DDTD500

TOP DRIVE
MANUAL
for

Ali & Sons Company

Letourneau Technologies, Inc., PO Box 41343, Houston, Texas 77241 Phone: 832-782-6500
www.letourneau-inc.com
Published: Oct 2007 PLM-500-122-00
PARTS LIST INDEX
CUSTOMER: ALI & SONS COMPANY
RIG:

SECTION 1: PARTS LIST PART/DRG NO. REV.

500 TON TOP DRIVE COMPLETE DDTD500-122 00
TOP DRIVE ASSEMBLY 330-0008 04
BODY STRUCTURE ASSEMBLY 330-0604 06
DRIVE MOTOR ASSEMBLY 330-0434 06
HANDLING RING ASSEMBLY 330-0602 03
HYDRAULIC MOTOR ASSEMBLY 330-0581 04
RING LOCK ASSEMBLY 330-0312 03
RING LOCK ASSEMBLY 330-0417 02
PIPE HANDLER ASSEMBLY 330-0403 08
LINK TILT ASSEMBLY 330-0560 02
IBOP VALVE STACK 330-0627 00
IBOP ACTUATOR ASSEMBLY 330-0267 04
ENCODER ASSEMBLY 330-0496 02
ELECTRICAL INTERCONNECT ASSEMBLY 330-0638 02
PLC JUNCTION BOX OEM3043A-L001-xx --
ELECTRICAL SCHEMATICS OEM3043A-E001-xx --
HYDRAULIC CONTROL SYSTEM 330-0523 03
HYDRAULIC CONTROL MANIFOLD 330-0167 01
HYDRAULIC SYSTEM PIPING SCHEMATIC 330-0719 00
WASHPIPE ASSEMBLY EW132 --
LUBE OIL ASSEMBLY 330-0608 02
MOTOR/PUMP ASSEMBLY 115-0235 00
COUNTERBALANCE ASSEMBLY 330-0960 06
COMMISSIONING SPARES 330-0739 01
PORTABLE TRACK SYSTEM 330-1016 01
TRACK SUSPENSION ASSEMBLY 330-1058 01
INTERMEDIATE GIRT CONNECTION ASSY 330-1059 00
TORQUE REACTION SPREADER ASSY 330-1060 00
TOP DRIVE SHIPPING SKID ASSY 330-1011 00
PORTABLE TRACK DOLLY ASSY 330-0963 00
PORTABLE TRACK SHIPPING SKID ASSY 330-1061 00
SERVICE LOOP ASSEMBLY (inner) 330-0629 03
SERVICE LOOP ASSEMBLY (outer) 330-1037 00
SERVICE LOOP CONNECTION KIT 330-0635 00

SECTION 2: RECOMMENDED SPARES DRG NO. REV.

TOP DRIVE RECOMMENDED OPERATING SPARES RS-500-122 00

SECTION 3: MAINTENANCE DOC NO. REV.

INTRODUCTION TD001 01
SAFETY PROVISION TD002 00
RECOMMENDED BOLT TORQUE TD003 00
RECOMMENDED LUBRICANTS AND FLUIDS TD202 00
GENERAL MAINTENANCE TD302 01
PRE/POST JARRING INSPECTION TD602 00
1 of 2
PARTS LIST INDEX
CUSTOMER: ALI & SONS COMPANY
RIG:

SECTION 4: SYSTEM DESCRIPTION & OPERATION DRG NO. REV.

TOP DRIVE SYSTEMS CONTROL TD401 00

SECTION 5: INSTALLATION & COMMISSIONING DOC NO. REV.

TRACK INSTALLATION TD701 00
IBOP SAFETY CLAMP INSTALLATION TD702 00
MECHANICAL COMPLETION TD703 00
TOP DRIVE COMMISSIONING TD704 00
COMMISSIONING ACCEPTANCE CHECKLIST TD705 00
TOP DRIVE DECOMMISSIONING TD710 00

SECTION 6: PRODUCT BULLETINS DOC NO. REV.

SERVICE LOOP CABLE SUPPORT GRIPS TD801 00
TOP DRIVE BAIL BUSHINGS TD802 00
TOP DRIVE ENCODERS TD803 00
IBOP ACTUATOR STABILIZER TD804 00
TOP DRIVE GUARD DOOR HINGES TD805 00
TOP DRIVE UPPER IBOP VALVE & CRANK ASSY TD806 00
TOP DRIVE UPPER IBOP ACTUATOR CRANK COVER TD807 00

SECTION 7: OUTSOURCED PRODUCT MANUALS DOC NO. REV.

GLOBAL UPPER IBOP VALVE TD901 00
GLOBAL LOWER IBOP VALVE TD902 00
FLO-TORK ROTARY ACTUATOR TD903 00
JOHNSON CALIPER BRAKE TD904 00
HAWE MANIFOLD PARTS BREAKDOWN TD905 00

2 of 2
 SECTION
1
PARTS LIST
Parts list for :
330-0719

HYDRAULIC SYSTEM PIPING/SCHEM

SEQ PART QUANTITY DESCRIPTION

1 115-0182 1.00 FTG 1-1/4"SAE X 1-1/4"SAE

2 115-0176 1.00 COUPLER-QUICK, 1" SAE FEMALE

3 115-0177 1.00 NIPPLE, 1 SAE MALE

4 500-1037 1.00 FTG HYD 0º #16 FJ SWIV X 1"MP

5 EF583 1.00 FTG HYD 90º #16 MJ X #20 ORING

6 EF571 1.00 FTG HYD 0º #20 MJ X #20 ORING

7 EF572 2.00 FTG CRIMP 0º 16H X 20 FJ SWIV

8 EH138 62.00 HOSE-HYD BULK 1.000 4000 PSI

9 EF508 1.00 FTG HYD 0º #20 MJ X 1-1/2 SF

10 EO341 2.00 O-RING 2-225 BUNA 90

11 EF510 2.00 FLANGE-SPLIT 1.5" CODE 62 HALF

12 EC334 8.00 CSCR SK M16 X 50 G8 DH

13 EW141 8.00 WASHER-LOCK, METRIC M16

14 400-2425 1.00 FTG HYD 0º #20 MJ X 1-1/4 MP

15 115-0178 1.00 COUPLER 1-1/4" SAE FEMALE

16 115-0179 1.00 NIPPLE, 1-1/4 SAE MALE

17 EF597 1.00 FTG HYD 0º #20 FJ X 1-1/4 MP

18 400-2422 1.00 FTG HYD 0º #12 MJ X 3/4 MP

19 115-0180 1.00 COUPLER-QUICK, 1/2 SAE FEMALE

20 115-0181 1.00 NIPPLE, 1/2 SAE MALE

21 EF372 1.00 FTG HYD 0º # 8 MJ X 3/4 MP

22 EF307 2.00 FTG TEE #10 MJ X MJ X O RING

23 407-8968 5.00 FTG TEE #8 MJ X MJ X FJ SWIV

24 EF430 3.00 FTG CRIMP 90º 6H X 8 FJ SWIV

25 EH129 107.00 HOSE-HYD BULK .375 5000 PSI

26 EF420 7.00 FTG CRIMP 90º 6H X 6 FJ SWIV

Page 1 of 3
Parts list for :
330-0719

HYDRAULIC SYSTEM PIPING/SCHEM

SEQ PART QUANTITY DESCRIPTION

27 EF573 1.00 FTG HYD 0º # 6 MJ X #4 BPP

28 115-0184 1.00 GAUGE 1/4" BTM LIQ. FILLED

29 115-0194 11.00 ADAPTER, 5/8 MJIC X 1/2 MJIC

30 EF536 8.00 FTG CRIMP 90º 8H X 10 FJ SWIV

31 EH130 2,488.00 HOSE-HYD BULK .500 4250 PSI

32 EF416 11.00 FTG CRIMP 45º 8H X 8 FJ SWIV

33 400-2420 1.00 FTG HYD 0º # 8 MJ X 3/8 MP

34 EF421 40.00 FTG CRIMP 90º 8H X 8 FJ SWIV

35 EF217 6.00 FTG HYD 0º # 8 MJ X # 4 ORING

36 EF407 33.00 FTG CRIMP 0º 8H X 8 FJ SWIV

37 115-0192 1.00 ADAPTER, 1" MSAE X 1" FJIC

38 402-0757 2.00 FTG HYD 90º # 8 MJ X 1/2 MP

39 EF216 1.00 FTG TEE #8 MJ X MJ X FJ SWIV

40 402-1571 3.00 FTG HYD 0º # 8 MJ X 1/4 MP

41 EV331 1.00 VALVE-SPEED CONTROL, 1/4" NPT

42 EF390 2.00 FTG HYD 0º # 8 MJ X # 6 ORING

43 EF538 16.00 FTG HYD 0º # 8 MJ X #10 ORING

44 EF539 8.00 FTG HYD 90º # 8 MJ X #10 ORING

45 400-2455 8.00 FTG HYD 0º # 8 MJ X # 8 ORING

46 EF514 11.00 FTG HYD 0º # 8 MJ X # 8 ORING

47 EF522 4.00 FTG PLUG # 8 O-RING

48 EF442 4.00 FTG UNION 0º #12 JIC

49 EF549 2.00 FTG TEE #8 MJ X MJ X MJ

50 EF509 2.00 FTG HYD 0º #16 MJ X 1 SF

51 EO340 4.00 O-RING 2-219 BUNA 90

52 EF511 4.00 FLANGE-SPLIT 1" CODE 62 HALF

Page 2 of 3
Parts list for :
330-0719

HYDRAULIC SYSTEM PIPING/SCHEM

SEQ PART QUANTITY DESCRIPTION

53 EC336 16.00 CSCR SK M12 X 40 G8 DH

54 EW142 16.00 WASHER-LOCK, METRIC M12

55 EF409 2.00 FTG CRIMP 0º 12H X 12 FJ SWIV

56 EH132 228.00 HOSE-HYD BULK .750 3125 PSI

57 115-0196 2.00 ADAPTER, 1" MSAE X 1/2" MJIC

58 EF409 2.00 FTG CRIMP 0º 12H X 12 FJ SWIV

59 EF422 4.00 FTG CRIMP 90º 12H X 12 FJ SWIV

60 EF556 2.00 FTG HYD 0º #12 MJ X # 8 ORING

61 EF558 3.00 FTG PLUG #10 O-RING

62 EF272 4.00 FTG HYD 0º # 8 MJ X #12 ORING

63 EF582 2.00 PLUG-FLANGE, CODE 62 1"

64 EF214 2.00 FTG TEE #6 MJ X MJ X FJ SWIV

65 EF585 4.00 FTG HYD 0º # 6 MJ X #4 ORING

66 115-0183 1.00 ADAPTER, 1" MSAE X 1-1/4" FSAE

67 EF587 1.00 FTG HYD 90º #20 MJ X 1-1/2 SF

68 EF546 3.00 FTG HYD 90º # 8 MJ X # 8 ORING

69 EF588 1.00 FTG HYD 90º # 8 MJ X # 6 ORING

70 115-0190 2.00 ADAPTER, 1" FJIC X 3/4" MJIC

71 115-0193 1.00 FTG CRIMP 3/8 FJIC X 1/2

72 115-0185 1.00 ADAPTER, 3/8" FJIC X 1/4" NPTF

73 115-0186 1.00 NIPPLE-PIPE, 1/4 HEX X 4 LN

74 115-0187 1.00 PIPE CPLG 1/4" NPTF

Page 3 of 3
 LeTourneau Technologies
P/N: EW132

SNAP RING

O-RING
O-RING HOLDING NUT

HOLDING RING

LTI P/N: EW132

WASHPIPE W/
SNAP RING

LTI P/N: EP426

PACKING SET W/ O-RING

SPACER

1/8-27 NPT
ZERT FITTING
SPACER

SPACER

CAP SCREW

PACKING BOX

O-RING
 7 6 5 4 3 2 1
DWG NO.

330-0608 ITEM QTY PART NO. DESCRIPTION

2 1 1 115-0235 ASSEMBLY-LUBE PUMP, 1S-1HP, 480V
2 1 330-0708 ASSEMBLY-HOSE, LUBE PUMP
3 1 330-0709 ASSEMBLY-HOSE, LUBE PUMP
4 1 330-0713 ASSEMBLY-HOSE, LUBE PUMP
5 1 330-0710 ASSEMBLY-HOSE, LUBE PUMP

D 6 1 402-0757 FTG HYD 90 DEG 8MJ X 1/2MP D

7 1 401-8666 FTG HYD 0 DEG 8MJ X 1/2MP
8 1 330-0714 ASSEMBLY-HOSE, LUBE PUMP
1
9 1 400-2420 FTG HYD 0 DEG 8MJ X 3/8MP
10 1 115-0108 SENSOR-RTD, OIL
11 2 115-0188 FTG HYD 37 DEG SAE (JIC) FLARE UNION
12 2 400-2429 FTG HYD 45 DEG 6MJ X 1/4MP
13 1 EF214 FTG TEE 6MJ X MJ X FJ SWIV
14 1 EF216 FTG TEE 8MJ X MJ X FJ SWIV
15 1 115-0111 GUAGE-LEVEL, OIL
16 2 402-1571 FTG HYD 0 DEG 8MJ X 1/4MP
17 4 ES476 CLAMP-BEHRINGER PIPE, 3/8"
18 1 401-1744 FTG HYD 90 DEG 6MJ X 1/2MP
9 19 1 115-0189 FTG 1/2" MNPT X 3/4" FNPT

C C

18

B B
1

NOTES:
1 REPLACMENT FILTER CARTRIDGE
FOR ITEM 5 IS P/N 115-0137.

18

A A
UNLESS OTHERWISE SPECIFIED: USED ON
R ZONE REV DESCRIPTION ECN DATE CHG CHK APP
E 00 RELEASE 7-0056RTD 04/04/07 RJM RML
NHL
DIMENSIONS ARE IN INCHES & APPLY
BEFORE PLATING OR FINISH COATINGS.
TOLERANCES ON: ANGLES ±1°
330-0007 ASSEMBLY-OIL LUBE, 480V
DWN DATE

V
I 01 SEE ECN FOR CHANGES 7-0178CTD 05/09/07RJM RML CDD LeTourneau FRACTIONS
.XX DECIMAL
±1/16
±.03 CHK
NHL
RJM
04/04/07
04/25/07
S 02 SEE ECN FOR CHANGES 7-0285CTD 07/20/07 RJM RML HCD TECHNOLOGIES
.XXX DECIMAL ±.015
MACHINED CORNERS 1/64 X 45°
WELD PROPERTIES SHALL MEET THE
ENGR
RML 04/25/07 500 TON TOP DRIVE
I MINIMUM REQUIREMENTS OF THE MATL
HOUSTON, TEXAS MATL SIZE DWG NO. REV
O BASE MATERIAL.

N
THIS DRAWING AND ALL DATA THEREIN IS THE PROPERTY OF THE
LeTOURNEAU ELLIS WILLIAMS COMPANY. IT IS CONFIDENTIAL AND MUST
THIRD ANGLE PROJECTION
D DO NOT SCALE 330-0608 02
01
NOT BE COPIED. IT IS LOANED SUBJECT TO RETURN UPON DEMAND
S AND IS NOT TO BE USED IN ANYWAY DETRIMENTAL TO OUR INTEREST.
SCALE EST WT 150.0 lbm SHEET 1 OF 3
8 7 6 5 4 3 2 1
 7 6 5 4 3 2 1
DWG NO.

330-0608

D D

2 9

C C
13 3 18
4

11
15
12
19

BONNET-TOP DRIVE
11

STRUCTURE-BODY
12
**
B B
10
5
16
14
6
7 RETAINER-BEARING
8 16

PIPING SCHEMATIC
A A
UNLESS OTHERWISE SPECIFIED: USED ON
R ZONE REV DESCRIPTION ECN DATE CHG CHK APP
E 00 RELEASE 7-0056RTD 04/04/07 RJM RML
NHL
DIMENSIONS ARE IN INCHES & APPLY
BEFORE PLATING OR FINISH COATINGS.
TOLERANCES ON: ANGLES ±1°
330-0007 ASSEMBLY-OIL LUBE, 480V
DWN DATE

V
I 01 SEE ECN FOR CHANGES 7-0178CTD 05/09/07RJM RML CDD LeTourneau FRACTIONS
.XX DECIMAL
±1/16
±.03 CHK
NHL
RJM
04/04/07
04/25/07
S 02 SEE ECN FOR CHANGES 7-0285CTD 07/20/07 RJM RML HCD TECHNOLOGIES
.XXX DECIMAL ±.015
MACHINED CORNERS 1/64 X 45°
WELD PROPERTIES SHALL MEET THE
ENGR
RML 04/25/07 500 TON TOP DRIVE
I MINIMUM REQUIREMENTS OF THE MATL
HOUSTON, TEXAS MATL SIZE DWG NO. REV
O BASE MATERIAL.

N
THIS DRAWING AND ALL DATA THEREIN IS THE PROPERTY OF THE
LeTOURNEAU ELLIS WILLIAMS COMPANY. IT IS CONFIDENTIAL AND MUST
THIRD ANGLE PROJECTION
D DO NOT SCALE 330-0608 02
01
NOT BE COPIED. IT IS LOANED SUBJECT TO RETURN UPON DEMAND
S AND IS NOT TO BE USED IN ANYWAY DETRIMENTAL TO OUR INTEREST.
SCALE EST WT 150.0 lbm SHEET 2 OF 3
8 7 6 5 4 3 2 1
 7 6 5 4 3 2 1
DWG NO.

330-0608

D D

BONNET 24

29 34
29
STRUCTURE-BODY 29 19

24
34
19

C C

B B

A A
UNLESS OTHERWISE SPECIFIED: USED ON
R ZONE REV DESCRIPTION ECN DATE CHG CHK APP
E 00 RELEASE 7-0056RTD 04/04/07 RJM RML
NHL
DIMENSIONS ARE IN INCHES & APPLY
BEFORE PLATING OR FINISH COATINGS.
TOLERANCES ON: ANGLES ±1°
330-0007 ASSEMBLY-OIL LUBE, 480V
DWN DATE

V
I 01 SEE ECN FOR CHANGES 7-0178CTD 05/09/07RJM RML CDD LeTourneau FRACTIONS
.XX DECIMAL
±1/16
±.03 CHK
NHL
RJM
04/04/07
04/25/07
S 02 SEE ECN FOR CHANGES 7-0285CTD 07/20/07 RJM RML HCD TECHNOLOGIES
.XXX DECIMAL ±.015
MACHINED CORNERS 1/64 X 45°
WELD PROPERTIES SHALL MEET THE
ENGR
RML 04/25/07 500 TON TOP DRIVE
I MINIMUM REQUIREMENTS OF THE MATL
HOUSTON, TEXAS MATL SIZE DWG NO. REV
O BASE MATERIAL.

N
THIS DRAWING AND ALL DATA THEREIN IS THE PROPERTY OF THE
LeTOURNEAU ELLIS WILLIAMS COMPANY. IT IS CONFIDENTIAL AND MUST
THIRD ANGLE PROJECTION
D DO NOT SCALE 330-0608 02
01
NOT BE COPIED. IT IS LOANED SUBJECT TO RETURN UPON DEMAND
S AND IS NOT TO BE USED IN ANYWAY DETRIMENTAL TO OUR INTEREST.
SCALE EST WT 150.0 lbm SHEET 3 OF 3
8 7 6 5 4 3 2 1
 7 6 5 4 3 2 1
DWG NO.

