e-784 .
. .'
2 X 6 ~errick L~g
2 X 6 Derrick Leg
r
t4--------~~
SCOPE RAM S¡TA~ILIZER ASSEMBLY
r
[
- 2 1/8 ---------.J
PEMCO EQUIPMENT COMP,ANY
Odessa, TX
Scope Ram Stabilizers for
96,-150-C,96-180-C
Draw,n By
R. V~ga
Scale
Date
None
12.. 12-79
C-299
Plan View
Side View
I ner Tube
~.
r-
31 /4
.
1I
¡\
~\
"
,~
~
Crown
I
N
FrontView
~I!=~
~. Qnty.
..
2
2
..
2
e
12
3
De sc rlpt Ion
1/.... 8-209 S.P.A.S.
1
il250':522 SPRING .
A-346 P.LATE
C-285 SeO PE RAM STABILIZER
A~59 BRACKET
1
5
2
7
8
9
10
112 NC X 11/2 CAPSCREW
12
12
2
112 Loe W\SHER
112 FLAT WASHER
A-5()~BRAOKET.
:2
A·360 BRAC.K ET
PEMCO EQUIPMENT COMP~Y
Odes. TX
......1 - - - - 3 8 1 / 8 - - -.......
¡
I!
J
Sc~pe
Ram Stablllzer .Assem bly
ifor 96-n ~c or96M18Q.C
Drawn ay R. Vega scale
118
_.
.oeto 4-5-83
,
I
D-419
I
~
1.
SCOPING CYLlNDER -+-~-I
GAUGES
11
¡
B"
ti
A"
USH SI DE
7904
fLOW CONTROL VALVE
ULL SIDE
!
¡
I
I
I
,
i
~ 79~
FLO r. OONT1 0L VALVE
:
:
.
j
1-- -
I
t - - - : - - -.......t - - - - - PUMP
¡
!
I¡
í
¡
¡
RAISING CYLlNDER
!
!
;
2 CYUNDER
-PRESSURE REGULATOR
L -_ _ _ _ _ _ _ _ _ _--I..._ _ _ _ ____..
...
- - - TANK RETURN
--1
i
i
MAST HYDAAULIIC
CONTROL
DIf\Gf1AM
.
I
fI
,
!¡
¡
I
¡
.
_ 1
PEMCO EmUIPMENT COMPANY
ODESSA, TX
Mast Hfydraulic Con1rol .
FFor Standard PEMCO Mast
D
. ....
- - By~
. . Vega ¡Selle · None .
Date
9-27-79
B:.s87
SYMBOL
CAPPEDADJUSTMENT:
SCREWIN, TO INCREASI!! PRESSURE SETTING.
1.62MAX.
3.00
LCD
---L.-r--...L--H--'-'---I-- ·
NOTES:
2.12
*
1. SEALS: BUNA-N
2. RPECJEN CARTRID~E
ADJUST RAN~E: 25 - 400 PSI
3. CXDAXAN CARTRID~E:
CHECK SEAT: STEEL
.91
4 . PORTS: .500 - 14 NPTF
.25
_IT~EM~P~_~H=~~PA~~_N_AM_E__,O=N~,'
.28 OlA. MTG. HOlE
TYP . 121 PLCS
I
o
.62
TYP.
á.
1
1B:>-3:'Q.O)J
BOOY
2
C,)DA~
CHB: KV.ALVE CART.
1 .25
All PORTS .
PEMCO EQUIPMENT COMP,ANY
Odessa, TX
Relief Valve with
Reverse Free Flow
Drawh By
Scale
Date
1: 1
5-21-79
7904
OlA. MTL. HOI.ES
9113"
PEMCOEQUIJPMENTCOMP.ANY
.
Ode$$a,TX
.
I
A20 INLET sEq·mQ~ ASSEMSL y
,
[
f
I
!
.. J.
• •••••••
•
O'M
,_ ,
• •
~"
• • • _.
• •• . ~ • • •.• _"
."
. " ••• . ,
.
_ ••.•.••.••••.••• " . .
.. .
. •• ' . _ .
.. '0_ - '
_ •• _.. ...... . .
. _.
• •.•. . _ •
. ... . . . . . . . . _ ..• •• .•• _ • . .•• • •
mM
,
1
3
•
~
6
7
I
9
10
11
/l
Pt ,
1lCJU;!>G VALVE
VALVESI'OCl..
VAl ,VE CAP
~cAP
CHECI:POI'I'!IT
O!ECl:SPJUNO
sl'RlIG CAl'
GIAIE
~TRIrPER DOLT
FDJJSTER SCKEW
I\ETAINER Pl.A-re
ll40;·(J'lWO;¡
IJ
QUU) SEA!. (SPOOL)
"
"O" ~"'""EALICHECh')
I~
16
17
11
19
1 10~
Rno:i SEA!. (NJT m:JWN)
-rr IUNG SEAL (NJT SOOWN)
"O·
NI.!hlEIl I>.SS·Y CAATRlDGI!
~ ASS'V CAATlUDCiE
I REQ'D
I
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
I
COMr.l.íER
~O.
I
PAllT ~o.
NBtIIl-U
'<lP<01 1!j
>< 11r7oo0<3
hAll28C-1
><1~100
ANllU
n.
VAVLl A$S'Y
NO.
A2().H8166-1
AI)]'·]l_
A1MiBl66-1
A»H!lI66-!
A»HBI6604
A2>HBI660l
A2>HBI6(,.6
C!.<10l)
AJO.H9I66-1
HI()q
Al<J.Hll~
X-I\.lO
.u¡.HB I66-9
801011
391"'1"'1
J9 1 ~(OO
YAI~lO
391 1I1111
19I 1II11U
,91 164'00
"IIUlOZl
191IU)(DO
Alm,lll
3911113001
3911681<XÍ7
RAlSll
VIH2·1
J9 1 1 9MO~
~I"
.,
VALvr: ASSV. COMPlITER NO.
>41 tlOl4(1'7
:t-I19ID).("
3419101 $l5
L't,(05.. 11]
RNPART!'iO.
RN COMPlITER Na.
L'OO(,.I06
UOO>l ll
CA66l.lK-1
CA6GlSI(.l
" S91C771111
"'91C77Qll
19I181~
c~
1
C~
,
,CA66l5O(.,
GROlP "Ir' AlIOVE
íSEE RN GRCXl' "Ir' ABOVE
~------r------------- Io ~r ----------------~
17/32'
35.SSlI07QD
~ RN
1 S'IS"
I
I
.1
,
J. ;
,
l'
1
1
!
1
1
1
1
.,.,
.,,
19I18Il :lÓ:I
,
lVY LOCA TlO"
11
1
1
"'9Ial su
;r::n
39 1_1
I
3<19100 ""
:\419J01.t65
1
l
1
2
P'SI RA.""C!
OOI,JO:k)
lro l,SOOI)
lm.,,-,'
___~
4·
I
"
• oor
, ,ca:r
37 ~·
DLA PN HOLE
A20 D.A. HIGHBq)Y ALVE ASSEMB LY
, ' ,'
SP RI NIG R TURN
S~ppe J bol lo bo
ouembledw:f¡ 1117
PEMCO EQUIPMENT COMPANY
Odes'sa, TX
'
, ~~D.A. HIGH80YVALVE
ASSEMBL y SPRING RET U R N
Dra'M1 By '
.
Scale
Date
.
None
-
A20
ITEM
1
:COMP,UTtR NO.
PART NO,
1k1l51NO VAlVE
3041~4I011t6
1'1111'--.$
Vhl.VESP<XX.
)41:naJ06l
!:Alllle·1
... SCRlnION
REQ'D
RNLOCATIOf'(
VAVU ÁU'YPT. 1'tu. "
""'111166.1
VAJ.Vf;CAP
l41'«m 100
CllECI(CAP
391 ,ÓOOI 001
ANllII
OOlcal
ClIa:K l'OM'Ef
)91 [lCJlOO
VAISlO
O-lr:.CJ\.SPJU1'o()
19IINlllI
391 '_010
"lm.1J)
A»HII66-)
""'111166-4
AJl>IIlI66.S
=10
AlO-JfJl66.6
191i~11lO
Alm·m
AJO.If1I~7
Xllll
,4.2f>.HJI66-I
"",,"11J166-9
llAU.
SPlUhQ
POI'I'CT RIJT AI1Q
)?I
:scooa
10
FlWSlU< SCJUoW
39111m lIJO
X<4~lO
11
R&TAIIUl PV.1E
19111(\(1).
HAISll
AJO-llIll6-l
VALV1: ASSY, COMPUT[R NO,
J.l191(111OO
:><191111 419
12
~CJ\.-U'HJNO
191;16I1 cm
lll351-1
QUADSI:Al..(SI"OOl.)
191!ISIISOJ.4
MAltIY.. , ..
JI
I!
16
11
'"O" ~SEAl(CHEC/()
J9 Jl*lX17
191_IDl
LlCO(;.lIl
RNPARTNo..
l.)(.(t,.106
<:.A662JI:·1
JS5'9107C111
L.JCl'ri.lIl
XIJ9-14
~-l
JS5 9107 cm
3519IO'1C1Zl
'"(1' ~ SEA!. (NOT SID".",
CLOSLRI!
191,_'_
)91~l2IJ
999
l'
CYl.JJoUJ\ ASS'Y CARl1UIJGE
=~
OU' ~ IT ABOYE
19
CY1.IKE\ ASS'Y CARl1UIJGE
SCERN
0lI'"1r ABO\II!
Jl
PO!'PET lit H:VlO
CA662SIW
RN COMJ'tlTER
J'(o.
19
·1
·2
·2
:
Il
"O" IUNO SEA!. (NOT SHO_
ti
-1
,
;
.]
.'-
-1
-1
.,-2
·2
4
-,
-1
.,
-,
·1
-2
PSIRAJ'(CI.
IkH-lOO)
lCOl·5IXI:)
'M.Jm
FOR AOHESIVE INSTRuc;rrONS SEE H.E..sTO. 35·20
~11I7
)9\3lIl015
10. 16
1.75
l i
3.1
Ji
I
.437
7
42
I
1
-tt-~I-t+ll--ilf-----z.._-X.I
538
_~_1
i
j
I
i
l
i
I
. /
I
PEMCO EQUIPMENT COMPANY
Odessa, TX
A20D.A. HIGHBOY VALVE ASSY.
.
POPPET DET.
LJIalJI1 By
Seafe
Nene
Date
-
A20-H8166
,
rrrM
¡lP'TIOfo
I
oousm. 0UI1El' sr"cnON
1
Cl.OSU\E
1
1" Nr.T.
I
R~D
I
I
( O m:TER NO.
1 ~~)1116
SEECIWIT
SF.H1WU
PARTNO.
NJI II ~S
CODENO.
11"t'.Q""
J.:.A1l1OC·l
AlIJ.J: I6
1 f:I(¡i 100
ANUH
A.2l'J..Z'fI.. l
A»ZI('·l
COMPtlTtR tio.
J.4191OG0 16
. TOP
1
l '
~ 1 9 1 060S7
,
CODE
SIDI
1
1
,1
)
AlO-Zl6-l
OIlTUT
TOP
AJO.ZI6
I
I
so::e
l·~P .T.
I
1" N.P.T.
Jl--- ~_/1_6_'1
'f\
__
~~~:~~:~~~______~
'--~.
27/64" OlA. MTG HaLE
37/16"
r
i
I
3
. 13~16"
1" N.P.T.
3 1/8"
I
,i
A20 OUTLET
SECTION
'1
PEMCO EQUIPMENT COMPANY
Odessa, TX
I
I
I
'. '
:
A20 Outlet Section
I
"1
I
.1
I
I
I
I
Dri:twn By
Scale
Date
1-10-65 . A20-Z16
MAST RAISING CYLINDER
MANUFACTURER:
SIZE:
MODEL:
MAXIMUM OPERATING
PRESSURE
COMMERC/AL iNTERTECH
MAIN CYLlNOER 0.0. - 9 1/2"
STROKE - 131 1/2"
3 - STAGE
OOUBLE ACTING PLUNGER
SD83CC-24-131 1/2
2000 P.S.I.
REPAIR PARTS:
PLUNGER PACKING
PLUNGER WIPER
2ND SLEEVE PACKING
2ND SLEEVE WIPER
1ST SLEEVE PACKING
1ST SLEEVE WIPER
-..---- - --.. -- '~~' RING
n
_ _ _ _ _ _ _ _ _ _ _ ___
. __.. _._...___ .... ___ -- _o ... __ ••...•__ •__
' 0
'0" .
0-3009
Y-3026-37
0-7009
Y-3026-67
0-8009
Y-3026-79
~g¡-----
__ •
•
_. _ _ _ _ _ _
_
..... _._- .,.. .._"-
--_ ........... - ..... ,............... -.........
.-.
-'--'-'-~
-- ----_._---.- -------'
COMMERCIAL INTERTECH
CYLINDER PACKING INSTALLATION
in~ rings one al a ¡ime Oñ iop o( !he bollom IId3rlor.
Sel sofl black cbcvroD or lourth chevron. whichever
is included, on Ihree píete ,Iack. Place IOp adaplor
(femaie)'on ¡OlrOr ¡Iack.
A Few Ho'pfuJ TiPISoa1. Plcking in bydrlulie oil for 1 few minutes.
Cliécl -¡lIcompon-entsfor proper lit --Repl!" or
replir 111 damlged pUIS. Keep all -pl11J c:\ean.
espedll/y Iny Ihrcaded portions. Uic propcr tOóll-
Mmure .he sealed der1h of .he paelcln, nul
-MelSure Ihe deplh oC Ihe paeking. Add shims un!il
Ibc packing nnl will compru5 the paclcinr al lcut .
1/32' bUI nOI more -Ihln 1/16-, This Imoual oC
squuu: is reqcired Bnd neccssary lo oblain propcr
Icaling.
Be lure Ibat 'he ehevron, b.ve ar:ated witbOut
bueleling. Loo" carerully lo ICC Ib.1 lhey blvc DOt
been cul by lbe thread •. Set Ibe p1eklnl nut. h~k
up .11 conneetion•• Ind cllFrcllc the cyllndcr ICYcnl
Ineomplt:tc .lro~t:I under no IOld. Blced Ind check
lor ICBkage. Olmplele rclnllall.t1oa o( eylindct
Apply Brease or heavy oil to an parts lo prevent
corrodon. This coating will make assembly easier.
Do NOT mishandle a cyli"d::r. It is JI finely micbinc:d and bighly linlshed mechanism cveD thougb
its outsidc appearancc: migbt nol 10 indicatc.
How to Inltall New Packlng
Jusi before you arc'rcady lo Install the new Plcklnr.
aeparate Plc"lnS slae" and Inslan botlom .daplor
(male) into Iluffing bol hore.l"stln ebcvron pae"-
"O' RING SEAL
HOMOGENEOUS
STUFFING BOX
J~/
,LI-7"-7""-/"-/--;-7-r/7·~/""~yr_:./i'>_::.A;¡;¡_:JT;",
~PACKING N1Jf
\
-- -- ---- ---.-------t--.--------
t
I
~L L //ht."~L/
:rJTJi'7i?\.
~
---WrPERRiN(j" ------
1776 LOGAN AVENUE .. YOUNGSTOwN. OHIO «501 .. U. S.A.
j.
_________
.~
ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
ESCRlPTION
WIPER RING
WIPER RING
WIPER RING
PACKING NUT
BEARING RING
BEARING RING
PACKING NUT
PACKING NUT
SET SCREW 1/4"-20"
PACKING ASSEMBL y
PACKING ASSEMBL y
PACKING ASSEMBL y
BRONZE BUSHING (W/ITEM #18)
STOP RING
STOP RING
BACK·\:)P RING
O·RING
STUFF ING BOX
NYLON BALL
PIPE PLUG 1/2" NPT
REQ'O
1
1
1
1
1
1
1
1
2
1
1
1
O
1
1
1
1
1
2
2
COM'UTERtI
391 3882053
391 388205E
391 388205
391 147007
391268200
391 268200
391147016
391 147016
391 1431 14
391 198208
391 198210
391198210
391048207
375702000
376802000
391269103
391 288116
378250425
391028400
391 2282 O 5
PAR; O.
¡Y3026·3 :
·Y3026·6
Y3026·7 .
:MA3011· 7
:Jl003·1·
,Jl003-1
·YA3011· 7
:YA3011· 9
·X30·4·1
03009
107009
08009-1
I H1003·8 50
F7020
Ga020
U3006·
L3006·6
I BN6204
ITEM
21
22
23
24
25
26
27
28
29
30
31
32 - 37
38 '
39
40
41
42
43
44
45
I X~4 5,4
JXl-5
~_._----------t---2.0 0'
OESCRP ION
GREASE FITTING
'kl:Q'
2
COM' rER#
391 1281 005
PARTNO.
X5·5
C1633·2
X78·8.25
U3023-62
U3023-72
U3023·84
X29·1
P1327-67
P1327-79
X l·2
A3937-367K-1
A3867-155K·4
A3819-250K-20
A3779·284K·1
A3937 ·367K·2
A3667-155K·5
A3879-250K-21
A3779·284K-2
NYLOC
PISTON RING
PISTON BEARING
PISTON BEARING
PISTON BEARING
AIR RELEASE
WAVE SPRING
WAVE SPR ING
PIPE PLUG FOR SHIPPING
1
3
2
1
1
2
1
2
391 2284003
3912683024
391 2684071 .
3912684072
391 2864073
391 1281 014
391 3561 303
391 '3581304
391 2262002
PLUNGER
2ND SLEEVE
1ST SLEEVE
MAIN CYLlNOER
PLUNGER
2ND SLEEVE
1ST SLEEVE
MAIN CYLlNDER
1
1
1
1
1
1
1
1
3733666701
371 6775504
371 7925020
3727926401
3733688702
371 877f¡ 505
371 7925021 '
3727926402
1
i
1
""O.,
""~~~IIl~
1.50'
~
1ST SLEEVE . ...... 97,400 . . ..
.. .. ..
- --
52.50"
--
1 Thru 31
42 43
44 45
132"
..
O.L
..
4.12"
4.06"
3.81"
"W"
"VII
55.50"
63"
O.L.
B.31"
8.38"
3.81"
42.06"
43.12"
46.81"
.~ ..
