DW Operating and Maintenance Manual

8/20/2019 DW Operating and Maintenance Manual

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6500 Brit tmoore, Houston, Texas 77041 PO Box 41343, Houston, Texas 77241-1343832-872-6500 1-866-946-5333 FAX: 832-782-6627

www.letourneau-inc.com/drilling [email protected]

LDW1000K Drawworks

Operating and MaintenanceManual

Mesa Rig Construction

LDW1000K-122


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Table of ContentsBuyer and Operator Responsibility ......................................................................................................................1

Integration of Control System .............................................................................................................................................. 1 Introduction ............................................................................................................................................................ 2

Accessories and Safety Equipment....................................................................................................................................... 2 Servicing Procedures ............................................................................................................................................................ 2

Drawworks Overview.............................................................................................................................................3 Testing .....................................................................................................................................................................3 Utilities Requirements............................................................................................................................................4 Installation ..............................................................................................................................................................4

Inspection ............................................................................................................................................................................. 4 Support Structure.................................................................................................................................................................. 5 Mounting ..............................................................................................................................................................................5 Assembly.............................................................................................................................................................................. 6

Lubrication..............................................................................................................................................................7 Oil......................................................................................................................................................................................... 7 Grease...................................................................................................................................................................................7

Lubrication Summary ...................................................................................................................................8 Startup.....................................................................................................................................................................9

Startup Checklist................................................................................................................................................................... 9 Startup Procedure ............................................................................................................................................................... 10

Operation ..............................................................................................................................................................11 Function Check................................................................................................................................................................... 11 Drawworks Control System................................................................................................................................................ 11 Emergency Brake System................................................................................................................................................... 11 Operating Pressures ............................................................................................................................................................ 12 Operating Temperatures ..................................................................................................................................................... 12 Emergency Operation (Loss of Air Pressure).....................................................................................................................14 Safe Operating Practices..................................................................................................................................................... 14

Maintenance..........................................................................................................................................................15 General Information ........................................................................................................................................................... 16 Parts Fit............................................................................................................................................................................... 16

Shafts ..................................................................................................................................................................................18 Bearings..............................................................................................................................................................................19 Spacers................................................................................................................................................................................20 Sprockets ............................................................................................................................................................................ 20 Clutch Hubs ........................................................................................................................................................................ 21 Drive System ......................................................................................................................................................................22 Emergency Air Storage....................................................................................................................................................... 22 Brake System...................................................................................................................................................................... 22 Daily Use ............................................................................................................................................................................ 23 Daily Maintenance.............................................................................................................................................................. 23 Weekly Brake Disc Inspection and Cleaning ..................................................................................................................... 23 Contamination ....................................................................................................................................................................25 Auxiliary Brake (Optional)................................................................................................................................................. 26

Auxiliary Brake Alignment ................................................................................................................................................. 26 Preservation and Storage.....................................................................................................................................27 Location..............................................................................................................................................................................27 Cleaning.............................................................................................................................................................................. 27 Preservation........................................................................................................................................................................ 27 Storage................................................................................................................................................................................ 27

Torque Specifications...........................................................................................................................................28


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Introduction

This manual is produced as a guide for normal operations of LTI equipment. This manual will not detail

all aspects of installation, operation, and maintenance of the drawworks because of the many factors that

contribute to its proper function and operation. When situations that are not discussed occur, they should

be referred to LTI personnel for detailed instruction.

Maintenance, beyond routine service, requires adequate space with dedicated lifting equipment and

specialized tools, and it can be more efficiently performed in a facility equipped for such service.

Improvements in purchased components, design, materials, or production methods may be made fromtime to time. These changes may generate differences between this manual and the actual product. LTI

reserves the right to make these changes without incurring any liability beyond that stipulated in the

purchase contract.

A serial number is assigned to each drawworks. All inquiries concerning the drawworks must include this

serial number. The serial number is on a nameplate located on the driller’s side of the drawworks frame.

The version of the drawworks being provided can be determined by reviewing the final assembly in the

drawing reference section in the back of this manual.

Accessories and Safety EquipmentThis product is supplied in accordance with the buyer’s specifications and does not necessarily include

all accessories and safety devices required to put this product into operation. Power equipment and

safety devices such as, but not limited to, motors and controls, rotating equipment guards, chains,

cables, and wrenches are available from other suppliers.

Servicing ProceduresUse proper procedures when using or servicing this machinery. Use approved methods, materials, andtools. This product and many of its parts are heavy or difficult to handle. Plan lifts carefully and use

proper lifting gear to avoid severe personal injury. Provide safe supports for all equipment and parts.

• Shut down equipment and disconnect power during maintenance.

• In order to prevent accident and injury during maintenance or inspection, shut down the equipmentand disconnect the power. This will include the electrical and air power. Air tanks and spring-

operated devices should be drained or released before starting service. Employ good and safe

mechanical practices when making maintenance repairs and adjustments.

• Lubricate the drawworks before starting operation.

•

Prior to shipment, all lubricant is drained. Before starting operation, the drawworks must belubricated as outlined in the lubrication section.


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Drawworks Overview

The version of the drawworks being provided can be determined by reviewing the final assembly in the

Parts Catalogue section of this manual

The drawworks is a single, skid-mounted unit with the following:

• A hoisting drum mounted on a heavy-duty shaft with two brake discs for the spring-and air-operated brake calipers

• The shaft is supported by two large self-aligning roller bearings with provision for a splined hub toconnect an optional auxiliary brake...

• Wire rope (supplied by the end user)The diameter of the wire rope is determined by the end user.

• Variable frequency drive motors coupled to a constant engagement gearbox.The motors are capable of raising and lowering the load when operated by the proper control system

and connected to sufficient power dissipation equipment.

• A transmission shaft coupling the gearbox to the drum shaft

• Spring-actuated, air-returned emergency/parking brake calipersThe spring brakes are applied by actuating the emergency stop button on the driller’s console, by loss

of electric power, or by various functions of the operating system.

• An optional auxiliary brake coupled to the drum shaft through a manually shifted splined coupling.

Testing

Note

The electrical contro l system is not tested.