115-0235 ITEM QTY PART NO. DESCRIPTION

1 1 115-0161 MOTOR-ELEC, 1HP EXPL PRF 480V
2 1 330-0634 BRACKET-OIL BATH ASSEMBLY
3 1 115-0131 HEAT SINK, LUBE PUMP TOP DRIVE
4 1 115-0138 GUAGE-OIL FILTER, LUBE PUMP
5 1 115-0136 FILTER-OIL, LUBE PUMP TOP DRIVE

D 6 1 330-0648 TUBING SET-OIL BATH D

7 4 EF164 FTG HYD 90 DEG 6COMP X 3/8MPSS
1
8 2 078-0035 BUSHING-PIPE, 3/4" X 3/8" FS
9 1 401-3789 BUSHING-PIPE, 1/2" X 3/8" FS
10 1 330-0649 COVER-HEAT SINK, OIL BATH
11 1 330-0699 COVER-COUPLING
12 1 330-0703 SPACER-LUBE PUMP ASSEMBLY
14 13 2 108-0472 CLAMP-BEHRINGER PIPE, 3/4"
14 1 115-0162 REDUCER-GEAR, 3:1 583RPM
16
15 1 115-0110 PUMP-GEAR, OIL BATH
16 1 115-0197 COUPLING-SPIDER TYPE, ML050
15
17 1 115-0137 FILTER CARTRIDGE - OIL, LUBE PUMP

12

C C

11

6
7

13

7
8

B B
4
7

8
13

17

10
7

A A
UNLESS OTHERWISE SPECIFIED: USED ON
R ZONE REV DESCRIPTION ECN DATE CHG CHK APP DIMENSIONS ARE IN INCHES & APPLY

E RELEASE
BEFORE PLATING OR FINISH COATINGS.
TOLERANCES ON: ANGLES ±1° DWN DATE
REPLACEMENT LIST- LUBE PUMP ASSEMBLY
V
I
LeTourneau FRACTIONS
.XX DECIMAL
±1/16
±.03 CHK

S TECHNOLOGIES
.XXX DECIMAL ±.015
MACHINED CORNERS 1/64 X 45°
WELD PROPERTIES SHALL MEET THE
ENGR 500 TON TOP DRIVE
I MINIMUM REQUIREMENTS OF THE MATL
HOUSTON, TEXAS MATL SIZE DWG NO. REV
O BASE MATERIAL.

N
THIS DRAWING AND ALL DATA THEREIN IS THE PROPERTY OF THE
LeTOURNEAU ELLIS WILLIAMS COMPANY. IT IS CONFIDENTIAL AND MUST
THIRD ANGLE PROJECTION
D DO NOT SCALE 115-0235 00
01
NOT BE COPIED. IT IS LOANED SUBJECT TO RETURN UPON DEMAND
S AND IS NOT TO BE USED IN ANYWAY DETRIMENTAL TO OUR INTEREST.
SCALE EST WT 150.0 lbm SHEET 1 OF 1
8 7 6 5 4 3 2 1
 SECTION
2
RECOMMENDED
SPARES
 TOP DRIVE RECOMMENDED OPERATING SPARES

*Priority 1 (Expendable) - These items typically require periodic replacement.

*Priority 2 (Repair) - These items typically wear with extended use.
*Priority 3 (Overhaul) - These items are typically replaced during major rebuild.
Recommended quantities are for one (1) unit operating for one year. Double the 'Priority 1' quantities for two (2) years of operation.
**Area 1 (Regional) - Recommended spares for equipment operating in an area accessible to regional warehouse.
***Area 2 (Remote) - Recommended spares for equipment operating in a remote area.

ASSEMBLY DESCRIPTION / QTY PER RECOMMENDED QTY

PART NUMBER *PRIORITY SPARE P/N SPARE PART DESCRIPTION ASSY **Area 1 ***Area 2

TOP DRIVE ASSEMBLY 1 EW133 WASHPIPE W/ SNAP RING 1 1 2

1 EA 330-0008 1 EP426 WASHPIPE PACKING & O-RING SET 1 3 6
2 EW132 WASHPIPE ASSEMBLY 1 1 2
2 115-0107 AIR RTD SENSOR 1 0 1
2 EC282 DISC BRAKE CALIPER, RH 1 1 1
2 EC283 DISC BRAKE CALIPER, LH 1 1 1

BODY STRUCTURE 1 ES258 OIL SEAL 3 3 4

ASSEMBLY 2 330-0084 SEAL RACE 1 1 1
1 EA 330-0604 2 330-0083 SEAL RACE 1 1 1
2 500-1563 MUD GUARD 1 1 1
2 ES235 UNION SEAL 1 1 1
2 115-0112 OIL SEAL 1 1 2
3 EB609 THRUST BEARING 1 1 1
3 EB611 CYLINDRICAL ROLLER BEARING 1 1 1
3 EB606 TAPERED ROLLER BEARING, CUP 1 1 1
3 EB607 TAPERED ROLLER BEARING, CONE 1 1 1
3 EB620 NEEDLE ROLLER BEARING 1 1 1
3 EB630 FLANGE BEARING 1 1 1

DRIVE MOTOR ASSY 2 330-0081 SEAL RACE 1 1 1

1 EA 330-0434

HANDLING RING ASSEMBLY 1 ES259 OIL SEAL 2 2 4

1 EA 330-0602 1 115-0127 SEAL KIT-ROTARY DISTRIBUTOR 1 1 2
2 330-0094 BRONZE BUSHING 1 0 1
2 330-0082 SEAL RACE 1 1 1
3 115-0099 ROTARY DISTRIBUTOR 1 1 1
3 EB608 THRUST BEARING 1 0 1
3 EB610 CYLINDRICAL ROLLER BEARING 1 1 1

HYDRAULIC MTR ASSY 2 EM115 HYDRAULIC MOTOR 1 1 1

1 EA 330-0581

LOCK RING ASSEMBLY 2 EA109 HYDRAULIC ROTARY ACTUATOR 2 1 2

330-0312 & 330-0417

PIPE HANDLER ASSEMBLY 1 ED114 PIPE DIE 4 8 16

1 EA 330-0403 1 300-0400 WEAR RING, 5-1/2 ID 1 1 2
1 330-0401 WEAR RING, 4-7/8 ID 1 1 2
1 330-0402 WEAR RING, 7-1/2 ID 1 1 2
1 330-0256 SLIDE PAD 4 4 8
2 330-0382 WEAR PAD 4 4 4
2 330-0379 WEAR PAD 4 4 4
2 330-0200 WEAR PAD 4 4 4
2 330-0201 WEAR PAD 4 4 4
2 330-0378 WEAR PAD 4 4 4
2 ES317 SEAL KIT-CLAMP CYL 1 1 2
2 EC349 CYLINDER-CLAMP 1 1 1
2 EC292 CYLINDER-LIFT 1 1 1

LINK TILT ASSEMBLY 2 115-0077 BEARING-PLAIN SPHERICAL 2 2 4

1 EA 330-0560 2 115-0074 LINK TILT CYLINDER 2 1 2

IBOP VALVE STACK 1 115-0203 REPAIR KIT - UPPER VALVE 1 2 4

330-0627 1 115-0204 REPAIR KIT - LOWER VALVE 1 2 4
2 EV312 UPPER IBOP VALVE 1 1 1
2 EV311 LOWER IBOP VALVE 1 1 1
2 330-0538 SAVER SUB - 6-5/8R X 5-1/2FH 1 1 1

Sheet 1 of 3 RS-500-122-00.xls
 TOP DRIVE RECOMMENDED OPERATING SPARES

ASSEMBLY DESCRIPTION / QTY PER RECOMMENDED QTY

PART NUMBER *PRIORITY SPARE P/N SPARE PART DESCRIPTION ASSY **Area 1 ***Area 2

IBOP ACTUATOR ASSY 2 EC296 CYLINDER-ACTUATOR 2 1 2

1 EA 330-0267 2 EC297 CRANK-VALVE, UPPER IBOP 2 1 2

ENCODER ASSEMBLY 1 115-0094 TIMING BELT 1 1 2

330-0496 2 EE116 ENCODER 2 1 2
3 115-0095 DRIVE TIGHTERNER 1 0 1

ELECTRICAL 3 EC353 CABLE-POWER, 12AWG-4C 45 FT 0 45 FT

INTERCONNECT 3 EC404 CABLE-CNTRL, 16AWG, 1P, TYPE P 30 FT 0 30 FT
330-0638 3 EC356 CABLE-CNTRL, 18AWG-3C 30 FT 0 30 FT
3 EC355 CABLE-CNTRL, 20AWG-4TSP 70 FT 0 70 FT

HYDRAULIC CONTROL 1 EE115 ELEMENT-FILTER, HYDRAULIC 1 1 2

SYSTEM 2 EV325 VALVE-COUNTERBALANCE, CART. 2 1 2
1 EA 330-0523 2 EV330 VALVE-DIVERTER 1 1 1
2 EV350 VALVE-COUNTERBALANCE, CART. 8 1 1
2 EV351 VALVE-COUNTERBALANCE, CART. 3 1 1
2 EV372 VALVE-DIR. CONTROL 1 1 1

HYDRAULIC CONTROL 1 ES332 SEAL KIT, EV332 1 1 2

MANIFOLD 1 ES333 SEAL KIT, EV333 & EV334 2 2 2
1 EA 330-0167 1 ES336 SEAL KIT, EV336 - EV340 6 2 2
2 EC394 SOLENOID COIL 8 2 2
2 EV333 SOLENOID VALVE, 42.3 GPM 1 1 1
2 EV334 SOLENOID VALVE, 42.3 GPM 1 1 1
2 EV336 SOLENOID VALVE, 6.6 GPM 1 1 1
2 EV337 SOLENOID VALVE, 16.6 GPM 1 1 1
2 EV338 SOLENOID VALVE, 21.1 GPM 1 1 1
2 EV339 SOLENOID VALVE, 2.6 GPM 1 1 1
2 EV340 SOLENOID VALVE, 2.6 GPM 2 1 1

HYDRAULIC SYSTEM 2 EH129 HYD HOSE- 3/8", 5000 PSI 107 IN 107 IN 107 IN
PIPING 2 EF420 CRIMP FTG-90DEG, 6H X 6FJ SW 7 2 7
1 EA 330-0719 2 EH130 HYD HOSE- 1/2", 4250 PSI 2488 IN 1000 IN 1000 IN
2 EF421 CRIMP FTG-90DEG, 8H X 8FJ SW 40 10 10
2 EF407 CRIMP FTG-0DEG, 8H X 8FJ SW 33 10 10
2 400-2455 HYD FTG- 0DEG, 8MJ X 8OR 8 4 4
2 EF514 HYD FTG- 0DEG, 8MJ X 8OR LG 11 4 4

LUBE OIL ASSEMBLY 2 330-0708 HOSE ASSEMBLY 1 1 2

1 EA 330-0608 2 330-0709 HOSE ASSEMBLY 1 1 2
2 330-0710 HOSE ASSEMBLY 1 1 2
2 330-0713 HOSE ASSEMBLY 1 1 2
2 330-0714 HOSE ASSEMBLY 1 1 2
2 115-0108 OIL RTD SENSOR 1 1 2

LUBE MTR/PUMP ASSY 1 115-0137 FILTER CARTIDGE 1 1 2

1 EA 115-0235 3 115-0162 GEAR REDUCER 1 0 1
3 115-0110 GEAR PUMP 1 0 1
3 115-0197 SPIDER COUPLING 1 0 1
3 115-0161 ELECTIC MOTOR 1 0 1

COUNTERBALANCE ASSY 1 115-0305 SEAL KIT-CNTRBLNC CYL 2 1 2

1 EA 330-0960 1 115-0307 SPHERICAL BEARING-CYL 2 1 2
2 115-0063 CYLINDER-COUNTERBALANCE 2 1 2

TD GUIDE DOLLY 1 ES262 SEAL-GREASE 16 4 8

ASSEMBLY 2 EB616 BEARING-TAPERED ROLLER, CUP 16 4 8
1 EA 330-0963 2 EB619 BEARING-TAPERED ROLLER, CONE 16 4 8
2 EB617 ROLLER-TRACK 4 1 2

Sheet 2 of 3 RS-500-122-00.xls
 TOP DRIVE RECOMMENDED OPERATING SPARES

ASSEMBLY DESCRIPTION / QTY PER RECOMMENDED QTY

PART NUMBER *PRIORITY SPARE P/N SPARE PART DESCRIPTION ASSY **Area 1 ***Area 2

SERVICE LOOP (Inner) 3 EC319 CABLE-POWER, 535 KMIL A&S 690 FT 0 690 FT
1 EA 330-0629 3 EC320 CABLE-CONTROL, 12 AWG 20C 115 FT 0 115 FT
3 EC321 CONTROL CABLE 115 FT 0 115 FT
3 EC322 CABLE-GROUND, 4/0 115 FT 0 115 FT
3 115-0144 ASSEMBLY-FIBER OPTIC CABLE 2 0 1
3 115-0080 HOSE-ASSEMBLY, 3/4 X 115' 1 0 1
3 115-0081 HOSE-ASSEMBLY, 1 X 115' 1 0 1
3 115-0082 HOSE-ASSEMBLY, 1-1/4 X 115' 1 0 1
3 115-0083 HOSE-ASSEMBLY, 3/4 X 115' 1 0 1

SERVICE LOOP (Outer) 3 EC319 CABLE-POWER, 535 KMIL A&S 900 FT 0 900 FT
1 EA 330-1037 3 EC320 CABLE-CONTROL, 12 AWG 20C 150 FT 0 150 FT
3 EC321 CONTROL CABLE 150 FT 0 150 FT
3 EC322 CABLE-GROUND, 4/0 150 FT 0 150 FT
3 EC390 ASSEMBLY-FIBER OPTIC CABLE 2 0 1
3 330-0319 HOSE-ASSEMBLY, 3/4 X 100' 1 0 1
3 330-0320 HOSE-ASSEMBLY, 1 X 100' 1 0 1
3 330-0328 HOSE-ASSEMBLY, 1-1/4 X 100' 1 0 1
3 330-0329 HOSE-ASSEMBLY, 3/4 X 100' 1 0 1
3 330-1038 HOSE-ASSEMBLY, 3/4 X 50' 1 0 1
3 330-1039 HOSE-ASSEMBLY, 1 X 50' 1 0 1
3 330-1040 HOSE-ASSEMBLY, 1-1/4 X 50' 1 0 1
3 330-1041 HOSE-ASSEMBLY, 3/4 X 50' 1 0 1

Sheet 3 of 3 RS-500-122-00.xls
 SECTION
3
MAINTENANCE
 INTRODUCTION
TD001-01
1 of 1

This manual is published as a general guide for the service of your LEWCO Top Drive.
Because of the many factors which normally contribute to the proper function or
malfunction of the Power Swivel, and not having complete knowledge of each factor or
combination of factors, we cannot detail all facets of this subject. We therefore confine
the scope of this presentation, and when situations encountered are not fully
encompassed by complete and understandable instructions, these situations must then
be referred to LEWCO.

When other than routine maintenance or servicing is necessary, it can be most

efficiently performed if the unit or primary component is removed from service to an
area of adequate space where an overhead crane, hydraulic lift, beating pullers, impact
tools, shelter, etc., are available and readily accessible.

The dimensions and tolerances specified in this publication are those desirable for the
most efficient operations of the Top Drive. When components become worn beyond
limits specified, they should be replaced.

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

necessitate changes in the Top Drive and result in inconsistencies between the
contents of this publication and the physical equipment. LEWCO reserves the right to
make these changes.

The drawings, pictures and photographs may be of similar equipment and may not
appear exactly like your product.
 SAFETY PROVISIONS
TD002-00
1 of 1

Before conducting maintenance or repair operations, the following safety provisions

should be followed. Other provisions not listed here may be necessary. Precaution and
good judgment should always be used when working on this equipment.

FAILURE TO FOLLOW THESE PROVISIONS AND GOOD JUDGMENT COULD RESULT IN

INJURY OR DEATH TO PERSONNEL, OR DAMAGE TO EQUIPMENT.

• Wear eye protection such as safety glasses.

• Remove jewelry, such as rings, watch, necklace, etc.
• Wear appropriate protective clothing, such as steel toe footwear, hard hat, etc.
• Wear and properly secure a safety harness when working at an elevated level.
• Personnel performing the operations should be familiar with the equipment and
the manuals for the equipment they are working on.
• Turn off and lock-out electrical power prior to working on electrical equipment.
• Turn off and bleed down hydraulic pressure prior to working on hydraulic
equipment.
• Avoid working with loose tools or components directly overhead, above
personnel.
• Safely secure heavy and/or overhead components being removed or installed.
• Use appropriate tools to work on the equipment.
 STEEL FASTENER TORQUE SPECIFICATIONS (LUBED)
SAE GRADE 5 SAE GRADE 8 ASTM A193 GRADE B7
FASTENER THREAD FASTENERS FASTENERS FASTENERS
SIZE SERIES USA METRIC USA METRIC USA METRIC
fractional UNITS UNITS UNITS UNITS UNITS UNITS
(decimal) (ft-lb) (N-m) (ft-lb) (N-m) (ft-lb) (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 93 126
0.5625 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 4474
2
2.000 8 UN 5018 6804

BOLT AND
CAPSCREW
B7 Studs
MARKINGS ON HEAD

1) ALL TORQUE VALUES GIVEN ARE FOR LUBRICATED FASTENERS.

2) ALL STUDS USED ON LEWCO PUMPS ARE GRADE B7. NUTS ON STUDS SHOULD BE
TORQUED TO GRADE B7 SPEC EVEN IF THE NUT ITSELF IS GRADE 8.
 RECOMMENDED LUBRICANTS & FLUIDS
TD202-00
1 of 2

Points of Interest

• Before conducting maintenance operations, follow the recommended safety

provisions outlined previously in this manual.
• Prevent contamination while adding or changing lubricants or fluids.
• Use the correct fluids for the working environmental conditions. Fluids must pour
freely at minimum operating temperatures.
• Fluids should be changed every six (6) months minimum, or as frequently as
operating conditions require, to maintain a clean fluid of proper viscosity.
• Do NOT mix different types of fluids or lubricants, since many
are not compatible with one another.

Recommended Lubricants
(Standard Environment Conditions – NLGI #2)
(Sub-Freezing Environment Conditions – NLGI #1)

LOWER THRUST BEARING GREASE:

• Lithium Complex, Extreme Pressure, with Anti-Wear Additives (ex. Fina Marson
Liplex).
• Aluminum Complex, Multi-Purpose, Synthetic (ex. Royal Purple Ultra-
Performance Grease).

DRILLING MOTOR GREASE:

• Aluminum Complex, Multi-Purpose, Synthetic.

GENERAL ALL-PURPOSE GREASE:

• Lithium Based, Multi-Purpose.
• Aluminum Complex, Multi-Purpose, Synthetic.