900' [lA
M ~mum Opel'liing Pre99Ure -2,CIXl P.S.!.
Al! Sleeves .0:)1" Thick Chrane Plate
e
leal Load -171,~
P eS9ure Burst -5,295 P.S.!.
2m'
1.75 1l,
PEMCO EQUIPMENT COMP,ANY
OdeSS8, TX
. Special S.O. 83 Cyl.
S,ap-A-Sleeve Construction
DraWn By
Stale
T SnNGNOTE:
PLLNGER ....... . . 61,360 .... . 39,2 O
60"
43.25"
44.44"
43.81"
STROK
,
L-____________~__-~_.~.;--------------~~
2ND SLEEVE .. ..... 71,660 . . ..
131 .5
I
~ . 62'
2.00 11
PUlJ...
SD83CC-24-132"
'W'
5.6)'
~Ui' : v=Ulr~~J~~;~~ln~'N~n~~~I~~~~~~~~~~I~~l~~~~~~~;.~~~~~~~.~.j_~2.~~"~
PUSH
SD83CC-24-1311/2"
1 Thru 31
3B 39
40 41
S R KE
OF PIH E'l'ES - - - - - - - - - - - - - - - - - - - - -......,
~._~~;
... JI ,,,,J f?1~' " -¡
CAPACITY @2,000P.S.!.
P_' NO.
ASSEr.'SLY PART NO.
" ·2
i= t t
W·=.""',,",,"
TO
ASS~IIIBL
F Ir dtiailfld Sklp-A-Sloove test
p pcewre, see CXL-248
Date 4-21-81
SD83CC-24
" .. Transfer
CYlin~er
Foot Control
I
Rod Hang~ _Ba_
:Ske_t =."- -- - _ l
~'-~~~.--~------~-:~------'----~
- +-...-!- -.. -----......:--~-----.
I
!
¡
I
I
1
I
Pres'sure Regulator _1_
I
I
I
I
!
Pressure Gauge
~
I Vent
I
I
I
I
!
I
v71ve
I
I
I
I
t----------t----.
.
L _________
I
--I
.-J
i
I
.¡ LlIbricator
I
I
:
PEMCOEQUiPM'E:NT: CQMP.ANV
AirSupply ;
.
Odessa,. TX
,,',
Air .$chematiQ for
Rod iransfer 'System
D~wnBy
,
'
.iR. Veg~ . ~ca/e ,
' Date
None
12.. ~';'7.9
A~505
ReXRDTH T A5K.MA=:' I I:H\!J ....~I:'"".y •
.#"'t&...... ...... _...
_.-;,~-
S TANDARD R E PAIR KITS
Repair parts induded in the following repair kits are avaaable only in kit formo Kits should be ordered by kit part num ber PLUS
cylinder part number when possible.
Other parts not ¡nduded in repair kits muS! be ordered separately by reference number, description and cylinder pan number.
Reference numbers are from parts list on page 29 for 1-1/2" - 4" bore, and page 31 for S' - 6" bore.
IORE
1-1/2'
2'
2·1/2'
3·1/4'
4'
S'
S'
6'
6'
ROD
PART NUMIlER
SIZl
518
P68148"
P68148*
P68t48"
P68149"
P68149"
518
518
1
1
1
1-318
PARTNUMBER
1-1/2'
P6815(H)()()2"
P68151-OOO2"
P68152-OOO2*
P68146
5'.6'
P68146
P68147
P68147
P67964
P67965
P62622-OOO1
P62~22
P67693
Kit ¡ndudes needle, o-ring, Escutchen Plate
and screws.
Kit ¡ndudes cushion seal &
retaining ring (arder two kits
for cushion both ends}..for both
. current and previous design
PISTON WITH NUT
WITH TUBE SEAL
PISTON LESS NUTWlTH
TUBE SEAL KIT
IORE
PARTNUMBER
aDRE
PARTNUMBER
1-1/2'
P68150-0001
P68151.ooo1
P68152-OOO1
P68153·0001
P68154-0001
1· 1/2'
2'
2·1/2'
3· 1/4'
4'
P68150
P68151
P681$2
P68153
P68154
2'
2-112'
3-1/4'
4'
P6815~2"
P681S4-0002"
P67966-0002t
P67967-OOO2t
6'
PART NUMIU:R
cytinders.
IORE
5'
2'
2-1/2'
).1/4'
1·1/2'
2'. 2-1/2', 3·1/4', 4'
6'
PISTON & TUBE SEAL KIT
4'
IORE
P2890S
S'
-'ndudes Ref. 3, 4, 5 & 6
tlndudes Ref. 4d, 4e, 4f & 4g
2-1/2'
3-1/4'
PARTNUMBER
P67968-0001 t
1-3/4
2'
BORE
1-112'
4'
P67969·0001 t
P67970-OOO1t
P67971-OOO 1t
!.?/8
NEEOLE VALVE KIT
CUSHION SEAL KIT
ROO CARTRIOGE KIT
Indudes Ref. 8, 9, 10,
11 , 12&13
*Indudes Ret. 8. 9, 10 & 11
t'ndudes Ref. 6C. 60, 6E & 6F
Ineludes Ref. 8, 9, lO, 11, 12, 13 & 14
S P EelAL AEPAIR KlTS
RORE
RODSIZE
WITH vrrONGD ROO SEAL
PART
NUMBEA
I
1·1/2',2',
2·1{2'
5/8
3· 1/2',4'
1
P6286~
P66023
RORE
ROO SIZE
\·1/2'
2,
2· 1/2'
S!8
_ . _ ._.u_.. u ........... . ...
' .00.' · '
' _
I
P68959
ulCuut;:)
'C ••
,
.
.o • • _ . _
:--.
2'
2·1/2'
3·1/4'
4'
PARTNUMBER
P2/46O"OOOt
P271 14-0001
P26368-000 1
P68153-0004
P681 S4-OOO4
J,",
J ,
(JI
BORE
PARr NUMBER
1· 1/2'
2'
2·1/2'
3·1/4'
4-
P27460-OOO2
P27114-0002
P26368-OOO2
P681S3-OOO5
PCu8~ 54..croS
Ineludes Ret. 8, 9, lO, 11, 12, 13 & 14
l ' ,11M ¡;'"'" ----:r" .. ;;: . ...-?- .. . _. __ . - ..... _ . . - -~A
PlSTON lESS NUT wNITON TUBE SEAl KIT**
_
PART
NUMBER
P62711
I3.1f.",
Includes Ref. 3, 4, 5&6
BORESlZE
I-I/i
PISTON ANO TUBE SEAl KIT WITH
VITON® TUBe SEAlS*
ROO CARTRIDGE KIT
ROO CARTRIDGE KIT WITH
POLVPAKROO SEAL
o
liea l s-MeAGeate9-BI:INA
N-~ ... _-~. __ .
PISTON WITH NUT wlVlTON TUBE SEAl KIT**
+_ ... -
IORE SIZE
PART N\JMBER
HU"
P27460
2'
2·.1/2'
P27114
P26368
P6815HlOO3
P68154-0003
3-1/4'
'"
Includes Ref. 8, 9, lO, 11 , 12 & 13
Indudes Ret. 8, 9, 10, 11 , 12, 13 & 14
"* Piston Seals Teflon Coated Buna-N
... Pistan Seals Teflon Coated Buna·N
The Tasl<master Cylinder is pre-Iubricated at the factory.
However, when repladng the seals during routine
maintenance, lubricate all rubber parts with GoIden Grease
No. 2 (manufactured by Uníon Oil Co.) prior to assembly.
Grease tubes are available from the factory or your local
distributor.
GOLDEN GREASE No. 2 - 5cc P48311-0001
5 oz. P48311-0003
NOTE: FOOD SERVIU USAGE req",ires
NORDTROM 234 (STR) Grease - SOl. P4831O-3
I
REXAOTH TASKMASTER® PNEUMATIC CYLlNDER5
1-1/2·' -
4" eCRE
BASle CYUNDER PARTS UST ANO ASSEMBLY DRAWlNG
BASle MS4 PARTS lIST - SINGLE ROO MODEL •
REf.
1
]
.
3
5
6
7
8
9
10
11
11
13
14
15
15.>
16
17
111
19
QJy.
.
1
1
1
1
1
2
]
1
]
1
I
2
1
1
1
1
,
1
4
DfSOlIPTION
1·1/2"
P6921S0001
PS74S2.()())0
P68148
Se,.,..; Ifead
Hr'" Complete (wilh nct.'<lIc lIollve ,-..semblyl
Re'aining Rlng. Rod ~,in9
Roda.,,,,ing
!lepair Kit
RodW;pe.
Indudes Re! .
.lIod.Seal
3,"• .5 .&6
P68146
Pf>81 50000]
úisllion lGt
Tul><! S<!"I O.nng
Pkton Rod Sedl
!'islan Sea!
Pislon Wra, RinQ
Repair J(i!
Indudes Ild
8,9,10& 11
Pistan
r!i~~8
folfower. Pist",.
R~tainitlg Nul. Pi1ton. Rod
Piston Rod. M~'"
1/7·20 Th,,,ól(j
7/fr·H 1"'"",¡
Pistlln Rod. f""",1e
]/16"·20 Ihr/!.}'J
1/4".16 Thrl!a<l
MaJe Stud
""tlr 're 15.)
7/16.]0 Th'ead
3{4'·16 ThrNd
Tulle.8ody
CaP. Compkte ("';111 ,,,,,,die vahrc!
SeIC:W Cap
. _ ..
P5 7l90.OQO 1
.' P5748()
P571118-!
...
P57}43·1 .
-
e"",
1'49599
~s",,,.bly
PART NUMBER BY BORE SIZE
l-1j4"
2-1/ZO
P6911S.OQOS
P69]IS~3
P6921S-0003
P57482-OO13
PS!48H101l
P57482.(J()11
P68149
P68148
P68148
Rép.:Jir ICJt
Repa~ Kit
Repai< Kit
!nch,dr.s Re!'
Indu~ReI.
Indudes Rel.
3.4.5&6
3.4.5 & 6
3. 4.5&6
P68147
P68146
1'68146
P681S1.ooo1
P68153-OOO1
P681SI-OOO]
Repo'i, Kit
Rep.oi, kit
I\q>;!i' Kil
tndudnRcl.
Indudes Rel.
Indudes Re!.
8 . 9.10& 11
8.9.10 & 11
8.9.10& 11
P678280003
!'§71f21HKJOl
.Pf??-ª1~1
PS7190
P57190~1
PS7302
PS7~80
PS7480
P574800002
2"
1'57188'1 ··
P57143·! .
P49599
-J -
1'57266·1..
P57481-OOO1
P69]15
_
1'571118·1
P57243·1
P49S99
-
P5718!>-1 .
PS1482·0003
PS7267-t · .
PS7481.oooS
P69]1~2
P§!ll1_~2
1'5/310' ..
1'49599')002
1'57268-1 .,
PS7482{){)()7
P§92IS¡¡OO.4
Specily this part number of pisto n rod (15) o, tube (17) PLUS Ihe 4di!iit suffix f'om cyfínder part number as shown on nameplale_
... __ ._. ___ [')IEEQlE..~LY-E
ASSEMBLY
SINGLE ROO MOOEL*
~"Kit
Ineludes Ret.
3.-4.5 & 6
P68147
P681 S4.ooo]
Rcp.si, Kil
Indu<ks Ket .
8.9.10 & 11
P6 7828-0004
P57319
PS74800001
.-
1'57301
• Order repaír parts for double rod cyfínders by desaiption and complete cylínder par! number. Se@ page 33 lO' assembly dtawing _
t
4"
P6971 S oc.os
PS'J482·0014
P68149
1'51301
.PS7310 1
P49599 0001
PS7269· I .·
PS/JI/i] 0009
"'-G.'U 15.000·1
I
)*
Versatilepneumatic valveideal whe,l 'e
dependa·b ility aild performa·n ce are critical
modero styling enhances the appearant e vf ~'our
equipment.
Super Spool is a vcrutile valve with inter\."hangea b1c
operators and valve bodies lo providc a ""'¡de variety
of stock cornbinattvD!>_ Sorne modc1s are av~d8ble from
dislributor stocks a~-ross the country; ~ny f~om C?UI'
()wn factor)' stock. The availability ofvarious models is
coded in this cazalog _nd explained in :mure ~cuil on
WABCO's ne\\' Super Spool Valvc: Impcuvements mean
raster rcspunse. incrcased n:hahlJity and simplified
maintenancc. And it aJl adds up lo more profitable per(onnancc.
Tbe new Super Spool high-capacity valve deJivcrs air
al up to 600 cycles per minute. Rcpeat cyeljng 1S accurate an~ rdiable, Simplificd désign ;lccounts for Su~r
Spool's cunsistently reliablc performance on the rough
jobs. WABCO builds it lo take vibration and shock.
Compact design of the Super Spool saves valuable space;
page 6.
STANDARD SPECIFJCATIONS
MATERIALS
Bodies, bases :and operalou: Anodized
pressure-die-casl aluminum construct ioo.
Spools: Machined from high·tensile aluminum.
hard anodized. ground and polished lO g:micro¡nch fil'lish_
Scah: Huna N. oil-resistant. sclf-]l1bricating
(compounded with ETaphile) and bonded lo a
metaJlic ringo
RESPONSE TIME These curves show that "sp]jt-sccond" response is a
rea.lity ;1.1 the Super Spool. This response means delivery cf air-Dot jusr
spool movemcnt bul air whích can be pul to work.
NORMAlLy CLOSEO
Cai, opened lo till)
NORMALLy OPEN
(s·p ri,,9 opene<f"lo fill)
I
I
.250
..
..,
2OO1r----+----+----+----~~~
3·15ar~--~----~--~~---
~,~--~----4-----~--~--~
g~~r---_+----~----~~~~~
.;
C>
.!!.
PRESSURES
.
"O
CONOITlONS :
V.Jvc: ¡nIer and air pilot maximum au p re5sure: J SO psi.
Minimum air pilot pressure: 15 psi wit bou!
Ter·u m springs; 30 psi witb certtering springs;
50 psi lor ~ and "" v;Ilves witb fuD retum
springs: 40 psi JOT ~- and Yc" valves with full
rc:turn springs; 30 psi Jer 1- and IX" valves
witb full relurn springs..
II------,j.........::=--',,¡f!, prJe""..su,,,: eo psi
FILL-Oto64 psi
¡¡
,
EXHAUST- SO lo 16 psi ,
50
"100
150
200
250
O'L----;!:~__:;-!.;;---_=:!-::---_=:!::::--_::!
SO
..
100
1 SO
200
VOWME (eubic inches)
VOLUME {Cllbic ¡",ches)
250
l-i. VALVE RESPONSE-Actual test data sbows ooly ]56 milli-secoilds is
required to 611 a 250-<:ubie-inch vo!ume to80% of ¡me prcssure With a .norriially
closed solcnoíd opaated valve. Where a spriDg · is used 10 open tl1e valve
(nonr..ally open valve) only 175 milli-sec:onds is rcquired lo fill lbe same
·volume.
.
CAPACITY Thc Super Spool Valvc gives maximum capadty flow to spec:d
TEMPERATURE
vperating temperalure range:
D
-20 F lo
+ 160°F.
ope.rnti~>ns and pro~des fuIl powc:r for your air operatcd cquipment. To
~etennmc flo~ fr(>m mJ-:! to o!.....¿e! !~ ~;:;; ¡;¡=S1.oT<! ,uúj) witi:i lOO psi suppiy
prcssure, pro)ect up from the pressurc orop scale (permissible djffcrence
betWteO ¡olet ano oullet pres5ures) to !he solid curve_ Al this intersection.
~ lO 'be Jef! 'ú)I:.Lbe. TA:'$ultiRg tl a .... es !!he . ~.iad seA. HIlO
MEDIA
Air 3nd mert gases (consulr factory lor olher
uses);
.
1000 .
!lOO
500
N.E.M-A _ Class A inorganic ins~13tion_
Power Consumption maximum:
AC 60 cyde
23 vol! ampcrcs
A C 50 cycle
17 volt amperes
OC'
1] watts
l nrush current is t""ice rated curren!.
l emperat\lre Risc: 75°C. Within Vl . specification limiration oí 85°C. SuitabJe for
contmuously encrgiz:ed scrvic.e or cycling
opera I ion.
«JO
300
-
;--
._.
-'"
......-..--
~
700
600 .
COIL DATA
-_.
...
--
7/
//
~l
----.
/"'"
<wfi/~~--..,...
1
U.
.
1) ~
I
1
I
I
.l'I.~.
--
CONDITIONS:
.c. way. closr,od
.J l.-
I
,
I
I
40
5(t
60
PAESSURE DAD? (PSI)
The C. factor from supply to ddivery
for tapped bodv val ves is shown in
the accompanyiog graph. C. factor
Cor subplatc mountcd valves is approximately 15% lcss tnan that shov.'TI
70
6-17
'1,---
,
I
. 7_ 88
'/,·
I
.---r
I
'1."-
SCFM
C.
= -Ln
~.39
100
for each tapped body ....alve. When llow
factor is desired. use lhe f ollowing:
FloVo' factor
i~~
(Ocote,
I
I
"l5:
1·
--'-
TAPPED EXHAUST MOOEl
'NlET PRESSURE-100 psi
I~"""""l
7 [7
.1
=Flow factor x maximum psia
.73
To order, ¡nelude piece number and descript ion.
3-WAY
Approx.
Port
Size
Cenler Springs
IClosed Centerl
No Springs
X"
PT2210I-1200
PT3210I-1200
PT42101-1200
PT6210l-1200
PT22101-1100
PT32101-1100
PT42101-1100
PT62101-1100
55
54
Ya"
~"
Ya"
51mbal Na.
(se e !lace 13)
Wgt.
(Lbs.!
3~
3~
4X
4X
4-WAY, OPEN EXHAUST
Port
Size
CIDsed
Cenler
~"
PT23101-]200
,r:r~~.~~1~~?91!J.
PT43101-1200
PT63101-]200
Ya"
~
~
.
.
51mbol No.
(ni· paie' 13)
Center Springs
Inlet Dpen
Ccnter
EIhaust Dpen
Cen!er
PT2340l-1200
P13340l-I?OO
PT4340l-1200
P163401-1200
PT23501-1200
PT3350l-1200
PT43501-1200
PT63501-1200
58
59
!i7
-.