Prior to shipment, LTI personnel functionally test the drawworks—and all related mechanical

components—for an extended period to verify that the drawworks and components operate in accordance

with the stated requirements.

• The complete drawworks is aligned and all locating pins, or chocks, are secured.

• All mechanical and air control systems are operated and functionally checked.

• The lubrication system, air system, and brakes are pressure checked and inspected.

• The brake discs and pads are burnished, and the brake torque is checked to ensure full brakingcapability.

• Guards, covers, and inspection openings are checked to ensure that the proper safety measures are in place. These components serve as enclosures for the gearbox, provide safety protection for personnel,

and prevent foreign material from entering the working parts. Guards, covers and doors should be

closed and in place when the drawworks is operating and should only be opened for drawworks

service.


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Warning

Carefully read and understand the operation and maintenanceinstructions for the drawworks, drive motors, and controls.

Failure to follow these instructions may cause seriousequipment damage, severe personal injury, or loss of l ife.

Buyer and Operator Responsibil ityIt is the buyer’s and operator’s responsibility to obtain proper instruction and to train personnel in the safe

operation and maintenance of the equipment. The buyer and operator must obtain instruction in safe

operation and maintenance of the drawworks, motors, controls, and any accessories and safety devices

required to safely operate this equipment and to complete the application of this product.

Integration of Control System

The owner, operator, or buyer of this drawworks needs to know that the proper integration of thecontroller system with the drawworks is critical to the safe operation of the Letourneau

Technologies™ (LTI) Model K drawworks in accordance with its specifications.

Failure to properly integrate the chosen control system with the Model K drawworks can result in

severe property damage, personal injury, or death.

Integration of the Model K drawworks with the chosen control system is the responsibility of the

manufacturer of such control system, whomever that may be, and LTI is neither responsible nor liable

for any damage or injuries that may result from use of the drawworks, where the drawworks and the

chosen controller system have not been properly integrated.

In addition, even if the drawworks is properly integrated with the control system chosen by the owner,

operator, or buyer, malfunctions of the control system can still result in unpredictable operation or

failure of the drawworks, which in turn, can result in severe property damage, personal injury, ordeath. The functionality of the chosen control system is the responsibility of the manufacturer of such

control system, whomever that may be, and LTI is not responsible or liable for any damage or injuries

that may result from the drawworks because of a malfunction of the control system.

Finally, even if the drawworks is properly integrated with the control system selected by the owner,operator, or buyer and the control system functions properly, errors in the operation of such control

system—or the people operating such controller system other than in strict conformance with the

control system manufacturer’s instructions—can result in unpredictable operation or failure of thedrawworks, which also can result in severe property damage, personal injury or death.

Training operators to properly use the chosen control system is the responsibility of the manufacturer

of such control system. The actual operation of such control system is the responsibility of the drillingcontractor or other person running drilling operations. LTI is not responsible or liable for any damage

or injuries that may result from the drawworks, either as a result of incorrect use of the control system

or as a result of the control system being used other than in strict conformance with the manufacturer’s

instructions.


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Utility Requirements

Air and water connections, marked with appropriate nameplates, are located on the drawworks skid.

For detailed information, see the Utility Requirements section of this manual. .

Installation

Recommendations for rig-up, operation, and maintenance of LTI drilling equipment are based on the

knowledge and experience of LTI engineers and operating personnel. Following these

recommendations will result in better overall rig performance and increased equipment operating life.

InspectionCheck the drawworks at each rig-up or rig-down.

• Inspect the drawworks to ensure that all components are in place and undamaged.

• Make sure that all attaching bolts are tight.

• Check for wear and or damage of key components and replace if necessary.

Damage (bending) of the skid can cause misalignment resulting in serious wear or damage to theoperating parts. Failure to repair damage to the skid can lead to dangerous operating conditions

unless corrected.

• Make sure that all covers are in place and secured.

• Inspect the brake system every day for any corrosion that might prevent or obstruct themovement of any brake parts.

• Open the valve on the air tank for at least 5 seconds to drain any water that may haveaccumulated in the tank (Fig. 1).

• Release the ball valve in the air filter with a ¼-in. flat end rod to drain any water that may haveaccumulated in the line. (Fig. 2)

Fig. 1 The air tank release valve islocated on the outside of the skid orunder the rig floor depending on theinstallation requirements.

Fig. 2 Releasing the ball valvein the air filter


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Support StructureThe drawworks relies on the support structure to provide the rigidity required to prevent deflection

during operation. The support structure must be flat and correctly sized to provide the necessary cross

section and rigidity. Contact LTI for assistance.

The drawworks’ weight and operating loads are distributed in the skid mounting points under the

drawworks, the gearbox, the drive motors, and the auxiliary brake. See the drawworks tie-downinformation in the Parts Catalog section of this book.

Mounting

Caution

The drawworks cannot be aligned unt il it is properly attached tothe substructure. If an alignment is attempted before it isattached to the substructure, the drawworks’ components can

be pulled out of alignment, which could cause an unsafecondit ion, erratic operation, and premature wear.

NoteOn permanent installations (offshore rigs), the drawworksbeams may be welded to the substructure at the samelocations.

1. Align the drawworks with the centerline of the well in accordance with the foundation locationdrawing.

2. Secure the drawworks to the substructure, either with bolts or clamp plates, using the

recommended locations on the front and rear skid beams of the drawworks frame.i. under each drawworks side plate,

ii. under the auxiliary brake,iii. under the gearbox,iv. at the skid ends.

3. Use stops and location blocks to help relocate the drawworks after each move.4. See the drawworks tie-down drawing for tie-down locations.

If substructure support beams are not flat and true, shim the contact areas between the drawworks skid

beams and the substructure beams.

NoteTake care not to distort the drawworks frame during tie-down.The drawworks was manufactured and aligned while resting ona true flat surface.


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AssemblyAfter stringing the block,

1. remove the brake cover from the side of the main drum containing the wireline dead end slot.2. Slide the end of the line through the slot provided in the drum flange.3. Slip the main drum wireline clamp over the end of the line, and secure the bolts attaching the

clamp. (See the Torque Specification table for recommended torque specification)

4. Make sure that a length of line equivalent to 2- or 3-line diameters extends beyond the clamp.5. Slide the line back though the drum flange until the clamp is properly seated in the socket of the

drum flange.