HANDLING RING GEAR/PINION LUBRICANT:

• Aluminum Based, Extreme Pressure, with Anti-Wear Additives (ex. Jet Lube
Kopr-Kote)
 RECOMMENDED LUBRICANTS & FLUIDS
TD202-00
2 of 2

Recommended Fluids
(Standard Environment Conditions)

UPPER THRUST BEARING:

• Synthetic Gear/Bearing Oil with Anti-Wear and Anti-Rust Additives (ex.
ExxonMobil SHC 632) [LTI P/N: 115-0132 for 5 gallon bucket]
o ISO Viscosity Grade 320
o Viscosity = 38.6 cSt @ 100C
o Viscosity Index = 169
o Pour Point = -38F (-39C)

HYDRAULIC SYSTEM:
• Hydraulic Oil with Anti-Wear and Anti-Rust Additives
o ISO Viscosity Grade 46
o Viscosity = 6.8 - 8.9 cSt @ 100C
o Viscosity Index = 132
o Pour Point = -30F (-34C)

Recommended Fluids
(Sub-Freezing Environment Conditions)

UPPER THRUST BEARING:

• Synthetic Gear/Bearing Oil with Anti-Wear and Anti-Rust Additives (ex.
ExxonMobil SHC 629) [LTI P/N: 151-0133 for 5 gallon bucket]
o ISO Viscosity Grade 150
o Viscosity = 18.3 cSt @ 100C
o Viscosity Index = 144
o Pour Point = -49F (-45C)

HYDRAULIC SYSTEM:
• Hydraulic Oil with Anti-Wear and Anti-Rust Additives
o ISO Viscosity Grade 32
o Viscosity = 6.1 cSt @ 100C
o Viscosity Index = 153
o Pour Point = -58F (-50C)
 GENERAL MAINTENANCE
TD302-01
1 of 10

Daily Maintenance Procedures

The following are general procedures for maintaining the top drive on a daily basis. For
specifications on lubricants to use, refer to the ‘Recommended Lubricants & Fluids’
document located in this manual.

LUBRICATION:

(1-3 Strokes of Hand-Operated Grease Gun at each point)

1. Grease Dolly Rollers (12 total).

 GENERAL MAINTENANCE
TD302-01
2 of 10

2. Grease Washpipe Packing Assembly

Note: Grease Washpipe Packing every 8 hours with Mud Pumps OFF.

3. Grease Link Tilt Cylinder End-Connections (4 total)

4. Grease Upper IBOP Actuator Crank (1 fitting/crank)
5. Grease IBOP roller bearings (2 fitting/roller)
 GENERAL MAINTENANCE
TD302-01
3 of 10

6. Lubricate the inside walls of the Pipe Clamp adequately to prevent the Die Heads
from sticking, and wash out any accumulated drilling fluid

INSPECTION:

1. Visually Inspect the Pipe Clamp and Dies daily.

 GENERAL MAINTENANCE
TD302-01
4 of 10

Weekly Maintenance Procedures

The following are general procedures for maintaining the top drive on a weekly basis.
For specifications on lubricants to use, refer to the ‘Recommended Lubricants & Fluids’
document located in this manual.

LUBRICATION:

(1-3 Strokes of Hand-Operated Grease Gun at each point)

1. Grease Bail Pins (2 fitting/pin)

2. Grease Handling Ring Lock Assembly (2 locks)

 GENERAL MAINTENANCE
TD302-01
5 of 10

3. Grease Handling Ring Bronze Bushing

4. Grease Handling Ring Thrust Bearing – Apply 4 strokes if grease to each of 2

fittings, rotate the Handling Ring 1 turn and apply 4 more strokes, then rotate the
Handling Ring once to distribute the grease.
 GENERAL MAINTENANCE
TD302-01
6 of 10

5. Grease Handling Ring Lower Cylindrical Bearing

6. Grease Upper IBOP Valve (refer to manufacturer’s manual)

7. Grease Lower IBOP Valve (refer to manufacturer’s manual)
Remove ¼” NPT plug and install ¼” NPT grease port.
With the ball valve open apply 8-10 strokes with manual grease gun.
Remove the fitting and reinstall the NPT plug.
 GENERAL MAINTENANCE
TD302-01
7 of 10

Monthly Maintenance Procedures

The following are general procedures for maintaining the top drive on a monthly basis.
For specifications on lubricants to use, refer to the ‘Recommended Lubricants & Fluids’
document located in this manual.

LUBRICATION:

1. Grease Brake Calipers (1-2 Strokes of Hand-Operated Grease Gun)

2. Grease Handling Ring Gear and Pinion (Heavy Duty Lubricant).

 GENERAL MAINTENANCE
TD302-01
8 of 10

INSPECTION:

1. Check and clean all foreign material (ex. dirt and grease) from brake pad area.
2. Check clearance between motor and brake pad for recommended minimum
clearance of 1/8” between the brake pad and the rotor (rotate set screw to adjust
caliper if necessary).
3. Check all hydraulic lines for leaks and replace or repair as needed.

Quarterly Maintenance Procedures

The following are general procedures for maintaining the top drive on a quarterly basis.
For specifications on lubricants to use, refer to the ‘Recommended Lubricants & Fluids’
document located in this manual.

LUBRICATION:

1. Grease Drilling Motor Upper and Lower Bearings (5-6 Strokes of Hand-Operated
Grease Gun at each point)

Lower grease port

 GENERAL MAINTENANCE
TD302-01
9 of 10

Upper grease port

2. Drain, flush, and replace Upper Main Thrust Bearing oil.

Drain thrust bearing oil from this port.

 GENERAL MAINTENANCE
TD302-01
10 of 10

INSPECTION:

1. Check and clean all foreign material (ex. dirt and grease) from brake pad area
2. Check clearance between motor and brake pad for recommended minimum
clearance of 1/8” between the brake pad and the rotor (rotate set screw to adjust
caliper if necessary)
3. Check all hydraulic lines for leaks and replace or repair as needed
4. Change Hydraulic Manifold Filter Element
5. Change Upper Main Thrust Bearing Lube System Filter Cartridge
 INSPECTION – PRE & POST JARRING
TD602-00
1 of 1

Jarring a stuck pipe is an intense situation that must be handled with extreme caution,
due to the stress on the equipment. It is important to make certain that the expected
jarring load does not exceed the rating of the Top Drive. The following
recommendations should be carried out each time jarring is to be performed with the
Top Drive.

Pre-Jarring
Important precautions should be taken before jarring stuck pipe. The following is a
recommended list of pre-jarring procedures to be performed in order to have an
understanding of the conditions of the Top Drive prior to jarring.

1. Inspect all fasteners, safety wires, lock nuts, cotter pins, and any other piece of
equipment that may need to be replaced.
2. Check for loose connections (electrical, hydraulic, mudline, etc).
3. Perform a function test on the entire Top Drive to ensure electrical and hydraulic
connections are working properly.
4. Check for fluid leaks.
5. Remove or restrain all loose items, such as the elevators and elevator links.
6. Disconnect (unpin) the counterbalance cylinders from the Top Drive.
7. Visually inspect the welds of the upper body structure and handling ring, as well as
the various brackets, for cracks or damage.

While Jarring
It is important to continuously inspect the Top Drive during jarring operations. Pre-
Jarring procedures 1, 2, 4, & 7 should be performed periodically during the jarring
operations. If any problems are found, correct them immediately before resuming the
jarring operation.

Post-Jarring
Once jarring is finished, inspect the Top Drive again per the Pre-Jarring procedures with
the following exceptions.

1. Reconnect the counterbalance cylinders to the Top Drive.

2. Reinstall or release all removed or restrained items, such as the elevators and
elevator links.
3. Open electrical junction boxes and inspect for loose or broken components.
 SECTION
4
SYSTEM
DESCRIPTION &
OPERATION
 TOP DRIVE SYSTEMS CONTROL
TD401-01
1 of 7

This document provides general descriptions of the proper function for the various
systems that make up the top drive. Since control interface may be different for each
control system, inconsistencies may exist between the description in this document and
the actual control equipment. Precaution and good judgment should always be used
when working with this equipment.

Drill Motor Brake System

The Drill Motor Brake System is used to prevent the drive stem/drill shaft from rotating.
Hydraulic fluid is used to engage the brake and a spring is used to release the brake.

Brake Selector -- 3-position switch (On, Off, Auto), maintain all position.
Brake Lamp ----- Red

• Set the Brake selector to “On”.

o Brake solenoid energizes, and hydraulic fluid flows to the brake cylinders to
close/engage the brake.
o Brake lamp illuminates while brake is engaged.
IF THROTTLE IS INCREASED FROM ZERO WHILE THE BRAKE IS ENGAGED, BRAKE
WILL NOT RELEASE, AND THE MOTOR WILL TORQUE UP AGAINST THE BRAKE
(THE BRAKE LAMP WILL FLASH AND ALARM WILL ENERGIZE SIGNIFYING THAT
THE BRAKE IS STILL ENGAGED).

• Set the Brake selector to “Off”.

o Brake solenoid de-energizes, relieving hydraulic pressure at the solenoid valve.
o The spring in the brake cylinder force the hydraulic fluid back to tank, which
releases the brake.
o Brake lamp de-energizes while brake is released.

• Set the Brake selector to “Auto”.

o When throttle is set to zero, the brake solenoid energizes, and the brake
engages.
o Brake lamp illuminates while brake is engaged.
o When throttle is increased, the brake solenoid de-energizes, and the brake
releases.
o Brake lamp will de-energize while brake is released.
 TOP DRIVE SYSTEMS CONTROL
TD401-01
2 of 7

Stand Jump System

The weight compensator is used to “jump” the stand of pipe out of the box connection.
Hydraulic fluid is used to actuate cylinders, which raise and lower the top drive.
Counterbalance valves are used to hold the cylinders in place when hydraulic pressure
from the solenoid valve is relieved.

Stand Jump Selector --- 3-position switch (Drill, Off, Stand Jump); maintain Off &
Jump positions, spring return Drill position.
Stand Jump Lamp ------ Amber

• Set the Stand Jump selector to “Stand Jump”.

o Stand Jump solenoid energizes for 5 minutes, and hydraulic fluid flows to the
cylinders to raise and hold the top drive.
o The Stand Jump lamp illuminates while the Stand Jump solenoid is energized.
o After the 5 minute time lapse, the Stand Jump solenoid de-energizes, relieving
hydraulic pressure at the solenoid valve.
TOP DRIVE WILL NOT LOWER UNLESS THE WEIGHT/LOAD EXCEEDS THE
COUNTERBALANCE VALVE PRESSURE SETTING.
o The Stand Jump lamp de-energizes when the solenoid de-energizes (lamp is
reset when the selector is set to “Off”)

• Set the Stand Jump selector to “Off”.

o Stand Jump solenoid de-energizes, relieving hydraulic pressure at the solenoid
valve.
IF TOP DRIVE IS IN A RAISED POSITION, IT WILL NOT LOWER UNLESS THE
WEIGHT/LOAD EXCEEDS THE COUNTERBALANCE VALVE PRESSURE SETTING.
o The Stand Jump lamp de-energizes when the solenoid de-energizes.

• Set the Stand Jump selector to “Drill” and hold.

o Stand Jump solenoid energizes, and hydraulic fluid flows to the cylinders to lower
the top drive.
! CAUTION !
SETTING THE STAND JUMP TO “DRILL” WILL CAUSE THE TOP DRIVE TO LOWER.
TOP DRIVE SHOULD BE CLEAR OF THE DRILL PIPE. PERSONNEL SHOULD STAND
CLEAR OF THE TOP DRIVE.
o At full cylinder stroke, the top drive weight/load is passed directly through the
main load path components.
o If selector is released and returns to the “Off” position before reaching full
cylinder stroke, solenoid de-energizes, relieving hydraulic pressure at the
solenoid. The top drive will stop lowering and the counterbalance valves will hold
the top drive in the position it was stopped.
 TOP DRIVE SYSTEMS CONTROL
TD401-01
3 of 7

Handling Ring Rotation & Lock System

The Handling Ring Rotation System is used to position the elevator links and elevator in
preparation for link tilt operations. Hydraulic fluid is used to drive a motor and pinion
gear, which drives the handling ring. The Handling Ring Lock System is used to hold
the handling ring in a set position during drilling, makeup, and breakout operations.
Hydraulic fluid is used to rotate actuators, which engage and disengage the lock. A
counterbalance valve is used to hold the actuators in the Unlock position when hydraulic
pressure at the solenoid valve is relieved.

Handling Ring Lock Selector -- 2-position switch (Lock, Unlock); maintain both
positions.
Handling Ring Selector --------- 3-position switch (Left, Right), spring return to
center from both positions.

• Set Handling Ring Lock selector to “Lock”.

o Handling Ring Lock solenoid energizes, and hydraulic fluid flows to the actuator
to lock and hold the handling ring in place.

• Set Handling Ring Lock selector to “Unlock”.

o Handling Ring Unlock solenoid energizes for 10 seconds, and hydraulic fluid
flows to the actuator to unlock the handling ring lock.
o After the 10 second time lapse, the Unlock solenoid de-energizes, relieving
hydraulic pressure at the solenoid valve. The counterbalance valve holds the
fluid in the actuators, and the lock remains in the unlock position.

• Set Handling Ring selector to “Left” or “Right”, and hold.

o Handling Ring Rotation solenoid energizes, and hydraulic fluid flows to the motor
to rotate the handling ring clockwise for “Left”, and counterclockwise for “Right”.
IF HANDLING RING LOCK SELECTOR IS IN THE “LOCK” POSITION, HANDLING
RING ROTATION SOLENOID WILL NOT ENERGIZE AND HANDLING RING WILL NOT
ROTATE.

• Release the Handling Ring selector and allow it to return to the centered position.
o Handling Ring Rotation solenoid de-energizes, relieving hydraulic pressure at the
solenoid, and the handling ring stops rotating.
 TOP DRIVE SYSTEMS CONTROL
TD401-01
4 of 7

Elevator Link Tilt System

The Elevator Link Tilt System is used to position the elevator links and elevator away
from well center for pipe handling operations. Hydraulic fluid is used to actuate
cylinders connected to the elevator links, which causes the elevator links to pivot about
the hanging point, positioning the elevators outward from well center. Counterbalance
valves are used to hold the cylinders in place when hydraulic pressure from the solenoid
valve is relieved.

Link Tilt Selector ----------- 3-position switch (Drill, Off, Racking), maintain Drill and
Off positions, spring return Racking position.
Link Tilt Float Selector --- 2-position lamp button, spring return.
Link Tilt Float Lamp ------- Amber

• Set Link Tilt selector to “Drill”.

o Link Tilt Drill solenoid energizes, and hydraulic fluid flows to the cylinders to tilt
the links toward the back from well center, or from a forward position.

• Set Link Tilt selector to “Off”.

o Link Tilt solenoids de-energize and hydraulic pressure at the solenoid valve is
relieved, which stops elevator link movement. The counterbalance valve holds
the fluid in the cylinders, and the links remain in the position they were stopped.

• Set Link Tilt selector to “Racking”, and hold.

o Link Tilt Racking solenoid energizes, and hydraulic fluid flows to the cylinders to
tilt the links in the Forward direction.
o If selector is released and returns to the “Off” position, the Link Tilt Racking
solenoid de-energizes, and hydraulic pressure is relieved, which stops forward
movement. The counterbalance valve holds the fluid in the cylinders, and the
links remain in the position they were stopped.

• Set Link Tilt Float push button to “On”.

o Link Tilt solenoids de-energize, and hydraulic pressure at the solenoid valve is
relieved.
o The Link Tilt Float solenoid energizes to bypass the counterbalance valves, and
hydraulic pressure in the cylinders is relieved. Gravity will cause the links to
move to well center.
o Link Tilt Float lamp will illuminate constant if Link Tilt selector is in the “Off”
position. If Link Tilt selector is in the “Drill” position, the lamp will flash.
o If Link Tilt Float button is released and returns to the “Off” position, Link Tilt Float
solenoid will de-energize and fluid will no longer bypass counterbalance valves.
IF THE LINK TILT FLOAT BUTTON RETURNS TO THE “OFF” POSITION AND THE
LINK TILT SELECTOR IS IN ANY POSITION OTHER THAN “OFF”, THE LINKS WILL
TILT TO THE SELECTED POSITION.
 TOP DRIVE SYSTEMS CONTROL
TD401-01
5 of 7

IBOP Actuator System

The IBOP Actuator System is used to open and close the upper IBOP valve. Hydraulic
fluid is used to actuate cylinders, which drive a sleeve that rotates the valve crank for
the open and close function. Counterbalance valves are used to hold the cylinders in
place when hydraulic pressure at the solenoid valve is relieved.

IBOP Selector --- 2-position switch (Open, Close), maintain both positions.
IBOP Lamp ------ Amber

• Set the IBOP selector to “Close”.

o IBOP Close solenoid energizes for 8 seconds, and hydraulic fluid flows to the
cylinders to close the IBOP.
o Pressure switch condition is checked and monitored. Once pressure switch
setting is reached, IBOP lamp flashes for 5 seconds, and then illuminates
constant (lamp is reset by the Open command).
o After the 8 second time lapse, the IBOP Close solenoid de-energizes, relieving
hydraulic pressure at the solenoid valve. The counterbalance valves hold the
fluid in the cylinders, and the IBOP remains in the closed position.

• Set the IBOP selector to “Open”.

o IBOP Open solenoid energizes for 8 seconds, and hydraulic fluid flows to the
cylinders to open the IBOP.
o Pressure switch condition is checked and monitored. Once pressure switch
setting is reached, IBOP lamp flashes for 5 seconds, and then de-energizes.
o After the 8 second time lapse, the IBOP Open solenoid de-energizes, relieving
hydraulic pressure at the solenoid valve.
o IBOP Close solenoid then energizes for 0.3 seconds, and hydraulic fluid flows to
the cylinders to reposition the rollers on the actuator sleeve.
o After the 0.3 second time lapse, the IBOP Close solenoid de-energizes, relieving
hydraulic pressure at the solenoid valve. The counterbalance valves hold the
fluid in the cylinders, and the IBOP remains in the open position.
 TOP DRIVE SYSTEMS CONTROL
TD401-01
6 of 7

Pipe Clamp System (Make/Break Tool Joint)

The Pipe Clamp System is used hold the drill pipe during tool joint make-up and break-
out operations. Hydraulic fluid is used to actuate a cylinder with pipe dies connected to
it, which grips the box connection of the drill pipe and prevents it from rotating while the
drill motor torques the connection.

Grabs On Selector ----------- 2-position mushroom lamp button, maintain both pos.
Motor Operation Selector -- 3-position switch (Drill, Spin, Torque), maintain Drill &
Spin positions, spring return Torque position.
Direction Selector ------------ 3-position switch (Fwd, Off, Rev), maintain all positions.

Spin-In:
• Check that Grabs button is “Off”.
• Check that Brake selector is set to “Off”, to allow the motor to rotate.
• Set Direction selector to “FWD”.
• Set Motor Operation selector to “Spin”, which begins pipe rotation.
o Pipe spins in at 10 RPM and torque limit of 5000 ft-lbs until the motor stalls.

Make Up:
• Check that Make-Up Torque preset value is set to the correct value for the tool joint.
• Once motor stalls from Spin-In, set Grabs button to “On”, which causes the pipe
clamp jaw to close.
• With the Direction selector in the “FWD” position, set Motor Operation selector to
“Torque” and hold while torque increases.
• Once the torque, indicated on the torque meter, increases to the preset value, hold
for 3 seconds, and then release selector and allow it to spring-return to the “Spin”
position.
SPIN SELECTION IS IGNORED ONCE TORQUE OPERATION HAS BEEN INITIATED.
SPIN SELECTION WILL RESET ONCE DIRECTION SELECTOR IS RETURNED TO THE
“OFF” POSITION.
• Set Direction selector to “Off”.
• Set Grabs button to “Off”.
• Prepare for next operation (i.e. drill ahead, trip out, etc.)

Breakout:
• Check that mud pumps are off.
• Check that Brake selector is set to “Off”, to allow the motor to spin.
• Set IBOP selector to “Close”
• Set Direction selector to “REV”.
• Set Stand Jump selector to “Stand Jump”.
• Set Grabs button to “On”.
• Set Motor Operation selector to “Torque” and hold while torque increases.
 TOP DRIVE SYSTEMS CONTROL
TD401-01
7 of 7

Spin Out:
• Once the tool joint breakout occurs, release Motor Operation selector and allow it
to spring-return to the “Spin” position.
o Once motor rotation is detected, the system changes to spin mode and pipe
spins out at 10 RPM and torque limit of 5000 ft-lbs.