•
Approx.
Wgl
(lbs]
No
Springs
PT2310l-1100 .
3~
......PT33
._ ..1in-llOO
- _..
3~
.
PT43101-1100
P163101-I100
4X
4X
56
oo ·
4-WAY, TAPPED EXHAUST
Port
Size
~"
:Ye"
)-S"
~"
r-s;-;bol Ha.
(see pa¡¡e 13)
_ . ."- '-.1 - -.-.-... ___.. .
~ . ("'- .
___
~_
Center Spñngs
Inlel Dpen
center
Closed
Cen!er
PT24 101-1200
PT34 101 -] 200
P1441QI-1200
PT64101-1200
57
-
Approx_
Wgl
(lbs]
No
Springs
Exhaust Dpen
Center
1'164401-]200
P124501-1200
PT34501-1200
PT44501-1200
1'164501-]200
PT24101-1l00
P1341!l!-11!lO
PT44101-1l00
PT64101-1100
58
59
56
P124401-] 200
P134401-12OO
PT4~401-1200
4~
4X
5X
5X
,__
3-WAY & 4-WAY, OPEN EXHAUST DlMENSIONS
A
B
e
D
~ -lB
~i -1B
IK,
H(,
3~,
13(,
11J{,
3Ya
)-S-14
~-14
M
1 L
2
r
. _. -
- _ _ _ _ _ . ..... _ . . .. _ _ _ .<1.._ .. . . _ • • __ ••
' "_
_
_ "
•
_
.• _ - ' _ . _
_
_
o
__ _
• •
1
Uí.
¿7.
___ . _
...
. __
_
N
D
2K,
3Y{,
..:l;¡.
¿'?j.
,_
•• _
.
_
. _
._
_
• ••
'
E
F
e
H
J
~.
BW.
IX
1){.
l1J{,
10K.
lYa
lK.
2
Q
R
s
5~
p
p~_. IX
. '
1
_ _ '' ' - - - •• •
_
j
_
2~
,
.~
1 :7.
__
- ._. _ ._0'
K
. 3
3Y,
u
T
lYa 1 lW.
'-m-i'cr.
5~
C':'j6
... _ _ __._ ' .
4-WAY, TAPPED EXHAUST DlMENSIONS
A
B
C
o
E
F
e
H
J
X -lB
Ya-lB
Y,-I4
Di'.
1 ~.
3X.
5~,
IOK,
1~
lJ(.
I'K,
3
lK~
IIJ{,
3Ya
5~
lJlX.
IYa
lX,
2
3~
~-14
K
N
o
P
Q
R
S
T
1
2K,
3~,
PXz
l~
2~
lYa
1%
7~
H(,
2W.
3Y{,
P~2
l~
3~
IX
2K,
8%
M
-
.
U
NIP·3SO
Ju 1V. 1974
Supersedes September, 1972
Type L02
CONSTANT DENSITY
LUBR/CATDR
114" PIPE SIZE 112" PT, RESERVOIR
_11-_ _ _ 0
QP-ERAT lO-N
A portion of the incoming air flows through the pressurizing valve !A) to pressurize
reservoir. The majar portion of the incoming air flows through the lubricator past the
flow sensor (B), kev to the lubricator's versatile performance. The flow sensor allows the
I~Qricato_r ªutomaticaJly ro maintain a !!onstant a:r/c-il dansity trom 3 to 60 scfm in the
112·pint unit. The combination of the pressurized.oil reservoir and the pressure differential created at the flow sensor causes the oil to flow up through the siphon tube (e).
The drip rate can be monitored through the sight-feed dome (O). AII of the oil passing
through the sight-feed dome to ~h":! fag generator is converted to oil fog and goes down
stream. The oil reservoir (El is 1/2 pint transparent or metal; or 1 qt., 2 qt., 2 gal. or
59111. metal.
t---tt--c
GRAPHIC SYMBOL
y
INSTALLATION
Thl! lubricator shovld be ínstaJled in the pipe line upstrearn
of the devic8 it is to lubricare. Preferablv. the line between
lubricator and tool should not ~ceed 15-feet.
'
The IIrrow embossed on the lubríc:ator bodV indicates direc:tion of air flow. Please oblerve direction of ~rrowwhen
instllllin¡.
it is -recommended that ~ filter, such ~s tlle Norgren F02
type, be used ahead of the lubricator to ¡nsure a supply of clean
_..___ . airo
_~.
___, ___ ._.-_..." --"
_.~
Lubricator with Manual Drain
112 PINT
_-____ .._
_. pchlU\\,
J
@
.: ::J. _._. _-.__
,_ u~i j
-3/4"
'-- 1
'fr-'-'---.f'
LITTLETON, COLORADO
©1974. e_A_ NORGREN CO .
-
83/4"
~
\
5
.• :2
'
:; - JII
. ....
_.~
JI!
]
i - -'
ea
....
9
~ ____ a
PARTS
(S2_tI
REPAIR KIT
contains 1, 2,4, 6a. lO, 11, 15,19,21 ...•........ 301~Ol
REPAIR KIT FOR OlllEVEL SIGHT-GlASS
U/2·Pint): contains :'0" ongs, gaskets, tube,
for 112.Pintmlrtal bowI •....•.. , ••.•.•..•..•.• .301~10
RUALB .KIT .FOR..Dll SIGHT·GLASS
(l.0t.: 2-0t., 2·Gal., 5-Gal.): contains
- - -.. 15
14
items 31, 32, 33, 34, 35, 36, 37
,-Ot. .................... __ ... _.. _.... , ... 2272-02
2·01. (F/at bottoml_ ....•...... _ ............. 2273-01
2-01. (~ound bottom). _ •.......• _..•........•. 2273-03
2 and S:-Gal_ •..••..•••••••.••••••••.•••••••• 22i4{)1
1~(,.O_16
1~'1
~~- -~
-ei/
17
.~-
CAPSULE ASSEMBL Y:contains .
items 1, 2, 5,6, 7, 9, 10, 11, 12 ....•........... .2612·55
REPLACEMENT BOWLS WITH MANUAL DRAIN
Transparent bowl· . . . . . . . . . . . • . . . . . .....•• .• 2487·51
. Transparent bowl (used with bowl guard onlyl .. .. 3053-60
Metal bowl . . . . . . . . . . . . . . . . . . . . . . . . . . . • . .3041-50
Metal bowl (with oillevel sight glass) . . . . . .. .. . ... 3047·63
19
r------/t
I
..
I~-j- 20
0_
'
NPT
·ASME Rated
Jj ..
,----
.~
rr. 3/4"
O-Rl!move charge plug litem 7) for rapid<vele. bi-directional flow
I
f
• ...,
OIL AESERVOIRS: 1/2 PINT TRANSPARENT !STANDAROJ
1 OUART METAL (STANDARDl
1/2 PINT METAL IOPTIONALl
1i2 PINT METAL WITH SIGHT·GLASS (OPTIONAL)
2 QUART METAL (OPTIONAÍ,J
-2 GALLON METAL (OPTIONALl
os GALLON METAL IOPTIONAU
MAXIMUM RECOMMENDED OPERATING CONOITIONS,
TRANSPARENT BOWLS
l!iO II'SIG AT 12SoF.
METAL BOWLS: 250 PSI!:; bT 1750 F.
BI·OIRECTIONAL AIR FLOW··
MOUNTING HOlES: 9/32'" DIAMETER
3
12 - _ - - - - ij
18
, ..... , . , # ,...."
PIPE SIZF.S: 1/4". 3/8", 7
A
==:::::_= i JI
10-
4... ...... , '
OIL RESERVOIRS (NOMINAL CAPACITIESI
•dD
\
....,.
.. 1
-25
• For .dded .,.fety • bo"W' guard is recommended.
MAINTENANCE
21
-
".
26
_m-
AlI of th .. WOf"king perts of thll lubricator a,e ~ontlljned in th. eapsule
r~, i, MC!mafY, lhe capsule may be remov.d from the
bodv without di$eQnnaeting any pipin~ To remow caPlUle from the lubdcat«:
1. Tum off the air lUpply to thlllubriCllror.
2. fTe5S the vent valvlI bunon 118) ro vent \he pressure in rile synem.
3. Remove rho top cep 13) by turning it cO\lnt.r~ockwiMl.
<l. Bacl< oH rhe tINO captóve lCntWI 191 untit lhey no longer engaga tlle
threads in body. They will rem.in with the C8psul •.
11 ir Í$ necesss,y ~o elean rhll .iptlon tube 1131. ungrew tM tip/lon tube
fitting 1121 IInd c:lellll entire a!lSlImbly by b8ck·fluÚling. A 1132" Afien wnmefl is
",quirfld to .emova· lhe pnmtJrizinO valve (7), When ~l?Iiog. tighten rhe two
bfy IS). If deenin!! o,
-~,
_27
CD-~
28
si.... _m . . ..... ",. . .__,.
cepsulll SCfIlWS 19111Venly.
CAUTION: Whan cleaninq the parU 01 the lubrigotpr 'd' onlv
-t-'¡---'t"· .. _.. _tllr ~ kllfOS8fUl. Ba ,ure mar the 112--90nt bowt is not croa-th~ded when
.....
-r~~±5~r
rlI3~mbling
and Úl8t bowl
Íl
turnee! in until
threads dilllpp8lr.
CAUTlON
THIS LUSR'CATOR SHOULD NOT BE USEO IN APPLICATIONS WHICH
MAY EXCEED MAXIMUM RECOMMENOEO OPERATING CONOITIONS.
DURING MAINTENANCE PERIOOS INSPECT ANO CLEAN EACH PART
CAREFULL Y, USING ONl Y CLEAR, WARM WATER OA KEROSENE.
00 NOT USE SOLVENTS AS THE POLYCARBONATE BOWL MAY SE .
DAMAGEO.
33 -
35
36
37
FOR ORDERING INFORMATION CONCERN1NG COMPLETE UNIT
REFER TO NC350
313
39. ",'·35017·7'-
1-,,0
c. A. NOFlGREN
LlTTLETON, COLORADO
CCJ.
80120 / 303·794·2611
Primed in U.S.A.
~
Parts For
Safcty Sub-Elevator
......
"
l.lff~)'
r-..
:iJ
_~
_ _. o
~
- -
-
~
_.
"4
~- Tran~ror Cyllndor
'~ -r---
l -- ._._ _¡::.-:
:-: .~=:::I"~/:
.. " /
' '''_'
Foot ConlrOlVal7
Rdd Hon¡¡er Ba.kat - ' "
-----~-' "- ---.-----" ]
.
r
I
1,
.
err
I
~
..." ._.
I Vont
........
I
..
.
-~.-
I
0
I
I
J--D :
PrUlIUlO Rogulotor _1_ _
-·"-ct". _", · "." "- . ._....._.· ."-..
r
I ·Piessure Gaug8
I
It
II
-l-.L ... _·~_ ____ _ . __ ._ .J
J.
2 - ~J8" Cables
l.lIbrlCIIlor
Alr Supply
/
¡
Schematic - Air
1/4" Wireline
Expanded Metal Bottom
Safety Sub-Elevators
Rodman's Basket
Oontrol Valve
_ Rodman's Baskét
Section A - A
Control Valve (Foot Operated)
Double Derrlck - 78 Fee!
PEMCO EQUIPMENT COMPANY
Odessa, TX
Single Derrick - 54 Feet
1/4" Pipo lIir $Uj)ply ~C'"
O."lck aoso Sedi", \VI
Quid< DlJconnecl b(lhv~n
dénicl<$odicn • .
-----~
, l. .. ,
Rod Transfer System
Gro"nd Leve'
Dravn By
-
GB
T"y~ical
-
Scale
Date
3-17-73
0-144
®
I
-0-
,
I
"-
"-
~,,
~-----~ ~-----..I
r
-rI
PEMCO EQUIPMENr COMPANY
Oda".; T)(
LATCH TUiB¡E )\SSEMBLY
,
Latqh Tube Assembly
Fbr Pemco,Ma.t
DrtNt/By 'R. Veaa
Scate
D••
... .. .
. .. .
~.
..
..
. - - .. .
• ••
O",
••••••• • •
_
••
_
•• • • • •, _
,, __ •
' ..
'"
•• •
••
•
"
.
....
O"
. " ••
•
• _
••••• • • • •
None
12-5-79
8-592
i,
t
"
.
:!
.
¡1
: ~',. .
xat' ..-~. ~
~
~~~.
~.. ·.··U...<
.'
~
.
.
.
~
\.~--­
•
"
'
~, '.
1
I
i
~~ I
,~A
.
'
l/~
F
LATCH SeAT ~SSEMBLy
PEMco'EaUIPMENTCOMPANY
,Odessal·TX
I
!
Laten 'Seat A8$embly
i
OraiM\IBv
' R~Vea.
¡'SCile
:0«8
•
'o .
_
"
., .
_,
• •
_l • •
..
.Nóne .
6.42-78
0-1'98
Well Side
Operatar's pide
PEMCO EQUIPMENT COMPANY
OdeSS8, TX
4 - Leg Base Section
for Perneo Masts
;
!I
I
\
... !.
J. . ..
Drawn [By
.R. Ve!g:a
Scale
Date
None
3-01-78
·8-487
111111111 .
111111111
I,
1
I
t
I
I
~--+--~---751/2 -------------a.I
iI
I
I
II
PEMCO C-78 aAC~BRACE TURNBUCKLE
PEMCO EQUIPMENT COMPANY
Odessa, TX
2 1/2 Backbrace Turnbuckle
I
i
Drawn By
1
.
'CK'D BY
~
,
...... . .-.... L oO '-- - ' ' . .. .. .. "
......... . _....
Scale
R. Veaa
"Date
None
6-16-80
A-541
MODEL~-- -- SERJALNO~ _.
HEIGHT
96
FT.
DATE ~I......:....:..--======~
I
I
MAXIMUMRATED STATIC HOOK LOAD:
, 180,000 I LBS. WITH
4 lUNES TO BLOCK
I
I
, -'i
20q,ooo .... I.LB& VVJTH I . _. ~ .
I
LJb!E~-Od3l-OCK=:-
· CAUTION: ACCElERATION OR IMPACT lOADS, ALSO
· SET BACK AND WIND LOADS WlLL REDUCE THE
MAXIMUM RATED STATIC HOOK LOAD CAPACITY.
· MAXIMUM DISTANCE FROM DERRICK INDEX MARK
TOWELLCENTERUNE
4.5
FT.
I
MAXIMUM WIND RESISTANCE
ACTUAL VELOCITY.
API STD..4
I
E
I
I
6p,
I
MILES PER HR.
'GT8
r
I SECONO I EDITION
.
i
.Q!~;L ~ ºHEC~.. º"HA~T ANQ__ B_~gº.MM.~.NDED GUYING
PATTERN PLATES MAY CAUSE RIG OVERTURN,
MAJOR PROPERTY DAMAGE, PERSONAL INJURY
ANDOEATH
ODESSA, TEXAS
(
PEMCOMAST
INSTRUCTIONS & PARTS BOOK
TABLE OF CONTENTS
1.
GUYING PATTERN SHEET
2.
CHECK CRART FOR PEMCO TELESCOPING MAST
3.
CAUTlON SHEET
4.
WARNING AS TO FITNESS
5.
OPERATING INSTRUCTIONS
6.
DERRICK SPEClFlCATIONS
7.
LVBRICATlON
A. LUBRICATlON CRART
B. LUBRICATlON DATA
8.
CROWN
A. SHEAVE LAYOUT
B. REEVING DlAGRAM
C. SHEAVE DESCRIPTlON SHEETS
D. SHEAVEDRAWINGS
E. CATLINE SHEAVE ASSEMBL y DRAWING
F. TUBING BOARD CROWN PULLEY DRAWING
9.
TUBING BOARD
A. RACKING CAP AClTY CHART
B. RACKING AREA.
10.
TELESCOPING CYLINDER
A. SCOPE RAM ASSEMBL y
-----------
B. SCOPE RAM BRACKET
C. SCOPE RAM STABLlZERS
11.
HYDRAULlC CONTROLS
A. HYDRAULIC CONTROL DIAGRAM
B. 7904 VAL VE
C. A20-CA 128 V AL VE
D. A20-HA 166 VALVE
E. A20-HB 166 VALVE
F. A20-Z16 V AL VE
Page 1 of 2
PEMCOMAST
INSTRUCTIONS & PARTS BOOK
TABLE OF CONTENTS
12.
RAISING CYLINDER
A. MAST RAISING CYLINDER - REPAIR P ARTS
B. CYLINDER P ACKING INSTALLATION
C. SD83CC24-131 1/2 COMMERCIAL CYLINDER
13.
ROD TRANSFER SYSTEM
A. MAINTENANCE INSTRUCTIONS
B . VALVE-FOOTCONTROL
C. LUBRICATOR
D. P ARTS FOR SAFETY SUB ELEVATOR
E. ROD TRANSFER SYSTEM
~----.....~_._
.
.
_.... . .. -.- ..
-
.... _
,
--- . -
14.
LATCH TUBE ASSEMBL y
15.
LATCH SEAT ASSEMBL y
16.
BASE SECTION
17.
BACKBRACETURNBUCKLE
_.__
_.... ----~.~.~._--_ ..'-._--_.__.,-'----_ ...._._~-~..............................~
...........
~~----
"-""-- -•
• • • • - ••
"•
••
•
___ _ o
-
•••
__ _ ____ •
_ _ _ _ •• _ _ _ _
page 2 of 2
~
.
SERIAL NO.
96.~180-C
MOOEL
l·
1292
RECOMMENDED GUYING PATTERN
~--~~~~~~----------.~
. . Xr--------
+-1601 ![JQJ--+
FEET
'1+-160 1~ ~
FEET
T-
I
160 I ~ ITQ] FEET
~--~­
I
-- <tt-:-=:WELL L---=_--I..
t
I
I
GUYLINE REQUIREMENTS
MINIMUM
BREAKING STRENGTH
o
=FOUR CROWN TO GROUNO GUYLlNES
G)
= TWO TUBING BOARD TO GROUNO GUYLlNES
.;--...