6. Install a line clamp retainer on each side of the line clamp.7. Replace the brake cover.

When setting the deadline anchor, be sure to leave 10- to 15-wraps (coils) of line on the drum when the

block is in the lowest operating position.

If the drawworks is installed on an offshore drilling rig with a heave compensator, leave extra line on

the drum to allow for the heave compensator requirement.

The drawworks is shipped with all the connection points for control and service lines capped or

plugged to protect them from damage, dirt, or other debris. (These lines should be capped or plugged

whenever the drawworks is moved.)

Warning

Improper control connections can cause a serious or deadlyoperating condition that could result in serious injury to

personnel or equipment

1. Remove the caps protecting the control and service line connection points.2. Inspect the ends of the lines, and remove any debris that may have entered.3. Make sure that that these connections are properly made up to prevent leaks and to provide proper

control.

The rig system will compensate for a moderate leakage of air or water, but the leakage will cause

an unnecessary demand on the rig supply.4. Connect the drawworks to the driller’s console and to other rig systems as required.5. Be sure the air and electrical connections are properly connected and sealed to ensure proper and

safe operation

6. Connect electrical service in accordance with the appropriate codes.Loose or improperly made electrical connections could cause improper signal transmission, fire, orexplosion.

7. Verify thatall connections properly made;

the covers are in place;

all bolts are tight and properly torqued.


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Lubrication

The lubrication system is made up of an oil pressure and cooling system for the gearbox and a manual

grease system for the remainder of the components. The oil filter is located on the well side (WS) of

the skid beneath a main drive motor, and it is positioned above the lube oil level for easy replacement.

The pressure pumps and motors are located under removable floor plates adjacent to the drawworks

side plates on the Driller Side (DS). See the Lubrication Summary table for more information.

OilAfter the drawworks as been assembled, fill the gearbox sump with 74 gal of ANSI/AGMA 9005-E02,

ISO VG220EP lubricating oil. The viscosity index of the oil should be 160 or greater.

1. After the sump has been filled, start the first lubrication pump.2. Allow the pump to run for a few minutes and then check the sump oil level. The dipstick is located

at the DS end.

3. Add oil through the dipstick pipe if required to maintain the correct level.4. Observe the pressure gage on the DS of the gear case; it should read at least 20 psi.5. Stop the first pump, and start the second pump.6. Repeat the pressure check for the second pump.7. Verify that the operating pump is functioning within acceptable limits each day and that both

pumps are functioning within acceptable limits each week.

Note:Do not run both pumps simultaneously.

GreaseOn initial startup, the drum shaft bearings, auxiliary brake shaft bearings, and auxiliary brake shifter

grease points should receive three to four shots from a standard grease gun. Check the splines of theauxiliary brake coupling. Apply EP#4 grease as necessary.

Grease all moving and exposed parts on the Johnson brakes monthly, or sooner if the parts are

corroded. Do not get any grease on the brake pads. Do not over grease. Wipe off any excess grease,

because it could contaminate the brakes.

This is particularly important in saltwater environments. In non-saltwater environments, operators

should base the lubrication schedule on usage to maintain the brakes in good working order.


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Lubrication Summary

LubricationSchedule

Lubrication

Point orSystem

Lubricant Remarks

Daily Shaft BearingsNLG I #2 Premium

Sodium GreaseTwo or three shots f roma standard grease gun

Daily Auxi liary BrakeShaft and Shifter

NLGI #2 PremiumSodium Grease

Two or three shots f roma standard grease gun

Daily(Checklevel)

Gear Box ANSI/AGMA 9005-EO2

ISO VG220EP

If contamination is found,drain and replace.

(If no contamination isfound, drain and replace

annually.)

Monthly Auxi liary Brake

Connectionsplines

EP #4 Grease Apply by hand

Monthly* Disc Brake

CalipersNLGI #2 EP Premium

Lithium Grease

Do not over grease. Wipeoff any excess. Excessgrease can contaminate

the brakes.

WarningDo not get any grease on

the brake pads. Do notover grease. Wipe off anyexcess grease, becauseit could contaminate the

brakes.

Every 6months

FlexibleCouplings

NLGI #2 PremiumSodium Grease

Remove and replace oldgrease.

Table 1 Lubrication Summary

*This is particularly important in saltwater environments. In non-saltwater environments, operators should base the lubricationschedule on usage.


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Startup

Startup ChecklistSpool the wire rope on the drum before completing the startup checklist.

• Verify that all covers, guards, etc. are in place and there is no loose equipment or tools aroundthe drawworks.

• Verify that all utility connections are properly made up and that they are tight and leak free.

• Verify that the drawworks has been lubricated and the gearbox sump is properly filled with oil.

• Determine if the auxiliary brake will or will not be engaged for startup. Take appropriate actionwith the coupling shifter. Lock shifter.

• Open the valve on the air tank for at least 5 seconds to drain any water that may haveaccumulated in the tank.( See Fig.)

• Release the ball valve in the air filter with ¼ flat end rod to drain any water that may haveaccumulated in the line. (See Fig. 2)

• Turn on the air to the drawworks. Verify that a minimum pressure of 110 psi is available.

• Turn on the first lube pump. Verify that the minimum pressure of 20 psi is being met. See Lubrication Instructions section. If the drawworks has a second lube pump, then turn off the first

pump and verify the pressure for the second pump.

Warning

Do not attempt to operate the drawworks unless all brakes areoperating properly. Brakes should move smoothly and withouthesitation. Service the brakes if the brakes fail to operatecorrectly. Operating the drawworks with faulty brakes couldcause serious injury to personnel and equipment.

• Push the emergency stop.

• Verify that the brake caliper pressure drops to zero (0).

• Verify that all brake calipers are closed.

• Pull the emergency stop button out, and verify that the pressure returns to normal and that the brakes open.

• Apply the auxiliary brake, if available, and verify that the pressure comes up smoothly todrawworks air pressure and that the brake discs close and open smoothly and evenly.

• Verify that all brake discs move smoothly with no hesitation.