• Set Grabs button to “Off”.

• Once tool joint connections separates, the stand jump will raise the top drive away
from the drill pipe.
• Set Direction selector to “Off”, which will stop the drive stem rotation.
• Lift top drive, and set Stand Jump Selector to “Drill”
! CAUTION !
SETTING THE STAND JUMP TO “DRILL” WILL CAUSE THE TOP DRIVE TO LOWER.
TOP DRIVE SHOULD BE CLEAR OF THE DRILL PIPE. PERSONNEL SHOULD STAND
CLEAR OF THE TOP DRIVE.
• Prepare for next operation (i.e. rack pipe, hoist top drive, etc.)
 SECTION
5
INSTALLATION &
COMMISSIONING
 TOP DRIVE TRACK INSTALLATION
TD701-00
1 of 1

Before conducting installation of the track and top drive, refer to the Safety Provisions
document located in the manual. Other provisions not listed may be necessary.
Precaution and good judgment should always be used when working with this
equipment.

The following are general procedures for installing the torque tube/track system and top
drive. Proper initial installation is very critical to the performance of the top drive and
track. Initial installation should be performed by qualified technicians familiar with the
system.

1. Upon initial installation, install the track support padeyes at the water table under
the crown. This can remain installed for subsequent rig-up. Alignment is located
35” from well center.
2. Attach support slings to the traveling block padeye for lifting the track sections.
3. Position top track section so that is can be lifted into the mast.
4. Attach top track section to support slings.
5. Connect each subsequent track section while raising the traveling block and top
track section.
6. Once all track sections have been installed, connect the turnbuckles to the
support slings and to the track support padeyes.
7. Check that the track is straight and adjust as necessary.
8. Install the torque transfer beams and attach to the bottom track section.
9. Install the track stabilizers at girt location and attach to track.
10. Check that the track is still straight and adjust as necessary.
11. Position the top drive w/ dolly so that it can be lifted into the mast.
12. Lift top drive into vertical position and install dolly onto track (removed roller
brackets if necessary).
13. Align top drive to well center.
14. Slowly raise top drive into mast while checking for straightness and any
interference.
15. Install service loop and rotary hose, and again slowly raise top drive while
checking for straightness and interference.

Refer to Parts List Assembly Drawings to identify components.

 IBOP SAFETY CLAMP INSTALLATION
TD702-00
1 of 1

Clamp Installation Procedures

The IBOP Safety Clamps should be installed to provide an added resistance to
accidental makeup or breakout of the IBOP Valve Stack tool joints. The following are
general procedures for installing the IBOP safety clamp.

! IMPORTANT !
Makeup each tool joint connection to the recommended torque prior to
installing the safety clamps. Failure to do so could result in damage to the
clamps and/or the tool joint components.

1. Remove the shipping spacers and screws, if any, provided for protection during
shipping.
2. Verify the lubrication of the supplied locking screw threads, screw head bearing area
and tapers of the inner rings. If necessary, lubricate them with a molybdenum
disulfide grease, such as Molykote Gn Paste.
Note: Do not grease the inside diameter of the inner ring or the outside diameter
of the mating components. These surfaces should be clean and free from
burs or marks to provide the maximum torque resistance.

3. Clean and lightly oil the inner ring bore and the outer diameter of the tool joint
connection.
4. Slide the clamp into place over the tool joint connection so that approximately half of
the inner ring is covering each of the mating tool joint components.
5. Tighten 3 or 4 locking screws that are equally spaced around the diameter of the
clamp to establish a perpendicular position of shrink disc collars relative to the tool
joint components. This step properly seats the collar on the taper of the inner ring.
6. Using a torque wrench, tighten all locking screws gradually and in a circular
sequence around the clamp (not in a diametrically opposite sequence). Several
passes may be required until all screws are torqued to the correct value of 185 ft-lbs.
7. Verify that the screws are completely tight by reapplying the specified torque to each
screw. The gap between the shrink disc collars should be evenly spaced around the
entire clamp.

Clamp Removal Procedures

1. Gradually release the locking screws in a circular sequence around the clamp by
releasing each screw only about one-quarter (1/4) turn each time.
2. Once the screws are loose, slide the clamp off the tool joint connection.
3. After it is removed and before reinstalling, disassemble the clamp, clean and inspect
all parts.
 MECHANICAL COMPLETION
TD703-00
PAGE 1 OF 15

Index
• Fasteners
• HPU Hydraulic Connection
• Top Drive to Dolly
• Stand Jump / Counter Balance Cylinders
• Service Loop Hydraulic Connection
• Top Drive Lube Oil Fill
• Main Power Electrical Connection
• ISO Box
• Link / Elevators
• Top Drive Guards
• Wash Pipe / Swivel Package
• S-Pipe
 MECHANICAL COMPLETION
TD703-00
PAGE 2 OF 15

Installation Safety

• Perform Job Safety Analysis.

• Ensure Electrical Power is “Off”.
• Ensure Hydraulic Power unit is “Off”.
• Ensure all proper Personal Protection Equipment is
Worn.
• Use proper Lifting Equipment.
• Stop all actions if an unsafe condition is identified.
Correct this condition before continuing on.
• Ensure that all shipping material and brackets are
removed prior to operation of Top Drive.
 MECHANICAL COMPLETION
TD703-00
PAGE 3 OF 15

Inspection of all Fasteners

• Before installation, Inspect all fasteners for
tightness and proper locking devices. Check
often, and after each step of the installation
process. This would include cotter pins,
safety wires, etc…

Safety Wires on Bolts

Cotter pins in Place

and secured.
 MECHANICAL COMPLETION
TD703-00
PAGE 4 OF 15

Top Drive Hydraulic Connections

• Ensure Hydraulic power unit is “off” before making
any connections and before correcting any
connector leaks.
• Do Not Tighten Hydraulic Connections under
pressure.
• Ensure Hydraulic power unit is serviced with ISO
32 Fluid and operates correctly.
• Ensure all manual valves are open prior to
energizing unit
• All pressures are preset during “Factory
Acceptance Test.

• Manual Hydraulic Valves Must be Open at Start-up

 MECHANICAL COMPLETION
TD703-00
PAGE 5 OF 15

Top Drive Hydraulic Connections

• Using the proper size wrenches, ensure that
all hydraulic connections are tightened
properly prior to start-up.

• Typical Hydraulic connections

 MECHANICAL COMPLETION
TD703-00
PAGE 6 OF 15

Mount Top Drive to Dolly

• Using proper rigging procedures, remove Top Drive

from the shipping stand.
• Install the dolly to the Top Drive.
• The Top Drive may now be installed in the Derrick.

Top Drive Mounted

to the Shipping Skid

Dolly Assembly
 MECHANICAL COMPLETION
TD703-00
PAGE 7 OF 15

Stand Jump / Counterbalance Cylinders

• Install Stand Jump cylinders as Engineering

Assembly drawings.
• Cylinders will connect the Block to the Bails.
• Install hydraulic lines as per drawings.
• Bleed cylinders before operation.
• To Bleed cylinders turn the HPU on, and pull
appropriate manual valve. Crack the lines until no air
bubbles are visible in the fluid. This operation
requires TWO personnel.

Block

Cylinders

Bails
 MECHANICAL COMPLETION
TD703-00
PAGE 8 OF 15

Service Loop Hydraulic Connections

• Ensure connections are clean and free of
moisture and dirt.
• Connect the ½”, 1” and 1 ¼” return line from
the hydraulic manifold.

1” Inlet Pressure
Connection

1 ¼” Return
Connection

½” Case Drain
Connection

Pictured connected
Properly
 MECHANICAL COMPLETION
TD703-00
PAGE 9 OF 15

Service Unit with Lube Oil

OIL FILL CAP

Between 2 and 3 inch oil level

in cold condition.

• Remove the Oil Cap at the top of the Top Drive and fill with
appropriate Lube oil until the level indicator on the Top Drive
is at between 2” and 3” in “cold condition”. This will allow
adequate space for the expansion of the lube oil during
normal drilling operation.
 MECHANICAL COMPLETION
TD703-00
PAGE 10 OF 15

Main Power Electrical Connections

from Service Loop
• Ensure electrical power is “off” before making all
electrical connections.
• Ensure connections are moisture free and clean.
• Terminate wires using proper electrical
schematics and wiring diagrams.
• NOTE: The phase 3 service line from the service
loop may be black (not blue as pictured).

Phase1 Phase 2 Phase 3

Main Power Connect From Service Loop

• Main power lines will come from the rig service

loop and lugs will terminate in the top drive main
power connections as pictured. Newer models
have quick connect plugs to terminate main power.
 MECHANICAL COMPLETION
TD703-00
PAGE 11 OF 15

ISO Box Electrical Connections

• Ensure electrical power is “off” before making all
electrical connections.
• Ensure connections are moisture free and clean.
• Terminate wires in the ISO Box using proper
electrical schematics and wiring diagrams.

Power “Off” before

Any wires are
Terminated inside
Panel boxes.

ISO Box

• NOTE: Newer Model Top Drive units have

quick connections for 37 and 19 pin connectors.
 MECHANICAL COMPLETION
TD703-00
PAGE 12 OF 15

Installation of Link / Elevators

• Safely rig elevators into position. Remove brackets on handling
ring hang elevators and install brackets. Ensure that cotter
pins are re-installed.
• Before installing clamps, operate link tilt several times. Ensure
that the link tilt operates smoothly and that they are timed
properly.
• Failure to time cylinders correctly will cause damage to the
cylinders.
• Operate links until 12 inches of chrome are showing.
• Pull elevators back with the air hoist and install clamps.
• Elevators should be marred with a chisel or other suitable
means “This prevents the clamp from slipping”
• Install clamps.

12” of chrome at
Install.

Clamps
 MECHANICAL COMPLETION
TD703-00
PAGE 13 OF 15

Installation of Top Drive Guards

• Verify Proper installation of all Top Drive Guards at
this time. This should be done after all hydraulic
mechanical and electrical connections are completed.
• Safety wire must be properly installed on all guard
bolting.

Guards bolted to
Motor Housing.

Properly Installed
Safety Wire.
 MECHANICAL COMPLETION
TD703-00
PAGE 14 OF 15

Wash pipe Assy./Swivel Package

• Ensure washpipe / Swivel package is pre-packed with
proper amount and type of grease before installation.
• Install washpipe / swivel package into gooseneck in location
indicated below.
• Note: The washpipe has “left-handed threads” or CCW.

Wash Pipe
Installed Here.

Side profile
Of Gooseneck.
 MECHANICAL COMPLETION
TD703-00
PAGE 15 OF 15

S-Pipe Install
• Install the S-Pipe onto gooseneck Assembly in
location circled in pictured.
• Install S-pipe clamp / bracket in accordance to
engineering drawings. This will have to be welded in-
place by a qualified / certified rig welder.
• The mud / kelly hose may now be attached to the
S-Pipe.

Install S-pipe to
Gooseneck

S-pipe
 COMMISSIONING
TD704-00
PAGE 1 OF 33

Site Acceptance Function Test

• Motor Brake Commissioning
• Handling Ring Lock Commissioning
• Handling Ring Commissioning
• IBOP Commissioning
• Link Tilt Commissioning
• Torque Tube Commissioning
• Grabs / Torque Wrench Commissioning
• Drive Motor Test Sequence
• Torque Feedback Test
 COMMISSIONING
TD704-00
PAGE 2 OF 33

Site Acceptance Function Test

(Electrical Set-up)
• Commissioning of equipment will commence
after all mechanical, hydraulic, and electrical
installation tasks have been completed.
• Ensure that the variable frequency drive house
“VFD” is set up with all correct drive
parameters. The drive must also
communicate with the Drillers Control Console
and Main PLC properly.
• Ensure that the Top Drive Smart Box is
communicating properly with the Main
PLC and that Correct Top Drive
information is entered in the Human
Machine Interface “HMI”.
• Trained Letourneau Electricians and
Programmers who are part of the
commissioning team will accomplish
these tasks.
 COMMISSIONING
TD704-00
PAGE 3 OF 33

Site Acceptance Function Test

(Mechanical)
• The following steps must be done to ensure
proper mechanical operations of the various
functions of the Top Drive Assembly.
• Note: The Acceptance Function Test must be
Stopped if the following conditions occur during
commissioning.
• -Oil leaks
-Abnormal noises
-Excessive electrical current
-Excessive Equipment Temperatures.
• Apply Proper Safety Steps and Correct any
discrepancy before continuing the Acceptance
Testing.
• Document each action taken to correct problems
on the appropriate Top-Drive Commissioning
Form.
• Trained Letourneau mechanical technicians who
are part of the commissioning team will
accomplish these tasks.
 COMMISSIONING
TD704-00
PAGE 4 OF 33

Motor Brake Commissioning

Function: The function of the motor brake is to
stop the rotation of the drill rotor.

Driller’s
Chair
Consoles

Left control
Console

• From the left side Driller’s control console,

Set the brake selector to the “on” position to
ensure motor brakes are engaged.
 COMMISSIONING
TD704-00
PAGE 5 OF 33

Motor Brake Commissioning

• Set the motor brake to “off” and ensure

brakes are disengaged.
• Check the break pads for proper clearance.
The clearance between the pads and the
break disk should be 0.020” minimum on
each break pad.
• Operate Brake several times ensuring
proper operation

Brake Pad Clearance

Of 0.020” minimum.
 COMMISSIONING
TD704-00
PAGE 6 OF 33

Handling Ring Lock Commissioning

Function: The handling ring lock is a
hydraulically controlled mechanism that locks
the entire bottom section of the top drive in
position.

• The Driller’s control console screen is pictured

above with the handling ring lock or “shot pin”
circled.
 COMMISSIONING
TD704-00
PAGE 7 OF 33

Handling Ring Lock Commissioning

• From the Driller’s control console touch

screen, Set the handling ring lock (indicated
as the shot pin on computer console) to the
“on” position. Ensure that the lock engages.
• Next, Set the handling ring lock to the “off”
position to ensure the lock disengages.
• Cycle the Lock several times ensuring proper
operation.

NOTES:
• Also note that the Top Drive Must be in the
“off” position to operate the “shot pin”
function.
• The lock must engage automatically when the
Top Drive is set to Drill mode, This is true in
both “Forward” or “Reverse” drill direction.
 COMMISSIONING
TD704-00
PAGE 8 OF 33

Handling Ring Commissioning

Function: The handling ring switch rotates the
entire bottom section of the top drive left or right.

• Set the handling ring rotation to the left or

counter-clockwise and hold in position. The
SV6B solenoid Energizes. Count the RPM’s
on the console. A range of 3 to 5 RPM’s is
acceptable.
• Set the handling ring to the right or clockwise
position and hold. A range of 3 to 5 RPM’s is
an acceptable range.
• Release the rotation selector and observe
that the ring rotation stops.

Switch must be held in

Position to rotate the
Bottom section of the
Top Drive.
 COMMISSIONING
TD704-00
PAGE 9 OF 33

IBOP Commissioning
Function: The IBOP switch will open or close the
intermediate Blow Out Preventer, thereby,
stopping the flow of drilling mud.

• Set the IBOP actuator to the “Close” position.

SV3B solenoid will energize. Observe that the
IBOP moves to the close position properly.
• Set the actuator to the “open” position. When
the SV3A solenoid energizes, you will observe
the IBOP move to the Open position.
 COMMISSIONING
TD704-00
PAGE 10 OF 33

IBOP Commissioning

• Ensure that the Rollers are in contact with IBOP

actuator ring in both positions.

Closed position (up)

Roller

Open position (down)

IBOP actuator ring
 COMMISSIONING
TD704-00
PAGE 11 OF 33

LINK TILT Commissioning

Function: The Link Tilt allows the elevators to be
moved. It is often used for grabbing pipe from
the mouse hole or racking back pipe.

• Set Link Tilt selector to “racking” position. Hold

for 2 seconds and release.
• Ensure that the links move forward and remain in
the partial forward position.
• Set the selector to “racking” position again, and
hold. Ensure that the links extend to the full
racking position.
 COMMISSIONING
TD704-00
PAGE 12 OF 33

LINK TILT Commissioning

• Release the selector switch to the “off” position.
Observe that the links are holding in the
racking position.
• Set the selector switch to “drill”. Observe that
the links move to the drilling position.
• Set the selector switch to “off”.
• Ensure links are in the neutral free
hanging position.
• Operate switch again in both positions
observe links travel fully to both positions
• Set switch to racking position ensure links
are in the racking position turn switch to
“off”
 COMMISSIONING
TD704-00
PAGE 13 OF 33

LINK TILT Commissioning

• Set the link tilt float selector to “on” hold for
two seconds and release.
• Observe the links are moving back to the
drillers position.
• Set the link tilt selector switch to “on” and hold.
Observe that the links return to the neutral/free
hanging position.
• Set the link tilt float selector to “off”. Observe
that the links are hanging in the free position.
 COMMISSIONING
TD704-00
PAGE 14 OF 33

Torque Tube
• Place selector valve in opposite position from link
tilt operation.
• Set grabs to “OFF” position on the Driller’s touch
screen.
 COMMISSIONING
TD704-00
PAGE 15 OF 33

Torque Tube
• Place selector valve in opposite position from link
tilt operation.
• Set grabs to “OFF” position
• Operate “Link Tilt” switch and observe Torque
tube move up and down ensure travel is full
length and smooth operation.
 COMMISSIONING
TD704-00
PAGE 16 OF 33

Torque Tube
• Place selector valve in opposite position from link
tilt operation.
• Set grabs to “OFF” position
• Operate “Link Tilt” switch and observe Torque
tube move up and down ensure travel is full
length and smooth operation.

Torque Tube
(retracted)

Torque Tube
(extended)
 COMMISSIONING
TD704-00
PAGE 17 OF 33

Grabs/Torque Wrench Commissioning

• NOTE: A PUP JOINT OR SIMILAR NEEDS TO BE

ATTACHED TO THE SAVER SUB TO PREVENT DAMAGE
TO THE SAVER SUB THREADS.

• Set the grabs selector to “on”. This is located on the Drillers

console screen. Observe that the clamp cylinder extends.
• Confirm the Draw Works cannot be moved at this time
(DWA, DWB, DWAB). This is testing the lockout function.

Extended
 COMMISSIONING
TD704-00
PAGE 18 OF 33

Grabs/Torque Wrench Commissioning

• NOTE: A PUP JOINT OR SIMILAR NEEDS TO BE

ATTACHED TO THE SAVER SUB TO PREVENT DAMAGE
TO THE SAVER SUB THREADS.

Set the Grabs selector to “off” Observe that the clamp cylinder is
retracted and that the grabs are in an open position.
• In “Drill” mode, Turn the throttle to 25% and set the grabs
selector to “on”. Ensure that the clamp cylinder grabs do not
extend. This test ensures that lock-out is working correctly.

Retracted
 COMMISSIONING
TD704-00
PAGE 19 OF 33

Drive Motor Test Sequence

• The following steps must be done to ensure
proper operations of the various functions of the
Top Drive Assembly.
• Note: The Acceptance Function Test must be
Stopped if the following conditions occur during
commissioning.
• -Oil leaks
-Abnormal noises
-Excessive electrical current
-Excessive Equipment Temperatures.
• Apply Proper Safety Steps and Correct any
discrepancy before continuing the Acceptance
Testing.
• Document each action taken to correct problems
on the appropriate Top-Drive Commissioning
Form.
• Trained Letourneau mechanical technicians who
are part of the commissioning team will
accomplish these tasks.
 COMMISSIONING
TD704-00
PAGE 20 OF 33

Drive Motor Test Sequence

• Ensure motor brake is operating correctly prior to
starting the drive motor test.