~
= TWO i.,.OAü Gü'r1.iNES
8.2
8.2
13.6
I
I
I
TONS
TONS
TONS
--_.'-~-'-'~--'--~~~~~~niIii:i~~-------.i
GUYLINE ANCHOR REQUIREMENT~
.@ _.....;::: ..¡:~:OIIR ANCH.QBS WITH EACH ANCHOR CAPABLE OF WITHSTANDING A
WORKlNG LOAD OF 17.0
1TONS IN THE DlRECTION OF THE WEtt---AT AN ANGLE OF I
45
I
TO
1
55 . I OEGREES TO HORIZONTAL.
WARNING
FOLLOW INSTRUCTlON CAREFULLy
THIS OERRICK SHOULO NOT BE OPERATÉD WITHOUT GUYLlNE ANO ANCHORS IN
ACCORO WITH THE ABOVE RECOMMENOATIONS. OPERATING WITHOUT SUCH
GUYLlNES ANO ANCHORS MAY CAUSE RIG OVERTURNS, SERIOUS PROPE;RTY
OAMAGE, PERSONAL INJURY ANO DEATH.
ODESSA, TEXAS
m
-
........
__ o
CHECK CHART FOR PEMCO TELESCOPING DERRICK
WARNING
FOLLOW INSlRUCTIONS CAREFULLY
FAILURE TO FOLLOW INSlRUCTIONS MAY CAUSE ACCIDENTS,
MAJOR PROPERTY DAMAGE, PERSONAL INJURIES AND DEATH
TO RAISE DERRICK
1. MOVE UNIT TO POSITION OVER WELL.
2.
CHECK GUYUNE ANCHORS TO BE SURE
THEIR PATIERN ANO CAPACITY ARE
COMPATIBLE
WITH
MANUFACTURER'S
RECOMMENDATIONS.
13. INSTALL FOUR CROWN TO GROUND ANO
lWO TUBING BOARD TO GROUND GUYLlNES
PER RECOMMENDED GUYING PATTERN.
AOJUST TENSION FOR 6" TO 10" CATENARY
SAG.
14. CONNECT
AIR SUPPLY UNE TO
TRANSFER AT MIDOLE OF OERRICK.
IMPORTANT
3. PLACE SUFFICIENT FOUNDATION UNDER
DERRICK SCREW JACKS TO CARRY THE
LOAD ON SOll AT THIS LOCATION.
4. LOWER SCREW JACKS UNDER DERRICK
BASE UNTIL DERRICK IS LEVEL ANO ALL
JACKS ARE FIRMLY SEATED . IN BASE
PLATI;S.
5. ADJUST
TILT
OF
DERRICK
WITH
tURNBUCKLES ON BASE SECTION. MOVE
LEVER "B" AS REQUIRED TO RELEASE
PRESSURE IN CYLlNDER.
6. RAISE CONTROL LEVER "B" TO RAISE
DERRICK. AS DERRICK NEARS VERTICAL
POSITION PARTIALLY LOWER LEVER "B" TO
S LOWLY SETILE DERRICK IN UPRIGHT
POSITION.
7.
INSERT PINS BETWEEN LOWER ANO BASE
SECTIONS.
8. RAISE LEVER "A" TO EXTEND DERRICK. Be:
SURE SCOPING CYLlNDER STABILlZERS
AS
SWING UP TO PROPER POSITION.
UPPER SECTION NEARS TOP OF TRAVEL
PARTIALLY LOWER LEVER "A" TO . SLOW
RISE. BE SURE TO SCOPE DERRICK HIGH
ROO
DURING RAISING ANO LOWERING OF OERRICK
BE SURE ALL [fNESARE -FREE 'AND SPool -Up
OR LET OUT SANOUNE ANO TUBING UNE IF
NECESSARY.
TOLOWERDERRICK
1.
OISCONNECT AIR SUPPLY UNE TO ROO
TRANSFER AT MIDDLE OF OERRICK.
2.
OISCONNECT CROWN ANO TUBING BOARD
GUYLlNES.
3. DISCONNECT LOAD GUYLlNES.
4.
CAREFULLY RAISE LEVER "A" TO EXTENO
OERRICK SLlGHTLY UNTIL LATCH PINS ARE
FREE.
5. PULL OOWN ON LEVER TO RETRACT LATCH
PINS.
6. LOWR LEVER "A" TO LOWER UPPER
SECTION ANO HOLO UNTIL UPPER SECTION
IS OOWN ON STOPS.
--·---·--¡EFlr'o;tl~O~U
Hl~
~
-F1
!9-~FAOrRR-+L~A.=MTCP.1HI-4-.--{;i
PIH'
IN~S~TTj
.O
~"¡::
F:f-IUII-<
LLI-l>,!!-' ~' -f.- CAREFUtt'i' MISE LE'VER V' U~T¡L ~~!-~
EXTEND.
9. CAREFULLy LOWER CONTROL LEVER "A"
----- UN1IL LAICFrPINS RESTlN-sEAIS:-LB\VEVALVE IN "LOWER" POSITION.
10. MAKE VISUAL INSPECTION TO INSURE ALL
FOUR (4) LATCH PINS ARE FULLY EXTENDED
ANO SEATED.
11. HOOK UP LOAD GUYLlNES ANO ADJUST
TENSION WITH BINDERS FOR 6" TO 10"
CATENARY SAG.
12. RECHECK DERRICK FOR LEVEL. BE SURE
ALL JACKS ARE BEARING FIRMLY ON
SUPPORT PLATES.
IS MAINTAINED ON GAUGE "B". RELEASE
AIR FROM TOP OF RAISING CYllNQ~R .~Y
_Q~\lE~L.JffiLVE, REPRESSURE AS
REQUIRED TO REMOvE ALL AIR FROM
CYLlNDER.
8. REMOVE PINSBElWEEN LOWER AN O BASE
SECTIONS.
9. CAREFULLY LOWER LEVER "B" TO LOWER
DERRICK ANO HOLD UNTIL DERRICK RESTS
ON FRONT SUPPORTS.
10. STOW ALL GUYLlNES.
11 . RAISE DERRICK JACKS.
GAUGEB
GAUGEA
CAUTION
-
-
.,
--
....
-'
.'
. -
- -:. .
- ,.-
.;;
- . - . -.-..:
- - .-~
~
BEFORE LOWERING lVlAST ENGAGE
HYDRAULIC PUMP AND CARE-F ULLY
. RAISE LEVER "B" UNTIL 300 P.S.I. IS
MAINTAINED ON GUAGE "B".
,
~
RELEASE ANY AIR TRAPPED IN
RAISING CYLINDER BY CAREFULL y
OPENING AIR RELEAS E VAL VE
LOCATED ON TOP OF RAISING
CYLINDER.
~
-- REPRESSURE AS REQUIRED TO
- RE-MOVE ALhAIR EROM CYLINDER.
~
CLOSE AIR RELEASE VAL VE AND
LOWERMAST.
WARNING AS TO FITNESS FOR ANY
PARTICULAR PURPOSE
~
This pr.oduct is supplied in acc.ordance
with tbe Purchaser's specification-s ao-d
d.oes n.ot necessarily iDclude all accessories
and safety devices required to p'u t this
pr.oduct int.o .operation.
.
'
)- Safety devices such as, but Bot limited to,
traveling bl.ock safety c.ontrols, ladder
climbing
devices,
derrickman
and
floorman escape devices, traveling block
travel limits, spinning wrenches, chains,
cables, etc. are available from .other
suppliers and it is the Purchaser's
responsibility to .obtain aIl accessories and
saf-ety · ,devi~,e-s D-ecessary to ,co,m plete Jhe '-"--_.-~~
. ,
'- product so tbat tbe·--'-product --" ca-o -be
.
.operated safely.
~
Perneo makes no warranties as t.o the
fitness of tbis prodllct for any particular
purposeo
SAFEOPERATION OF A \tVELL
SERVICING UNIT
THE FOLLOWING ARE POINTS OF PARTICULAR IMPORTANCE IN
TIlE SAFE OPERATION OF A WELL SERVICING UNIT.
DO NOT
Raise the mast in to the vertical position without adequate
foundation under the mast and rig for any loads that might be
encountered.
DO NOT
Raise the mast to vertical -position withOüt Vv'heel chocks, spri...~g
applied brake chambers or other means which are adequate to
prevent the unit from rolling to or away from the well.
DO NOT
Operate mast near power lines that might contact the mast or its
guylines when it is being raised or moved. If an electrical line is apossible hazard, the line should be de-energized by qualified
personnel.
DO NOT
Extend the upper section of the mast until you are ready to install
guylines in accordance with one ofthe following:
1. Perneo Mast Recommended Guying Partem.
2. API Specifications 4G (RP4G) First Edition.
3. Texas or Wyoming State Standards.
DO NOT
Extend uppe,r section of the mast if the scope ram stabilizers are not
in the proper operating position or proper operating condition .
Operate the rig until the latching mechanism between the upper and
"_." --"--- "----~_""H ]ower masE sectlons"-llave -~5eeiC chécked mm foulld-ttr-be fully
extended and properly seated.
. _._ _
DO NOT
Do-"NOT Lower -nÜist -into"-tfieuu roadlng position ·[refuTe" fiIst detennining
without any doubt that the hydraulic raising ram is full of oil (on the
raising side) and is ready to receive the weight of the mast after it
breaks over center.
DO NOT
Go up in mast without a safety belt. Safety belt should be wom at
all times when working in the mast.
Spec 4E. Drilling!ijld Well Servicing Structures
APPENDIXA
RECOMMENDED PRACTlCE FORMAINTENANCE AND USE OF
,
DRILLING AND WELL SERVICING STRUCTURES
A.l These general reeornmendations, jf followed
should result m longer satisfactory service from the
equipment. These reeommendations should in every
case be considered as supplemental to, and oot as a
substitute for, the manufacturer's instructions.
A2 The safe operation of the drilling and well
servi~ structure, and consequently the success of
the drilling operation, depends on whether the
foundation is adequate for fue 193d imposed. The
desígn load for foundation requirementS Should be
the sum of the weight of the driIling or well servicing
structure, the weigbt of the machinery and equipment
on il, the maximum hook load of fue structure, and
the m3XÍmum setback load (See Par. A.17 for
PórtáOle-Mast w/6uy l,mes).
A.3. Consult with the manufacturer for approval.of
materials and methods before proceedíng-· WIth
repairs: Repair, straighteJl, or repface any beot. or
otherwlSe dam~ed membér. Daníaged compre5Slon
member should be replaced r.ither Iban repaired by
straightening. Drilling and well servicin"g structures
use rugh-sfrength steels which r~UlTe specific
welding electrodes and welding tecbniques.
A4 Fixtures and accessories are preferably
attached to structure by means of suitable cIamps. DO
not driU or bum holes in anymembers or vertorm
any welding without first obfaining approval of the
manufacturero
A5 Wire line slings or tag lines should have
suitable fittings to P!'event the TOpe frorn being bent
over sharp edges and damaged.
A.6 ~oads due to .impact, accelerapon, and
deceleranon may be lildicafed by fluctuatIon of fue
wei"ght indicator and the 9Perator should k~ fue
ind1ca.tor readings within tlíe name plate hook load
capacrty.
A.7 In the erecting and lowering operation, fue
s]owest practicalline speed should be used.
A.8 Girts, braces, and other members should nol,
onder any circumstances, be removed from fue
derrick while it ís onder load
A:9 The drilling and well servicing structure
manufactUieJ has u~ great C"Je
design and
selection of materials ror his portable IDa'St. The
1
. n_ ~: !~~d &V~ti;:i!f:dtlZa¡~!:i:aR1~ 1
m
_'.H
a~~ce . with fue instru~ions. Every opery¡tor
~ñol!}a be_ glven~ an op~l~ to stl;Idy .mstruC;tu;lnS
~ sIH~ulooe-gn~en-smtabhrmstructJe8 andtrainmg
10 ert¡lCfmg, lowermg, and usmg the mast.
A.IO The substructure should be restramea agamsI
up-lift, if necessary, by rneans of a suitable dead
weight or hold down anchor. The weight of the hoist
and vehic1e, where applicable, may be considered as
a part or all of the required anchorage.
AII Each part of a bolted structure is designed to
caqy its share of the load; therefore, parts ornitled
or improperly placed may contribute to the failure
of the strUcture. fu the erection of bolted structures;
so far as it can be done safe1y, the bolts should bé
tightened.only slight1y tighter tI!an fingertigD.t uotil
die erectIon of the structure IS complet~ after
which al! bolts shoüld be dravm tight This
procedure permits correet aligQI1!ent of the structure
Which wiIl result in proper load distribution.
-
_
A.l2 Slin,g Line Inspection and Replacement. There
a.:re . three ppncipal. factors, one or more of which ¡pay
luntt fue life oía sling. They are: wear due to operlitton,
cOIT<?Sion, and irt~dental damage. Th~ first may ~
conSldered a fimction of the numóer of times the mast IS
raised. Tbe second will be related to time and
atmospheric conditions, and the third will bear no
relation to either, since irtcidental dámage may occur at
the first locarion as well as any other. The following
points may be ~ful in determining inspection .ano
replacement procedures.
a.. cparting of sling line r!!J)lacement shows an
erratic pattem. Sorne reqmre replacement at a
relatively early date and Qthers last several years
lO!!g~:. _.~ly
rep]~~ents. generally
show
IOCldentái damage ·a ñditis posslble--fuat-some.of-.tbe
longer lived ones are useó beyond the time when
they should be replaced.
b. There ís no way of judgmg tbe remaining
strenl!th of a rus!}' rope, th~efore ~ sling lines
shouIa be replaced. Areas adJacent to end
connections should be examined closely for any
evidence of corrosion.
In fue caSe of operations in coastal areas, sling
lines left ~3g in the mast may become corroded
and found
t for further service.
C. It wou!d n9 do~bt be possible. to establish a
normal sling line hfe e1qJeetancy In terms of the
number of IOcations on Which jt was used, as long
as a set number of months was not exceedeá.
However, this would Dot preclude the neces5Í!}' for
careful mspection to gt!aTd against incidental
damage. A lirte with any broken wires should be
replaCéd.. A line showin.,g any material reduction of
meta] area from abras Ion should be rep]aced. A
line showirtg kinkin"g, crushin~, or any other
damage resufting in dtstortion ofIbe rope structure
shoula be replaced.
d Replacement oflines based on normallife
~xpectancy will provide sOlD.e degree of safety, but it
IS Important tItat such proVlslons 00 not cause any
degree of laxity in sling line inspection.
e. Sling lines should be maintaíned in a welllubricatéd condition. The field lubricant shou]d be
comQatible with tha original lubr!C"'...ut, and to ibis
end fue rqpe manufacturer shtmld be consulted. The
... obbir oC [ope lubrication .ís to reduce interna!
__ ___
ifñnatio5inrna."m.aftnof1pPlr-ee'~veeilitlt=tW:onH~"QSsiooi6ttn;;'.:.--.::-==~===- ~.
A.13 The following routirte check,s, a,s app1ícable,
shouldbemadeat-appropriate.inteI:Vals:
.. .- .
-8. mspect welds in erecting mechanism for cracks
and ol:her signs of deformrty.
b. Follow the rnanufacturer's instruction in checking
hydraulic circuits before each 10werinK ogery¡rion.
Make SUTe of adequate supply ofhydraulic HUId
C. Wire rope, including operating lines... raisingImes, and guy lmes shoilld be inSIJec::íed ror kinkS,
broken wires, or other damage. Make certain that
~ lines are not fouled and filat other lines are m
place. in sheav~ grooves before each raising or
lowenng operation.
mast manufacturer's recommendations, the following
minimum breaking strengtbs should be maintained: load
guylines 18 tons; external guylines - 12 tons; racking board
guylines - 10 toos.
d. Check safety latches and guides in telescoping mast
íor free operarion before each lowering operation.
w
Keep latches and guides c1ean and properly lubricated.
e. Check unit foc leve! and check foundation and
supports for correet placement before erecting
operatioil.
A.16 Guvline Anchors For Ponable Masts Witb Guyiínes.
Guvline añchors including expanding type anchors, concrete
deadmen, or any other approved techniques are acceptable.
Soilcondition may determine most applicable t:)pe.
Recommendations fur anchor design and testing are as
follows:
a. AlI anchors should be designed to withstand a tension
load in the direction of the well al angle of 45° aboye
horizontal of 7 teos minimum.
b. Anchors sbould be proof tested for 7 ton minimum
load capacity annually.
c. Metal components of anchors should be galvanízed or
otherwise protected against com>Sion. Sucker rods
sbould not be used in anchor consiruction. Anéhor
location should be marked witb a stake if projections
aboye ground are subject to bending or other abuse.
d. Care should be taken lO avoid old pitlocations oc other
di~ areas fur anchor location.
f. Check lubOcation of crown sheaves.
g. Check lubrication and condition of bearings in alJ
sbeaves, sprocke15, etc, which are pan of the erection
mechanism.
h. Check folding ladders fOr free operarion before
lowering operation.
i. Durin~ drilling operations, jt is advisable lO -make
scheduled inspections of ali bolted connections to
insure tbal they are tigbt.
j. The Visual Field InspectiOn of Derrick or Mast
and Substructure procedure is recommended fer use
by operating personnel (01' a designated
representative) to the extent tbat 1.15 use satisfies
conditions for which an inspection is ¡otended. A
sa:np!e -repert -romt fQr Ws .inspection .p.r:~~ is
shown in Figure A3. The fonns are available trom
Intemational Association of DrilHng Contractors
(JADe). The rADC address rnay be obtained from
the API Dalias office.
A .14 Splicing locks should be checked frequeody for
locking positioo or ti~ess, preferably on each tour
durin$ drilling operanoos. To deveIop íts rated load
capaeny, the axis ofthe structure must be in alignment
tbroughout its length. It is important that any- splice
mechanism or Jocles be maintained in such condition as
to insure structure aligrunent.
A.15 Guving for Portable Masts wim Guylines. This
recommendation is applicable for most conditions
encountered in the use oftbis type masL There will be
exceptions wbere location clearance. ground conditions
or omer unusual circumstances require speciaI
considerations. Figure A.I shows a recommended
guyÍn& pattero that may be used under general
conditlons in
absence of an authorized API
manufacturer's recommendations. Guvlines should be
maintained in good condition, free from rusl. corrosion,
frays, and kinks. Use of old sand line is not
recommended for guylines.