• Service the brakes if they do not operate smoothly without hesitation.

• Verify that cooling water is available for the gearbox heat exchanger and the auxiliary brake.


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Startup Procedure

Warning

Always make sure that motor power is available before

releasing the emergency brakes. Failure to do so can cause theloss of load control, major equipment damage, severe personalinjury, or loss of life.

Verify basic control functions as follows:

• Bring the main drive motors on line and make sure that the motor cooling system is operational.

Warning

Care should be taken when verifying the emergency stop function. Applying the brakes will quickly generate strongshock loads that could cause serious injury to personnel andequipment.

• Test the emergency brake function.

• Actuate the hoisting control lever to rotate the drum very slowly.

• Push the emergency stop button. The drum should stop immediately.

• Pull the emergency stop button. The drum should start to rotate smoothly.

• Actuate the hoisting control lever and rotate the drum to raise and lower the traveling block.

• Make sure that the drum rotates smoothly when it is operating.

• Make sure that the shift from the hoist function to the lower function is smooth andwithout excessive noise.


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Operation

WARNING

Qualified and trained personnel must control this equipment for

safe operation. Insufficient training and failure to read andunderstand the operation and maintenance instructions cancause major equipment damage, serious personal injury, ordeath.

Function CheckVerify that the emergency stop function and interlocks are functional both before a trip and on a

weekly basis. Use the same procedure detailed in the Startup section.

Drawworks Control System

The drawworks control system is specified by the buyer and is not manufactured by LTI. See thecontrol manufacturer’s operating instruction. Various pressure, temperature, and position sensors in the

drawworks provide information to the control package.

Emergency Brake SystemThe emergency brake is released by air pressure. A clean, dry air supply at the correct pressure is

essential to the operation of the drawworks. Monitor the drawworks air pressure gage on a regular

basis. At the beginning of each shift, or at least once a day,

A reduction in the air pressure will adversely affect the emergency brake and can cause partial

engagement of the brake. Operation with the brake partially engaged will seriously overheat the brake

and can harm the calipers and the discs.

Warning

Exercise caution and the appropriate safety measures whenpurging accumulated moisture from the air system. Water that

accumulates in the air tank and the air system will be released athigh-pressure and at the ambient pressure of the rig, whichcould cause injury to personnel. This could cause injury to

personnel.

Water that accumulates in the air system will also adversely affect the braking system. Water should be

purged from the drawworks’ air tank and air lines at the beginning of each shift or at least once a day.


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Operating Pressures Air Pressure

• Drawworks Air Pressure provides the main system air pressure in the drawworks. This pressureshould range from 95 psi to 130 psi. If the pressure falls below this, the emergency brake

calipers may partially engage, overheat, and cause serious damage to the brake.

Water Pressure (Optional Equipment)• Auxiliary Brake Water Pressure provides the cooling water pressure to the optional auxiliary

brake. This pressure should range from 30 psi to 45 psi. If the pressure falls below 30 psi, the

coolant flow through the auxiliary brake will be reduced, and the braking load must be reduced,

or the brake will overheat and cause damage to the brake discs.

• Gearbox Water Pressure provides the cooling water pressure to the gearbox heat exchangers.This pressure should range from 30 psi to 100 psi. If the pressure falls below psi, the cooling

capability of the heat exchanger will be reduced, and the gearbox may overheat.

Oil Pressure

• Gearbox Oil Pressure gage provides the gearbox lubrication oil pressure. The pressure should be 20 to 40 psi. If the pressure falls below 20 psi, the cooling and lubrication capabilities of thelubrication system will be compromised. Continued use of the drawworks could damage the

gearbox.

Operating TemperaturesWater Temperature

• Inlet water temperature for the optional auxiliary brake (Eaton) should be 50°F to 70°F. If thetemperature rises above 70° F, the braking load must be reduced or the brake will overheat and

cause damage to the brake discs.

• Inlet water temperature for the gearbox oil cooler should be 90°F to 100°F. If the temperature

rises above 100°F, the cooling and lubrication capabilities of the lubrication system will becompromised. Continued use of the drawworks could damage the gearbox.

Oil Temperature

• Gearbox oil temperature should be maintained in the 100°F to 140°F range. If the temperaturerises above 140°F, the cooling and lubrication capabilities of the lubrication system will be

compromised. Continued use of the drawworks could damage the gearbox.

The auxiliary brake inlet water temperature and the gearbox oil temperature should be monitored and a

warning issued if the temperatures exceed the levels shown above.


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Pressure and Temperature Chart

Category Description Pressure(psi)

Temperature(°F)

Comments

AirpressureDrawwork s The main system

air pressure in thedrawworks

95–130 NA PressureIf the pressure falls below this, theemergency brake calipers maypartially engage, overheat, and causeserious damage to the brake

Water Auxi liary

Brake The cooling waterpressure to theauxiliary brake

30–145 50–70 PressureIf the pressure falls below 30 psi, thecoolant flow through the auxiliarybrake will be diminished, and thebraking load must be reduced, or thebrake will overheat causing damageto the brake discs.

TemperatureIf the temperature rises above 70°F,the braking load must be reduced, orthe brake will overheat and causedamage to the brake discs.

Gearbox The cooling waterpressure to thegearbox heatexchangers

30–100 90–100 PressureIf the pressure falls below 30 psi, thecooling capability of the heatexchanger will be reduced, and thegearbox may overheat.

Temperatur eIf the temperature rises above 140°F,the cooling and lubrication capabilitiesof the system will be reduced, and thegearbox could be damaged.

OilGearbox The gearbox

lubrication oilpressure

20–140 100– 140 PressureIf the pressure falls below 20 psi, thecooling and lubrication capabilities ofthe lubrication system will becompromised. Continued use of thedrawworks could damage the

gearboxTemperature

If the temperature rises above 140° F,the cooling / lubrication capabilities ofthe lubrication system will becompromised. Continued use of thedrawworks could damage thegearbox.

Table 2 Pressure and Temperature Chart


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Emergency Operation (Loss of Air Pressure)In the event of air supply failure, the emergency brake calipers will set and lock the hoisting

drum. If the load needs to be lowered to a safe position, the emergency brakes can be released

with air pressure stored in the drawworks.