• Electrical technicians must check that the encoders are

properly wired and feedback is correct at this time.
• Confirm RTD temperature devices are reading
correctly. These are located on the lower left corner of
the driller’s screen.
 COMMISSIONING
TD704-00
PAGE 21 OF 33

Drive Motor Test Sequence

• Put the control switches into spin and forward
positions.

• Confirm that the blowers have started and magnetizing

current is available.

Blower
Indicator
 COMMISSIONING
TD704-00
PAGE 22 OF 33

Drive Motor Test Sequence

• Observe that the rotation of the Top Drive is correct,
operating smoothly and that no more than magnetizing
current is being used. The RPM indicator will show
approximately 26 RPM’s at this time.

RPM
Indicator

• Commissioning electricians must confirm the correct

operation of both encoders at this time. Encoder
reversals shall be ZERO.
 COMMISSIONING
TD704-00
PAGE 23 OF 33

Drive Motor Test Sequence

• Change the direction of the Drill switch to “Reverse”.
• Observe the operation of the Top Drive in the opposite
direction at the same speed as the “Forward direction
just tested (approximately 26 RPM).

RPM
Indicator

• Commissioning electricians must confirm the correct

operation of both encoders at this time. Encoder
reversals shall be ZERO.
 COMMISSIONING
TD704-00
PAGE 24 OF 33

Drive Motor Test Sequence

• Place the control switch on the “Torque” position and
the “Direction” to the forward position.

• Place the control switch on the “Torque” position and

the “Direction” to the forward position.

Zero Position

• Confirm that the Variable Frequency Drive House

“VFD” is running, and that magnetizing current is
available. The Top Drive does not rotate at this time
without torque applied.
 COMMISSIONING
TD704-00
PAGE 25 OF 33

Drive Motor Test Sequence

• Turn the Torque control one quarter turn.
• Observe the Top Drive rotating in the Forward Direction.

¼” Turn Position

• Turn the Torque control slowly to one full turn.

• Confirm in the VFD the torque reference coming in from
the communication network change at the same rate to
full reference.

Full Turn Position

 COMMISSIONING
TD704-00
PAGE 26 OF 33

Drive Motor Test Sequence

• Turn the torque control back to zero position. Observe
that the Top Drive coasts to a complete stop.
• Change directions to drill direction to reverse.

• Repeat the torque control sequence confirming that the

Top Drive will rotate in reverse properly; ¼ Turn position,
Full Turn position and back to Zero position again.
• Confirm in the VFD that the Torque reference changes in
each position.

Torque
Indicator
 COMMISSIONING
TD704-00
PAGE 27 OF 33

Drive Motor Test Sequence

• Place control switched in the “Drill” and “Forward”
Positions. Place Torque control in the zero position.
Increase drill speed reference to One quarter turn.
• Confirm the VFD is running, and magnetizing current is
available, and the Top Drive does not rotate at this time.
• Confirm correct readings on the Drillers Control console.
 COMMISSIONING
TD704-00
PAGE 28 OF 33

Drive Motor Test Sequence

• Turn the torque control one quarter turn , confirm correct
readings on the Drillers Control consol.
• Observe Top drive rotating in the forward direction and
operating smoothly with no abnormal noises.

• Confirm that the feedback in the VFD speed feedback

equals the speed reference.
• Confirm that the readings on the Drillers control console
display are correct.
• Run the Top Drive at this speed for Three hours.
• Monitor temperatures and listen for abnormal noises, Top
Drive Operates smoothly.
 COMMISSIONING
TD704-00
PAGE 29 OF 33

Drive Motor Test Sequence

• Increase drill speed to One Half of a turn, Observe Top Drive
speed increase.
• Confirm the feedback in the VFD speed feedback is equals
the speed reference.
• Monitor temperatures and listen for abnormal noises, Top
Drive Operates smoothly.

• Confirm that the readings on the Drillers control console

display are correct.
• Run the Top Drive at this speed for Three hours.
• Monitor temperatures and listen for abnormal noises, Top
Drive Operates smoothly.
 COMMISSIONING
TD704-00
PAGE 30 OF 33

Drive Motor Test Sequence

• Increase drill speed to three quarters of a turn, Observe Top
Drive speed increase.
• Confirm the feedback in the VFD speed feedback is equals
the speed reference.
• Monitor temperatures and listen for abnormal noises, Top
Drive Operates smoothly.

• Confirm that the readings on the Drillers control console

display are correct.
• Run the Top Drive at this speed for Three hours.
• Monitor temperatures and listen for abnormal noises, Top
Drive Operates smoothly.
 COMMISSIONING
TD704-00
PAGE 31 OF 33

Drive Motor Test Sequence

• Increase drill speed to one full turn, Observe Top Drive speed
increase.
• Confirm the feedback in the VFD speed feedback is equals
the speed reference.
• Monitor temperatures and listen for abnormal noises, Top
Drive Operates smoothly.

• Confirm that the readings on the Drillers control console

display are correct.
• Run the Top Drive at this speed for Three hours.
• Monitor temperatures and listen for abnormal noises, Top
Drive Operates smoothly.
• After three hours, slowly reduce the top drive speed to
ZERO and switch the top drive switch to the “Off” position.
The Commissioning Drive Motor test is now complete.
 COMMISSIONING
TD704-00
PAGE 32 OF 33

Torque Feedback Test

• With the Switches in the “OFF” position connect Tongs and lines to the
sub saver.
• Confirm the spin torque equals the transducer pull and meets or exceeds
customer requirements.
• Place Control switches in “Spin” and “Forward” Place Torque in Zero
Position.
• Slowly increase “Torque” Control until Drillers Control Consol displays
5000ft/lbs of torque, confirm reading with tong line pull indicator.
• Slowly increase “Torque” Control until Drillers Control Consol displays
10000ft/lbs of torque, confirm reading with tong line pull indicator.
• Slowly increase “Torque” Control until Drillers Control Consol displays
17500ft/lbs of torque, confirm reading with tong line pull indicator.
• Slowly increase “Torque” Control until Drillers Control Consol displays
25000ft/lbs of torque, confirm reading with tong line pull indicator.
• Slowly increase “Torque” Control until Drillers Control Consol displays
32500ft/lbs of torque, confirm reading with tong line pull indicator.
• Slowly increase “Torque” Control until Drillers Control Consol displays
40000ft/lbs of torque, confirm reading with tong line pull indicator.

Drill Torque
Feedback
 COMMISSIONING
TD704-00
PAGE 33 OF 33

Post Commissioning of Top Drive

• Install all necessary auxiliary equipment to

begin your drilling process.
• Perform all necessary inspections
and Safety measures.
• Commissioning of the Top Drive is now
completed and you are ready to begin your
drilling process.
5-1
Site Acceptance Function Test Letourneau Technologies Top Drive

Serial Number
Customer
Type
Date

Once all applicable items for the Customer Site Acceptance have been
tested and confirmed, this completed and signed record shall be given to the Product Support Manager.
A copy will be left with the customer.

The following tasks should be completed prior to performing the function tests.
After each task is completed, the person performing the task shall initial in the space provided.

Pass
Inspect all hose connections for loose fittings
Inspect all electrical connections for tightness
Inspect for loose or missing fasteners
Inspect all fasteners for appropriate locking device such as safety wire, cotter pins etc
Apply proper amount of grease to all fittings.
Check that hydraulic filter located on the TD is fitted with appropriate filter element
Check the condition of the HPU hydraulic filter element, and check HPU fluid level
Connect the hydraulic supply, return and drain lines to the TD
Ensure that all manual valves for hydraulic supply, return and drain are open.
Connect electrical supply and control cables to the TD
Ensure that all electrical control switches are on the "off" or default position before applying electrical power
Once hydraulic fluid from the HPU is applied to the TD, check complete system for leaks, and recheck HPU level
All pressure control valves should be set prior to performing the function test.
Ensure that VFD is set up with all the correct drive parameters, and that drive is communicating with DCC and main PLC
Ensure that TD smart box is communicating with main plc.
Ensure that correct TD information is entered in the HMI.

The following check list should be used to verify the proper mechanical operation for the various functions of the TD.
The test shall be stopped due to an oil leak, abnormal noise, excessive current or excessive temperature.
After each function is tested and confirmed, the person performing the test shall initial in the space provided.

MOTOR BRAKE
Set the brake selector to "on"
Check that the motor brakes engage
Set the motor brake to "off"
Check that the motor brakes disengage and check for proper clearances between pads and disk.

HANDLING RING LOCK

Set the handling ring lock selector to "on"
Check that the handling ring lock engages
Set the handling ring lock to "off"
Check that the handling ring lock disengages
Set the handling ring rotation selector the to "left" and hold
Observe that the handling ring rotates to the left (3rpm)
Release the handling ring rotation selector to the center position
Observe that the handling ring stops rotating
Set the handling ring rotation selector to the "right" and hold
Observe that the handling rotates to the right (same rpm as to the left)
Release the handling ring rotation selector to the center position
Observe that the handling ring stops rotating

IBOP ACTUATOR
Set the IBOP selector to "close"
Check that IBOP actuator moves to the closed position
Set the IBOP selector to "open"
Check that IBOP actuator moves to the open position
Pulse the IBOP selector to "close" to raise rollers up to actuator flange.
Check that IBOP actuator rollers are in contact with actuator flange
 Confirm that the associated IBOP indication in the console indicated the correct position
and flickers during valve movement.

LINK TILT
Set the Link Tilt selector to "racking", hold for two seconds and release
Check that links move forward, stop, and remain in the partial forward position.
Set the Link Tilt selector to "racking" and hold
Check the links move forward fully to the racking position
Release the Link Tilt to the off position
Observe that links remain in the racking position
Set the Link Tilt selector to "drill"
Check that links move from the racking position to the drilling position
Set the Link Tilt selector to "off" position
Check that the links move to the neutral / free hanging position
Set the Link Tilt selector to "racking" and hold
Check that links again move to the forward fully racking position
Release the Link Tilt to the off position
Observe that links remain in the racking position
Set the link tilt float selector to "on", half for 2 seconds and release
Check that the links begin to move backward, stop, and remain in the partial forward position
Set the link tilt float selector to "on" and hold, while the links are still in the forward position
Check that the links move to the neutral / free hanging position
Release the Link Tilt Float selector to the off position
Check that links remain to the neutral / free hanging position

TORQUE TUBE
Move selector switch to opposite position
Operate Link Tilt switch in both directions observe Torque Tube fully extend and retract.
Observe smooth operation

GRABS / TORQUE WRENCH

!!!!!!!! A PUP JOINT OR SIMILAR NEEDS TO BE ATTACHED TO THE SAVER SUB TO PREVENT
DAMAGE TO THE SAVER SUB THREADS !!!!!!!!!!!
Set the grabs selector to "on"
Check that the clamp cylinder extends
Confirm that DW cannot be moved at this time, (DWA, DWB, DWAB)
Set the grabs selector to "off"
Check that the clamp cylinder retracts
Crank the throttle to 25%, and set the grabs selector to "on"
Confirm that the clamp cylinder DOES NOT extend.

The following check list should be used to verify the proper operation of the TD motor, encoders, TQ control
and electrical drilling operations. After each task is completed the person performing the task shall initial in
the space provided. The test shall be stopped due to an oil leak, abnormal noise, excessive current or excessive temperature.
Once the issue is remedied the test should be restarted.

DRIVE / MOTOR RUN TESTS

Adjust and flush the drive motor disc brake system
Check the motor cooling blowers for correct rotation
Check the encoders for correct wiring (shielding, power supply voltage, PPR).
Confirm that the RED readouts are reading correctly

Assign the TD
Confirm that the TD blowers will start and that the VFD will be started as well (magnetizing current available)
Put control switch in spin and forward.
Confirm that the TD rotates fwd, that it runs smoothly and that not more current is used other
than magnetizing current.
Confirm correct operation of both TD encoders. Encoder reversals shall be 0.
Change direction to reverse.
Confirm that TD will rotate in reverse direction at the same speed as the forward direction.
Confirm correct operation of both TD encoders. Encoder reversals shall be 0.
Put the control switch in "torque" and forward, and put the Make up torque pot to zero pisition..
Confirm that the VFD is running, magnetizing current is available, but TD does not rotate.
Turn TQ control pot a quarter turn.
Confirm that TD will rotate in forward direction.
Turn TQ control pot slowly to full turn.
Confirm in the VFD that the TQ reference coming in from the comms networks, also change at the same rate to full reference
Turn the TQ control pot to zero position.
Confirm that the TD will coast to a stop.
Change direction to reverse.
Confirm that the TD will rotate in reverse and that the TQ control pot has no affect on the TD operation.
Confirm in the VFD that the TQ reference is changed to full.
Put the control switch in "drill" and "fwd". Put drill TQ pot in zero position
Crank drill speed reference pot a quarter turn.
Confirm that the VFD is running, magnetizing current is available, but TD does not rotate.
Turn drill TQ pot a quarter turn.
Confirm that the HMI displays the correct TQ readings.
Confirm that the TD will rotate in forward direction, that the motor runs smoothly and that no abnormal
noises come from out of the TD.
Confirm in VFD that the speed feedback equals the speed reference.
Confirm that the Readings on the HMI screens, display the correct speed.
Run TD at this speed for 3 hours.
Confirm that all bearings are not getting hot and that motor does not start making any abnormal noises.
Turn TD drill speed half a turn.
Confirm that the TD will rotate in forward direction, that the motor runs smoothly and that no abnormal
noises come from out of the TD.
Confirm in VFD that the speed feedback equals the speed reference.
Confirm that the Readings on the HMI screens, display the correct speed.
Run TD at this speed for 3 hours.
Confirm that all bearings are not getting hot and that motor does not start making any abnormal noises.
Turn TD drill speed 3/4 turn.
Confirm that the TD will rotate in forward direction, that the motor runs smoothly and that no abnormal
noises come from out of the TD.
Confirm in VFD that the speed feedback equals the speed reference.
Confirm that the Readings on the HMI screens, display the correct speed.
Run TD at this speed for 3 hours.
Confirm that all bearings are not getting hot and that motor does not start making any abnormal noises.
Turn TD drill speed 3/4 turn.
Confirm that the TD will rotate in forward direction, that the motor runs smoothly and that no abnormal
noises come from out of the TD.
Confirm in VFD that the speed feedback equals the speed reference.
Confirm that the Readings on the HMI screens, display the correct speed.
Run TD at this speed for 3 hours.
Confirm that all bearings are not getting hot and that motor does not start making any abnormal noises.
Turn TD drill speed 1 turn.
Confirm that the TD will rotate in forward direction, that the motor runs smoothly and that no abnormal
noises come from out of the TD.
Confirm in VFD that the speed feedback equals the speed reference, and that this speed equals the full speed as required.
Confirm that the Readings on the HMI screens, display the correct speed.
Run TD at this speed for 3 hours.
Confirm that all bearings are not getting hot and that motor does not start making any abnormal noises.
Switch off TD and connect tongs and tong line pull transducer
Put TD in "spin" and forward.
Confirm that spin torque on HMI equals the transducer pull, and equals customer requirements.
Put TD in "torque" and forward and put TQ pot in zero position.
Slowly move torque pot until HMI screen displays 5000ft/lbs of torque
Confirm that tong line pull indication confirms this reading.
Slowly move torque pot until HMI screen displays 10000ft/lbs of torque
Confirm that tong line pull indication confirms this reading.
Slowly move torque pot until HMI screen displays 17500ft/lbs of torque
Confirm that tong line pull indication confirms this reading.
Slowly move torque pot until HMI screen displays 25000ft/lbs of torque
Confirm that tong line pull indication confirms this reading.
Slowly move torque pot until HMI screen displays 32500ft/lbs of torque
Confirm that tong line pull indication confirms this reading.
Slowly move torque pot until HMI screen displays 40000ft/lbs of torque
Confirm that tong line pull indication confirms this reading.
For approval:
Service Technician's)
Customer
 DECOMMISSIONING
TD710-00
PAGE 1 OF 6

Removal of Top Drive from Rig

• Remove lube oil feed lines. Place lines in suitable container
and energize lube oil pump to purge oil from the Bonnet.
• Rotate handling ring until it faces the V door. Set the Handling
Ring Locks.
• Disconnect links and remove elevators.

• Turn Hydraulic Pressure Unit (HPU) “off” and disconnect

hydraulic connections from the Top Drive.
• Turn the Main Power “off” and remove the 37 and 19 pin
connections from the ISO Box.
• Remove the Main Electrical Power Lines.
• The Top Drive is now ready to be removed following Proper
and Safe Rig procedures.
 DECOMMISSIONING
TD710-00
PAGE 2 OF 6

Storage and Preservation

• The Top Drive is shipped from the factory with necessary
preservation suitable for transportation to the
commissioning site.
• Application of proper preservation schedules should be
followed when storing the Top Drive for an extended
period of time. This will ensure that corrosion is kept to a
minimum and the unit will be maintained in sufficient
operating condition.
• The storage location should be indoors or under cover
when ever possible. Avoid areas with excessive amounts
of dust, salt spray, and rapid temperature changes.
• Rapid temperature changes cause condensation. The use
of desiccants and heaters (climate control devices), such
as explosion proof heaters and strip heaters will minimize
the effects of high humidity and rapid temperature
changes.
• Follow all Safety and Environmental procedures when
Applying preservation compounds and materials.
• Store unit on shipping skid to minimize mechanical stress
on Top Drive components.

Top Drive Properly Stored on Shipping Skid

 DECOMMISSIONING
TD710-00
PAGE 3 OF 6

Storage and Preservation

• Clean the unit prior to storage and pay special attention to
apply the proper cleaning methods to each area and apply
necessary method to minimize water intrusion into vent
covers and electrical boxes.
• Do not use petroleum solvents on electrical boxes or
components.
• Follow all Safety and Environmental procedures when
Applying preservation compounds and materials.
• Cap and plug all lines and connections.
• Seal all vents to prevent moisture intrusion.

Cap Hydraulic Connections

Bull Plug
Gooseneck
 DECOMMISSIONING
TD710-00
PAGE 4 OF 6

Storage and Preservation

• Coat all metal surfaces with a corrosion preventative
compound suitable for the environment.
• NOTE: Do Not apply preservation compound to the brake
disc.
• Refer to storage preservation schedule for periodical
preservation checks.

Grease all exposed

Metal surfaces.
 DECOMMISSIONING
TD710-00
PAGE 5 OF 6

PRESERVATION 6 12 26
SCHEDULE INITIAL WEEKS WEEKS WEEKS

Clean Unit to remove mud,

grease, dirt, and other
corrosive materials. Remove
rust from metal surfaces and
coat with corrosive resistant
primer.
Grease all fittings.