All chains.,boomers, clamps, and tensioning devices
used in me guylines shalJ satisfY
mast
me
A.17 Mast FoundatiooFor Ponable Masts
Witb
Guyl!nes.Foun~tions must consider gIOl!nd conditi~ns,
.,
locatIon preparabOn, and supplemental footing as required
to provide a stable base fur mast erection and lO suppon tbe
mast during the most exJreme foading that wilJ be
encountered. A recommended location preparation to
provide ground conditions necessary for safe operation is
shown in Figure A2.
A.18 SUp'p'lemental FootiDl~. Supplementing footíng
must be proVlded lo distnoute
concentrated loads froro
the mast and mast mouot to the $fOund. The manufucturer's
load distribution diagram indlcates the magnitude and
Iocation oftbese concentrated loads. lfmanufacturer's load
distribution diagram is Dót available, supplemental footing
should be provided to carry the DlaXlmUIn book land
encountered. plus
gross weight of mast and mast mount
under load -condinons and to carry me mast and mast
mount weight duríng mast erection. The area and type of
supplementilI footing must be such mal the safe bearing
capacitv of soils on location is no! exceeded. Table A.l
indicatés the safe bearing capacity of severa! types of soils.
me
me
me
manufucturer's recommendarlons. In me absence of
-_.-- ---- ------.- - - - -.--JAIll.E._h,l
..
_.- ..-- ........ __ .............. - ........................
SAFE BJ;:f\RING CAPACI1Y OF SOILSt
(pounds per square foot)
-.--- -- ----._- -------- - ---- - ---- ---::--- - -- SoIid ledge ofhard rock, sucb as gnmite. trap, etc.~--o----...,----------_50,006
Sound shale and otber medium rock requiring blasting fur removal _ _ _ _ _ _ _ _ _ _ _ _20,OOO
Hard pan, cemented sand and gravel difficult to remove by picking
16,000
Soft rocIc, disintegrated ledge; in naturalledge. difficult to remove by picking
10,000
Compact sand and grave! requiring picking for removal
8,000
Hard clay requiring picking fur removal
8,000
Gravel, coarse sand. in natural mick beds
8,000
Loose, medium, and coarse sand, fine compact sand
3,000
Medium clay, stiffbut capable of being spaded
4,000
Fine loose sand
2,000
Soft day
- 200,000
- 30,000
20,000
- 20,000
- 12.000
- 10,000
- 10,000
- 8,000
- 8,000
- 4,000
2,000
w
_._
........" ......................
~
American Petrolewn Institute
Poge 20. Add thefolIowing Toble A.2.
TABIEA2
RECOMMENDED GUYLINEANCHOR SPACJNG AND LOADS
See Par. A.16a and Fig. A.l
1
Míui.mnm
Spacing
2
4
3
Double Mast
.
,
,
~
Anchor
Test Load
tons
Anchor •
TestAngle
from Horiz.
toWdl
Centerline
20
25
30
N.A.
N.A.
15.6
13.'1
6.,.
~O
3.1
ll.O
6[)0
50
élJ
2.8
9.3
8.-4
7.8
1.4
UJ
!).f"
XorY
Dimension
SeeFig. A.1 ,
lee!
70
80
00
7
6
S
Single Mast
.
Pale Mast
,
Anchor
Test Load,
tons
Anchor "
Test'Aiigle
fromHoriz.
toWdl
Centerline
Anchor
Test Load
tons
Anchor
TestAngle
from Horiz.
toWdl
Centerline
3.7
70·
7.{)
67-
•.0
..9*
3,5
45·
3.0
.cS·
71·
4S"
2.7
2.1
45°
2.7
.45"
2.7
.(50
NOIE: PrefeITed, X greater fhan y, Limits, Y mus! not
exceed 1.5X and Z muS! be equaJ fo or less fhan
1.5Y, but no! less fhan Y. (Fig. Al).
2.7
60'"
53
0
45"
4S"
45"
4So
4S o
CAUTION: THEADDIDON OF WlNDSCREENS OR
THE RACKING OF PIPEABOVE
GROUND LEVEL CAN SIGNIFICANTL y
INCREASE TIffi ABOVE ANCHOR
REQUIREMENTS.
.. -- . '-
-----,
----_.\. __ .__....... _--- ...........................
_......
_-
:spec. 41:.:
1X1UU1~ <Il'U . . " .. ~_ • • ____... _ __
A.19 Precautions and Procedures for Low T emperature
Operations. A surve)' of 13 drilling oontractors operatiog 193
oiJwell drillíng rigs in northem ('.anada and A1aska indicated
that therc is a wide range of experience and operating
practices under extremely low tempcrature conditions. \Vhile
tbere is verv littlc precise information available.. there bave
been a sizeáb1c number of fuilures in portable m3.sts while in
the lowcring or raísing ~s in tbe winter. There aJso seems
to be no tendency on !he par! of superYisory personncl to
restnct operating praClices. such as running hcavy stñngs of
casing or jarring on stuck drill pipe, because of!he risk of
faiIure due to high impact or load conditions, even thOiigb
temper.nurcs ma)' be extreme/y low_ Thus the exposure to low
temperature fai/ures focuscs on mast lowering and raising
opcrations. Based on rcports, this operarion has been
accomplished in lemperatUreS as 10w as -50F. -While-tlle-risk
may be eonsíderably grcater because ofthe changc in physicaJ
characteristics of $lee! at low tcmperatures, operators may
carry on "normal" operations even at extrem¡;1y low
tem¡xr41ures. This may be accomplisbed by a program of
close/y controlled inspection proccdures and carcfuI handling
and operation. This should reduce damage and impact loading
during raising and lowcring operatíons. Al the prcsent, therc
seems lo be no widely accepted or soundly supported basjs fur
cstablishing a criiicai temper;iture fcrlimi!mg-tre\lSe.Qfjhese
oilfield structurcs. Experience in the operation of trucks and
other heavy equipment exposed to impact forces indicares tbat
-40F ma)' be the thrcsbold of the temperature range at which
the risk of structural [ailure may ¡ncrease rapidly.
Prccautionary measurcs should be more rigidIy practiced al
trus point The folJowing reeommended practices are induded
for reference:
a. To the ex"tent possible, schedule mast raising and
lowering oJX.'ra1ions to takc place at the "warmest" time
of day; take advantagc of any sunligbt or predictablc
atmospheric eonditions. Take into accOW1t wind velocity
faClOrs.
b. Make use of any practical, available means to warm
seClions ofthe mast, such as using high prcssure steam to
heat the points of attachment between the mas! and its
base; aJso timba bonfires, and thc likc.
c. Talee up and looscn mas! raíSÍng lines severaJ limes to
assure the free movemcot ofall parts.
d. Warm up engioes and check. the properfunctioningof
all machinery lO assure that there
be no
maJfunctions which wQUld result In sudden braking or
jarring of the mast. Mast travel, once begun. must be
slow, srnooth, and oontinuous.
e. Inspection and repair as prmided In paragraphs A.3
and A 13 are extremely critica! under low temperature
oonditions. Masts shouId be maintained in excelleot
condition.
f.. In makin~ fieki wcias the tempcrnlli:"e of -st~
members snould pz-cferablv be aboye zero degrees
Fahrenheit. In the immediÍJ1e weld ateas" steel sOOuld
be pr~ w~ to the hand, before startíng weJding
or cuttmg operatlons.
""in
Page 27, Appendix B. Replace lhe lisl if authorizd
manufacturers in Appendix B wiJh thefollowing currem list_
Companies authorized to use !he API monogram on drilling
and well servicing structures (as of October, 1987) in
accordance with API Spec 4E are listed below.
Branharn Industries, Ine., Conroe,. TX
Cooper Manufacturing Company. Brad:y, TX
Drilling Slructures Intl.. Inc.. Houston, TX
Equipctrol SlA. Sirnoes Fílho Bahía. Brazil
KADS, Mcckcr, OK
National - OiJwelL Stockpon, England
Nuovo Pignone SPA M.a.<¡sa. ltaIy
Perneo Equiprnent Co., Ü<lessa , TX
Speedstar AJ\1CA Intemational, Enid. OK
Harold Lee Enginecring Co., Beaumonl., TX
Stru<.:tures & Systerns Engineermg. lnc.. Houston, TX
Industrial Del Hierro SAo Qucretam, Me.'(ico
Turmaie, Ltd. (Eogland), Conroe. TX
JRI IntemarionaL Pampa. TX
---- -- ---- ---- ----------_...•- ... --
.-.- . -. ...
--- ----_.-
-- -
-- - .._-------
American Petrolenm Institute
.- - - - - - 90' ±. 10'
----1
+--'---01
--------t---- 90' ±. 10'
-o
ctr
+,
Pumping Unit
Second Preference
él
al
10'
-
...._ _ _ _ _ _ 45' _ _ _ _ _ _..,.1 4' ....-
+1
b
al
_.- 0 - - - - - - - - - - - - - - - -
Q
Deadman Capacity 12 Tons
Grade
1:20 MAX.
_
~
Load Bearing Area
- --
------
.
__ _
Oh
-
Rig Location Area
-
I -tE -A.21
----- - - - - - - --- - - - - -
FIG.A.2
PORTABLE MAST LOCATION PREPARATlON
Load Bearing Area: Compacted sand or gravel requiring pickiDg fOl removal or better base.
Safe Bearing Capacity Desired - Min. 8000 p5f, level and drained.
Rig Location Area: May grade away from wcll along centerline II at max. drop of 1:20.
Should be level across grades para1.lel to centerline 1
Safe Beari.ng Capacity Desired - Min. 6000 psi Alowmaneuvering entIy fOl drive in 01 back in.
Drninage of en1ire area required.
Spcc 4"E: Drinh,t:' ano! WeU S<erv;c;of.' StrlKlur..
Repwt Of Visual F~d Inspection Of
Derridc Or Ma5t Aod SubstroctllTe- .. JrDiftl~.,.U.~a.~~""ttw
............. ~af~CooIISf.ct~_~~J~
PURPOSE ANO SCOPE OF INSPECTlON: This report form and inspection procedure was developed as a guide for
making and reporting field inspections in a thorough and uniform manner. It has been approved for reference in API
Std 4E, Appendix A Recommended Practice for Maintenance and use of Drilling and Well Servicing Structures. The
procedure is intended tor use by operating pen;ormel (or a designated representative) to the extent that its use
satisfies conditions for which . an inspection is íntended. More detailed and critica! inspections may be scheduled
periodica!ly, or ordered to supplement a program c¡f these ins~ons; íf masts or derricks are used in the upper range
of. their load Iimits, or if strudures may have !:leen subjected to critical conditions which could affect safe performance.
MARKlNG OAMAGE: A! the time of inspection, damaged sections ore equipment m!J~ be clearty and visibly mal1<ed
so that needed repairs may be macia A briglJt, contrasting spray on paint is suggested for this. Wheo repairs are
made, !he visible markings should be rerTlO\l8d by painting over them. It is a1s0 necessary for the ins~or 10 write
"None" when no damage markings are needed, as this is his indication that the ítem has passed inspectión. It is
recornmended that inspection be made with assistance of manufadur's assembly drawing and operating instuctions.
Tor items not accessible or that do not apply, draw a line through the item pertaining to the component.
BOLTED STRUCTURES: Section XIV is provided for a rig builder to use in reporting the results of his inspection .and
tightening bo!ted connections, in making an inspection of a standing denick. The rig builder is a1so to make inspection
and report his findings as called for in Sections 111, IV, VI, VII, IX, X, and XV.
Company Name._ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _,Rig No. _ _ _ _ _ _ _ _ _ _ __
Lócatíon
Oate_ _ _ _ _ _ _ _ _ _ _,...-_
MastlDerrick
Iden~on._ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _.Ser.No._ _ _ _ _ _ _ _ _ ____
Rig Standina""_ _ _ _ _ _ _ _.Lying Down._ _ _ _ _ _ _ _Disassernbled._ _ _ _ _ _ _ _ __
Inspected Ey._ _ _ _ _ _ _ _ _ _ _ _ _,Representing_ _ _ _ _ _ _ _ _ _ _ _ __
Original Of Report Sent To._ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
DERRICKS ANO MASTS
1.
Crown Assembly
Sheaves
No. _ _ _ _-'Main ClusterSíze_ _ _ _ _ _ _ _ _ _,Fastline Síze._ _ _ _ _ _ _ __
A
B. Condition
OK
1. Sheaves: Warped
Groove: Wom
OK
2. Spacers Or Seals: Bad
OK
Grease Fitting: Missing
OK
3. Searings: Loase
Bad
OK
4. Crown Safety Platform: Minor Damage
Badly Damaged
OK
5. Handrails: Minor Damage
Badly Damaged
racked Welds
OK
6. Crown Frame: Bent Beam Fianges _ _ _ __
Cracked Welds
Location _ _ _ _ _ _ _ _ _ __
7. Comment Rusty
Needs Repairs _ _ _ _ _ _ _ __
- - . ¡>jeeds r'aiui.íul:I
._- _. . .. ..
. ~== ::::;"= = = = = = = - - - - 8. Number Of Visible Marks Aplied._ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
. . :.. .;
11.
Additional Sheave Assemblies: Name._ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ OK
111.
Crown Support Beams
Or
- ---- ----- - -- - - _.
No. Of Visible Marks Applied_ _ _ _ _ _ _ _ __
Sean Flanges Bent_
' _ _ _ _Beam Webs Bent,_ _ _ _Cracked Welds _ _ __
Needs Repair
No. Of Visible Marks Applied
OK
FIG. A.3
J.U;PORT OF VISUAL FlELD INSPECTION OF DERRICK OR MAST AND SUBSTRUCTURE
Perneo 96-180--C S/N# 1292
Page 1 of 3
IV.
Legs
A. Front Leg, Drillers Side:
Slight Bow
Bad Bow_ _ _ _ __ Needs Repruring
OK
Pin Connection: Bad,_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __ OK
OK
Pin Hole: Bad,_ _ _ _ _ _ _ _ _ __ Cracked Welds
Safety Pin: Nlissing,_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __ OK
B. Front Leg, Off~rillers Side:
Bad Bow_ _ _ _----'Needs Repruring
OK
Slight Bow .
Pin Connection: Bad,_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __ OK
Pin Hole: Bad_ _ _ _ _ _ _ _ _ __ Cracked Welds
OK
Safety Pin: Missing_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __ OK
C. Rear Leg, Drillers Side:
Bad BON_ _ _ _ _,Needs Repruring
OK
Slight Bow
Pin Connection: Bad,_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __ OK
Pin Hale: Bad_ _----'-_ _ _ _ _ __
OK
Cracked Welds
Safety Pin: Missing_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __ OK
D. Rear Leg, Off~rillers Side:
Slight Sow
Bad Bow_ _ _ __ Needs Repairing
OK
Pin Connection: Bad,_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __ OK
Pin Hole: Bad,_ _ _ _ _ _ _ _ _ __ Cracked Welds
OK
Safety Pin: Missing,_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __ OK
E. Number of Visible Marks Applied_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
V.
Spreaders (Back Panel Trusses)
Slight Damaged
Bad Damaged_ _ _ _Cracked
.
Welds
Needs Repairs_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ OK
Bolt And Pin: Improper Length
Safety Pin: Missing
Bolt And Pin Holes: Oval
Number of Visible Marks Appliedc...-_ _ _ _ _ _ _ _ _-:--_ _ _ _ _ __
Vj .
OK
OK
OK
Girts And Bracing
B~~_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ OK
Number Ben!: Sligh!
Badly
Cracked Welds, _ _ _-'--_
NeedsReprurs._ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Number of Visible Marks Applied.__________________________
VII. Feet Or Pivots
Damaged
Cracked Welds
Corroded
Worn Holes______
Worn Pins_ _ _ _ _ _ _Needs Repairs _ _ _ _ _ _ _ _ _ _ _ _ _ OK
Number of Visible Marks Applied,_______________________
VIII. A-Frame - Base
A Legs: Damaged Mernbers_____________Cracked Welds____________ OK
B.
Spreaders Or Trusses: Damaged Members
C.
D.
I,Jpper Conn~ions: Damaged
Cracked Welds
Raising Sheaves And Shafts: Damaged
Lubrication:
Fittings: Missing_ _ _ _ _ _ _ _Cracked Welds._ _ _ _ _ _ _ _ _ _ _
Cracked Welds
E.
Lovver Connections: Corroded
OK
Pin Connections: Loose._ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ OK
Pin: Worn
Sarety P:n: Misslng
F.
IX.
OK
OK
OK
OK
OK
OK
OK
Number of Visible Marks Applied,_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Working Platform
A
Racking Platform: __ ._.
Frame: Damaged_ _ _ _ _ _ _C.racKed Wetos._ _ _ _ _ _-'-_
'-·_·_.._·_' _-_ ·..QK.. - -- --.---..._.__.. _______ ~
Pin Connections: Wom
OK
Safety Pin: Missing
OK
Fingers: Damaged_ _ _ _ _Cracked Welds, ______ Needs Repairs _ _ _ _ _ OK
8.
Rod Hangers:
_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ OK
Fram~D~.
Fingers: Damaged,_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ OK
Basket Damaged__________Cracked Welds_ _ _ _ _ _ _ _ _ _ _ _ OK
C.
Working Platform: Damaged,_ _ _ _ _ _ _ _ _Cracked Welds_ _ _ _ _ _ _ OK
D.
Tubing Support Frame: Damaged
OK
FIG. A.3
REPORT OF VISUAL FIELD INSPECTION OF DERRICK OR MAST AND SUBSTRUCTURE
Perneo 96-180-C S/N# 1292
Page 2 of3
Connection: Damaged,_ _ _ _ _ _ _ _Cracked Welds _ _ _ _ _ _ _ _ _ _ OK
E.
x
XI.