To release the emergency brakes,

1. Turn the handle of both of the 3-waygate valves located under the floor on

both sides of the drawworks. (Fig 3)

2. Pull the handle of the manualemergency lowering valve. This

operation should be performedcarefully, because there is a limited

amount of stored air. (Fig. 4)

In an extreme emergency, the brake calipers can be released mechanically. Consult the

operating instructions in the brake caliper user’s manual for instructions.

Safe Operating Practices

• Know the load being lifted.

•

Do not exceed the lifting capacity of the drawworks.• Use the correct reeving for the load.

• Be sure that the brakes, hoist, hoisting gear, and controls are properly serviced and inspected atthe beginning of each tour and before starting each trip.

• Move loads smoothly without sudden starts or stops.

• Know the position of the traveling block in the derrick at all times.

• Do not allow personnel to ride the hoisting equipment.

• Check and service the hoist both when a load approaching the rated load is anticipated and afterthe load is removed.

• Do not leave the drawworks controls unattended with a suspended load. Set the load on a firmsupport (e.g., a casing spider or slips in the rotary table).

• Do not use the motor to leave, or suspend, the traveling block for an extended period. Set theemergency brake.

• Make sure that the brake is holding the load before releasing the motor power.

Fig. 3 Three-way gate valve

Fig. 4 Emergency loweringvalve handle


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Maintenance

WARNING

Carefully read and understand the operation and maintenance

instructions. Failure to follow these instructions could causeserious equipment damage, severe personal injury, or loss oflife.

This manual is supplied as a guide for normal operation. Because many factors contribute to proper

operation, and because installations vary, not all situations are covered by this manual. Please contact LTI

for specific situations that are not covered by this manual.

This product and many of its parts may be heavy or difficult to handle. Plan lifts carefully and use proper

lifting gear to avoid severe personal injury. Provide safe supports for all components.

Maintenance Procedures Before Starting Operations• Fill the gearbox sump with lubricant before starting. All fluids are drained from the equipment

prior to shipping.

• Make sure that the oil pressure, the air pressure, the cooling water pressure, and the coolingwater volume are satisfactory.

• Lubricate each grease fitting on the unit.

• Open the valve on the air tank for at least 5 seconds to drain any water that may have accumulatedin the tank. (Fig. 1)

• Release the ball valve in the air filter with ¼ in. flat end rod to drain any water that may haveaccumulated in the lines. (Fig. 2)

Warning

Shut down the equipment and disconnect air and electric powerfrom the unit before starting repair or maintenance. In order toprevent personal injury during maintenance or inspection theequipment should be shut down with the electrical and airpower disconnected. The spring-operated brake calipers shouldbe engaged. If the calipers must be open (released) duringmaintenance, the springs must caged before starting service.Use good safety and mechanical practices when making

maintenance repairs and adjustments.


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Maintenance After MovingWhen the drawworks is moved between locations, the following maintenance procedures should be

performed. Repair or replacement of worn or damaged items will increase the life and efficiency of the

unit and improve safety for personnel.

• Check for missing or loose bolts, and tighten or replace as needed.

• Check, repair, and adjust the brake discs and pads as needed.• Clean and replace all filters (both air and oil) as needed.

• Check, clean, and repair the mechanical shifter on the auxiliary brake to ensure it is operatingcorrectly.

• Inspect all hoses for wear, fraying, flattening, or kinking.

• Replace damaged hoses.

• Check the water supply system for the gearbox heat exchanger and auxiliary brake. Make surethat sufficient water is flowing and that all connections are leak free. Repair as necessary.

• Check the main drum bearing housing bolts for loose bolts or movement. Tighten or replace.

• Check each grease line for flow and leakage. Make sure that grease is reaching the proper

bearing. Repair as necessary.• Inspect the lube oil pumps and the motor couplings. Repair as necessary.

• Clean the gearbox breather.

General InformationWhen undertaking a major overhaul, it is cost effective to replace aging parts that are still working inaddition to those needing repair. While no one wants to incur extra expense, it is easier to replace parts

close to the end of their life when the unit is already down rather than waiting for the part to fail after

the unit has been overhauled and put back into service.

During a drawworks overhaul, many operators will have repair facilities replace roller bearing

throughout the drawworks, because it is more cost-effective than leaving the bearing in service andhaving it fail after the overhaul. The costs of the downtime and emergency repairs will be more then

the cost of replacement during a regular overhaul.

Parts FitWhen replacing parts on a shaft assembly, be sure that the new part fits within the tolerance shown. For

assembly or removal of parts that fit from 0.000-in. to 0.004-in. tight, heat them to approximately

350°F. For parts that fit from 0.005-in. to 0.015-in. tight, heat them to approximately 600°F.


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Hub and Shaft FitsUse the following equation to determine the temperature required to expand the hub and facilitate an

easy interference fit.

T = Heated Temperature (°F)

E = Expansion of Bore Diameter Required (in.)

B = Bore Diameter (in.)

T R = Room Temperature (°F)

0.0000061 = Approximate Coefficient of Expansion of Steel per

Degree Fahrenheit per inch of Length or Diameter.

Example

A hub with an 8.500 in. diameter bore hub has an 0.008-in. interference fit with the shaft.There should

be 0.010-in. clearance while assembling the hub over the shaft. The total bore expansion needs to be

0.018 in.

E =0.018 in

B = 8.500 in

T R = 70°F

The general rule for the interference used in cylindrical fits is as follows:

• Press Fit: 0.0005 in. × shaft diameter.

• Shrink fit: 0.001 in. × shaft diameter.

Tolerance will affect the overall fit, depending on the precision of the allowance.

ET R+

0.0000061 B=T

0.01870 +

0.000061 8.500= 417°F


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Shafts

Warning

Replace cracked shafts. A cracked shaft wi ll cause acatastrophic failure and result in damage to equipment and

personnel.

When possible, a shaft that has been stripped for repair should be inspected for cracks using

Magnaflux or other nondestructive testing. Cracks are most likely to appear at the corners or ends of

keyways and at major changes in shaft diameter. Cracked shafts must be replaced. A cracked shaft is

dangerous and could result in a catastrophic failure.