Lightly coat electrical

connections with a dielectric
grease. Place desiccant
packs inside main power and
ISO Box. Seal as necessary
to prevent water intrusion.
Remove wash pipe and S-
pipe. Clean and coat threads
with rust inhibiting grease.
Install covers, and store
separately.
Install and apply caps, plugs
& seals to all lines and
openings ensuring a tight
seal.
Coat all exposed bare metal
and moving parts with a
corrosion preventive
compound (grease, dry film
types). Remove guards as
needed, ensuring a full even
coat. Reinstall guards.
If possible, rotate unit
periodically to prevent
staining or etching.
 DECOMMISSIONING
TD710-00
PAGE 6 OF 6

Storage Removal Procedure

• Remove all protective covers, plugs, caps and seals.
• Inspect for corrosion and make necessary repairs.
• Change all oil and hydraulic filters.
• Inspect all hoses and seals. Repair and replace if
necessary.
• Using a qualified electrician, test motor windings using
approved methods for drying the Top Drive Motor.
• Remove all preservation compounds and service the Top
Drive with recommended grease and lubricants.
• Prior to starting and operating the Top Drive, Inspect and
check each component to verify that all are functioning
properly.
• Operate the Top Drive slowly for a “run In” period to verify
that there is no hidden damage. This should be done for
a minimum of 2 hours.
SECTION
6
PRODUCT
BULLETINS
 PRODUCT BULLETIN
TD801-00
Aug-07

SUBJECT: Service Loop Cable Support Grips

PERTAINS: All LTI 500T Top Drives delivered prior to mid-2007

ISSUE: The support cable grips loosen allowing cables to slip due to cable
movement as the drag chain moves up and down in the derrick.

All drag chain style service loops should be modified by securing the cable support grips
using standard electrical tape as shown in the photo below. The electrical tape will help
prevent the cables from working the grips loose during normal raising and lowering of
the Top Drive and Service Loop. If service loop is spooled on a reel, grips will need to
be loosened on one end to allow the cables to move naturally as it is being spooled.

Page 1 of 1
 PRODUCT BULLETIN
TD802-00
Aug-07

SUBJECT: Top Drive Bail Bushings

PERTAINS: All LTI 500T Top Drives with Split Block and original Bail Bushings prior to
mid-2007

ISSUE: The shape of the ID in the block adapter links is contoured while the OD of
the original bail bushing is straight along the centerline axis. This causes
the bushing to bind to the bail pin, which causes the bail pin to rotate and
damage the bail pin retainer pin.

A product improvement is available that will better match the bushing and bail, while
retaining the original design intention. In addition, a new bail pin retainer is included to
better restrain the bail pin from rotating. Parts required are included in the retrofit kit
(LTI P/N 330-0803). In addition, the pin bore in the block adapter links will need to be
machined to a straight bore with a 6.375” / 6.373” inside diameter.

Page 1 of 1
 PRODUCT BULLETIN
TD803-00
Aug-07

SUBJECT: Top Drive Encoders

PERTAINS: All LTI 500T Top Drives with Hollow Shaft Encoders

ISSUE: Encoders are located inside the brake housing, making it difficult to
access. In addition, signal interference could possibly occur due to the
low voltage signaling used by the encoders.

A product improvement is available to locate new encoders to the outside of the body
structure. The new encoders are explosion proof, allowing a higher voltage signal to be
used, which is less susceptible to electrical signal interference. Modifications to the
electrical system are required, which should be performed by an authorized LTI Service
Technician. The mounting bracket can be used as a template for drilling and tapping
the holes in the body structure that are used to support the assembly. DO NOT WELD
TO THE BODY STRUCTURE. Parts required are:

ITEM QTY P/N DESCRIPTION

1 1 330-0496 ASSEMBLY-ENCODER
2 1 330-0592 SHAFT-ENCODER
3 1 330-0155 GEAR-ENCODER DRIVE
4 2 330-0580 KEY-3/8 X 3/8 X 1.75

Page 1 of 1
 PRODUCT BULLETIN
TD804-00
Aug-07

SUBJECT: IBOP Actuator Stabilizer

PERTAINS: All LTI 500T Top Drives delivered prior to mid-2007

ISSUE: The actuator cylinders tend to move outward during the actuation of the
sleeve which may cause premature wear on the sleeve.

A product improvement is available to stabilize the cylinders to keep them from moving
outward during actuation. Parts required are:

ITEM QTY P/N DESCRIPTION

1 2 330-0736 BRACKET-ACTUATOR IBOP
2 4 115-0229 BOLT-HX .375-16NC 4.75 G8 DH DT
3 4 500-1241 NUT-LOCK, NYL HX .375 NC G8
4 4 115-0228 PIN-COTTER, 3/32 X 1.00 ZINC
5 2 FT EW109 SAFETY WIRE, .047 SS

Page 1 of 1
 PRODUCT BULLETIN
TD805-00
Sep-07

SUBJECT: Top Drive Guard Door Hinges

PERTAINS: All LTI 500T Top Drives delivered prior to mid-2007 which have hinged
doors integrated into the guards

ISSUE: ! WARNING !
A safety hazard exists that should be address at the earliest convenience.
The hinges for some doors located on the guards around the drill motor
may have been manufactured incorrectly, which could allow the door to
separate from the guard. If the door is not secured, it could then fall and
possibly cause damage to other equipment or personal injury or death.

All top drives which have hinged doors integrated into the guards should be checked for
proper hinge orientation. Each door should have at least two hinges on each end
oriented opposite each other, as shown below, so that the door cannot separate from
the guard. If a hinge is found to be oriented incorrectly, one hinge should be removed,
re-oriented, and re-welded so that the door cannot separate from the guard. If existing
hinge cannot be reused, a new one can be ordered with part number 108-1094.

NOTE THE WELD

ORIENTATION ON
OPPOSING HINGES

Page 1 of 1
 PRODUCT BULLETIN
TD806-00
Sep-07

SUBJECT: Top Drive Upper IBOP Valve & Crank Assembly.

PERTAINS: All LTI 500T Top Drives delivered prior to mid-2007 which have original
valve and crank assembly components.

ISSUE: ! WARNING !
A safety hazard exists that should be address at the earliest convenience.
The IBOP Valve stems for some valves may have been manufactured
incorrectly, which could keep the crank assembly from seating correctly
due to interference with the retainer on the crank assembly. If interference
is present, the retainer could work loose and allow part of the crank
assembly to slide out and fall, which could possibly cause damage to
other equipment or personal injury.

All top drive upper IBOP valves should be checked for correct stem height. In addition,
each crank assembly should be checked for new inverted style retainer ring, and should
be installed to the IBOP valve with Nord-Lock washers. The parts required to correct
IBOP valve (left & right stems) and crank assemblies (retainers & washers), are
included in retrofit kit part number 330-1042. The following should be performed to
check and, if applicable, correct the components.

PROCEDURE:

1. REMOVE BOTH VALVE CRANK ASSEMBLIES (NOTE: SEE STEP 8 FOR CRANK
ASSEMBLY CHANGES)
2. REMOVE ACTUATOR SLEEVE.
3. MEASURE DISTANCE FROM VALVE O.D. TO THE FACE OF THE STEM. IF
DISTANCE IS LESS THAN .427 INCHES, THAN STEM IS TOO TALL AND MUST BE
REPLACED.
4. IF STEM REPLACEMENT IS REQUIRED, CONTINUE BY REMOVING IBOP VALVE.
5. REPLACE LEFT & RIGHT STEMS, PER MANUFACTURER’S INSTRUCTIONS GIVEN
IN THE DOCUMENT TD901, LOCATED IN TOP DRIVE MANUAL.
6. ONCE VALVE IS RE-ASSEMBLED, RE-INSTALL ON TOP DRIVE.
7. RE-INSTALL ACTUATOR SLEEVE.
8. WHILE CRANK ASSEMBLIES ARE REMOVED, REMOVE EXISTING RETAINER AND
REPLACE WITH NEW EXTERNAL INVERTED SNAP RING.
9. RE-INSTALL CRANK ASSEMBLIES WITH THE NORD-LOCK WASHERS AND
EXISTING BOLTS. TORQUE BOLTS TO 33 FT-LBS.

Refer to Figures on sheet 2.

Page 1 of 2
 PRODUCT BULLETIN
TD806-00
Sep-07

Page 2 of 2
 PRODUCT BULLETIN
TD807-00
Sep-07

SUBJECT: Top Drive Upper IBOP Actuator Crank Assembly Cover.

PERTAINS: All LTI 500T Top Drives delivered prior to late-2007 which have original
actuator sleeve.

ISSUE: ! WARNING !
A safety hazard may exist if IBOP Actuator Crank Assembly retainer fails
and assembly is allowed to slide apart, which could possibly cause
damage to other equipment or personal injury.

A product safety improvement is available to add crank assembly covers to the actuator
sleeve to help retain crank assembly component in the event that the retainer fails. The
parts required to add the cover are included in retrofit kit part number 330-1034. In
addition, modifications to the actuator sleeve are shown on drawing 330-1034.

Page 1 of 1
 SECTION
7
OUTSOURCED
PRODUCT MANUALS
PSVFA.../...-5
PSVFA.../...-5

HAWE Hydraulik München © 2003, page 1 of 9, (CD3 Juni 2005)

PSVFA.../...-5
PSVFA.../...-5
Part No. Qty. Item Nomenclature Drawing No. Add. Information
6900 601301 1 F; D WN 1 D-G 12 PLANT SP 7470 000 C acc. D 7470A/1; max. torque 4Nm
6900 601302 1 F; D WN 1 D-G 24 PLANT SP 7470 000 C acc. D 7470A/1; max. torque 4Nm
6900 602701 1 F; D WN 1 F-G 12 LANT SP 7470 000 D acc. D 7470A/1; max. torque 4Nm
6900 602702 1 F; D WN 1 F-G 24 LANT SP 7470 000 D acc. D 7470A/1; max. torque 4Nm
2. DRUCKSTUFE FÜR F...;
1 2. pressure step for WN 1 SK 7470 104
WN 1 D...
PA;
PA;PB;PD 1 PB; PA;PB;PD
PC; PD
100-10
6800 665700 1 DS 7700-F 51 SEAL KIT FOR PSLF SIZE 5 CONNECTION BLOCK
9
3408 500200 1 1 CONTROLLER BODY 7807 451
6005 029300 4 2 SKT.-HEAD SCREW ISO 4762 10X60 8.8 A2K
6393 310200 1 3 CARBURETOR JET 4X0,6
6005 025900 1 4 SKT.-HEAD SCREW ISO 4762 8X10 A 2-70
6095 110100 2 5 COPPER RING SHAPE A DIN 7603 4X8X1
6000 422700 2 6 HEXAGON HEAD SCREW
3037 419900 1 7 VALVE CONE 7700 057/1
3008 459600 1 8 SPRING 7700 051
3014 448000 1 9 SCREW 8X20,5 9 S MN 28 K 7700 058
6065 540700 1 10 HEXAGON NUT TURNED SW 12 SHAPE B WITH SW 12
3604 405200 1 11 CAP NUT 7700 054
3032 434000 1 12 BOLT 7807 021
3008 470200 1 13 SPRING 7807 015
3036 426400 1 14 CONTROLLER PISTON SECTION 7807 019
4002 403300 1 15 FLANGE 7807 017
6005 026500 3 16 SKT.-HEAD SCREW
3004 433200 1 17 PLUG 7625 110 complete with seals part 103, 105
3014 447200 1 18 SCREW 13,16X3,5 9 S MN 28 K 7625 172 complete with seal part 104; max. torque 15Nm
6800 325000 1 19 7625 200 A with coding 1; max. torque 15Nm
6800 344600 1 19 AM 1 D-40 FOR PSL 7625 200 C with coding 2; max. torque 15Nm
3013 409600 1 20 TAPPED PLUG 10X6 9 S MN 28 K 7778 036
6007 019600 1 21 SKT.-HEAD SCREW ISO 1207 4X4 4.8 A2K
6800 819200 1 22 SEQUENCE AND DAMPENING VALVE COMPLETE PSL 3 & 5 7778 301 with coding S

HAWE Hydraulik München © 2003, page 2 of 9, (CD3 Juni 2005)

PSVFA.../...-5
PSVFA.../...-5
Part No. Qty. Item Nomenclature Drawing No. Add. Information
3014 421800 1 23 SCREW 10X15 9 S MN 28 K 7778 062 with coding B
3047 408800 1 24 GAP TYPE FILTER 7778 048/1
6013 250600 1 25 TAPPED PLUG COMPLETE WITH ELASTIC SEAL G 1/4 A NBR ST

HAWE Hydraulik München © 2003, page 3 of 9, (CD3 Juni 2005)

PSVFA.../...-5
DS 7700-F 51 SEAL KIT FOR PSLF SIZE 5 CONNECTION BLOCK

HAWE Hydraulik München © 2003, page 8 of 9, (CD3 Juni 2005)

PSVFA.../...-5
DS 7700-F 51 SEAL KIT FOR PSLF SIZE 5 CONNECTION BLOCK
Part No. Qty. Item Nomenclature Drawing No. Add. Information
6096 408700 5 100 Since 12/2004; Individual not available!
6096 915000 5 100 O-RING 4,47X1,78 HNBR 90 SH RED SPOT Individual not available!
6096 435000 2 101 Since 12/2004; Individual not available!
6096 918500 2 101 O-RING 17,12X2,62 HNBR 90 SH RED SPOT Individual not available!
6095 120900 1 102 COPPER RING SHAPE A DIN 7603 10X14X1,5 Individual not available!
4065 411000 1 103 SEAL RING 8,3X11X1,15 TEFLON 7625 109/1 Individual not available!
M 14X1,5 ODER G
3401 411100 1 104 SEAL G 1/4" DRV 100116-NB 650 NBR Individual not available!
1/4"
6096 927300 1 105 O-RING 9X1,5 NBR 90 SH Individual not available!
6096 421400 1 106 Since 12/2004; Individual not available!
6096 812100 1 106 O-RING 21,89X2,62 HNBR 90 SH RED SPOT Individual not available!
6095 129800 3 107 COPPER RING DIN 7603 8X12X2 Individual not available!
6096 916300 3 108 O-RING 6X1,5 NBR 90 SH Individual not available!
3001 458400 3 109 RING 4,2X6,4X1,2 35 S 20 K 6540 049 Individual not available!

HAWE Hydraulik München © 2003, page 9 of 9, (CD3 Juni 2005)

PSL(V)F-5-/7 SAE
PSL(V)F-5-/7 SAE

HAWE Hydraulik München © 2003, page 1 of 4, (CD3 Juni 2005)

PSL(V)F-5-/7 SAE
PSL(V)F-5-/7 SAE
Part No. Qty. Item Nomenclature Drawing No. Add. Information
3407 425500 1 1 CONNECTION PLATE SAE 7805 421
6013 250600 4 2 TAPPED PLUG COMPLETE WITH ELASTIC SEAL G 1/4 A NBR ST
173-17
6800 892700 1
4

HAWE Hydraulik München © 2003, page 2 of 4, (CD3 Juni 2005)

PSL(V)F-5-/7 SAE

HAWE Hydraulik München © 2003, page 3 of 4, (CD3 Juni 2005)

PSL(V)F-5-/7 SAE

Part No. Qty. Item Nomenclature Drawing No. Add. Information

6096 953700 3 173 O-RING 29,82X2,62 NBR 90 SH Individual not available!
6096 420600 4 174 Since 12/2004; Individual not available!
6096 920100 4 174 O-RING 6,07X1,78 NBR 90 SH Individual not available!

HAWE Hydraulik München © 2003, page 4 of 4, (CD3 Juni 2005)

PSLF/PSVF-5 Valve sections (functional block)
PSLF/PSVF-5 Valve sections (functional block)

HAWE Hydraulik München © 2003, page 1 of 92, (CD3 Juni 2005)

PSLF/PSVF-5 Valve sections (functional block)
PSLF/PSVF-5 Valve sections (functional block)
Part No. Qty. Item Nomenclature Drawing No. Add. Information
SLF5-Ventilbl. 1 PSLF/PSVF-5 Valve blocks
SLF5-Ventilbl-Zusatzf. 2 PSLF/PSVF-5 Valve block - additional functions
SLF5-Betätigungen 3 PSLF/PSVF-5 Actuations
SLF5-Betät-Zusatzf. 4 PSLF/PSVF-5 Actuations - additional functions
PSL/PSV-5-Schieber 5 PSL(F)/PSV(F)-5 Spools

HAWE Hydraulik München © 2003, page 2 of 92, (CD3 Juni 2005)

PSLF/PSVF-5 Valve sections (functional block)
DS 7700-F 52 SEAL KIT FOR SLF SIZE 5 VALVE SECTION

HAWE Hydraulik München © 2003, page 5 of 92, (CD3 Juni 2005)

PSLF/PSVF-5 Valve sections (functional block)
DS 7700-F 52 SEAL KIT FOR SLF SIZE 5 VALVE SECTION
Part No. Qty. Item Nomenclature Drawing No. Add. Information
6096 408700 8 140 Since 12/2004; Individual not available!
6096 915000 8 140 O-RING 4,47X1,78 HNBR 90 SH RED SPOT Individual not available!
6096 408600 1 141 Since 12/2004; Individual not available!
6096 915200 1 141 O-RING 7,65X1,78 HNBR 90 SH RED SPOT Individual not available!
6096 435000 5 142 Since 12/2004; Individual not available!
6096 918500 5 142 O-RING 17,12X2,62 HNBR 90 SH RED SPOT Individual not available!
6096 408900 1 143 Since 12/2004; Individual not available!
6096 919500 1 143 O-RING 13X1,5 HNBR 90 SH RED SPOT Individual not available!
6096 421500 1 144 Since 12/2004; Individual not available!
6096 841000 1 144 O-RING 21,95X1,78 HNBR 90 SH Individual not available!
6096 439500 2 147 Since 12/2004; Individual not available!
6096 918300 2 147 O-RING 13,94X2,62 HNBR 90 SH RED SPOT Individual not available!
6096 422000 1 148 Since 12/2004; Individual not available!
6096 991700 1 148 O-RING 40,94X2,62 HNBR 90 SH RED SPOT Individual not available!
6095 129800 4 149 COPPER RING DIN 7603 8X12X2 Individual not available!
6096 420900 2 150 Since 12/2004; Individual not available!
6096 916500 2 150 O-RING 12,42X1,78 HNBR 90 SH RED SPOT Individual not available!
6096 421300 1 151 Since 12/2004; Individual not available!
6096 811100 1 151 O-RING 50,52X1,78 HNBR 90 SH RED SPOT Individual not available!
4065 411000 2 152 SEAL RING 8,3X11X1,15 TEFLON 7625 109/1 Individual not available!
6096 920500 2 153 O-RING 8X1,5 NBR 90 SH Individual not available!