Handrails:
Damages: MinOf_ _ _ _ _ _M,ajOf_ _ _ _ _ _CI<lCked Welds,_ _ _ _ _ _ OK
Connections: Need Repairs
OK
F. Number ofVisible mar1<s Aplied,_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _Ladders: Oacked Welds
Bad Rungs,_ _ _ _,Bad Connections,_ _ _ _ _ _ OK
Damages: Minor
Major_ _ _ _ _ _ _ _- - - - - - - - Number of VISible Mar1<s Applied,_ _ _ _ _ _ _ _- - - - - - - - Raising And T elesccping System
A. Wireline Systenn Refer To API Std. 4E For Spefication
OK
1, Wireline: Frayed
Kinked,_ _ _ _ _Corroded,_ _ _ _ _ _ _ _ OK
2, Cable Clamps: Loase
No. Of Clamps Properly Installed
OK
3. Sheaves And Mounting: Damaged
OK
4, Equalizer Assembly: Damaged
OK
B.
5. Sockets And Pins: Damaged
OK
Hydraulic Systenn:
1. Hydraulic Cylinders:
a. Raising: Leakin".g--'-___,Exposed Surface,_ _ _Corroded,_ _ _ _ _ _ _ OK
a. Scoping: Leaking
Exposed Surface
Corroded
OK
2, Connections: Leaking,_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ OK
3. Hoses & Hose End Fitting: Exposed Wtne._ _ _ _ _Corroded,_ _ _ _ _ __
Damaged
OK
4, Pin Holes: Oval
OK
5. Scoping Cylinder Stabilizers: Bent
OK
Lubrication:
OK
C. Mast Guides: Cleaned And Lubricated,_ _ _ _ _Needs Attention,_ _ _ _ _ _ _ OK
D. Number Of Visible Marks Applied,_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
XII. Lccking Device & Seats-Telescoping Masts
A. Pins, Bars or Pawls: Damaged_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ OK
B.
Seats: Deformed
OK
C
D.
Mechanism: Damaged
Needs Cleaning & Lubrication
Number ofVisible Marks Applied,_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
OK
XIII. Guyline An¡;horage
A. Guyline: Damaged
Needs Adjusting
Needs Replacing,_ _ _ _ _ OK
B, Cable Clamps: Loase
Properly Installed
Sorne Missing
OK
C. Pins And Safety Pins: Missing
OK
D. Tumbuckles: Locked
Damaged
Replace
OK
E. Anchor & Deadmen: Replace_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ OK
F. Number ofVisible Marks Applied_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
XIV. BoIted Structures
AH bolted connections are to be inspected, tightened, and missing parts replaced or vísibly marked as
missing or damaged and in need of repair.
A. AII bolted connections found to be satisfactory as checked and loase bolts tightened, or
OK
B, A11 boIted connections visuaUy inspected and spot-checked for tightness and no
further boIt-tíghteníng or repairs necessary.
OK
C. Number of Visible Marks Applied,_ _ _ _ _ _ _---'_ _ _ _ _ _ _ _ _ __
XN. Summary Of Inspection
A Was Manufactur's Asssrr.bly Dm.'lIing Used?
Ves
No'--_ _ _ __
B. Appearance: GOOd
~a!r_-._
--_.-_ _
..-_. _··--_ _PGOf- ·---- .,. -.-. .
. . _ . ____ ._ _ _ _ _ _ _ _ _ _~
C, Repairs Needed: None
Minor
Major_ _ _ _ _ _ __
D. Number of Missing Parts_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
SÜSSTRUC:TURE& VER I ICAL EX 11::J'~;:'lvN
h
--
.
.
----------- _.... .... __ ._-----. -.. _-- - - - - -
Shoes, Pedestals, Or Pivotd: Damaged._ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ OK
Hales: Worn
BoIts: Need Replacing
Pins: Worn
Safety Pins: Missing
Support Beams: Damaged_ _ _ _ _ _ _ _ Corroded._ _ _ _ _ _ _ _ _ _
OK
OK
OK
OK
OK
Number of Visible Marks Applied
OK
FIG. A.3
REPORT OF VISUAL FIELD INSPECTION OF DERRICK OR MAST AND SUBSTRUCTURE
Perneo 96-180-C S/N# 1292
Page 3 of3
í
HIIJ/lEIT
I
MANUFACTURING
COMPANY
UMITED
8238 - 129th Street
Surrey, B.C.
Canada
V3W OA6
Telephone:
(604)
572-3935
Fax:- ' (664) . 590-:831.3-.---- .
htto :/Iwww.kobelt.com
.
•
~-
,
.
.
.. .. ",~ ..",-.,:.:......~~::.,".~.: .~ ",.~_._
~-"' "
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•• _
, . •_ ' •
•• _,
_
._. . _
• ....:.. _ _ _ _ _ _ _ _ _ _ • _ _ _ _ ... _ _ __
_
••• • . •
KOBELT MANUFACTURING
. .(.. . ,".€-. . : ..
·
-~1
, ",- " . ,
____--:-_ ., __ ..... .. _ . _._ ._ - • __ • - _.
"
.
.
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'
· .· · G·O .M- PA:NY~·'·L~fM:I··TE:D~;· ·:·
•...
_. " ... .. _ ,' __ ' _
o ••
'0 _ _ •
• ' . '___ _
• •••
_
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_.
•
MA'I NTENANCE & INSTALLATION
INSTRUCTION'S
.~_.~~---_.~-_._
.
..
_- -
... . _... .......
~
_-_ ..•..._-..
,
••
"' . _ •. ,
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_ _ • _ _ • _ _ ' •• _ _ _ _
. . . . . . . _ . • _ . _ _ _ . _ _ _ _ _ _ _ -.... _
••. _
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..... -
_
.~-
._-_._-_
.
- . _ .• -. _ _
ALL KOBEL T Dlse BRAK"E S
').-
..
.
..-
. ..
"LEADERS IN QUALlTY MARINE CONTROLS, STEERING GEAR AND DISC BRAKES"
.
,..,IIíIII&"A
I1II11~JII!'IT MANUFACTURING
.!
COMPANY LIMITEO
I
) )
AIR APPLIED DISC BRAKES
CALIPER" No~ 5040
INDUSTRIAL BRAKE
I
I
I
J
DESCRIPTIQN
The air applieci'model 5040 is a pneumatically operated
caliper requiring orily an air supply arid a pressure
regu'lator. The pressure regulator can be adjl)sted to
provid~ the customer with the desiredtorqiJe or stoppin
characteristics. Twoair-on actuators consisting of a
double diaphragm systetn provide an equal force to eac
brake shoe when an air pressure is applied. The action
compression springs return the caliper to the "brake-off
position when the air pressure is shut off.
CALlPER
), ..!
Total normal force
Total shoe area
Allowable shoe wear
Maximuni air pressure
Maximum power input
Assembly weight
DISC -
Caliper 5040 is also available in a mechanicallyapplied
modelo A 5400 lb. PLilling force is required to drive a we(
between the two brake arm levers thereby applyin
brake.
52,560 lb (23,890 Kg)
320 in 2 (2064.cm 2 )
0.56 in (1'4 mm)
100 psi (7.03 Kgicm 2 )
768 hp (572.3Kw)
570 lb (259 Kg)
80th types emp,loy the balancing link which ensures eq
wear on both liriings.
4" (102 mm)
Disc Día. In.
mm
42.5
(1079)
48.5
(1232)
54.5
(1384)
60.5
(1537)
72.0
(1829)
84.0
(2134)
96.0
(2438)
Acting Rad . Ft.
mm
1.33
(405)
1.58
(482)
1.83
(558)
2.08
(634)
2:54
(774)
3.04
(927)
3.54
(1079)
Max. RPM
1300
1100
1000
900
700
600
500
* HP - Seco
(Kw - Hr.)
54,000
(671 .3)
69,qOO
(857.7)
78,000
(96-9.6)
86,000
(1069.0)
128,000
(1591.1)
163,000
(2026.2)
200,000
(2486.1)
.-
.
KOBELT BRAKES ARE PROTECTE[
UNDER ONE OR MORE
OF THE FOLLOWING PATENTS:
NOTE:
Specifications in metric units shown in parentheses .
\.
~
i
* Figures are based on a continuous application of braking force.
Allowable values will be higher for one-stop applications where disc
is allowed to cool between uses .
For more detailed technical information refer to Kobelt'sGeneral
Engineering section on disc brakes.
U.S. PATENT Nos.
3722636
3815471
4013148
4060153
4164993
4121697
4108285
4236608
CAN . PATENT l'
895693
922603
1069066
1072025
FURTHER PATENTS PENDING ,
Apól 200c
DIM ENSION AN D PARTS
5040
'
'
%1~)=1
2 HOLE~ 1ft, DIA . FOR ~.-------:.¡.++-------------,­
CENTRE 'OUT~M;OU~N~Tr.i'~~l?~~~======~
ITEM
OUAN"TlTY
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
1
1
1
1
1
2
4
2
4
4
2.
...
. 2·'
:
1
2
2 .:
2 '
" ':, ''"~035-16104
~~:
5
'''''5040-0022
2""
;S
12
10
4
4 "'
A,
25
26
27
28
29
30
31
32
33
3-4
35
5040-0009
1035-1240
1035-0880
5040-0012
1oQJ;Q.124
5040:0014
5040-0015
1001-1116
5Ó4G-0017
4'
80
22
DESCRIPnON
Mounting toOl
Centre mounl saddle centre
Double loot meun! saddle end (AH)
Double '1001 meun,t 'saddle end (LH)
Saddle centre
Saddle spacer
Clevis
Brakeshoe
Lever
Actuator pin Balanc:ing link pin
Batancing link
Ca¡jscrew
5Q4()-()()()8
2
23
24
PART NUMBER
5040-0001
5040-0002
5040-0003
5040-0004
5040-0005
5040-0006
5040-0007
12 .
12 :'
12
-4
2
16
16
r-
Eild" i;~: ,.,
'.
Ac:luator meun!ing bracke!
Gapscrew
Saddle end
Unlng
AI,et
Shoe.pln
Lever piYot pin
':Úo$203:!s
~~¡"1
',1022:0123
~026-1022
Cóller, pln
Coller pin
C3pscrew
Spring cap
PuSh rod ·
spring
Spring guide red
Locknut
Dlaphragm
", Centre housing
Nut o'
,Gapscrew
1026-0512
i001-l116
~:' ,
. 120HlOS9
, 5049-0030
, 1022-0311
1105;0036') .
5040-0033
1002:0112
100]71296 ,
n~1J49,31
I
I
}I
787
,l ;
:'
~ ,,~'--' 1,;".,
't
;
"PPR.13
~ ¡:33~,7)
-----J
. _ _ _ _ _ _ -. -
.g~1241.31
=s-
4HOLES
,/¡/, :
DI".
~L4k
J
f~
J; @ ~~~/ioq
SI DE FOOl
1104.8)
I--- - .."o~ 1257. 2f-..
12.~1307.91
29~1749, 3) . - ...
,~
MOUNT
-
I
. '\254\
~
All DIMENSIONS IN INCHES (MM)
NOTE: AII data on this brake selection sheet are for reference and estimating purposes only. To ensure against
tt:le...hazards of brake misapplication, the Customer is urged to fill out the Customer Application Dat a sheet and
include itwith each enquiry.
"~"Il!'IT MA,NUFACTURING
1II111"':;"'J
COMPANY LlMITED
Printed in Canada
April 20
1)
BASIC PRINCIPLE OF OPERA TION FOR KOBEL T DlSC BRAKES
Low pressure actuators with large areas are used to apply the force against a
,mechanical lever,mulíiplying the brake application forces with a lever ratio af
approximately 3.6: 1 and up to 5:1. The application force 'o f the actuator is therefore
directly related to the brake force. Varyingthe pre$sure results in an abs01ute '.
proportional brake torque reduction or increase. This results in very high torque
cqP?bilities. Kobelt manufactures basically two different types of.calipers. The box
shpe.typeandthe ,open shge.type.The boxshoe .typecaliper ismainly used for high
torque applications with relati'lely Ibw energyinpuL .This is due to ,fhe areaof square
inches of Iining available. The open shoe type calipers have enormous lining surfaces
andJendthemselves. ,extremely well for continuous high energy absorption. 80th
calipecty.p es are available in either air or hydraulic applied version or in the spring
applIe.d configuration. Some of the brake calipers are éilso manufactured with a
combination actuator which will provide both air applied and spring applied functions.
\
I \
DISC BRAKE L1NINGS
Kobelt engineers have developed a unique disc brake Iining material. Available only
from Kobelt, it offers acombination of advantages over most othér materials. In
situations where the brake discis operating in relatively high temperatures, or where the
P.V.* ratio will ex,eeed normal all.oWé3ble levels. localized plastic deformation ,in the disc
wi!l occur.f3rake discs that are 'subject to high eriergy input, which goes ;beyond the
thermalcondLl,ctiyity of the disc brake material. will result in plastic deformation of the
disco This results in uneven energy ctistribution which in turn causes discJailure. Kobelt
lining material. with its slight abrasive characteristics. will minimize the unevén energy
distribution. Unless Kobelt disc brake lining material is used , guarantees on the brake
disc may be void.
OISes
Kobelt brake discs are available in a variety of diameters and thicknesses to
accommodate nearly unlimited combinations of torque and energy input requirements .
Kobelt provides four different types of standard discs.
(1)
Medium ehergy input - solid steel discs. These discs are used for infrequent
stopping applications. The energy in these discs is absorbed rapidly in the disc
mass. but the disc requires a long cooling time.
(2)
Medium energy input - ductile iron, internal aircooled discs. These discs are
designed for general purposes and witl perfonrn much better than a solid disc at
higher speeds and continuous or intermitlent brake applications. since the fan
action of the disc will increase the heat transfer by drawing air over the internal
cooling fin designo
*P.V. - Pressure velocity - pounds per square inch x feet per minute .
I \
. I
Basic PrincipIe of Operation fot Kobetl Disc Brakes
Page 1
DISCS
(3)
(cont'd)
High energy input - ductile iron, intémal aircooled discs. These patented discs
providethe most refined internal cooling fin designand are idealiy suited for
continuous high energy input at h¡'gher speeds.
(4) " Very highenetgy input"..: duCtile iron, internal wafer cooled discs. These patented
discs, desighed for high torque, lowspeed appllcations, have intemáJ water
"
pass'ageswhlch pertnit high ráte of ériergy di'sslpatióri.
a
"
(5)
"
Sorne Kobelf bráke disCs aré'ávailable segmentéd (hálf or quarteréd). The
purpose of these 'SegineriteddisCs is to facilitate disC installcitioh or remóvalon
dist adaptar f1anges locatédbétween machiriery parts whith do not állow for a
one piece disc ihsta:llátiori Without the "removal of other components.
AIR COOLED BRAKE DlSCS
Air cooled brake' discs are designed té pUmp air effidently when rotating quickly. In
most cases a guardor sorne: protedrve :coveris "needed to shield the brake disco An
improper design of coversmay caúse air recirculatibn 'throLigh the disc br radiant heat
reflectión, which may resúlt in the disc overheating~ The cooling air pumped through
the disc ml;lstbe exhcüisted ·away.frbm thedisc toallowfresh, cool 'air16 enter the inner
verit operiings' of the disco No back pressure'should be generated oh the exhaust side
ófthe disco
CAUTION:
UNDER NO CIRCUMSTANCES SHOULD THE DISC COOLlNG FINS BE PAINTED.
Basic Principie of Operation for Kobelt Disc Brakes
Page 2
) )
INSTAL LATION ANO ADJUSTMENT IN5TRUCTIONS FOR
KOs'ELT OISCBRÁKE CALIPERS
Bffi\KE DISC INSTALLATION
It is important to remeniber that the brake disc itself must be insta"ed onto the rotating
.eleinent befo re installiqg 'fhe ealiper. This will then allow proper alignmellt of the brake
cal¡'per to fue disco Thédisc mounting bolts must be suitable to absorb the brake torque
plus any shock load in the system. For high temperature dise applications, the holes for
the ' mouriting bolts must be oversize lb allow the disc to expand and contraet during
opération.
DISC INSTALLATION MA"
DISC INSTALLATION M8"
TYPICAL DISC INSTALLATIONS RECOMMENDED
FOR HIGH TEMPERATURE APPLlCAnONS
;
THIS TYPE OF SPIGOT DETAlL IS NOT SATISFACTORY
FOR HIGH TEMPERATURE APPlICATIONS
1i
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OvE~SJZE
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-
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"'USt
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-- - --~
WIHCH
DISC INSTALLATION FOR WINCH
)
.
DISC MACHINING DETAlL ·C1" & ·C2"
:
!
Basic PrincipIe of Operation for Kobelt Disc Brakes
Page 3 .
BOLT MOUNTING HOlE DIAMETER OVER SIZING,
Disc Bolt
Circle, iD..
10
15
20
25
30
35
40
45
50
55
60
65
70
75
80
Maximum Disc Temperature,
. ,.
.'
400
500
600 . .
.013
.020
.026
.033
.039
:046
.052
.059
.065
.072
.078
.085
.0'91
.098
.104
.016
.024
.033
.041
.049
.057
.065
.073
.081
.089
.097
.106
.114
.122
.130
.020
.029
.039
.049
. . ',
.059
.068
.078
.088
.098
.107
.117
.127
.137
.147
.156
IN.
F
'
700
,023
.034
.046
.057
.068
.080
.091
.102
.114
.125
.137
.148
.159
.171
.182
The brake disc must be installed onto a rotating element that is machined flat and clean
for the disc mounting·surface ...,.The rotating element should ,have bearings sufficient to
carry the weight of the disc and also absorb the additional stress when the disc brake is
applied. The bearings should be of sufficient quality to make the shaft run through
without wobbling. Anyexcess runout of the disc (wobble) could cause premature lining
wear and also cause the lever arm bearings to wear out prematurely. For special
applications, sorne end f10at in the shaft can be tolerated.
Consult Kobelt for maximum float in shaft bearings.
It is important to remember that the brake disc itself must be installed onto the rotating
element before installing the caliper. This will then allow proper alignment of the brake
caliper to the disco The disc mounting bolts must be suitable to absorb the brake torque
plus any shock load in the system.
Since a brake disc is absorbing energy during operation, it will, in this process, become
hot and consequently, expando The hotler a brake disc becomes; the more it will
expand because of the coefficient"of expansion pertaining to a specific material. It is
therefore very important that the mounting holes are oversized to let the disc expand
and contract during normal operation. Depending on the type of material used, a disc
will also shrink during initial start-up and could become considerably smaller depending
on the maximum operating temperature. Therefore the spigot diameter between the
Basic Principie of Operation for Kobelt Disc Brakes
Page4
.i
) )
male and female bore must-be machined to allów for the shrinkage of disco We would
highly recommend that you cóntact Kobelt with all the operating criteria for a·s sistance.