Check shafts to make sure they are straight. If shafts in a drawworks are not straight, they can cause

vibration, whipping of chains, and a generally poor running rig.1. Support the shaft at the normal bearing locations.2. Rotate the it on a steady, low-friction support

3. Use a dial indicator to check for run-out at the ends and the middle of the shaft.

The total indicator reading (TIR) should not exceed 0.010 in. Excessive TIR will cause vibration. Lack

of straightness is an indicator of other problems, such as cracking or overstressing.

Generally, the shafts require little or no maintenance other than periodic greasing of the bearings. The

exception to this rule is the auxiliary brake shaft. The splined shifter connecting the auxiliary brake

shaft to the drum shaft uses a bronze follower to move the spline sleeve. The follower will wear overtime. Difficulty in shifting or excessive clearance in the shift mechanism are good indicators of a wear

problem that must be addressed.


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Bearings

Caution

Hardened parts such as bearing races should not be heatedabove 400-450° F because the hardness may be affected. Heat

should be applied carefully and evenly to prevent distort ion. Usea bearing heater to heat bearings.

Bearings are usually lightly tight on the shaft and slip fit in the housing. If a bearing is to be reused, it

must not be heated with a torch as this may damage the bearing. Use an oven or oil bath to heat a bearing for installation. Do not use a torch because bearing material is very high-carbon steel that is

subject to microcracking when a torch is used. If a bearing is to be discarded, it may be heated with a

torch to ease the removal.

Do not overheat the bearing; 400° to 450°F is sufficient. Higher temperature will damage the bearing.

Discard roller bearings if they show

• pitting,

• rusting or corrosion,

• chipping or spalling,

• excessive internal looseness (which indicates extreme wear),

• cracking in either the rollers or the races.

The inner race usually must be heated in order to remove it from the shaft. For reassembly, the inner

race is always heated and mounted on an unheated shaft.

Removing a bearing or inner race

3. Place a U puller behind the bearing or the inner race.4. Balance the pulling mechanism and remove all the slack by tightening.5. While evenly applying heat to the bearing or inner race, increase the tension on the pulling

mechanism until the part is free.

Removing an outer race

The tolerances for fitting outer races to the bearing housings range from 0.005-in. tight to 0.004-in.

loose. If the outer race is a tight fit, the housing must be heated to remove it.

1. Arrange the puller mechanism to apply pressure toward the open end of the housing.2. Apply heat to the housing and at the same time increase the pressure on the puller mechanism.

Note

The bearing must be cool before it can be reassembled.


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SpacersSpacers that are used between bearings to maintain the centerlines of bearings or between bearings andother parts are usually 0.002-in. to 0.006-in. loose. Spacers that are used to hold a bearing in position—

which is not adjacent to another part that is securely fixed to the shaft—are usually 0.001-in. to 0.003-

in. tight.

To remove a spacer that has a shrink fit, follow the same procedure used to remove a bearing. To

replace a spacer, heat the spacer evenly and install the heated spacer on a cool shaft.

SprocketsMost sprocket teeth are surface hardened to a depth of approximately 1/8 in. After several years of

service, the chain may wear into the sprocket teeth. The wearing is easily seen. When the wear reachesa depth near 1/8-in, the rate of wear accelerates, and the sprockets should be replaced when the

drawworks is overhauled.

Before starting installation, pre-fit the parts. Remove any burrs or raised metal on both the shaft andhub. Replace the key if it contains grooves or burred edges. Measure the hub or sprocket bore and the

shaft diameter to determine the interference of the fit. Refer to the Parts Fit section ti determine the

heating temperature required for installations. To prevent damages, Do not heat flexible couplings

above 400°F or sprocket hubs above 600°.

Caution

It is possible to bend a sprocket during removal. Do notconcentrate heat at the hub if you are attempting to pull the

sprocket using a chain—attached to the outer rim—powered by a jack at the end of the hub. The sprocket wil l bend under these

condi tions. Shrink-fit sprockets are extremely hard to remove.They should only be removed in facility with a hydraulic press.

Do not overheat the parts.

Note

It may be necessary to put a U plate behind the sprocket and securethe puller studs to the plate.

1. Insert puller studs through openings between sprocket spokes 180 degrees apart.

2. Place steel plates and nuts on stud ends extending through the openings.3. Arrange balance of pulling mechanism and tighten only enough to remove any slack.4. Apply heat evenly and as near to the hub as possible while increasing tension with the puller at the

same time. Be sure to keep the flame moving. Do not concentrate heat at the hub.

5. To replace the sprocket, heat the sprocket to approximately 400° F. Install the new sprocket on acool shaft. Align the sprocket and insert any keys.

If the sprocket is being removed for salvage and a new shaft is being installed,

1. cut the shaft near the sprocket.


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2. Machine part of the metal from the shaft under the sprocket.3. Heat the sprocket and press out the remaining material ( the dutchman).

If the sprocket is being replaced

1. machine or torch cut the old sprocket to remove it.2. Let the shaft cool.

To replace a sprocket

1. prefit all keys and keyways.2. Heat the sprocket to approximately 400°F.3. Fit the sprocket onto a cool shaft4. Align and insert any keys.

Clutch Hubs

Caution

Do not heat flexible coupling hubs beyond a maximum

temperature of 400 F to prevent hub damage.

Keyed or unkeyed hubs are always tight on the shaft. Do not pull on the outer rim of a hub when

removing it from the shaft. If the hub has puller holes, screw the puller bolts into the tapped holes;

otherwise, use a U-shaped puller behind the part. Heat may be used to assist the removal. Apply theheat evenly around and on, or as near, the hub as possible. Do not overheat.

Before starting installation, pre-fit the parts. Remove any burrs or raised metal on both the shaft and

hub. Replace the key if it contains grooves or burred edges. Measure the hub or sprocket bore and the

shaft diameter to determine the interference of the fit. Refer to the Parts Fit section ti determine theheating temperature required for installations. To prevent damages, Do not heat flexible couplings

above 400°F or sprocket hubs above 600°.