HAWE Hydraulik München © 2003, page 6 of 92, (CD3 Juni 2005)

PSLF/PSVF-5 Valve sections (functional block)
SLF5-A2(A5) without add. functions

HAWE Hydraulik München © 2003, page 7 of 92, (CD3 Juni 2005)

PSLF/PSVF-5 Valve sections (functional block)
SLF5-A2(A5) without add. functions
Part No. Qty. Item Nomenclature Drawing No. Add. Information
PSLF/PSVF-5-Schieber 1 1 Spools
140-15
6800 665800 1 DS 7700-F 52 SEAL KIT FOR SLF SIZE 5 VALVE SECTION
4
3406 501600 1 2 SPOOL VALVE BODY 7805 451
3406 542500 1 2 SPOOL VALVE BODY 7805 456 with actuation type .E
6190 010500 1 3 BALL CLASS I DIN 5401 4 1.3505 included in part 4
6800 421300 1 4 SLEEVE COMPLETE WITH O-RING+BALL 3X8X12 9 S MN 28 K 7620 042 completed with part 3 and part 140
3016 419000 1 5 TAPPED PLUG 7700 044
max. torque 65Nm; Intermediate plate type /Z AN...BN...
6005 021200 4 6 SKT.-HEAD SCREW ISO 4762 10X90 10.9 ZINC PLATED
with 30 mm prolonged screws!
3014 500200 1 7 SCREW 7805 440
3008 468300 1 8 SPRING 7805 048/2 with coding A2, A5, A7
3008 468900 1 9 SPRING 7805 049 with coding A5
3008 473200 1 9 SPRING 7805 049 D with coding A7
3036 426500 1 10 CONTROLLER PISTON SECTION 7805 047/1
6800 529900 1 10 INFLOW CONTROLLER WITH REBOUND DAMPENING 7805 037 with coding 6 (526, 556)
3013 418400 1 11 TAPPED PLUG COMPLETE WITH SEAL 22X6 C 35 PB 7480 033

HAWE Hydraulik München © 2003, page 8 of 92, (CD3 Juni 2005)

PSLF/PSVF-5 Valve sections (functional block)
SLF3(5) - ...A...B... (Secondary pressure lim. at port A,B)

HAWE Hydraulik München © 2003, page 29 of 92, (CD3 Juni 2005)

PSLF/PSVF-5 Valve sections (functional block)
SLF3(5) - ...A...B... (Secondary pressure lim. at port A,B)
Part No. Qty. Item Nomenclature Drawing No. Add. Information
3037 419900 2 1 VALVE CONE 7700 057/1
3008 459600 2 2 SPRING 7700 051
3014 448000 2 3 SCREW 8X20,5 9 S MN 28 K 7700 058
6065 540600 2 4 HEXAGON NUT TURNED SHAPE B ISO 4035 8X1 A 2-70
3604 405200 2 5 CAP NUT 7700 054
6095 129800 4 100 COPPER RING DIN 7603 8X12X2 Part of the valve block seal kit!

HAWE Hydraulik München © 2003, page 30 of 92, (CD3 Juni 2005)

PSLF/PSVF-5 Valve sections (functional block)
SLF5 - EA(1,2)-EX

HAWE Hydraulik München © 2003, page 67 of 92, (CD3 Juni 2005)

PSLF/PSVF-5 Valve sections (functional block)
SLF5 - EA(1,2)-EX
Part No. Qty. Item Nomenclature Drawing No. Add. Information
6800 307499 1 EA-EX-24 FOR PSL SIZE 5 7806 124 A-C actuation complete 24V DC
SL5-Handhebelgehäus
1 1 SL5 - Lever housing
e
3009 406900 1 2 SPRING CAP COMPLETE 7806 026
3008 464900 1 3 SPRING 7806 030
3008 464300 1 4 SPRING 7806 031
3009 407000 1 5 SPRING CAP COMPLETE 7806 027
3001 409900 1 6 WASHER 9,2X18X4 9 S MN PB 28 K 7806 029
6005 320900 1 7 FLAT HEAD SCREW DIN 7991 8X40 8.8
3701 402800 1 8 SPRING HOUSING 7806 021
4703 430300 4 9 FLANGE 7806 010 with coding G
6005 026000 4 10 SKT.-HEAD SCREW ISO 4762 6X6 A 2-70
6005 019200 4 11 SKT.-HEAD SCREW ISO 4762 6X12 12.9 ZINC PLATED with coding G
3408 806900 2 12 PM 1-11 NBR 7625 150 E complete with O-ring, seal ring part 143;153 and 128;152
7709 050 A-24 V 24V DC; Please follow the operation manual B ATEX, B
4704 890200 1 13 TWIN SOLENOID PROP. EEX 3-METER LEAD LENGTH
EEX 01/2002!
6005 042400 3 14 SKT.-HEAD SCREW NEW VERSION
127-14
6800 348400 1 DS 7700-52 Seal kit for add-on spool valves size 5
3
140-15
6800 665800 1 DS 7700-F 52 SEAL KIT FOR SLF SIZE 5 VALVE SECTION
4

HAWE Hydraulik München © 2003, page 68 of 92, (CD3 Juni 2005)

PSLF/PSVF-5 Valve sections (functional block)
PSL(F)/PSV(F)-5 Spools

HAWE Hydraulik München © 2003, page 91 of 92, (CD3 Juni 2005)

PSLF/PSVF-5 Valve sections (functional block)
PSL(F)/PSV(F)-5 Spools
Part No. Qty. Item Nomenclature Drawing No. Add. Information
0003 001900 1 1-4 SL5 - L.../... Insert consumer flow coding (e.g. L 160/40); L__/__
0003 002000 1 1-4 SL5 - M.../... Insert consumer flow coding (e.g. M 160/40); M__/__
0003 002100 1 1-4 SL5 - F.../... Insert consumer flow coding (e.g. F 160/40); F__/__
0003 002200 1 1-4 SL5 - H.../... Insert consumer flow coding (e.g. H 160/40); H__/__
0003 002300 1 1-4 SL5 - J.../... Insert consumer flow coding (e.g. J 160/40); J__/__
0003 002400 1 1-4 SL5 - B.../... Insert consumer flow coding (e.g. B 160/40); B__/__
0003 002500 1 1-4 SL5 - R.../... Insert consumer flow coding (e.g. R 160/40); R__/__
0003 002600 1 1-4 SL5 - O.../... Insert consumer flow coding (e.g. O 160/40); O__/__

HAWE Hydraulik München © 2003, page 92 of 92, (CD3 Juni 2005)

SLF5-/5 SAE
SLF5-/5 SAE

HAWE Hydraulik München © 2003, page 1 of 4, (CD3 Juni 2005)

SLF5-/5 SAE
SLF5-/5 SAE
Part No. Qty. Item Nomenclature Drawing No. Add. Information
3407 424700 1 1 SUB-PLATE SAE 7805 423
173-17
6800 892700 1
4

HAWE Hydraulik München © 2003, page 2 of 4, (CD3 Juni 2005)

SLF5-/5 SAE

HAWE Hydraulik München © 2003, page 3 of 4, (CD3 Juni 2005)

SLF5-/5 SAE

Part No. Qty. Item Nomenclature Drawing No. Add. Information

6096 953700 3 173 O-RING 29,82X2,62 NBR 90 SH Individual not available!
6096 420600 4 174 Since 12/2004; Individual not available!
6096 920100 4 174 O-RING 6,07X1,78 NBR 90 SH Individual not available!

HAWE Hydraulik München © 2003, page 4 of 4, (CD3 Juni 2005)

SLF5-ZPL 5 SAE 3
SLF5-ZPL 5 SAE 3

HAWE Hydraulik München © 2003, page 1 of 7, (CD3 Juni 2005)

SLF5-ZPL 5 SAE 3
SLF5-ZPL 5 SAE 3
Part No. Qty. Item Nomenclature Drawing No. Add. Information
3407 110500 1 1 INTERMEDIATE PLATE 7805 426
4708 474200 1 2 TYPE PLATE STAMPED STANDARD VERSION 7778 029 blank
6140 400000 6 3 GROOVED DRIVE STUD ISO 8746 2,3X4 A 2-70
SLF5-Zuganker ZPL 5
1 20-22 SLF5 - Tire rods ZPL 5 SAE 3 max. torque 180 Nm
SAE 3
171-17
6800 892800 1
6

HAWE Hydraulik München © 2003, page 2 of 7, (CD3 Juni 2005)

SLF5 - Tire rods ZPL 5 SAE 3

HAWE Hydraulik München © 2003, page 1 of 3, (CD8 Mai 2006)

SLF5 - Tire rods ZPL 5 SAE 3
Part No. Qty. Item Nomenclature Drawing No. Add. Information
Lcompl.=(x*99,5)+(y*180)+60,5; x=number of single
3024 440300 2 20 TENSION ROD M 16 X 160 7778 916
subpl., y= number of double subpl.
Lcompl.=(x*99,5)+(y*180)+60,5; x=number of single
3024 443300 2 20 TENSION ROD M 16 X 241 7778 916
subpl., y= number of double subpl.
Lcompl.=(x*99,5)+(y*180)+60,5; x=number of single
3024 440400 2 20 TENSION ROD M 16 X 260 7778 916
subpl., y= number of double subpl.
Lcompl.=(x*99,5)+(y*180)+60,5; x=number of single
3024 441300 2 20 TENSION ROD M 16 X 340 7778 916
subpl., y= number of double subpl.
Lcompl.=(x*99,5)+(y*180)+60,5; x=number of single
3024 440500 2 20 TENSION ROD M 16 X 359 7778 916
subpl., y= number of double subpl.
Lcompl.=(x*99,5)+(y*180)+60,5; x=number of single
3024 443400 2 20 TENSION ROD M 16 X 421 7778 916
subpl., y= number of double subpl.
Lcompl.=(x*99,5)+(y*180)+60,5; x=number of single
3024 441700 2 20 TENSION ROD M 16 X 440 7778 916
subpl., y= number of double subpl.
Lcompl.=(x*99,5)+(y*180)+60,5; x=number of single
3024 440600 2 20 TENSION ROD M 16 X 459 7778 916
subpl., y= number of double subpl.
Lcompl.=(x*99,5)+(y*180)+60,5; x=number of single
3024 441400 2 20 TENSION ROD M 16 X 520 7778 916
subpl., y= number of double subpl.
Lcompl.=(x*99,5)+(y*180)+60,5; x=number of single
3024 442100 2 20 TENSION ROD M 16 X 539 7778 916
subpl., y= number of double subpl.
Lcompl.=(x*99,5)+(y*180)+60,5; x=number of single
3024 440700 2 20 TENSION ROD M 16 X 558 7778 916
subpl., y= number of double subpl.
Lcompl.=(x*99,5)+(y*180)+60,5; x=number of single
3024 443500 2 20 TENSION ROD M 16 X 601 7778 916
subpl., y= number of double subpl.
Lcompl.=(x*99,5)+(y*180)+60,5; x=number of single
3024 441800 2 20 TENSION ROD M 16 X 620 7778 916
subpl., y= number of double subpl.
Lcompl.=(x*99,5)+(y*180)+60,5; x=number of single
3024 442400 2 20 TENSION ROD M 16 X 639 7778 916
subpl., y= number of double subpl.
Lcompl.=(x*99,5)+(y*180)+60,5; x=number of single
3024 440800 2 20 TENSION ROD M 16 X 658 7778 916
subpl., y= number of double subpl.
Lcompl.=(x*99,5)+(y*180)+60,5; x=number of single
3024 441500 2 20 TENSION ROD M 16 X 700 7778 916
subpl., y= number of double subpl.
Lcompl.=(x*99,5)+(y*180)+60,5; x=number of single
3024 442200 2 20 TENSION ROD M 16 X 719 7778 916
subpl., y= number of double subpl.
Lcompl.=(x*99,5)+(y*180)+60,5; x=number of single
3024 442700 2 20 TENSION ROD M 16 X 738 7778 916
subpl., y= number of double subpl.
Lcompl.=(x*99,5)+(y*180)+60,5; x=number of single
3024 440900 2 20 TENSION ROD M 16 X 757 7778 916
subpl., y= number of double subpl.
Lcompl.=(x*99,5)+(y*180)+60,5; x=number of single
3024 443600 2 20 TENSION ROD M 16 X 781 7778 916
subpl., y= number of double subpl.
Lcompl.=(x*99,5)+(y*180)+60,5; x=number of single
3024 441900 2 20 TENSION ROD M 16 X 800 7778 916
subpl., y= number of double subpl.
Lcompl.=(x*99,5)+(y*180)+60,5; x=number of single
3024 442500 2 20 TENSION ROD M 16 X 819 7778 916
subpl., y= number of double subpl.
Lcompl.=(x*99,5)+(y*180)+60,5; x=number of single
3024 442900 2 20 TENSION ROD M 16 X 838 7778 916
subpl., y= number of double subpl.

HAWE Hydraulik München © 2003, page 2 of 3, (CD8 Mai 2006)

SLF5 - Tire rods ZPL 5 SAE 3
Part No. Qty. Item Nomenclature Drawing No. Add. Information
Lcompl.=(x*99,5)+(y*180)+60,5; x=number of single
3024 441000 2 20 TENSION ROD M 16 X 857 7778 916
subpl., y= number of double subpl.
Lcompl.=(x*99,5)+(y*180)+60,5; x=number of single
3024 441600 2 20 TENSION ROD M 16 X 880 7778 916
subpl., y= number of double subpl.
Lcompl.=(x*99,5)+(y*180)+60,5; x=number of single
3024 442300 2 20 TENSION ROD M 16 X 899 7778 916
subpl., y= number of double subpl.
Lcompl.=(x*99,5)+(y*180)+60,5; x=number of single
3024 442800 2 20 TENSION ROD M 16 X 918 7778 916
subpl., y= number of double subpl.
Lcompl.=(x*99,5)+(y*180)+60,5; x=number of single
3024 443100 2 20 TENSION ROD M 16 X 937 7778 916
subpl., y= number of double subpl.
Lcompl.=(x*99,5)+(y*180)+60,5; x=number of single
3024 443700 2 20 TENSION ROD M 16 X 961 7778 916
subpl., y= number of double subpl.
Lcompl.=(x*99,5)+(y*180)+60,5; x=number of single
3024 442000 2 20 TENSION ROD M 16 X 980 7778 916
subpl., y= number of double subpl.
Lcompl.=(x*99,5)+(y*180)+60,5; x=number of single
3024 442600 2 20 TENSION ROD M 16 X 999 7778 916
subpl., y= number of double subpl.
Lcompl.=(x*99,5)+(y*180)+60,5; x=number of single
3024 441100 2 20 TENSION ROD M 16 X 956 7778 916
subpl., y= number of double subpl.
Lcompl.=(x*99,5)+(y*180)+60,5; x=number of single
3024 443000 2 20 TENSION ROD M 16 X 1018 7778 916
subpl., y= number of double subpl.
Lcompl.=(x*99,5)+(y*180)+60,5; x=number of single
3024 443200 2 20 TENSION ROD M 16 X 1037 7778 916
subpl., y= number of double subpl.
Lcompl.=(x*99,5)+(y*180)+60,5; x=number of single
3024 441200 2 20 TENSION ROD M 16 X 1056 7778 916
subpl., y= number of double subpl.
6075 040200 2 21 DISC SHAPE B 140 HV
6065 530400 2 22 HEXAGON NUT max. torque 180 Nm

HAWE Hydraulik München © 2003, page 3 of 3, (CD8 Mai 2006)

SLF5-ZPL 5 SAE 3

HAWE Hydraulik München © 2003, page 6 of 7, (CD3 Juni 2005)

SLF5-ZPL 5 SAE 3

Part No. Qty. Item Nomenclature Drawing No. Add. Information

6096 408700 4 171 Since 12/2004; Individual not available!
6096 915000 4 171 O-RING 4,47X1,78 HNBR 90 SH RED SPOT Individual not available!
6096 434800 1 175 Since 12/2004; Individual not available!
6096 918300 1 175 O-RING 13,94X2,62 HNBR 90 SH RED SPOT Individual not available!
6096 409000 2 176 Since 12/2004; Individual not available!
6096 917000 2 176 O-RING 14X1,78 HNBR 90 SH RED SPOT Individual not available!

HAWE Hydraulik München © 2003, page 7 of 7, (CD3 Juni 2005)

PSLF/PSVF-3 Valve blocks

HAWE Hydraulik München © 2003, page 3 of 93, (CD3 Juni 2005)

PSLF/PSVF-3 Valve sections (functional block)
SLF3-A1 without additional function
Part No. Qty. Item Nomenclature Drawing No. Add. Information
PSL/PSV-3-Schieber 1 1 PSL(F)/PSV(F)-3 Spools
130-14
6800 632300 1 DS 7700-F 32 SEAL KIT FOR VALVE SECTION SLF3
9
3406 435900 1 2 SPOOL VALVE BODY 7620 165
3406 633500 1 2 SPOOL VALVE BODY 7620 168 with actuation type .E.
6190 010500 1 3 BALL CLASS I DIN 5401 4 1.3505 included in part 4
6800 421300 1 4 SLEEVE COMPLETE WITH O-RING+BALL 3X8X12 9 S MN 28 K 7620 042 completed with part 3 and part 132
3016 419000 1 5 TAPPED PLUG 7700 044
6005 027700 4 6 SKT.-HEAD SCREW ISO 4762 8X90 8.8 A2K max. torque 23 Nm

HAWE Hydraulik München © 2003, page 6 of 93, (CD3 Juni 2005)

PSLF/PSVF-3 Valve sections (functional block)
PSL(F)/PSV(F)-3 Spools

HAWE Hydraulik München © 2003, page 7 of 93, (CD3 Juni 2005)

PSLF/PSVF-3 Valve sections (functional block)
PSL(F)/PSV(F)-3 Spools
Part No. Qty. Item Nomenclature Drawing No. Add. Information
0003 000100 1 1-4 SL3 - L../.. Insert consumer flow coding (e.g. L 16/80); L__/__
0003 000200 1 1-4 SL3 - F../.. Insert consumer flow coding (e.g. F 16/80); F__/__
0003 000300 1 1-4 SL3 - M../.. Insert consumer flow coding (e.g. M 16/80); M__/__
0003 000400 1 1-4 SL3 - H../.. Insert consumer flow coding (e.g. H 16/80); H__/__
0003 000500 1 1-4 SL3 - B../.. Insert consumer flow coding (e.g. B 16/80); B__/__
0003 000600 1 1-4 SL3 - R../.. Insert consumer flow coding (e.g. R 16/80); R__/__
0003 000700 1 1-4 SL3 - O../.. Insert consumer flow coding (e.g. O 16/80); O__/__
0003 000800 1 1-4 SL3 - P../.. Insert consumer flow coding (e.g. P 16/80); P__/__
0003 000900 1 1-4 SL3 - A../.. Insert consumer flow coding (e.g. A 16/80); A__/__
0003 001000 1 1-4 SL3 - Q../.. Insert consumer flow coding (e.g. Q 16/80); Q__/__
0003 001100 1 1-4 SL3 - T../.. Insert consumer flow coding (e.g. T 16/80); T__/__
0003 001200 1 1-4 SL3 - K../.. Insert consumer flow coding (e.g. K 16/80); K__/__
0003 001300 1 1-4 SL3 - N../.. Insert consumer flow coding (e.g. N 16/80); N__/__
0003 001400 1 1-4 SL3 - I../.. Insert consumer flow coding (e.g. I 16/80); I__/__
0003 003200 1 1-4 SL3 - V../.. Insert consumer flow coding (e.g. V 16/80); V__/__

HAWE Hydraulik München © 2003, page 8 of 93, (CD3 Juni 2005)

PSLF/PSVF-3 Valve sections (functional block)
DS 7700-F 32 SEAL KIT FOR VALVE SECTION SLF3

HAWE Hydraulik München © 2003, page 9 of 93, (CD3 Juni 2005)

PSLF/PSVF-3 Valve sections (functional block)
DS 7700-F 32 SEAL KIT FOR VALVE SECTION SLF3
Part No. Qty. Item Nomenclature Drawing No. Add. Information
6096 420000 2 130 Since 12/2004; Individual not available!
6096 917400 2 130 O-RING 17,17X1,78 HNBR 90 SH RED SPOT Individual not available!
6096 408900 1 131 Since 12/2004; Individual not available!
6096 919500 1 131 O-RING 13X1,5 HNBR 90 SH RED SPOT Individual not available!
6096 408700 8 132 Since 12/2004; Individual not available!
6096 915000 8 132 O-RING 4,47X1,78 HNBR 90 SH RED SPOT Individual not available!
6096 408600 1 133 Since 12/2004; Individual not available!
6096 915200 1 133 O-RING 7,65X1,78 HNBR 90 SH RED SPOT Individual not available!
6096 408800 5 134 Since 12/2004; Individual not available!
6096 918100 5 134 O-RING 12,37X2,62 HNBR 90 SH RED SPOT Individual not available!
6096 409100 1 135 O-RING 34,65 X 1,78 VI 110 S 80 SH Since 12/2004; Individual not available!
6096 917200 1 135 O-RING 34,65X1,78 HNBR 90 SH RED SPOT Individual not available!
6096 500400 2 136 O-Ring 12,42 x 1,78 90 Sh P 5008 since 03/2005; individual not available!
6096 918800 1 137 O-RING 36,17X2,62 HNBR 90 SH RED SPOT Individual not available!
6096 437000 2 138 Since 12/2004; Individual not available!
6096 916500 2 138 O-RING 12,42X1,78 HNBR 90 SH RED SPOT Individual not available!
6096 963900 2 139 O-RING 3X1,5 NBR 90 SH Individual not available!
6096 421100 2 140 Since 12/2004; Individual not available!
6096 999000 2 140 O-RING 6,86X1,78 HNBR 90 SH RED SPOT Individual not available!
6095 110200 4 141 COPPER RING DIN 7603 6X10X1 Individual not available!
6095 129800 4 142 COPPER RING DIN 7603 8X12X2 Individual not available!
4065 411000 2 143 SEAL RING 8,3X11X1,15 TEFLON 7625 109/1 Individual not available!
6096 920500 2 144 O-RING 8X1,5 NBR 90 SH Individual not available!