The disc musí nevér bémachihed witha male spigot"for high temperature ápplications
sincé'such a ~.#)igót (see detaW"B") willprevent th'e' disé frbmexP?nding dueto heat.
.: . :.
.
..
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.
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The caliper brake Uriit shoLild al50 be 'mounted to allow for disc expansion with6ut
Céiusing contacfbetWeéi1\he oJté;i cir6Gmfetenc\e bf d'¡sc afia ttl'e 'inrüú cálIpet frame .
.-
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The hé~t ,tr¡:itlSf~r fro~tH.~~i~(; ,.tq.:.th.~ mÓl}n!lePP~,D.géi~r~latively~bw. th~refore fitted
b.olt~ 9.nndt bé LJsed. lt !hé' rnSl,$,dtn4rn cip~f.atiríg J~fT1P~ratyre of the di se is .~~own. the
dé§,rarice arrowance' can'easily 'be' calculatédafter'the~olt CircJ~ is estaólished.
.
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In order to prevent disc deflection. the mountlngflange of the disc can be machined or
cast with
relief cut-outs
asindicated -under
.
'
.
.
. disc machining . details "C1" and "C2".
"
is
.
" '.
. .
-
.
It also very important to of:)tain a fin~ grain casting disc material whieh should be
machlned to a fine finish (32 micro preferably). This will eliminate excessive Jining
wear.
OISC BRAKE CALlPER INSTALLA TION
\ ,
.
i
Basic Principie of Operation for Kobelt Disc Brakes
Page 5
Afoundation plate to support the brake caliper must bestrong enough to withstand the
maximum torque ,generated by the brake caliper. The foundation must also be tlat and
square to the brake disco The caliper must be installed with the proper size bolts (grade
5,9,f beJter) as spe,cified in our drawjngand underno ;circumstance$:emust there be a
bolt:missing. , ItisaJ~9 important thaHhese, bbl~sbe properly and; ev~nly tO.rqued.
Failing to do so could cause the foot of the brake to fail. It is also very important that
the as~embly bolts,.(~tuds and ,n~ts), ; Flretightenªq o~for~_ plaGingFl brake caliper into
operatlqn. ; ~gajn',ló6se boltsv{W c,a'y$,E?-,lhe,qr,a,ke tg.f?l! ..:-Vfith.the 5000 s~rie~ brakes.
it is póssible tcundo the assemblib61ts, (nuts), and 'ráisethe whole caliper
.
arrang~me!Jtaway from ihe foot tO,allowJostaJlatipn QfJh.e mOLJoting bolts ¡nto the,brake
f()6(After th~ ~¿Its in 'pJ~'q~rt5~~br$](K~~6' ~~f~~:~.~,~tn~I,ecL The d~~ran.cy '. ,
bétween thé brake ánd discshoe'shouldDe equállydivideo On both sidés ofthé brake
disc and thé'shoé' should be pkr~l¡el toth:~ 'd'tsc~ fhk 'rLigged' design of Kobeitb'rake
calipers al}ows for some inaccuracy withoutaffecting the performance.
'are
.
Ori the die-cast bronz:~' 5000seriés b'rake 'calipérs shims car{b-e pí'aced between the
shoe bearing and the shoe to allow the calipers to be adapted to various sizes of disc
thickness. The actuator themselves also nave an adjustable cJevis to allo"" tor brake
lining wear Or to adapt to various sizes ofdisc~ ' Itis'importáriftn'a't 'the clearaffcé '
between the shoe and the disc be maintained at a minimum for fast response, and 'also
. minimum air consumption in air applied calipers. The spring applied actuators are
equipped with a single pipeport at the actuator piston housing, either 1/4" or 3/8"
N.P.T. The air applied actuators from the bronze die-cast series have two supply ports
per actuator. These ports are common internally, and normally only one port is
connected to the control circuit. Only in cases of extremely fast response will it become
necessary to connect both ports.
Basic PrincipIe of Operation for Kobelt Disc Brakes
Page 6
I
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CLEARANCE ADJUSTMENT
Before making any adjustment ensure·thélt the brake is released
__ _ _ _
~:=s:;Mr-"..:..,..-hrr APPLlEO ACTUATOR
S¡:»RJ~<;;
The clearance
FLIJID
ÁPPLlED ACTUATOR
can beádjusted
lt======i====~. by 'removing'pin-"A· and by
tuming clévis "B·~ Itcanfurther
beadjusted by Joosening jam
nut "C·. Then removing bolts
in bracket "O" androtating
same.
r
!
Rémove both pins "A"
andtum botll clevises
an equ~1 amount Tum
counter clockwise to
decrease cle~rance
and clockwise to
increase clearance.
BALANCING LINK ADJUSTMENT
Al! calipers are equipped with balancing Iinks to enslite even lining
A
wear. To adjust, loosen screws "B" and adjust link "A" to align the
e shoe parallel with the disco
SHIM "KITS
) )
\
-_ OUX.Ct.EUAH([--
c~I~-
.DtO·I"" .. I~.$lO(
--
h;;;:=:::::---+~::::::*--o
(
00 -
o' o __ o_.- - -- - • - - __
_-
In ordertoadaptacaliper for a thinner disc shim kits are available.
These shims"D" tit between the brake shoe and the bearing. See
ptbduct sheets for ordering information.
LlNING REPLACEMENT
It is important to replace the lining before the rivets make contact
with the disco By removing screws "e" or pin "E" the shoes can be
taken off the caliper assembly. Dril/out rivets and install new lining
with thé proper rivets. When re-installing shoes into the caliper
assembly be sure to re-engage the balancing link u A".
,
:
,
}
Basic Principie of Operation for Kobelt Disc Brakes
Page 7
)
!
ACTUATOR MAINTENANCE
Kobeltactuators require very Iittle maintenance. Ho~ever, should it become necessary
.
to repla-ce seals, proceed as follows:
Spring Applied Actuators
In order to remove the actuator
pressure must be applied td'the,.
actLiator to release the ·brake( or use
manUal reléase screw) . . After '
removal, place actuator intD a' press to
retain the two housings befare
removing assembly bolts. Once
dismantled, e/ea n and replace parts
as needed . . When ¡-á~assembling,
lubricateall moving parts.
Fluid Appli~d ACtuators
(hese actuatórs are in most Cases
diaphragm operated; Ihere are two
diaphtagms -p eractuator and one "O"
ringbetween the centre housjngs. To
rep1act3 $eals remove the adtuator and
dismantle same. Clean all parts and
instal/ new seals (diaphragms).
SPRING APPLlED ACTUATORS WITH MANUAL RELEAS E SCREWS
AII Kobelt springapplied actuators can' be supplied with manual release screws. This
manual release: screw serves to release the btake upon failure of the fluid pressure. It
is very important that the fluid supp1y line is open to tank or atmosphere when winding
the manual release screw inward, since the piston cavity requires a fluid supply source
when doing this. This holds especial/y true in hydraulic systems, where a vacuum plus
the spring tension is generated. The manual release screw mechanism will fail if no
source of fluid supply is available.
BRAKE SHOE CLEARANCE ADJUSTMENT FOR SPRING APPLlED ACTUATORS
On the spring applied calipers it is eXtremely important that the proper e/earance is
mairitained between shoe and disco On the manual adjust actuators the e/evis pin can
be removed and the e/evis can be manually rotated to maintain a minimum e/earance
between disc and shoe. When the new Iining is inserted it wil/ be necessary to turn the
e/evis inward to allow for the extra thickness of the new lining. Our automatic adjust
spring applied brake actuators will take up the excess e/earance between brake Iining
and disc during normal use automatical/y. ' When new Iining is installed again the e/evis
pin must be removed from the actuator rod and turned 90 0 • . This will al/ow the actuator
rod to be pushed in completely to al/ow for the extra lining thickness. Re-insert clevis
pin after adjustment.
Basic PrincipIe of Operation for Kobelt Disc Brakes
Page 8
'\ i
j.
It is important that the c1earance between the shoes and disc is kept at a minimum without
causing drago The c1earance should not exceed .040" (1.0mm) per side. This will allow for fast
response and a minimum for fluid consumption with fluid applied actuator. On spring applied
calipers a minimum of c1earance is necessary to maintain maximum brake torque.
ACTUA TOR MAINTENANCE · ·
Airapplied a~tl,lator's in most cases are diaphragm operated and consist of two opposite
diaphragms spring returned. If diaphragm failure occurs, remove actuator, dismantle same,
dean and re-instal! neW diaphragms.
SPRING APPLlED ACTUATORS
If maintenance is required on our spring applied actuator it must be first removed from the brake
assembly. After removal it must be retained in apress strong enough to retain the spring
tension of the actuator. . It is also important that this holding device maintairis the actuator in a
square position to the press. The assembly bolts holding the pisto n housing to the spring
housing can now be removed and the pressure of the press can be slowly released allowing the
actuator to separate. Clean actuator, replace seals, inspect springs and change same if
necessary.
Re-:.assemble and reinstall actuator in reverse order.
i )
Al! Kobelt piston type actuators, which are air actuated, must have a filter and lubricator in the air
line which is filled with'a' light-hydraulic oil to lubricate the seals and piston as well as the piston
rad .
INITIAL BRAKE START UP
In order to achieve maximum brake torque it is of the utmost importance that the brake lihe is
bumished. This can only be accomplished if the brake is applied with the engine or motor
driving the brake disc on the relatively low pressure. This should be done approximately three
times; The maximum disc temperature that should be achieved is approximately 600 0 F and
each run should takeapproximately 10-15 minutes . .Our normal brake lining will provide a
coefficient of friction of 0.45 at approximately 200 0 F and can go as high as .6 at approximately
400 - 450 0 F.
.
If the lining is not properly bumished a coefficient of 0.3 is all that can be obtained. Care must
be taken not to overheat the disc during this pracess. If the brakesystem is running in an
environment where maximum brake torque is required, bumishing has to be done all over again
after lining replacement. On large brake shoes it becomes necessary to cut grooves into' the
lining to allow lining vapourto escape between the Hning and th.e disco On water cooled discs it
is extremely difficult to bumish the lining unless a limited amount of water is fed into the disc
during the burnishing operation .. Again , extn~me care must be taken no to overheat the disco
(.
Basic Principie of Operation for Kobelt Disc Brakes
Page 9
CHECK LlST:
BEFaRE STARTING OISC BRAKES
(1)
Ensure that all bolts are of good quality and instálled properly .(no bolts missing).
(2)
Make sure that brake lining does not make contact with the disc when the brake is
released. Also ensure the brake is reasonably square to the:disco
(3)
Brake levers must have no'obstruction and allow actuator rod to come out completely,
without interfering with other obstructions.
(4)
Check the brake disc surface for foreign matter and grease. Remove alllubricants from
the disc with a cleaning solvent. If the disc was damaged during installation with nicks or
welding marks, remove same.
(5)
Check the source of fluid supplied that it complies with the specified pressure range from
Kobelt and that it is also properly interlocked with other machinery, such as cJutches,
electric motors, etc.
(6)
Check that bólts are tight and cotter keys are in place.
In order to calculate the brake torque, the clamping fotce of the caliper must be multiplied by the
coefficient of friction and the acting radius of the disc;
(Clamping force x coefficient of friction
x acting radius of disc = brake torque).
Note: When selecting a disc brake, the coupling f1ahge to which the brake disc is
attached
must fit within the inner adaptar flange Df the disc (dimension
B).
LlNING REPLACEMENT FOR OPEN SHOE TYPE BRAKE CALlPERS
On these calipers the brake shoes are attached with pins to the brake open lever. These pins
must be removed in Order to detach the brake shoe from the caliper. New lining can be installed
and the brake re-assembled. With brake shoes it is important that the balandng link be
conoected to the back of the brake shoe.
LlNING REPLACEMENT FOR BOX SHOE TYPE BRAKE CALlPERS
The shoe is retained within the framework of the caliper by the upper retainer plate. In order to
remove the brake shoe, this plate has to be removed. The pin attaching the clevis to the brake
lever must also be removed. This will allow the clevis to be moved, to clear the lever and the
brake shoe can rlbw be removed. · Newlining can be installed and the brake re-assembled .
MAINTENANCE
Over the years it has been proven that very little goes wrong with Kobelt dísc brake calipers and
discs. It is important that periodic brake lining wear inspection takes place. The lining must be
replaced before the shoe lining bolts or rivets start making contact with the brake disco
Basic Principie of Operation for Kobelt Disc Brakes
Page 10
=======================================================================:===
19-0CT-01
12:58 PM
PAGE
WICHITA CLUTCH
MANUFACTURING DATABAS E
j },
/ j/
PARTS LIST NO.
6-014-200-435-0001
ATD-214 LI HT CLUTCH
DRAWING NO.6-014-200-911-9
REVISION .
RENEWAL KIT NO.
----------------------------------------------------------------------_.
PART NUMBER
KEY
NO.
2
3
4
*
5
6
7
8
9
*
10
*
12
13
14
15
*
11
1
) i
)
)
*
NOTE:
6-014-200-435-0999
4-271-011-012-2
4 - 253 -897-000-0
4-271-004-022-1
4-271-009-009-3
2-177-062-024-0
4-271-002-023-1
4-271-003-007-5
4-271-020-000-0
2-740-016-001-4
2- 745-024-001-1
8-240-706-003-3
4 - 295-033-000-4
2-170-037-024-0
. 2-113-037-012-0
5-404-001-064-4
DESCRIPTION
ATD-214LI HT CLUTCH LESS HUB
CENTER PLATE 14 LI CLDTCH
FDI 14" .BLANK 88 TEETH
RING 214 LI CLUTCH OR BRK
G-SHIM,14, 4/SET
SRCS 5/8NC X 2.50 GRADE 9
14" LI HT ATHP
PRESSURE P~TE-14 LI CLUTCH-HT
AIRTUBE 14 HT
O-RING
SNAP RING,INTERNAL
1!2"ROTOSEAL!INT-l!2NPT-FEMALE
SPR 19!32X1.3125
HHCS 3 18NF X 2. 5 O GRADE 5
NUT 3!8NF FLEXLOC HALF HEIGHT
HUB 214 LI
QTY
REQ
1
2
3
1
24
8
1
1
1
1
1
1
4
4
4
1
RECOMMENDED SPARE PARTS
PLEASE STATE SERIAL NUMBER OF UNIT WHEN ORDERING SPARE PARTS
TOTAL WEIGHT
21
8
50
80
11
5
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)
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I
BEWAR··~
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.
,
.
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11
~sen Iy
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..
-
. -."
.
G·enulne
· ,Jr,l
I AI'CU'T/J.®
nI .•.
Replacement Parts
i
,I
,
I
The use of non-genuine replacement parts in Wichita® clutches
and brakes shall cause loss of warranty protection. If a non-genuine
part leads to failure of the clutch or brake, all warranty protection
wi 1'1 be void.
:
Those persons who knowingly or unknowingly choose to use
non-genuine parts are advised to review both warranty and liability
coverage capabilities of suppliers of these parts.
) }
9
2
E
iD
6-014-200-91 1-9
PARTS LIST NUMBER
6-014--200-4-35-0
)
DATE
1/19/98
)
' A
B
~
1
16.250
H.C.
---
I
e
17.50
1
15.128
15.125
). )
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~
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:
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~------------,-------------------------~
98
is
WICHITA
CLUTCH
5CALE:
HALF
ATO-214 LI CLUTCH
HIGH TOROUE
E
6-0 I 4-200 -9 I 1-9
e
[WC-61
I
12/2000
Installation &Operat_on M·a nual
-Low Inertia Clutc·h /Brake '
:
..
These instructions serve as a general guideline for the installation
and maintenance of Wichita low Inertia (lI) clutches or brakes.
Each low Inertia unit has an assembly drawing that is supplied
from the factory that details any information specific to that brake . .
When ordering parts for Wichita products, always h~ve the serial
. number 9vailable. This number is stamped on a brass tag riveted
to the brake. In addition, it is stamped into the airtube holding
plate on most units.
i
I
¡
j
!
i
j
I
!
¡
)
CAUTION: Only qualified personnel should perform .
maintenance on these clutches and brakes. Failure to
follow the instructions in this publication may result in .
serious injury.
CONTENTS
U.l INSTALLATION OF THE CLUTCH/BRAKE ......................................... 2
U.1.1 MOUNTING AN ASSEMBLED UNIT ...................................... 2
U.1.2 MOUNTING A DISASSEMBLED UNIT ................................... 3
U.2 CLEARANCE ADJUSTMENT ........................................ ~ .•.................. 4
U.3 LUBRICATION ................................................................................ 4
U.4 MAINTENANCE ............................................................ ~ .................... 5
.. t~H:\ :. <:· u.4:~i "REPLACEMENT OF THE AIRTUBE ............ ;.......•.•... ............. 5
.~'"~~:·s~'::LI.4.2'REPLACEMENTOF'FRICfION DIscs ' . . . . ., . .
i,~~~~y~')!: .,~~
.' AN D CENTERPLATES ................................. ~ . e: ..... ~ ..... ~ ........ 5
iJ:..s ' RECOMMENDED SPARE PARTS ,,, .. ............................ :.................... 6
U.6 AUGNMENT INSTRUcnONS ......................................................... 7
.TABLE 1 ..............................................................'... ;...................... 8
. TABLE 2 ................................................................. :....................... 8
·TABLE 3 ....................................................................................... . ... 9
.PARTS ·UST ........................................ ,.... ~ ........... ...................... : ...... 9
FIGU'RES 1 & 2 .............................................. :............................. 10
FIGURES 3 & 4 .............................................. : ............................. 11
FIGURES 5 & 6 ............................................. ~ ............. ................. 12
FIGURE 7 ........................................................................... ......... 13
:.~
LI.l
.
INSTALLATION OF THE CLUTCH/BRAKE
1. Low Inertiéi units may be mounted assembled or disassembled.
2. Before installing the brake insure all mounting dimensions are known and
correcto Refer to the assembly drawing supplied with the clutch/brake. A
machined pilot is required to concentrically locate the clutch/brake.
3. Check that the clutch/brake mounting interface falls within the alignment
. :speclfication shown in LI.6.