NOTEWhen a shaft assembly is disassembled for any reason, be sure that allair, grease, and water lines are thoroughly cleaned.

.


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Drive SystemMotorsThe main drive motors are factory sealed. Consult the drive motor’s user manual for maintenance

instructions.

• Inspect the intake filters on the blowers once a month and remove any debris.

Blocked intakes will cause motor overheating under high-load conditions and possibly damagethe blower impellers.

Controls

• Inspect and maintain the drawworks controls in accordance with the manufacturer’s maintenanceinstructions.

Emergency Air StorageAir storage tanks, usually located under the hoisting drum in the drawworks skid, provide auxiliary

pressure for emergency release of the spring brakes. The tanks are charged by the rig air system andthe charge is retained by two gate valves, in the charge line. (Fig. 3) The gate valves are located on

both sides of the drawworks. The handle on each valve must be turned 90° to release the charge. These

tanks are capable of actuating their brake system at least one (1) time without additional air volume

from the rig system.

• Make sure there is at least 110-psi rig air pressure to properly charge these tanks.

Brake System

Warning

The braking system must be correctly adjusted and maintained.Failure to perform regular maintenance and to correctly adjustthe brakes will effect the reliability of the braking system andcause an unsafe operating condi tion.

The cylinders have a limited amount of travel. Lack of properadjustment can cause the cylinders to stroke more thanintended.

Excessive air gap will reduce braking capability and couldcause complete loss of brake power that could result in serious

injury to personnel and equipment.

Always secure the drawworks and the load before performingmaintenance on the brakes. Set the load on the slips andsupport the traveling block.

The standard drawworks’ brake system consists of two drum-mounted discs with air-released, spring-engaged emergency brake calipers and an optional air-engaged, water-cooled auxiliary brake. The


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auxiliary brake is a disc brake connected to the end of the drum shaft by a manually operated splined

coupling. To operate properly the brake system must be properly adjusted and free of contamination.

Daily UseIn addition to the daily maintenance inspection, operators should activate the Johnson brake systemseveral times a day. The Johnson brake functions as both an emergency brake and a parking brake. To

make sure that the brake system is functioning properly, operators should use the brake to park a loadfor a short period.

Operators should also test the emergency brake function:

• Actuate the hoisting control lever to rotate the drum very slowly.

• Push the emergency stop button. The drum should stop immediately.

• Pull the emergency stop button. The drum should start to rotate smoothly.

When testing the brake system, operators must use safe operating procedures and be aware of the

Warnings and Cautions found in the LTI Drawworks Operating and Maintenance Manual.

Daily MaintenanceTo ensure proper and safe operation, operators should inspect the brake system every day to make sure

that it is clean and free of contamination from dirt and corrosion. If the daily inspection finds anycontamination, dirt, or corrosion, the brake should be immediately cleaned to remove any

contamination or corrosion.

Water should be purged from the drawworks’ air tank and the air lines at the beginning of each shift, or

at least once a day.

Weekly Brake Disc Inspection and Cleaning

Emergency Brake• Inspect and adjust the brakes on either a weekly basis, or more frequently as indicated by

experience.

• The operating clearance between each brake pad and the brake disc should be between 1/16 in.and 3/32 in. Operating clearance should not exceed these dimensions.

• The brake pad clearance should be checked and adjusted weekly. During periods of heavy usage,it should be checked more frequently.


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Adjustment Procedure

Warning

Always secure the drawworks and the load before performing

maintenance on the spring brakes. Set the load on the slips.Support the traveling block.

See the Air Gap Adjustment Instructions in the brake service manual.

The following condensed instruction is provided for convenience and is not a replacement for the

instruction in the brake service manual.

1. Apply air pressure to release the brakes and to cage the actuators.

2. Remove the three pins that connect the actuator to the toggle link and the toggle link to the caliper.3. Swing the caliper arms open to gain access to the actuator rod clevis.4. Turn the actuator clevis counterclockwise to decrease the air gap.5. The air gap can also be adjusted by turning the toggle yoke between the toggle lever and the

caliper arm after removing the toggle link pin and loosening the jam nut.

6. When the proper pad clearance is achieved, reassemble the components and tighten all nuts.7. Apply air pressure and encage the actuator.8. Cycle the brake a few times and verify the air gap by pushing one shoe against the disc and

measuring the clearance on the other side of the disc.

9. Reset the centering screws to properly center the air gap. Check for adequate lateral float in the pads.

10. Repeat these steps for each caliper.

Pad Replacement ProcedureBrake pads must be replaced when they are ¼-in. thick. Allowing further wear will result in attachment

rivets touching and scoring the disc. Loose debris packed in the grooves of the scored disc will cause

loss of brake capability. A beveled edge indicates improper clearance between the pad and disc.

Adjust the pad as needed to maintain proper running clearance.

• Apply air pressure to release the brakes and cage the actuators.

1. Remove the pin attaching the pad holder to the caliper lever.

2. Slide the pad holder toward the center of the disc and remove the pad holder from the caliper arm.3. Remove the rivets holding the pad to the pad holder and remove the pad.4. Clean the pad holder with a wire brush. Do not use petroleum solvent.5. Make sure that the pad is properly placed on the pad holder. It should not hang over the edge.6. Rivet the pad to the pad holder. Make sure that the rivets pull up properly against the pad and the

pad holder. Do not crush the pad under the rivet head.7. Follow the air gap adjustment procedure (in the brake service manual) to increase the air gap and

allow for the new caliper. Be sure that there is sufficient clearance.


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8. Place the pad holder next to the caliper arm and toward the center of the disc. Slide the pad holderoutward until the pinholes in the holder align with the pinholes in the caliper arm.

9. Lubricate and replace the pins.10. Adjust the air gap in accordance with the Pad Adjustment Procedure.11. Burnish the pads in accordance with the Caliper Brake User’s Manual.

Holding Capability1. Place the traveling block near the lower travel limit before starting the test.2. Actuate the calipers on one brake disc and attempt to turn the drum with the motors.3. Repeat this procedure for each disc.

The brake passes the test if the drum cannot be rotated at full-rated torque.

ContaminationOil, Grease, Line Dope1. Clean and replace the brake pads2. Locate and remove the cause of the contamination.