HAWE Hydraulik München © 2003, page 10 of 93, (CD3 Juni 2005)

PSLF/PSVF-3 Valve sections (functional block)
SLF3-A2(A5,A6) without additional functions

HAWE Hydraulik München © 2003, page 11 of 93, (CD3 Juni 2005)

PSLF/PSVF-3 Valve sections (functional block)
SLF3-A2(A5,A6) without additional functions
Part No. Qty. Item Nomenclature Drawing No. Add. Information
PSL/PSV-3-Schieber 1 1 PSL(F)/PSV(F)-3 Spools
130-14
6800 632300 1 DS 7700-F 32 SEAL KIT FOR VALVE SECTION SLF3
9
3406 543800 1 2 SPOOL VALVE BODY 7620 151
3406 544800 1 2 SPOOL VALVE BODY 7620 161 with actuation type .E.
6190 010500 1 3 BALL CLASS I DIN 5401 4 1.3505 included in part 4
6800 421300 1 4 SLEEVE COMPLETE WITH O-RING+BALL 3X8X12 9 S MN 28 K 7620 042 completed with part 3 and part 132
3016 419000 1 5 TAPPED PLUG 7700 044
6005 027700 4 6 SKT.-HEAD SCREW ISO 4762 8X90 8.8 A2K max. torque 23 Nm
3008 459500 1 7 SPRING 7700 048 with coding A2, A6
3008 465100 1 7 SPRING 7700 050 with coding A5
6800 354600 1 8 INFLOW CONTROLLER WITH DAMPENING VIA ORIFICE 7700 049/1 with coding A2, A5
6800 367400 1 8 INFLOW CONTROLLER WITH REBOUND DAMPENING 7700 037 with coding A6
6800 447900 1 8 INFLOW CONTROLLER WITH DAMPENING VIA ORIFICE DU 0,4 7700 046 with coding 4 (A24; A54)
3013 406800 1 9 TAPPED PLUG WITH TUFLOK-COATING 7620 041/1 secured with LOCTITE!
3013 408900 1 10 SCREW WITH TUFLOK-COATING 7620 040 secured with LOCTITE!

HAWE Hydraulik München © 2003, page 12 of 93, (CD3 Juni 2005)

PSLF/PSVF-3 Valve sections (functional block)
SLF3-A2(A5,A6) Pressure limitation C

HAWE Hydraulik München © 2003, page 15 of 93, (CD3 Juni 2005)

PSLF/PSVF-3 Valve sections (functional block)
SLF3-A2(A5,A6) Pressure limitation C
Part No. Qty. Item Nomenclature Drawing No. Add. Information
PSL/PSV-3-Schieber 1 1 PSL(F)/PSV(F)-3 Spools
130-14
6800 632300 1 DS 7700-F 32 SEAL KIT FOR VALVE SECTION SLF3
9
3406 543900 1 2 SPOOL VALVE BODY 7620 152
3406 544100 1 2 SPOOL VALVE BODY 7620 157 with actuation type .E.
6190 010500 1 3 BALL CLASS I DIN 5401 4 1.3505 included in part 4
6800 421300 1 4 SLEEVE COMPLETE WITH O-RING+BALL 3X8X12 9 S MN 28 K 7620 042 completed with part 3 and part 132
3016 419000 1 5 TAPPED PLUG 7700 044
6005 027700 4 6 SKT.-HEAD SCREW ISO 4762 8X90 8.8 A2K max. torque 23 Nm
3008 459500 1 7 SPRING 7700 048 with coding A2, A6
3008 465100 1 7 SPRING 7700 050 with coding A5
6800 354600 1 8 INFLOW CONTROLLER WITH DAMPENING VIA ORIFICE 7700 049/1 with coding A2, A5
6800 367400 1 8 INFLOW CONTROLLER WITH REBOUND DAMPENING 7700 037 with coding A6
6800 447900 1 8 INFLOW CONTROLLER WITH DAMPENING VIA ORIFICE DU 0,4 7700 046 with coding 4 (A24; A54)
3013 406800 1 9 TAPPED PLUG WITH TUFLOK-COATING 7620 041/1 secured with LOCTITE!
3013 408900 1 10 SCREW WITH TUFLOK-COATING 7620 040 secured with LOCTITE!
3047 407800 1 11 FINE FILTER 7700 034
6095 110500 1 12 COPPER RING DIN 7603 5X9X1
6005 026100 1 13 SKT.-HEAD SCREW

HAWE Hydraulik München © 2003, page 16 of 93, (CD3 Juni 2005)

PSLF/PSVF-3 Valve sections (functional block)
SLF3(5) - ...A...B... (Secondary pressure lim. at port A,B)

HAWE Hydraulik München © 2003, page 29 of 93, (CD3 Juni 2005)

PSLF/PSVF-3 Valve sections (functional block)
SLF3(5) - ...A...B... (Secondary pressure lim. at port A,B)
Part No. Qty. Item Nomenclature Drawing No. Add. Information
3037 419900 2 1 VALVE CONE 7700 057/1
3008 459600 2 2 SPRING 7700 051
3014 448000 2 3 SCREW 8X20,5 9 S MN 28 K 7700 058
6065 540600 2 4 HEXAGON NUT TURNED SHAPE B ISO 4035 8X1 A 2-70
3604 405200 2 5 CAP NUT 7700 054
6095 129800 4 100 COPPER RING DIN 7603 8X12X2 Part of the valve block seal kit!

HAWE Hydraulik München © 2003, page 30 of 93, (CD3 Juni 2005)

PSLF/PSVF-3 Valve sections (functional block)
SLF3(5) - ...C... (Secondary press. lim. at port A and B)

HAWE Hydraulik München © 2003, page 31 of 93, (CD3 Juni 2005)

PSLF/PSVF-3 Valve sections (functional block)
SLF3(5) - ...C... (Secondary press. lim. at port A and B)
Part No. Qty. Item Nomenclature Drawing No. Add. Information
3037 419900 1 1 VALVE CONE 7700 057/1
3008 459600 1 2 SPRING 7700 051
3014 448000 1 3 SCREW 8X20,5 9 S MN 28 K 7700 058
6065 540600 1 4 HEXAGON NUT TURNED SHAPE B ISO 4035 8X1 A 2-70
3604 405200 1 5 CAP NUT 7700 054
6095 129800 2 100 COPPER RING DIN 7603 8X12X2 Part of the valve block seal kit!

HAWE Hydraulik München © 2003, page 32 of 93, (CD3 Juni 2005)

PSLF/PSVF-3 Valve sections (functional block)
SLF3 - Lever housing

HAWE Hydraulik München © 2003, page 49 of 93, (CD3 Juni 2005)

PSLF/PSVF-3 Valve sections (functional block)
SLF3 - Lever housing
Part No. Qty. Item Nomenclature Drawing No. Add. Information
6800 144202 1 MANUAL ACTUATION SL SIZE 3 FOR TYPE A 1 7709 100 B lever housing complete, no hand lever
6800 144302 1 MANUAL ACTUATION SL SIZE 3 FOR TYPE HA 1 7709 100 H lever housing complete, no hand lever
6800 890502 1 7709 100 O lever housing complete, no hand lever
6800 541902 1 LEVER HOUSING HA UNF 1 SIZE 3 7709 500 H lever housing complete, no hand lever
6800 541905 1 LEVER HOUSING FA UNF 1 SIZE 3 7709 500 L lever housing complete, no hand lever
0000 00000H 1 1 lever housing with shaft and lock (individual not available) (indiv. not available)
6005 042400 4 2 SKT.-HEAD SCREW NEW VERSION
with type FA, housing with non-prolonging screw heads,
6005 043400 4 2 SKT.-HEAD SCREW
from 11/2003
4065 412100 2 3 BACK-UP RING 12,1X15X1 PTFE 7709 009
4065 412200 2 4 BACK-UP RING 12,1X14,95X1 X 5 CR NI 1810 7709 017
3001 456700 2 5 WASHER 12,1X16X1 X 5 CR NI 1810 7709 007
6075 620300 1 6 LOCK WASHER STAINLESS DIN 6799 9 1.4122
fill up with grease e.g. OPTITEMP HT2EP prior to
3065 402600 1 7 CAP 7709 018
assembly
fill up with grease e.g. OPTITEMP HT2EP prior to
4703 422100 1 8 SHELL 7709 019
assembly
3401 409100 1 9 ACTUATION SHAFT 7709 008
6019 311100 2 10 GRUB SCREW ISO 4026 6X6 A 2-70 NO SURFACE PROTECTION
6019 311200 2 11 GRUB SCREW ISO 4026 6X16 A 2-70 NO SURFACE PROTECTION
6140 519700 1 12 ROLLPIN ISO 8750 5X20 ST
3024 401200 1 13 LEVER COMPLETE 7709 020 standard
3024 402000 1 13 LEVER COMPLETE ôNEWô ! LENGTH 95 MM 7709 070 with coding 2; short hand lever
3032 421400 1 14 BOLT 7709 004 scope of delivery with any valve spool
6075 610100 2 15 LOCK WASHER DIN 6799 3,2 scope of delivery with any valve spool
3407 418600 1 16 SPACER 7709 003
6095 110100 1 17 COPPER RING SHAPE A DIN 7603 4X8X1
6000 422700 1 18 HEXAGON HEAD SCREW
3100 002100 1 43-50 DS 7700-32 SEAL KIT FOR ADD-ON SPOOL VALVE SECTIONS SL 3
130-14
6800 632300 1 DS 7700-F 32 SEAL KIT FOR VALVE SECTION SLF3
3

HAWE Hydraulik München © 2003, page 50 of 93, (CD3 Juni 2005)

PSLF/PSVF-3 Valve sections (functional block)
SLF3 - EA;EA1(2)

HAWE Hydraulik München © 2003, page 61 of 93, (CD3 Juni 2005)

PSLF/PSVF-3 Valve sections (functional block)
SLF3 - EA;EA1(2)
Part No. Qty. Item Nomenclature Drawing No. Add. Information
6800 144603 EA 1-G 12 FOR PSL SIZE 3 7709 104 C
6800 144604 EA 1-G 24 FOR PSL SIZE 3 7709 104 D
7709 100a-c 1 1 SLF3 - Lever housing
3001 454600 1 2 SPRING CAP 7709 026 complete with sleeve part-no. 7709 028
3008 459200 1 3 SPRING 7709 030
3008 459300 1 4 SPRING 7709 031
3001 455000 1 5 SPRING CAP 7709 027 complete with sleeve part-no. 7709 028
3001 456600 1 6 WASHER 7,2X14,5X3 9 S MN PB 28 K 7709 029
6005 320300 1 7 FLAT HEAD SCREW DIN 7991 6X35 8.8 A2K
3701 400100 1 8 SPRING HOUSING 7709 021/1
4703 423600 1 9 FLANGE 7709 048 with coding G
6005 042300 4 10 SKT.-HEAD SCREW ISO 4762 5X8 A 2-70
6005 014000 4 11 SKT.-HEAD SCREW ISO 4762 5X16 12.9 ZINC PLATED with coding G
6800 398200 2 12 BLANKING SCREW COMPLETE 7709 047 with coding E0; complete with O-rings 9x1,5; 12,42x1,78
3408 806900 2 13 PM 1-11 NBR 7625 150 E complete with O-ring, seal ring part 55,56
4704 859100 1 14 TWIN SOLENOID PROP. 7709 050-12 V 12V DC
4704 859200 1 14 TWIN SOLENOID PROP. 7709 050-24 V 24V DC
7709 050 B/HS-12
4704 868300 1 14 PROP. TWIN SOLENOID ND WITH MANUAL EMERGENCY ACTUATION with emergency actuation; 12V DC
V
7709 050 B/HS-24
4704 868400 1 14 PROP. TWIN SOLENOID ND WITH MANUAL EMERGENCY ACTUATION with emergency actuation; 24V DC
V
7709 050 A-24 V 24V DC; Please follow the operation manual B ATEX, B
4704 890200 1 14 TWIN SOLENOID PROP. EEX 3-METER LEAD LENGTH
EEX 01/2002!
6005 042400 3 15 SKT.-HEAD SCREW NEW VERSION
6217 000200 1 16 MSD 3-309 LUG BLACK with coding G12, G24
3100 002100 1 43-50 DS 7700-32 SEAL KIT FOR ADD-ON SPOOL VALVE SECTIONS SL 3
130-14
6800 632300 1 DS 7700-F 32 SEAL KIT FOR VALVE SECTION SLF3
3

HAWE Hydraulik München © 2003, page 62 of 93, (CD3 Juni 2005)

SLF3-/UNF 3

HAWE Hydraulik München © 2003, page 1 of 2, (CD8 Mai 2006)

SLF3-/UNF 3
Part No. Qty. Item Nomenclature Drawing No. Add. Information
3407 503600 1 1 SUB-PLATE 7620 523
120-12
6800 632500 1 DS 7700-F 34 SEAL KIT FOR SUB-PLATE
2

HAWE Hydraulik München © 2003, page 2 of 2, (CD8 Mai 2006)

SLF3-/UNF 3 AN...BN...

HAWE Hydraulik München © 2003, page 1 of 2, (CD8 Mai 2006)

SLF3-/UNF 3 AN...BN...
Part No. Qty. Item Nomenclature Drawing No. Add. Information
3407 503800 1 1 SUB-PLATE 7620 505
6800 205006 2 2 RE 30 7555 000 F max. torque 30 Nm
6013 150900 2 3 TAPPED PLUG DIN 908 20X1,5 ST A2K
6800 199201 2 4 CMV 2 F 0-80 BAR 7710 000 C max. torque valve body 40 Nm, counter nut 35 Nm
6800 199202 2 4 CMV 2 E 0-160 BAR 7710 000 C max. torque valve body 40 Nm, counter nut 35 Nm
6800 199203 2 4 CMV 2 C-... 0-315 BAR 7710 000 C max. torque valve body 40 Nm, counter nut 35 Nm
6800 199204 2 4 CMV 2 B 0-500 BAR 7710 000 C max. torque valve body 40 Nm, counter nut 35 Nm
6096 982300 2 5 O-RING 17,17X1,78 AU 90 SH replaceable
6096 520600 2 6 SEAL RING KANTSIL DKAR 00018-N 90 18,77X replaceable, X = orientation when installed
120-12
6800 632500 1 DS 7700-F 34 SEAL KIT FOR SUB-PLATE
3

HAWE Hydraulik München © 2003, page 2 of 2, (CD8 Mai 2006)

SLF3-/UNF 4
DS 7700-F 34 SEAL KIT FOR SUB-PLATE

HAWE Hydraulik München © 2003, page 3 of 4, (CD3 Juni 2005)

SLF3-/UNF 4
DS 7700-F 34 SEAL KIT FOR SUB-PLATE
Part No. Qty. Item Nomenclature Drawing No. Add. Information
6096 434800 1 120 Since 12/2004; Individual not available!
6096 918300 1 120 O-RING 13,94X2,62 HNBR 90 SH RED SPOT Individual not available!
6096 408700 4 121 Since 12/2004; Individual not available!
6096 915000 4 121 O-RING 4,47X1,78 HNBR 90 SH RED SPOT Individual not available!
6096 409000 2 122 Since 12/2004; Individual not available!
6096 917000 2 122 O-RING 14X1,78 HNBR 90 SH RED SPOT Individual not available!
6095 140800 2 123 COPPER RING DIN 7603 20X24X2,5 Individual not available!

HAWE Hydraulik München © 2003, page 4 of 4, (CD3 Juni 2005)

SLF3-E1
SLF3-E1

HAWE Hydraulik München © 2003, page 1 of 4, (CD3 Juni 2005)

SLF3-E1
SLF3-E1
Part No. Qty. Item Nomenclature Drawing No. Add. Information
3407 119700 1 1 END PLATE 7620 031/1
6019 420100 1 2 GRUB SCREW ISO 4027 8X10 10.9
6095 129800 1 3 COPPER RING DIN 7603 8X12X2
6005 026400 1 4 SKT.-HEAD SCREW
SLF3-Zuganker E1-E5 1 50-52 SLF3 - Tire rods E1-E2; E4-E5

HAWE Hydraulik München © 2003, page 2 of 4, (CD3 Juni 2005)

SLF3-Tie rod sets E1; E2; E4; E5

HAWE Hydraulik München © 2003, page 1 of 2, (CD8 Mai 2006)

SLF3-Tie rod sets E1; E2; E4; E5
Part No. Qty. Item Nomenclature Drawing No. Add. Information
6800 861901 1 1 TENSION ROD & ACCESSORY PSLF 3 1 ADD-ON SECT. E 1,E 2 7620 190 A Complete, individual not available!
6800 861902 1 1 TENSION ROD & ACCESSORY PSLF 3 2 ADD-ON SECT. E 1,E 2,E 4,E 5 7620 190 B Complete, individual not available!
6800 861903 1 1 TENSION ROD & ACCESSORY PSLF 3 3 ADD-ON SECT. E 1,E 2,E 4,E 5 7620 190 C Complete, individual not available!
6800 861904 1 1 TENSION ROD & ACCESSORY PSLF 3 4 ADD-ON SECT. E 1,E 2,E 4,E 5 7620 190 D Complete, individual not available!
6800 861905 1 1 TENSION ROD & ACCESSORY PSLF 3 5 ADD-ON SECT. E 1,E 2,E 4,E 5 7620 190 E Complete, individual not available!
6800 861906 1 1 TENSION ROD & ACCESSORY PSLF 3 6 ADD-ON SECT. E 1,E 2,E 4,E 5 7620 190 F Complete, individual not available!
6800 861907 1 1 TENSION ROD & ACCESSORY PSLF 3 7 ADD-ON SECT. E 1,E 2,E 4,E 5 7620 190 G Complete, individual not available!
6800 861908 1 1 TENSION ROD & ACCESSORY PSLF 3 8 ADD-ON SECT. E 1,E 2,E 4,E 5 7620 190 H Complete, individual not available!
6800 861909 1 1 TENSION ROD & ACCESSORY PSLF 3 9 ADD-ON SECT. E 1,E 2,E 4,E 5 7620 190 I Complete, individual not available!
6800 861910 1 1 TENSION ROD & ACCESSORY PSLF 3 10 ADD-ON SECT. E 1,E 2,E 4,E 7620 190 J Complete, individual not available!

HAWE Hydraulik München © 2003, page 2 of 2, (CD8 Mai 2006)