4. Insure properfit between the hub and shaft. The desired fit may be a sli~
fitor a press fit depending on the application.
5. Position hub (1) into correct location on shaft and restrain hub from axial
movement by a set screw, endplate, or another industry accepted
method . .'
lI1.1
Mounting an Assembled Unit
1. Slide the unit over the hub (1) ensuring that the teeth on the center plate
(7) are properly engaged in the teeth of the hub (i)
2. Fit the backplate (2) to the mounting surface, and insert moLinting
fasteners in backplate (2) and tighten according to specifications supplied
2
I WC-61
by themanufacturer. These fasteners are not supplied with the
c1utch/brake. Wichita recommends the use of socket head capscrews,
conforming to ASTM-AS74-97a, for mounting fasteners.
Use of mounting fastenersof insufficient strength may cause unit
, failure resulting in injury.
3. Connect air supply to unit using a flexible hose(s). Air supply muSt
provide adequate pressure and volume to operate the c1utchjbrake.
4. Insure c1utch/brake c1earance is properly adjusted before placing unit into
service. See Table 1 for recommended minimum c!earance,
LI1.2
Mountirig a Disassembled Unit
;
1. Fit the backplate (2) to the mounting surface, and insertmounting
fasteners in backplate (2) and tighten according to specifications supplied
by the manufacturero These fastehers are not supplied with the
c1utch/brake.Wichifa recommends the use 6f sockét head capscréws,
conforming to AsTM.:.AS74-:-97a, for mountlng fastenérs. '
"
Useof mounting fasteners of insufficient strength rnay cause unit "
failure resulting ininjlirY~
,,
2. Slide friction discs (6) into the ring (4) and centerplates (7) over the hub
(1) ensuring that the teeth on the centerplate (7) are properlyaligned -,
with the teeth of the hub (1). If separator springs (5) areincluded
,between the friction discs (6), ensure that the springs are properly seated
in the counterbores. Refer to Figures 1 - 6 or the drawing supplied with
tlJeunit for proper placement of the parts.
3. Ass~mble the aetuator subassembly. This subassembly consists of:
airtube holding plate (13), airtube (11), pressure plate (lO), release spring
bolt (20), release spring (21), and release spring nut (22) Refer ta
Figures 1 ,- 6 or the drawing that was sent with the unit.
4. Align the airtube (11) spuds with the spud openings in the airtube holding
plate (13) and fit into place. The pressure plate(10)is thenattached to
the airtube holding plate (13) by using the release spring bolts (20),
release springs (21) and release spring nuts (22). Ensure that the release
springs are properly seated in the counterbores and attach the-spring
release nuts (22). Make sure the nuts are equally located on the bolts
and that only one to two threads show past the nut. , Do not over
tighten!
5. Fasten the aetuator assembly to the ring (4) using socket head capscrews
(14) . Torque according to specifications in Table 2.
6. Connect air supply to the unit using a flexible hose(s). Air supp~y must
nrn\finp rideauate pressure and volume to operate the c1utchjbrake.
IWC-6:
)
7. Insure c1utchjbrake c1earance is properly adjusted befare placing unit intc
. service.
tI.2 .'
CLEARANCE ADJUSTMENT
1. Clearance is required in the c1utchjbrake to assure fuI! disengagement of
the discS. Although the units are correctly set before leaving our factory,
,thedearance shoLild alwaysbe checked befare the unit is Pt)t intb '
. 'Óperation. See Table 1 for recomménded minimum c1earances.
2. The amount of torque output by the c1utchjbrake is affécted by clearance
in the unit. Maintaining the unit c!earance at the minimum recommended
c1earance, shown in Table 1, will maintain catalog torque ratings.
3. The amount of c1earance in the clutchjbrake may be measured by ,
applying abd releasing air from the airtube (11) and measuring the total
axial móvEjnent of tne pressure plate (10).
'
4. If cJearar)~e needs té be adjusted, this can be achieved by removiñg or
adding t~ shims (12) between the ring (4) and airtube holding plate
:, Ct?)·
¿;
.,
'
,
":',' ,
5. Shims ar§ supplied iri segmerits for easier instaJlatiórL ' Shims are
d~signéCJi'to be installed in stacksof segmentS to faCilitate removal and
n1é:1intain:proper clutchjbrake operatiori. To add or rernove shims (12);
Idósen aH fasteners, then remove the fasteners (14) through a shim stack.
Adg or remove shims (12) to achieve the desired stack thickness and
replace the fasteners, tightened hand tight. Repeat with the other shim
stácks.
6. When al! shim stacks have been adjusted, check that the stacks are equal
in thickness all around and tighten fasteners (14) to proper torquees)
listed in Table 2.
LI.3 '
LUBRICATION
1. Clutch/Brake
.NÓlubdcation is required, although a very light coat of molycote or
equivalent graphite grease niay be applied to gear teeth.
2. Roto Coupling
Any good bearing oH or grease, depending on type of nipple, can be
used. Care should be taken not to over-Iubricate. The micro-Iapped
sealing faces aré lubricated by air passing through the coupling and for
this reason should not run dry for long periods of time.
4
LI.4
LI.4.1
. MAINTENANCE
I WC-:61
Replacement of the Airtube
1. Shut off air pressure to c1utchjbrake and then disconnect flexible air
hoses ta thé unit.
2." Remove qUlck release valves (43), or fittings from airtube (11) inlets.
3. If the .unit has release sp'rings (5) bétween friction discs (6) for .
d.isehgagement, wedge or damp frictibn discs so that release springs stay
in/ pilate .
.
.
4. Remove airtube holding plate fasteners (14).
5. Remove the actuator subassembly, consisting of: alítube holding p!ate
(13), airtube (11), and pressure plate (10). Refer to Figures 1- 60r the
. drawing that was sent with the unit. Take care that the shims (12)
between the airtube holding plate (13) and the ring (4) are not lost when
tl,1.€ airtube holding plate (13)is removed.
6. R.~move old airtube' (11) from airtube holding plate (13) ,by removing the
¿-efease nut (20), release spring (21) and release bolt (22) and removing
the pressure plate (10).
.
.
7. Align the newairtube (11) spuds with the spud openings in the airtube
holding plate (13) and fit into place. The pressure plate(10) is theri
.' ,qttached to the airtube holding plate (13) by using the release spring
bolts (20), release springs (21) and release spring nuts (22). Ensure that
the release springs are properly seated in the counterbores and attach
the spring release nuts (22). Make sure the nuts are equally located on
the bolts and that only one to two threads show past the nut. Do not
over tighten! '
8. Replace the actuator assembly on ring (4) insuring that shims (12) have
been reinstalled and thickness of all shim stacks are equal. Refer to U.2
steps 5-6 for shim replacement details.
9. Install and tighten fasteners (14) to the torque specifications Iisted in
Table 2.
LI.4.2
Replacement of Friction Discs and Centerplates
Friction discs should be replaced when the maximum clearance stated in
TabJe 1 has been reached, and no shims are ·Ieft.
1. Remove actuator subassenibly as described in LI.4.1 steps 1-5.
2. Slide fridion discs (6) and centerplates (7) off hub (1).
3. Replace friction discs (6) and centerplates {7) as required. Always c1ean
)
centerplates (7) of any protective coatings prior to use.
4. Centerplates (7) may have up to .030" removed from friction surface fron
original factory thickness for refurbishment.
5. Ifunit has separator springs (5) between friction discs (6) for
disengagement, they should be replaced whenever ffiction discs are
replaced. . Release sprihgs (21) on the airtube holding plate should also
be replaced when friction discs are replaced. Ensure that the release
'. .spr:ings are properly seated in the counterbores ahd attach the spring
release nuts (22). Make sure the nuts are equally !ocated on the bolts
and that only one to two threads show past the nut. Do not over
tighten!
6. Reassemble the unit as described in lI.l.2 steps 3-7.
LI.5 {'
RECOMMENDED SPARE PARTS
wH~mtorderin9 par-ts for Wichita
products, always have the serial number
available. This number is stamped on a brass tag riveted fo thé brake~ In
adqJ.ijon,
it iS.stamped
into the airtube
holding plate on m6st units .
.. . .:
.
~.
:~?~
l. Stocking Spares
A'lthough spares .ate held in stock at Wichitéi and distributor warehouses,
no'rmal retommended spares should be held by the custoIner to greatly
.' reducecostly downtime.
2.,PClrts list
Due to the many variations obtainable in a basic type and size .of
clutch/brake, spare parts lists are issued for specific' serial numbers.
However, for general guidance, the normal recommended spares are as
follows: '
A. Frictioli Material (6)
Friction material should be replaced whenever it becomes excessively
worn, contaminated, or no longer performs to specifications.
Friction material should be kept clean, dry, free from oil or grease, and
stored f1at to prevent warping.
.
B. Se"parator Springs (5)
It is recommended that the separator springs be replaced whenever the
friction discs are replaced. Always replaceseparator springs as completE
sets.
I WC-61 I
C. Airtube (11)
Failures may occasionally occur if the airtube becomes excessively hot,
sáturated with oil orover expanded.Over expansion is LJsually a result of
exéessive wear. Store airtubes f1at in a cool, dark place.
~ .
.
.
D. ". Roto Coupling (23)
RotQ touplings are sometimes damaged by anexternal blow or can wear
prernaturely if restrairied by.non-flexible hose connections. It is
recommended that a replacement unit be kept in stock.
.
.
E: "QUick Release Valves (QRV) (43)
. If quick release valves are fittéd they should be dismantled and cleaned
about every 6 months.
TO DISMANTLE:
.-Hold valve body with a wrench and disconneet air hose.
-Unscrew valve from airtube.
-Place body '@f~'ialy,e in a vice and remove end cap.
Do not attempt to J;emove end cap while valve"is fitted tÜ' airtube as valve
.
may break at threacfriێk.
. Keep complete QRVireplacément in stock.
. LI.6
ALIGNMENT INSTRUCTIONS
Check to see if the c1utchjbrake runs square and true by indicating to the
frame·ofmachine. If bearing c1earance will not position shaft axial/y,
then some method,ofpositioning shaft will be necessaryduring
alignment. Dial indicator-tó be located as shown in Figure 7 and .readings
should not exceed Iimitation set in alignment specificationson Table 3.
T.he readings under A and B are maximum deviations advi?able for
normalclutchjbrake running with no excessive;:wear on parts-or machine
bearings. Consult general arrangement drawing 6f machine tor initial
cold offset setting of shafts to compensate for thermal expansion of gear
case under running conditions.
TABLE 1: Recornmended Minimum Clearance
Brake Size
,. ~' 6 ;11
. .,S" .
11"
·14"
16"
2 Plate
1 Plate
.06";-.10"
.06"-.13"
.06"-.13",
,06"-,13"
,06"-.13"
.09":-.16"
.09"-.16;'
·lS~'
.O-6"~.13".
.O9.~-,16"
21"
24"or 24h
2T
30" or 30h
36"
or- 36h
.. .
42"
-4S"
60"
; ~O,9"-.lS" .
~o.9"-,15".
•O9 :'-,l!>""
.09"-,15"
.09"-,15"
. 15"-,22'¡
.12"-,25"
. lS"-,31"
.12"-.19"
,12"-.19"
. .,.,,
..L'" _.19"
¡ .
. !
.:.::
¡.
i
...
3Plate
.09"-.13"
.. 12"-.19"
.12"-,19"
.0.9 "-.13"
.09"-.16~
..
..
,09~'-:,16"
6
,~~"- . 19"
... ,
.12"-,i9"
,12"-.19"
.15"-,22"
.15"-,22"
,15"-,22"
,15"-,22"
.15"-,22"
.21"-,28"
• . 18"-,31" .
.25"-.38"
,12~':-.19"
f.."'"
. ' --.
.-
,12"-.19"
,1S"-.25"
.15"-.2S"
.18"-.31"
"
...
TABLE 2: Recornmended .BoltTorque
.'
5HCS , ~
Socket Head Capscrew .
Bolt
Thread
5/16 SHCS
18UNC
16UNC
3/8 SHCS
7/16 SHCS
14UNC
13UNC
1/2 SHCS
l1UNC
5/8 SHCS
314 ' SHCS
10UNC
1" '"
SHCS
· 8UNC
1-1/4SHCS
7UNC
·1.;;'lj2·· SHCS
· 6UNC
2"
SHCS
4.5UNC
2"
SHCS
" 8UN
HiUNC
3/8 ' 'HHCS
7/16 HHCS
14UNC
':1}2 '" HHCS
13UNC
11UNC
5/8 HHCS
10UNC
3/4 HHCS
1"
HHCS
8UNC
1-1/4 HHCS
7UNC
1-1/2 HHCS
6UNC
2"
HHCS
4.5UNC
.'HHCS 7' Hex' Head
Torque (ft-Ib)
",
..
. · 25~30
45-55
75-90
1]..5-140
220-265
3J~5-465
800-1000
1600-1920
2800-3360
6600-7920
7500~9000
' 30-36
50-60
75...;90
150-180
260-315
650-780
1300-1560
2200-2640
5200-6240
8
..
Grade
ASTM A574-97a
ASTM A574-97a
ASTM A574-97a
. ASTM A574-97a
ASTM A574-97a
ASTM A574-97a
. ASTM A574-97a
ASTM A574-97a
ASTMA574-97a
ASTM A574-97a
ASTM A574-97a
SAEGrade 8
SAEGrade 8
SAE Grade 8
SAE Grade 8
SAE Grade 8
SAE Grade 8
SAE Grade 8
SAEGrade 8
SAE Grade 8
-,
,
I WC-61
Table 3: Alignment.Speciflcations
Brake
Size
"-
6"
.
,
,
.
8"
11"
14"
io"
18"
21"
24" or 24h
27"
30" or 30h
36" or 36h
42"
4S"
. 60"
Parallel
A=T.I.R. ,
mm
Ineh
0.08
0.003
0.10
0.004
0.15
0'~0.Q6
0:007 ,
0.18
0.20
G~OOR
0.23
0.OO9~
0.28 ,
, o~o~l;
0.012' "
0.30
0.36
O~01'4
0.38
0~Oi5
0.46
00.18
0.53
0.021
0.61
0..024. .
0.76
0.030
PARTS LIST
l.
Hub
Backplate
2.
Bolts (Backplate to Ring)
3.
Drive Ring
4.
Separator Springs
5.
Fri-ction Disc (.U) or
6.
Drive Assembly (VU)
7. Centerplate (LI) or
Floating Plate (VU)
8. Friction 'Disc (LI)
9. Floating Plate (VLI)
10. Pressure Plate
1l. Airtube
12. Shims
13. Airtube Holding Plate
14. 80lts (Spring Plate to Ring)
Angular
B=T.I.R~
Q~70
Ineh
0.003 '
' 0.004
0.006
0.007
O.OOS
0.23
OJ109
0.28
0.011
0.012
0.014
0.015
00.18
0.021
0.024
0.030
mm
0~06
0.10
0.15
0.18
0.30
0.36
0.3'8
0.46
0.53
0.61
0.76
.'
.
19. Pressuré Plate Lug
20. Releasé Spring Bolt
21. Release Spring ,
22. .Release Spring Nut
23. Roto Coupling
24. O-Ring
25. Snap Ring
26. Pressure Plate Bolt
27. Pressu re PI ate Nut
33. Roto Coupling Adapter or
Spider
34. Bolts
40. Release Spring Bolt
41. Spring' Bar
42. . Washer
43. Quick Release VaIve CQRV)
Wichita Clutch
2800 Fisher Road, Wichita Fallsr Texas 76302
800-964-3262 Fax 800-999-9685
www.wichitac!utch.-com
]
[V/e-511
)
¡.
~'
.
VERY LOW INERTIA
FIGURE 1:
1 PLA TE HI - TOROUE CLUTCH
i·
LOW INERTIA 2
"C"ITTl
FIGURE 2:
PLATE BRAKE W/COREO
"Tcn
rC"ITCPPI
t, TcC:;
Iwe-511
LOW INERTIA 2
FIGURE 5:
PLA TE HI - TOROUE CLUTCH
FIGURE 6:
.... a
•
.---...--."""T'"""r
...
-;r
,,1
All
onl\l / C
IWC-611
. (ANGULARMISALIGNMENT)
=A (~ARALLEL ' MISALIGNMENT)
,
,
I
FIGURE 7:
CHECKING ALIGNMENT
WICHITA®
Warranty
Wichita Clutch warrants al! products leaving itsfactory against defects in workmanship
and material for a period of two (2) years after shipment. Adjustnient under this
warranty will be made after completion of inspection of the part or product in the
Wichita factory.
Uability under the warrantyshall extend only to the replacement or correction of any
defective part or product as determined by Wichita Clutch and extends only to the initial
pllrchaser and is not transferable or assignable without the prior consent of
Wichita C1utch.
"'
-
This warranty shall not apply to any product that has been repaired or altered without
the manufacturer's knowledge and consent. This warranty also does not cover damage
. or defects resulting from neglect, improper installation, improper maintenance or
operation, or accidents.
This warranty is made in Iieu of al! other warranties, expressed or implied, including but
not lir'nited to warranties of merchantability or fitnE!ss for particular purpose, and there
are no other warranties that extend beyond this expressed warranty. Wichita Clutch's
obligation under this warranty is Iimited to repair or replacement of the defective part
or product and in no event shall Wichita C1utch be liable for consequential, indirect, or
incidental damages of any kind incurred by reason of the manufacture, sale or use of
any defective producto
.
;
¡
:
~
,
~
;
Wichita Clutch reserves the right to discontinue models or to change specifications at
any time without notice. No discontinuance or change shal! create any Iiability on the
part of Wichifa C1utch in respect to its products in thehands of customers or products
on order not incorporating such changes even though delivered after any such change.
Cfutch
2800 Fisher Road, Wichita Falls, Texas 76302
800-964-3262 Fax 800-999-9685
www.wichitaclutch!com
ORIVE SHAFTS
P/N
1. 45-000424 Steering Column to Steering Box
2. 45-001054 Front ofEngine to Hydraulic Pump
3. 45-001048 Transmission to Transfer Case
4. 45-001049 Transfer Case to 1ST Rear End
5. 45-001050 Interaxle 1ST Rear End to 2nd Rear End
6. 45-001022 Transfer Case to Drawworks