Oxidization or Corrosion1. Burnish the discs by rotating the drums a few turns with the calipers slightly engaged.

Engage the calipers by reducing the drawworks air pressure to 80-85 psi

2. Inspect the discs and brake shoes, and check the holding capability after burnishing.

Moisture

Warning

Exercise caution and the appropriate safety measures when

purging accumulated moisture from the air system. Water thataccumulates in the air tank and the air system will be released at

high-pressure and at the ambient pressure of the rig, whichcould cause injury to personnel. This could cause injury to

personnel.

1. Open the valve on the air tank for at least 5 seconds to drain any water that may have accumulatedin the tank. (Fig 1)

2. Use a ¼ flat end rod to release the ball valve in the air filter to drain any water that may haveaccumulated in the line (Fig 2).


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Auxi liary Brake (Optional)Water connections for this brake are located in the web of the main skid beam below the brake and

near the end of the skid. Operate and maintain the brake according to the manufacturer’s instructions.

See these instructions for coolant volume and pressure requirements.

Auxiliary Brake Alignment

1. Use a dial indicator to check the alignment of the auxiliary brake after installation. Make sure thetwo spline hubs are concentric and axially aligned as shown below.

Fig. 5 Auxiliary Brake Alignment

2. Tighten the mounting bolts after the auxiliary brake has been aligned.3. Verify that the splined hub shifting mechanism operates smoothly and that the locking feature

works in both the engaged and retracted position.

4. Improper operation indicates a problem with alignment. Recheck the hub-to-hub total indicatorrun out (TIR) readings.


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Preservation and Storage

Location

• Store the drawworks in a location with good drainage to prevent the accumulation of standingwater.

• Support the drawworks in a manner similar to the working support.

• Make sure the temporary supports are high enough to allow free circulation of air below thedrawworks to prevent condensation and accumulated water.

• A drained location that prevents standing water is preferred.

Cleaning

• Clean the drawworks with a power cleaning system (steam or pressurized water is preferred).

• Make sure that dirt, grease, and other accumulated material is removed from the drawworks before storage.

• Protect the motors and controls from water intrusion during cleaning.

• Consult the manufacturer’s instructions for cleaning motors and controls.

• Flush and drain the oil system.

Preservation

• Remove any loose paint; clean rusted surfaces to bright metal; and repaint.

• Repaint any areas where the paint is thin.

• Circulate preservative oil through the lubrication system. If preservative oil is not available,circulate clean oil through the system to coat all parts with an oil film.

• Drain the oil sump after circulating the oil.

• Make sure that all grease-lubricated parts are completely greased (filled) with the usualoperating grease. Use preservative oil on areas where grease is not applicable.

• Cover the exposed parts (shaft, drum, etc) with a dry, film-type rust preventative. Do not coatthe braking surface of the brake discs.

• See the manufacturer’s manuals for preservation of the motors and controls.

Storage

Note:Condensation in the gearbox i s a main concern during s torage.

• Plug the breather opening.

• Use a small heater (100 to 200W) in the box. (This is the preferred preservation method. If a

heater is not available, use the following procedure.)• Plug the breather opening.

• Remove the sump drain plug.

• Tilt the drawworks if necessary to ensure the maximum, long-term drainage ofaccumulated condensation.

• Cover the drain with wire mesh to prevent the entrance of insects.

• Consult the manufacturer’s manuals for long-term storage of the motors and controls.


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Torque Specifications

Steel Fastener Torque Specifications (Lubed)

SAE Grade 5Fasteners

SAE Grade 8Fasteners

ASTM A193 Grade B7FastenersFastener Size

(Fractional-Decimal)

ThreadSeries USA

Units(ft-lb)

Metric

Units(N-m)

USA

Units(ft-lb)

Metric

Units(ft-lb)

USA

Units(ft-lb)

Metric Units

(N-m)

1/4 20 UNC 6 9 9 12 7 10

0.250 28 UNF 7 10 10 14 8 11

5/16 18 UNC 13 18 18 25 15 20

0.3125 24 UNF 14 20 20 28 16 22

3/8 16 UNC 23 31 33 44 26 36

.375 24 UNF 26 35 37 50 30 40

7/16 14 UNC 37 50 52 71 42 57

0.4375 20 UNF 41 56 58 79 47 64

1/2 13 UNC 56 76 80 108 64 87

0.500 20 UNF 63 86 90 122 72 98

9/16 12 UNC 81 110 115 156 93 1260.5625 18 UNF 91 123 128 174 103 140

5/8 11 UNC 112 152 158 215 128 173

0.625 18 UNF 127 172 179 243 145 196

3/4 10 UNC 199 270 281 381 227 308

0.750 16 UNF 222 301 314 425 253 343

7/8 9 UNC 321 435 453 614 366 496

0.875 14 UNF 354 480 500 678 404 547

1 8 UNC 481 652 679 921 549 744

1.000 14 UNF 539 731 762 1034 616 835

1-1/8 7 UNC 600 813 963 1305 778 1054

1.125 8 UN 621 842 997 1352 805 1092

12 UNF 673 912 1079 1463 872 1182

1-1/4 7 UNC 846 1147 1358 1842 1097 1487

1.250 8 UN 873 1184 1401 1900 1132 1534

12 UNF 937 1270 1504 2039 1215 1647

1-3/8 6 UNC 1109 1504 1781 2414 1438 1950

1.375 8 UN 1185 1607 1902 2578 1536 2083

12 UNF 1263 1712 2027 2748 1637 2220

1-1/2 6 UNC 1473 1997 2363 3204 1909 2588

1.500 8 UN 1563 2120 2509 3402 2027 2748

12 UNF 1657 2246 2659 3605 2148 2912

1-3/4

1.750 8 UN 3300 44742

2.000 8 UN 5018 6804

Bolt And Cap screw MarkingsOn Head

B7 Studs

1. All torque values given are for fasteners lubricated with 30 weight motor oil.2. All studs used on LTI pumps are Grade B7. Nuts on studs should be torqued to grade B7

specification even if the nut is Grade 8

DW Operating and Maintenance Manual

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